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Lechsys Hydro Case Histories
A new technological concept including innovative industrial production and painting systems, with a product range defining new performance frontiers for the water based generation.
Lampade in ABS
SITUAZIONE INIZIALE
Exenia, azienda italiana Leader nella produzione e vendita lampade, faretti e lampadari per il mondo dell’Habitat Interior, collabora da molti anni con Lechler. Ha sempre adottato soluzioni/cicli a solvente
MOTIVAZIONE SOSTITUZIONE
L’azienda decide nell’ultimo quinquennio di convertire parte della produzione in cicli all’acqua senza rinunciare ad un buon aspetto estetico ed elevate resistenze.
PROPOSTA LECHLER
La nostra proposta all’acqua è caratterizzata da una soluzione mano unica semiopaca L0YD0204 HYDROPLAST MATT, omologato presso i loro laboratori interni
RISULTATO
Eccellenti resistenze al graffio e ai detergenti, casta colorimetria disponibile per i prodotti all’acqua, cicli molto rapidi e semplici da gestire, nonostante siano molto opachi
SITUAZIONE ATTUALE
Exenia, grazie all’utilizzo di prodotti e cicli all’acqua, ha lanciato le bellissime nuove collezioni di lampadari sostenibili “WILLY”
Biciclette in carbonio
SITUAZIONE INIZIALE
Origine, azienda francese leader nella produzione e vendita di biciclette in carbonio, ha sempre usato cicli a solvente
MOTIVAZIONE SOSTITUZIONE
L’azienda decide negli ultimi anni di convertire gradualmente la produzione con cicli all’acqua, senza rinunciare all’eccellenza dell’aspetto estetico finale e alle resistenze agli agenti atmosferici
PROPOSTA LECHLER
La nostra proposta per la verniciatura dei telai in carbonio, prevede un primer LY109002 HYDROPUR PRIMER + base Hydro per tutti i colori pastello e/o metallizzati + trasparente L0YD0150 HYDROCRYL CLEAR 2K GRIP nella versione lucida e L0YD0855 MOTIVE WB 20 GLOSSY CLEARCOAT per la versione opaca
SITUAZIONE ATTUALE
Lechler negli ultimi anni è diventato il fornitore più importante, in quanto unico a proporre cicli alto di gamma per la fibra di carbonio,100% all’acqua
Infissi in PVC
SITUAZIONE INIZIALE
Proferm, azienda francese Leader nella produzione e vendita di articoli in PVC per il mondo degli infissi con cicli Certificati, collabora da molti anni con Lechler. Da sempre solo con soluzioni a solvente
MOTIVAZIONE SOSTITUZIONE
L’azienda decide nell’ultimo decennio di convertire parte della produzione in cicli all’acqua, senza rinunciare ad un buon aspetto estetico ed elevate resistenze all’esterno
PROPOSTA LECHLER
La nostra proposta all’acqua è caratterizzata da una soluzione a mano unica semiopaca L0YD0282 HYDROFRAME COAT PVC FLEX, omologata da un ente certificatore che garantisce la robustezza del film di vernice in tutti i test a cui è stato sottoposto il manufatto
RISULTATO
Considerando il tema della sostenibilità, la soluzione con cicli all’acqua ha permesso a PROFERM di utilizzarli come un PLUS verso i suoi clienti
Plachette interruttori Vimar
SITUAZIONE INIZIALE
VIMAR produttore leader di placche copri interruttori in plastica e zama ha verniciato sino ad alcuni anni fa con prodotti Lechler a solvente
MOTIVAZIONE SOSTITUZIONE
Per ridurre emissioni di solventi ha deciso di sostituire il ciclo a solvente con uno all’acqua per ridurre l'impatto ambientale
PROPOSTA LECHLER
Per la verniciatura di supporti in zama e plastica, abbiamo proposto una finitura monostrato L0YD0947 HYDROPLAST SATIN che, oltre a garantire una perfetta adesione e un eccellente resistenza al graffio, assicura un ottimo aspetto estetico finale
RISULTATO
Per non avere sprechi ed ottimizzare le tinte dei colori pastello o metallizzate scelte, hanno deciso di istallare un tintometro LECHSYS HYDRO per essere completamente autonomi nella gestione della verniciatura
SITUAZIONE ATTUALE
Risultato: maggiore sostenibilità del processo di verniciatura con eccellente aspetto estetico e elevate resistenze
Painting of a snowcat
SITUAZIONE INIZIALE
Utilisation of solvent-based products.
