Everyone involved in eyeglass coating knows perfectly well that it is, perhaps, the most decisive process when it comes to giving the final product aesthetic appeal. Design and materials are certainly crucial when it comes to building a good frame. However, vibrant colours, high-quality finishes and the right ‘feel’ are equally decisive factors, leading consumers to choose products that will match their own look and, possibly, improve it.

In other words, aesthetics are as important as the practical, protective characteristics provided by the coating process.

The major brands are well aware of this: that’s why they’re always looking for partners who can guarantee an optimal approach to eyeglass coating, minimising costs but without ever compromising on quality.

This article explores the main coating techniques used on plastic eyeglasses (and those made of other materials). It also illustrates how Cefla Finishing - by drawing on decades of experience and constantly striving to improve the efficiency and performance of finishing lines - has succeeded in designing an advanced system with customisable configurations.

Want to discover the universe of objects with complex geometric shapes that are coated with Cefla Finishing equipment?

The main eyeglass coating techniques

First of all, note that different techniques can be used to treat these semi-finished products, whether they be complete frames or individual components. However, if the goal is to achieve premium-level quality, it’s essential that plastic eyeglass coating be performed inside a pressurized area that is sealed off from the external environment.

In many cases it’s preferable to use a liquid coating as it allows fast drying, even at relatively low temperatures. Not only that, it ensures impeccable output on any type of material, guaranteeing a broad range of aesthetic results, from RAL colours and metallic/iridescent effects to soft-touch finishes.

Liquid coating is usually applied by spraying. This can be done using machines or by way of manual techniques, depending on the type of product being made.

Regardless of the type of process, the coating will have to be dried. For this reason, semi-finished products need to be placed, in series, in one or more ovens before proceeding to the next stage, which usually consists of polishing.

How to maximise eyeglass coating process flexibility (on plastic or other materials)

These are the most popular methods when it comes to plastic eyeglass coating: traditional approaches that have pros and cons, to be carefully assessed before starting up a finishing line. And then there's the Cefla Finishing approach, which has resulted in the development of an integrated solution that combines productivity, efficiency and precision.

On the Cefla-designed line, in fact, the various eyeglass components are attached to a rotating support. This is positioned underneath a series of spray guns, which coat them at high speed while any overspray is controlled and minimised using water filtration. The ability to configure the machines according to specific finishing requirements ensures coating is performed efficiently without having to program special trajectories.

All this takes place inside a pressurized, air-conditioned zone, ensuring the correct ambient conditions for the process in use. The system can also rapidly be adapted to different types of coatings. Moreover, simplified format changeover procedures guarantee greater flexibility.

By leveraging an integrated, fully automatic system, this approach improves energy/raw material management and delivers high-quality coating.

Which machines are used to coat eyeglasses? Building a high-performance line

The line designed by Cefla Finishing includes highly specialised machines. These are designed to simplify control of every step in the coating process, for eyeglasses or other objects of complex shape.

Let’s begin with iBotic, the one- or two-arm Cartesian spraying robot with interpolated axes that’s perfect for high output capacities and maximum quality. This machine stands out for its capacity to simultaneously process pieces of different shape and thickness, with the conveyor either at standstill or on the move, in tracking mode. Lastly, the passage in the oven features Aquadry technology, a combined in-line system that merges the effectiveness of high-speed hot air with the high radiant capacity of infra-red lamps. This is the most efficient acrylic coating drying method as it requires less time to evaporate the water contained in the coatings.

Cefla Finishing and tailor-made solutions to coat plastic eyeglasses and other items

The above is just one example of the potential of a dedicated metal and plastic eyeglass coating line. Thanks also to a vast selection of finishing solutions and a 3000 m2 lab facility where customers can engage in hands-on experimentation and development of customised equipment, Cefla Finishing is able to adapt each process technology to most of the market’s specific needs.

By leveraging a constantly-evolving machine range, it’s possible to use in-depth technological integration to optimise not just the coating of eyeglasses but also the finishing of wooden furnishing accessories, helmets, musical instruments, solar panels, car dashboards and ceramic slabs. In other words, the opportunities are practically limitless: all you need to do is contact one of our experts and come and see how the Cefla range can help you take your business to the next level!

