Ecofriendly finishing at FABTECH

Six years ago, the ever-expanding FABTECH® exposition opened its halls to include finishing technology. This year the Finishing Pavilion will comprise at least 318 exhibitors and four aisles directly adjacent to the metal forming section.

Ecofriendly finishing opportunities abound, from low-VOC coatings, low-cure coatings, and low-temperature cleaners to coatings and finishing techniques that reduce energy and, therefore, greenhouse gas emissions. Stamping manufacturers with cleaning, surface treatment, powder coating, and other coating operations can benefit from visiting these exhibits with green products.

“The driving force behind many coatings innovations today is the development of products that protect the environment without sacrificing overall coatings performance,” said a spokesperson for PPG.

Here are a few must-sees in the Finishing Pavilion.

1. Phosphate-free, Low-energy Pretreatment for Three-stage Washers

DuBois Chemicals, Booth A5812. Using an iron phosphate cleaner/coater in Stage 1 of a three-stage washer to pretreat parts before powder coating or liquid painting has been standard practice for decades. However, these cleaners/coaters have a limited ability to degrease and cannot remove inorganic soils such as rust and mill scale.

For ecoconscious stamping manufacturers and those located in geographies where phosphates are restricted or prohibited in wastewater streams, phosphate-free, zirconium-based cleaners/coaters are commercially available. However, some of these products have cleaning limitations.

New DuBois DuraLINK 500 is a phosphate-free pretreatment technology engineered to be applied in the third stage of a three-stage washer. It is zirconium-based with other proprietary additives. “This gives stampers the flexibility to choose a cleaner for Stage 1 that is better matched to removing their unique soils for a more efficient cleaning. The solutions do not need to be heated, and often the cleaner in the first stage can be run at lower temperatures than an iron phosphate cleaner/coater—saving energy,” said Bruce Dunham, marketing manager for DuBois Chemicals.

2. Low-temperature Immersion Cleaner

PPG, Booth A5712, will display its ULTRAX® low-temperature immersion cleaners that reduce energy and water use in coating facilities.

The manufacturer also will display its new Zircobond® pretreatment products that remove hazardous air pollutants, toxic sludge, and other harmful waste from numerous industrial coating processes, as well as ultraviolet and electron beam curing for industrial applications.

Its Duranar® powder coatings emit ultra-low volatile organic compounds (VOCs).

In addition, PPG will showcase a host of ecofriendly products under the ENVIRO-PRIME® brand. They are either lead-free, phosphate-free, metal-free, and dibutyloxotin (DBTO)-free, or all of the above.

PPG’s B1:B2™ and 3C1B compact paint systems allow the wet-on-wet-on-wet application of primer, basecoat, and clearcoat, moving the traditional primer application into the topcoat booth. The systems match any topcoat technology currently being used in automotive manufacturing facilities, the company says.

In water or solvent versions, the systems allow users to reduce VOC emissions, reduce energy consumption and associated CO2 emissions, as well as lower initial capital and operating costs by eliminating the need for a stand-alone primer and associated processing.

PPG’s commitment to sustainability led to the developments and will continue to encourage innovation, according to a spokesperson.

3. Zero-discharge Spray Washer Pretreatment Process

Houghton International, Booth A6581, will showcase its metalworking fluid chemistries for the painting, powder coating, anodizing, manganese, phosphate, and component remanufacturing industries designed to provide low-cost, environmentally friendly alternatives.

A common problem facing manufacturers using metal and surfacing finishing conversion coating processes is the expense and liabilities of discharging the effluent and process water. The company has developed a chemistry with related equipment that allows stampers to eliminate all process water discharge from their spray washers. Its zero-discharge spray washer pretreatment process allows stampers to eliminate spray washer chemical and rinse water effluent while maintaining high production quality, the company says.

This allows manufacturers to eliminate wastewater permitting, effluent violations, and related costs associated with excessive water usage.

The key feature of the Houghto-

Clean®, Houghto-Prep® ZP, and Houghto-Seal® technologies is that they provide extremely low conductivity in the processing baths and low bath solids, which reduces the volume of incoming water normally associated with traditional conversion coating processes.

4. Phosphate-free Conversion Coating

Bulk Chemicals Inc. (BCI), Booth A5848, will introduce phosphate-free, zirconium-based chemicals—ZIRCA-

SIL® SW- and ZIRCA-SIL® HD-1—that can clean and coat metals simultaneously with a phosphate-free conversion coating. They can be applied by hand wand or conventional spray systems.  The liquids are nonhazardous.S

Bulk Chemicals Inc., www.bulkchemicals.us

DuBois Chemicals, duboischemicals.com

Houghton Intl. Inc., www.houghtonintl.com

PPG Industries, www.ppg.com