MOTIVAZIONE SOSTITUZIONE
Need to switch to water-borne process to reduce emissions in the atmosphere, also driven by the certification process 14001: the company mission aims at an eco-friendly production with low environmental impact.
PROPOSTA LECHLER
The proposed painting process is equivalent to the previous solvent-based painting process: it envisages a water-borne epoxy anticorrosive primer Y175001 + a water-borne polyurethane enamel LH142 (YD142) for the chassis and other parts, while rollers are to be painted with a water-borne polyacrylic enamel LH155 (YD155).
SITUAZIONE ATTUALE
Satisfaction for the painting process: good resistances, application convenience and considerable reduction of solvent-based products.
Verniciatura carrelli e rimorchi agricoli
SITUAZIONE INIZIALE
Utilizzo prodotti a solvente in quanto refrattario ai prodotti all’acqua, ritenuti poco performanti.
MOTIVAZIONE SOSTITUZIONE
Lamentele continue da parte degli abitanti della zona, inducono a ridurre l’acquisto di prodotti al solvente, e sostituirli parzialmente con prodotti H2O.
PROPOSTA LECHLER
Visto che il cliente dispone di una cabina di verniciatura non riscaldata, l’utilizzo dei prodotti a basso impatto ambientale H2O vengono utilizzati per circa 5-6 mesi all’anno. La nostra proposta è stata Y109001 + YD144, in colorazioni New Holland.
SITUAZIONE ATTUALE
Il cliente è soddisfatto in primis perché non ha più ricevuto lamentele; si è inoltre totalmente ricreduto riguardo al ciclo H2O, ritenendolo migliorativo rispetto al precedente. Il suo obiettivo è di arrivare alla sostituzione completa dei prodotti a solvente, con un ciclo completo H2O.
Painting of lighting engineering products
SITUAZIONE INIZIALE
Utilisation of solvent-based products for the whole production.
MOTIVAZIONE SOSTITUZIONE
Need to use water-borne products to give an added value to your “creations”; moreover, a considerable part of manufactured items is destined for the North American market, that is very sensitive to ecological aspects.
PROPOSTA LECHLER
A whole range of processing, interior parts, one-coat painting process on both metal and alloy with one-coat products LH204 (YD204) and LH947 (YD947) or LH945 (YD945) + Y208010. On parts exposed outside: anticorrosive primer Y175001 overcoated with enamel LH203 (YD203), or LH945 (YD945) + YD850.
SITUAZIONE ATTUALE
Now the customer production is applied with water-borne products at 60% and the remainder with solvent-based products
Painting machines and plants for the environment
SITUAZIONE INIZIALE
Use of solvent-based products
MOTIVAZIONE SOSTITUZIONE
Need to change to a water-based cycle to reduce emissions, caused by the process to obtain 14001 certification and to respect the “ecological” philosophy that characterised their product.
PROPOSTA LECHLER
The cycle proposed retained the filler and solvent-based primer (29107 EPOXYPRIMER and 29105 HI BUILD FILLER) since it was necessary to use coloured primers. As a binder, YD155 HYDROCRYL for the glossy version in the company’s iconic colours orange, green and blue, and YD142 HYDROCRYL 2K MATT in grey for all machine interiors (and some bases or chassis). For the internal separator and sifting rollers, YD101 HYDROPRIMER in black.
SITUAZIONE ATTUALE
Now, they are very satisfied with the change, communicating between the lines that the coverage has proved to be almost better than the solvent-based cycle in some cases. They only had to reorganise the work differently and then they introduced hot air jets to accelerate the process during the more critical climatic season.