LOOKING FOR THE IDEAL SOLUTION FOR YOUR COATING LINE?

The manufacturing world is currently investigating ways to decrease production costs and increase productivity. The integration of automation technologies has helped the industry gradually evolve over the past few decades, with the introduction of sensors and robotic technology reducing the number of human workers needed on production lines. A Moody's survey on the margins of 24 industrial giants with credit ratings of A or higher found that the average margin (before interest, taxes, depreciation and amortisation) had risen to 16.4% last year, up from 13.1% in 2013, a result achieved through targeted actions in the field of automation.

Today, however, the pace at which this transformation is occurring is accelerating, and radical changes in the way in which manufacturing plants operate are expected by the end of the decade. This is revealed by a McKinsey report. The consulting firm estimates that the industrial automation market will be globally worth 115 billion dollars (around 108 billion euro) by 2025, with a very fast growth in the segment of cloud-based software and industrial Internet of Things (IIoT)
platforms.  

What are production costs?

More specifically, what are the production processes that could be the targets of an industrial automation strategy aimed at reducing the spending? To understand how to reduce production costs, it is first of all necessary to clarify the difference between fixed costs and variable costs.

Fixed costs do not depend on production volumes - in other words, they remain constant regardless of the quantity produced and include, for example, the rent of facilities, the salaries of employees, utilities, insurance, taxes and so on.

Variable costs, on the other hand, rise and fall as a function of the production volume. In manufacturing, variable costs include raw materials, overtime, sales commissions, transportation, and the efficiency of production processes.

And it is precisely on this last aspect that we should focus in order to obtain the greatest benefits from the introduction of innovative technologies. 
We at Cefla Finishing are well aware of this, and this is why we continue to make the most of the experience gained in various segments of the manufacturing sector, in order to develop ultra-efficient finishing lines, chosen by companies world-wide to cut the costs related to some of the most delicate phases of the production process. You can find some real-life examples in our Case Studies.

THE MOST INNOVATIVE FINISHING SOLUTIONS
Discover how highly advanced finishing solutions can elevate your competitiveness.

Obviously, by investing in technology and innovation. Basically, there are four lines of action that we follow to help companies determine how to reduce production costs. Our solutions aim to:

• how to reduce production costs. 
• optimise production processes;
• reduce waste;
• increase the efficiency of the systems;
• encourage the introduction of innovative technologies that act as catalysts for these objectives.

Optimise production processes

Naturally, every company that is wondering how to cut production costs must evaluate its own specific needs: the automation process should be gradual and personalised, including, for example, the introduction of machinery that can help the transition from manual operations to entirely software-managed production cycles. The implementation of semi-automated processes, with lines that minimise labour requirements, is one of the ways to make such a radical change less impacting.

Our oscillating spray coater with one or two arms Prima EVO perfectly embodies this line of thinking: it can be used as a stand-alone machine, not requiring the installation of complex systems, and managed by one or two operators for manual loading and unloading of the work pieces. But it can also be easily integrated into complete and higher-output lines.

Reduce waste

A solution like Prima EVO also allows actions to be taken in other specific areas which are critically conducive to reducing variable costs. We are referring to improved control of the materials used, with a consequent reduction of waste, especially as far as lacquer is concerned: by optimising the amount of consumables necessary to complete finishing operations, this machine allows significant savings to be obtained as early as in the medium term, with a fast return on investment. To reduce energy costs, we suggest the adoption of low-consumption techniques applied to machinery such as our UV oven UV-R. It is a compact, versatile and efficient plug & play solution, which can be easily integrated into complex finishing lines, too.  

Increase system efficiency

Optimising production processes and reducing waste is of little use if the overall efficiency of the system cannot be improved. Precisely with this in mind, at the latest edition of the Ligna show in Hannover we launched a range of solutions that help companies to carry out colour changes without having to stop production. Managed by a special software and a system which controls the equipment’s mixing valves, colour changeover requires less than 30 seconds compared to the standard 2 to 3 minutes usually needed today.

