Dezign A Door MD Duarte de Franca explains that the

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Dezign A Door implements first automated water-based UV coating line Krugersdorp-based indoor kitchen, cupboard and built-in door manufacturer Dezign A Door reports that it is the first manufacturer

specialist the ICA Group. Dezign A Door MD Duarte de Franca explains that the company has always been at the forefront of innovative wood and panel finishing solutions.

1 Dezign A Door implements first automated water-based UV coating line Krugersdorp-based indoor kitchen, cupboard and built-in door manufacturer Dezign A Door reports that it is the first manufacturer in the country to successfully operate a fully automated Italian Cefla coating line using an environment-friendly, water-based ultraviolet (UV) coating product, produced by Italian wood coatings specialist the ICA Group. Dezign A Door MD Duarte de Franca explains that the company has always been at the forefront of innovative wood and panel finishing solutions. We consider ourselves a specialist in the field of painting, spraying and coatings and we have always been investing in new technologies, machines and products to ensure that we maintain our position to offer the high-end local market the best quality products at a fast turnaround. De Franca adds that the company is extremely motivated to implement environment-friendly manufacturing processes and products. Globally governments, associations, industry bodies and educated consumers are putting pressure on many industries to reduce their carbon footprint and engage in more sustainable business practices. For Dezign A Door the shift towards more environmentallyfriendly processes is a natural progression that will enable it to better serve a large portion of the architectural and interior design markets that are increasingly opting for greener construction and decoration products. Our new environment-friendly, water-based coating product is one of a kind in South Africa and buyers that are involved in green-building projects are already showing a keen interest in the product. However, the water-based coated doors will not only be appealing to high-end architects and interior designers, they will most likely also become a favourite among many private buyers who prefer completely green products even though it may come at a higher price, notes de Franca. Dezign A Door MD Duarte de Franca, Geerlings director Cornelis Rostoll and WoodGlass Coatings owner John Wanliss The Cefla coating line used to coat the edges of boards Manufacturing process The Cefla coating line was commissioned by local woodworking machine supplier Geerlings. The line is equipped to apply solvent-based and water-based products without any modifications having to be made to the system. The line has been in operation as a solvent-based coating line for more than five years, but has been used as a waterbased line since December The line comprises two separate sections, the first line is designed to finish the edges of the board, and the second section is designed to finish the face of the board. Production starts with the preparation of high-quality medium-density fibreboards. The edges of the boards are sanded and the boards are then passed through a SCM cross-belt sander. The edges and faces of the boards receive a white filler coat. This UV base coat is applied with precision laser rollers and then cured by UV light. The boards are sanded again before the water-based UV matt top coat is applied. The coating is dried in the oven unit and then cured. This coat is then sanded before a second matt top coat is applied. To achieve a high gloss finish a UV cured gloss top coat is applied. Thereafter the components are processed on the polishing line. Perfecting the process Factors that need consideration when employing UV curable pigmented coatings include a good understanding of the products, the need for accurate application, the efficient removal of the water phase and the correct UV curing equipment. Once these are satisfied and correct QA to page May 2014

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From page 68 Dezign A Door implements first automated water-based UV coating line measures instituted application and curing of the coatings is relatively simple.

3 From page 68 Dezign A Door implements first automated water-based UV coating line measures instituted application and curing of the coatings is relatively simple. Local ICA Group agent WoodGlass Coatings owner John Wanliss and Geerlings director Cornelis Rostoll say they worked in close partnership with Dezign A Door to ensure the application, drying and curing challenges are addressed. There is a need for accuracy when applying pigmented water-based UV The DMC Unisand K calibrating sanding machine coatings and once the process has been fine-tuned, the manufacturer benefits from an environmentfriendly product that is formaldehyde free and emits almost no volatile organic compounds (VOC). The water-based product used by Dezign A Door also exhibits impressive qualities such as scratch and stain resistance, flexibility, toughness and hardness. It is also non-yellowing. Many solvent-based products do not achieve all these qualities, explains Wanliss. On the flash-off or drying side, Geerlings adjusted the drying oven in the Cefla line to ensure that the correct balance between heat and air circulation was achieved to effectively evaporate and remove the water from the coating after it has been sprayed onto the sealed board. Unlike some solvent-based paints which emit high quantities of VOCs and formaldehyde, waterbased products contain very little VOCs, and therefore the water, which is the main volatile compound, needs to be removed from the paint as efficiently as possible. Further, Geerlings installed the Cefla UV curing unit containing a combination of high pressure mercury and gallium lamps necessary to cure the coatings Wood 03/2014 This lamp combination is specially designed to cure pigmented water-based UV coatings, while conventional high-pressure mercury lamps are sufficient to cure clear water-based coatings. to page May 2014

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From page 70 Dezign A Door implements first automated water-based UV coating line Rostoll adds that the adjustments to the drying and UV curing units are very sophisticated and Dezign A Door is the

Geerlings in a nutshell Geerlings reports that it is proud to be a supplier of leaders like Dezign a Door, clients with insight and foresight that adapt to the world market and lead our local market