Painting for industrial vehicles with the “premium cycle”
SITUAZIONE INIZIALE
Use of solvent-based products
MOTIVAZIONE SOSTITUZIONE
Need to change to a water-based cycle to reduce emissions.
PROPOSTA LECHLER
Premium Cycle comprising an anti-corrosive primer HYDROPUR PRIMER PREMIUM WHITE Y109001 and a glossy enamel HYDROCRYL 2K PREMIUM YD144. The advantage obtained is the use of a single catalyser that allows you to rationalise the products, which results in savings in money, logistics and warehouse management.
RISULTATO
The advantage obtained is the use of a single catalyser that allows you to rationalise the products, which results in savings in money, logistics and warehouse management.e di gestione magazzino.
SITUAZIONE ATTUALE
All production uses the PREMIUM CYCLE.
Production and painting of roof panels
SITUAZIONE INIZIALE
Production of PA items. The painting had been commissioned to external companies
MOTIVAZIONE SOSTITUZIONE
Production with internal painting. Authorisation to open a new production area, depending on the dramatic reduction of the emissions into the atmosphere
PROPOSTA LECHLER
Solid colours Hydrocryl 2K Matt YD 142 topcoats.
RISULTATO
The painted manufactured products have very good finish with very good outdoor resistance
SITUAZIONE ATTUALE
The entire production is now completed with LECHLER top coats Hydrocryl 2K Matt YD 142
Painting of plastic items for furniture
SITUAZIONE INIZIALE
Production with solvent products
MOTIVAZIONE SOSTITUZIONE
Problems with plastics due to solvent aggression with high a percentage of manufactured waste.
PROPOSTA LECHLER
Hydroplast Matt YD 204 topcoat.
RISULTATO
All the problems related to the substrate and waste reduction have been definitely solved
SITUAZIONE ATTUALE
All painting of the articles with plastic substrates are completed with LECHLER Hydroplast Matt YD 204 top coats
Painting of urban transport vehicles
SITUAZIONE INIZIALE
Painting with solvent products in body shops that are not properly equipped
MOTIVAZIONE SOSTITUZIONE
The company is within a big metropolis and the transfer to products with low impact on the environment is an absolute necessity.
PROPOSTA LECHLER
For metallised colours: Hydroprimer 1K YD 101 basecoat Hydrocoat Motive YD 903 and YD 850 top coat. For solid colours: Hydrocryl 2K YD 155 topcoat.
RISULTATO
Dramatically reduced solvent emissions with a 50% saving on the painting processes’ application time, energy consumption and working costs.
SITUAZIONE ATTUALE
The customer used about 8.000 Lt of water based product every year.
Production and painting of steel machines
SITUAZIONE INIZIALE
The Customer used an Epoxylack Effect 29179 for the entire production.
MOTIVAZIONE SOSTITUZIONE
The tests on products have been conceived only for exploring new technologies with low impact on the environment and havenot been conceived on technical needs or to comply with any legislation requests.
PROPOSTA LECHLER
Hydropox 2K Str YD 179 finishing.
RISULTATO
Physical/Mechanical resistances better than the solvent product, easy application and the possibility to apply the paint in the plant without the utilisation of active carbon filters.
SITUAZIONE ATTUALE
All the production is with LECHLER Hydropox 2K Str YD 179 topcoats.
Production and painting of plastic switches/plates
SITUAZIONE INIZIALE
Use of metallic, pearled solvent based topcoats.
MOTIVAZIONE SOSTITUZIONE
Strategic choice of the company to gradually turn the solvent processes into water based cycles and the eradication of problems concerning environment legislation.
PROPOSTA LECHLER
Replacing of the solvent enamels/basecoats with water based products belonging to our Water Base product range.
RISULTATO
The excellent aesthetic results, application and very good yield have caused an acceleration of the project of turning to a water based product line with a specific painting process.