In particular, the FCS (Fast Color Switch) system installed on our Easy spray coater aroused considerable interest: visitors discovered that, if standard work shifts and colour changes are considered, FCS is able to reduce downtime by at least 30 minutes per day. This translates into a productivity increase of 2-3 hours per week.

The advantages of technology and innovation

The real advantages of Industry 4.0 and 5.0, however, derive from the integration of these platforms into IoT ecosystems: our software and connectivity solutions allow to not only evaluate and enhance production performance but also work without having to stop any processes and even by receiving remote support in case of slowdowns or bottlenecks.

Leveraging this expertise, we have created a complete package of services – called for good reason Ubiquo – which combines applications for machine monitoring, technical service and consultancy, available both on site and remotely. A combination of solutions spanning the physical, digital and virtual worlds, designed to continuously maximise the productivity of Cefla lines wherever they are located.

A laboratory to experiment with and reduce production costs

For us, moving from theory to practice means asking our customers to experience these and many other solutions first-hand at our Cefla Finishing Lab: a proper technological hub where over one hundred Cefla Finishing machines can be seen in operation and entire processes and production lines can be created and tested, sharing experiences, business objectives and new opportunities to meet specific needs. And there's more: visiting our Cefla Finishing Lab also means having a chance to identify the most suitable configuration parameters for specific cases and calculating the ROI after the investments made to support 4.0- and 5.0-oriented process evolution. 

So what are you waiting for? If you are wondering how to cut the production costs of your manufacturing company, come and find out all about the ideal machinery and services for your business: you will be able to explore all the innovative features developed by Cefla Finishing, and evaluate and customise each solution with the help of experts.

LOOKING FOR THE IDEAL SOLUTION FOR YOUR COATING LINE?

UV technology and sustainability: a viable combination

UV technology is an innovative paint drying solution guaranteeing shorter drying times and greater energy efficiency. However, one of the main obstacles to the widespread adoption of this technology is the use of photoinitiators, which can be harmful to the environment and to human health. Fortunately, UV technology and sustainability can now be combined by minimising the use of photoinitiators.

UV drying can be made more sustainable by minimising the amount of photoinitiators used, as well as by decreasing energy consumption or reducing the use of mercury (present in UV lamps).

Thanks to UV technology, it is possible to obtain much faster drying times than traditional solvent-based or water-based drying systems, and it is for this reason that this solution is now increasingly popular.

Reduced photoinitiator use: environmental and health benefits

Reducing the use of photoinitiators implies a number of advantages for both the environment and human health. Photoinitiators are chemical compounds that can damage human health if inhaled or in contact with the skin. Additionally, once released into the environment, they can persist for a long time and cause pollution.

By using 100% UV paints with a reduced amount of photoinitiators, the risk of exposure to harmful substances is significantly reduced. This is particularly important for workers in the painting industry, who may be exposed to these substances on a daily basis. Reducing the amount of photoinitiators needed also contributes to preserving the environment, reducing pollution and the potential damage to ecosystems.

Innovation in UV drying: use of nitrogen

A major breakthrough in UV drying: use of nitrogen. Our UV-I oven allows nitrogen to be used to reduce the environmental impact. In this way we can reduce the amount of photoinitiators used, reduce the energy requirements of the cross-linking oven and minimise the impact of mercury by using fewer crosslinking lamps.

In each of the previously listed cases (or combinations of them), while reducing the amount of oxygen inside the oven, we are still able to guarantee perfect (and in some cases even superior) drying of the workpieces.

Future outlook: trends and developments in sustainable UV drying

Sustainable UV drying is a growing trend in the painting industry. Companies are increasingly aware of the importance of reducing their environmental impact and improving the health of their workers. Environmental regulations are becoming increasingly strict, encouraging companies to seek sustainable solutions for their paint-finishing processes.