5 From page 70 Dezign A Door implements first automated water-based UV coating line Rostoll adds that the adjustments to the drying and UV curing units are very sophisticated and Dezign A Door is the first company to use this technology in the South African furniture industry to cure spray applied pigmented coatings on wood and board products. Geerlings in a nutshell Geerlings reports that it is proud to be a supplier of leaders like Dezign a Door, clients with insight and foresight that adapt to the world market and lead our local market and will stand the test of time. It is a pleasure to work with clients who grow from strength to strength by being ahead of the opposition and creative thinking and action, says Geerlings MD Arnold Geerlings. Geerlings has been a major supplier to most of the leading manufacturers in South Africa since Geerlings offers clients the best knowledge of machinery, new developments and technical support from a team that has been servicing the same brands for 18 years. Geerlings has held our international partners SCM Group, Cefla Group and many more. These relationships are of the oldest and most established in South Africa. Geerlings believes that building long-term supplier relationships gives our clients stability into the future. In the tooling category, Geerlings has represented Freud for over 15 years, as well as the Geerlings and FOM Industries partnership to service and supply aluminium machinery. Geerlings has branches in Cape Town and Durban as well as a satellite office in the Eastern Cape. Geerlings currently has sales, administration and technical support staff in all of its four centres offering commitment to better service delivery nationally. The Wagner high-pressure pumps that regulate the volume of coating product applied to the board The whole coating line has been set up to spray extremely accurately. If too much coating is applied it will not cure properly and if too little is applied the desired finish will not be achieved. The machine operator weighs boards on a very accurate scale to determine the amount of coating applied, says Wanliss. Meanwhile, the Cefla line is designed to enter a powersaving mode when idle. This offers great savings in electricity, which is not only ideal for the manufacturer, but also for the environment, notes Rostoll. Trends and colour innovation Dezign A Door reports that it regularly visits international trade shows to stay updated on the latest trends in door manufacturing and wood finishing. De Franca explains that it was during one of these shows that he came in contact with the ICA Group and Wanliss. De Franca and Wanliss agree that European wood finishing trends are moving towards extra-matt finishes and naturaleffect wood stains which are glare-free. They report that locally, high-gloss remains very popular, but among local high-end buyers European trends will definitely catch on. Wanliss has finalised a standard range of modern coloured water-based coatings from the ICA Group to be used by Dezign A Door. Wanliss has spent several months perfecting the various colours using the ICA Group s innovative ICA Colour Tintometric System. The ICA Colour Tintometric System is an integrated system for the formulation and preparation of pigmented coatings for wood and glass, based on the addition of concentrated colouring pastes to various base products. This enables the Wood 04/ May 2014

shades of the ICA colour chart, the 195 shades of the Reichs-Ausschuß für Lieferbedingungen und Gütesicherung (RAL) colour chart and the 1 950 shades of the natural colour system (NCS) colour chart,

6 manufactured for Dezign A Door s first water-based project were all in white with a clear UV finish. The Cefla UV curing unit, equipped with gallium nitrate UV fluorescent tube lamps creation of any type of pigmented coating such as polyurethane, acrylic, water-based and more, selected from the 160 shades of the ICA colour chart, the 195 shades of the Reichs-Ausschuß für Lieferbedingungen und Gütesicherung (RAL) colour chart and the shades of the natural colour system (NCS) colour chart, or almost any colour required by customers. Colours developed by Wanliss for Dezign A Door include modern natural shades of white such as cream, ivory, beige, and several shades of grey as well as black. Dezign A Door reports that its second job will soon be produced using the new water-based colours. Components WoodGlass Coatings company overview WoodGlass Coatings is a specialist supplier of finishes to furniture manufacturers, shopfitters and allied wood industries. It also supplies a comprehensive range of coatings for use on all types of interior glass panelling and components. Dezign A Door company overview Dezign A Door is a family run manufacturing business that produces doors for indoor applications. Products include solid wood, veneered, sprayed and laminated doors for kitchens, cabinets and built-in wardrobes and cupboards. The company s m 2 factory is equipped with several high-end sanders, computer numerical control (CNC) machining centres, beam saws, panel saws, guillotines and edgebanders amongst others. Most of Dezign A Door s machines were supplied by Geerlings and the two companies have had a successful business partnership for over 16 years. Further, Dezign A Door implements Teowin computer aided manufacturing software from local software group Furnspace. This software enables the company to streamline its operations and it will soon enable clients to place online orders through an online enterprise resource management system. Dezign A Door also uses barcoded scanning technology to track components and job specifications in the production line. The technology is also used to activate cutting patterns on beam saws and CNCs. Dezign A Door s products are shipped all over the country and the company offers an outsourced finishing service to other manufacturers. S G As the distributor for the Italian company ICA Group, WoodGlass Coatings has access to one of the most sophisticated and well-equipped laboratories and research centres in Europe specialising in the development of coatings for wood and glass. ICA Group is a market leader in its field. Its products will not only be found in Europe but on many continents across the globe. Specialised industrial coatings for interior and exterior wood furniture, panelling, components, etc are available within the pallet of ICA products. Products such as its high solids polyurethanes, polyesters, UV systems, solvent and water-based coatings for parquet and strip flooring have been welcomed by the industry and systems are tailored to suit each manufacturer s specific needs. More recently water-based coatings for both interior and exterior applications are making inroads in southern Africa as environmental issues and the emission of VOCs become more of a focal point. More than 40 years of experience in wood coatings exists within the WoodGlass Coatings Company and together with the computerised colour matching system, technological advances are at the forefront of its strategy. WoodGlass Coatings offers products of superior quality backed up by sound technical service and advice Wood 12/2009 May

Coatings. Industrial wood. Technically advanced and environmentally friendly solutions for machine manufactured and hand-crafted joinery

Coatings. Industrial wood. Technically advanced and environmentally friendly solutions for machine manufactured and hand-crafted joinery Industrial wood Coatings Banbury, England 01608 683 494 sales@teknos.co.uk Livingston, Scotland 01506 436 222 sales.scotland@teknos.co.uk Magherafelt, Ireland 02879 301 472 sales.ireland@teknos.co.uk Technically