SITUAZIONE ATTUALE
To tal evaluation of costs-benefits deriving from the introduction of the water based painting products brought a global saving calculated at about 5%.
Production and painting of gas/oil barrels
SITUAZIONE INIZIALE
The customer builds steel barrels. Their painting had been commissioned to external companies.
MOTIVAZIONE SOSTITUZIONE
Set up of an internal painting line. To avoid the useage of solvent paints, the customer has requested water based products with low V.O.C. emission
PROPOSTA LECHLER
Primer Hydroprimer 1K YD 101. Hydrolack 1K Rapid YD 114 solid colour topcoat
RISULTATO
A call for tenders has been organised among different possible painting suppliers. The Lechler painting process has resulted in an excellent performance both in finish and application.
SITUAZIONE ATTUALE
The Customers used about 1500 kg of Hydroprimer. YD 101 + 1500 kg Hydrolack 1K Rapid YD 114 top coat each month
Painting plastic home items
SITUAZIONE INIZIALE
Plastic items painted with solvent products with different finishes.
MOTIVAZIONE SOSTITUZIONE
Problems with plastics due to solvent aggression with a high percentage of unused pieces
PROPOSTA LECHLER
Base 1K Hydrocoat Motive YD 903 with direct application on the substrate.
RISULTATO
RESULT All the problems of substrate absorption have been definitively solved. Yield has been also improved with little waste of material.
SITUAZIONE ATTUALE
All production is painted with LECHLER water based coloured base coats.
Pumps building and painting
SITUAZIONE INIZIALE
The Customer used a nitro-combined product (theoretical yield 6 m2 at 25 micron). With a 200 kg daily consumption (VOC 734 g/l mixture with V.O.C. emissions of 150 kg)
MOTIVAZIONE SOSTITUZIONE
Need to reduce the VOC emissions and to remove within the working departments flammable products (labels with flames) and demand more yield in application for products used.
PROPOSTA LECHLER
Finishing with direct application on substrate with Hydrocryl 2K Grip YD 143.
RISULTATO
Excellent look with a glossy finish. More than a 130% product yield.
SITUAZIONE ATTUALE
About 50% of the production will turn to the water based system in the next few months (with a 80% VOC reduction).
Painting for articles for motorcycles
SITUAZIONE INIZIALE
The customer used solvent products with a daily consumption of about 50 kg of basecoat corresponding about to 32,5 kg of solvent emission into the atmosphere.
MOTIVAZIONE SOSTITUZIONE
Necessity of reducing the VOC emissions and possibility of guaranteeing the utilisation of water based products and an added value the painted product.
PROPOSTA LECHLER
Hydroplast Dualcoat Y 267 fillers and Hydrocoat Motive YD 903 with Motive WB Clearcoat YD 850 or Hydroplast Satin YD 947
RISULTATO
The filler has been a success and the basecoats and the finishing have obtained very good aesthetic results with very good adhesion and mechanical performances.
SITUAZIONE ATTUALE
The customer has proposed the process with LECHLER products to his purchaser to be homologated and introduced into their specifications. He will shortly use the filler Hydroplast Dualcoat for the painting of motorcycles with a brand leader in the field.
Helmets: production and painting
SITUAZIONE INIZIALE
The Customer used solvent products with a daily consumption of about 300 kg corresponding to about 150 kg of V.O.C. emissions.
MOTIVAZIONE SOSTITUZIONE
Authorisation to open a new establishment, dependent on the drastic reduction of the VOC emissions.
PROPOSTA LECHLER
Replacing of the solvent basecoats with the water based product, Hydrocoat Helmet, deriving from binders YD 925 and YD 927, application of decals and finishing with UV clearcoat.
RISULTATO
Very good finisht both for solid and for metallised basecoats. Good adhesion of decals and UV clearcoats.
SITUAZIONE ATTUALE
The actual production of helmets demands the daily consumption of about 50 kg of waterborne basecoats with a V.O.C. emission of about 10 kg. That is to say a 70% reduction of daily solvent emissions.
Copyright [2014] by Lechler SpA
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