In conclusion, UV-I drying is a valuable, eco-friendly solution for reducing mercury and photoinitiators requirements, improving environmental sustainability in the painting industry. Thanks to the use of nitrogen, it is possible to protect operators' health and safety with a lower impact on the environment.

Looking to future scenarios, further development of increasingly sustainable and high-quality UV drying technologies and materials is to be expected.

What are the strategies for industrial energy saving?

In general, lower energy consumption per unit of product can be obtained via three strategies. These can be applied individually or in combination. Again, according to the Confindustria Study Center, these respectively involve:

1. an increase in energy efficiency, with technology, plants and machines remaining equal
2. a sector-based reorganisation of production, towards sectors of lower energy intensity
3. a change in production technologies and/or plants and/or machinery.

On a purely practical level, manufacturing companies can generally reduce their energy consumption by, above all, adopting LED lighting in their plants, introducing high-efficiency motors and focusing on ‘smart’ energy management (e.g. by using their own photovoltaic and energy recovery systems).

More specifically, when it comes to finishing processes, it’s essential to access technologies and patents that allow manufacturers not only to reduce consumption but also stand out on international markets through the quality of their products and achieve ever-greater production flexibility. This is exactly what the Cefla Finishing range lets you do.

Industrial energy saving technologies and solutions

Automation and control

Low-temperature drying systems

Energy recovery systems

What are the benefits of industrial energy saving?

Why coat steel?

 

Industrial steel coating: types

Protective coatings used on steel can be divided by their surface film drying method or by function. The durability of on-steel coating depends on several factors. These include the design of the structure, preparation of the surface and, above all, the quality of the application and proper drying of the applied layer.

Steel coating can involve several different techniques. Liquid coating and powder coating are significantly different.

Powder Coating

In powder coating, the powder is applied to the substrate by way of an electrostatic charge. This technique subsequently involves a melting process in an oven: this allows the powder to fuse into a homogeneous layer and harden once cooled. Powder coating typically consists of a single layer.

Liquid coating

In liquid coating, polymerization can take place physically, simply through evaporation of the solvent or water (single-component coatings), or chemically, with the aid of a catalyst mixed with the coating resin to make it stronger (bi-component coatings). In both cases, coating curing temperatures are typically lower than those used in powder-based processes and less time is needed, resulting in energy savings for the company.

Liquid metal coatings generally consist of two layers: one that acts as a primer/corrosion inhibitor and the finishing layer that will be visible on the product. Compared to powder coating, liquid coating is generally easier to restore if damaged or if there are signs of corrosion.

Duplex systems

There are other methods. For example, ‘duplex systems’ involve hot-dip galvanizing followed by application of a coating film; this is a precise sequential procedure and is therefore less flexible from a production perspective.

Cefla Finishing steel coating solutions

How is industrial coating of steel performed?

Applying the coating

Drying and curing

Cefla Finishing and industrial steel coating: the CROMATICA case study

LOOKING FOR THE IDEAL SOLUTION FOR YOUR COATING LINE?

At first glance they might seem like simple objects, but they nevertheless require production processes that are anything but simple. Market operators engaged in the finishing of plastic objects know this only too well.

This article refers to manufacturing contexts, to those companies that make or finish the vases. It also refers to the many companies involved in processing three-dimensional objects that work within a wide range of sectors.

The best vase coating solution

To obtain objects with impeccable aesthetic and surface performance, nothing must be left to chance in the vase coating process. 

With years of experience in finishing, in numerous industries and with a broad range of materials, we’ve had the opportunity to test a wide range of solutions. Through this experience, we’ve now identified the most efficient, effective way of producing great, high-quality vase decoration while minimising the manual workload. 

This is spray coating: a finishing line technology that allows for customised use and configuration. 

Spray-coating: the perfect vase coating solution

Let's now look at the ‘made in Cefla’ spray-coating line set-up. One possible solution sees a line that includes a high-performance articulated robot, such as iGiotto. The vases in question are attached to rotating swivel pins that slide along a floor-mounted line.

The vase coating process

Stage 2: spraying

Customisation of finishing lines