More than just a perfect coating system
Our long-term partnership with the LPG storage cylinder manufacturer Merloni in Italy is one of our favorite examples of a collaboration that goes far beyond delivering the perfect powder coating system. This is the story of development and application of an innovative epoxy-polyester powder system that makes the difference in the balance of performance, economical and ecological goals.
Founded in 1954, Merloni pioneered LPG storage cylinder manufacturing with its automated vertical production process. As innovation continued, Merloni needed advanced coatings for their large storage tanks to match their core offerings’ toughness. Their goal was a coating system that withstands extreme outdoor conditions and maintains integrity over time. Producing both underground and above-ground tanks, Merloni faced unique challenges in surface performance and durability. Above-ground tanks require weather-resistant coatings, while underground tanks need enhanced corrosion protection for long-term reliability.
700 microns in a single layer
Merloni sought a coating that could achieve a thickness of over 500 microns to provide optimal protection, but also ensure that this thickness could be achieved in a single application to optimize production time and efficiency, while offering superior corrosion resistance, colour retention, and gloss durability. To meet these requirements, Merloni partnered with KANSAI HELIOS. Our technical expert team in Italy developed a high-performance epoxy gloss in the green colour tone desired by Merloni. In close cooperation, the original requirement was not only met but exceeded. The developed powder coating solution could be applied in a single layer to achieve up to 700 microns in thickness with no risk of detachment, providing the durability and protection needed.
While the epoxy solution worked perfectly for tanks that would be installed underground, tanks above ground required a different approach. Therefore, KANSAI HELIOS developed a Polyester powder version of the same Merloni glossy green. This time, the polyester coating was specifically designed for exterior application. The product not only protects the underlying epoxy layer from colour and gloss degradation but also enhances the tank’s weathering resistance, making it ideal for outdoor exposure.
To further enhance the performance and durability of the coatings, the solution incorporated a stock clearcoat in a glossy finish that could be applied as a two-layer system using the powder-on-powder approach. This coating system offers a highly efficient solution for applying two protective layers in a single oven cycle, reducing energy consumption and contributing to a sustainable production process.
Comprehensive support from coating to equipment setup
KANSAI HELIOS partnered with a leading spraying equipment producer to provide Merloni with the best tools and technology, optimizing their production process. This collaboration enabled tailored equipment and layout design for efficient Epoxy and Polyester coating application. The innovative spraying technology ensured high-quality results, transforming production capabilities and setting new standards for quality and efficiency.
Liquid coatings for Merloni on the horizon
Merloni’s collaboration with KANSAI HELIOS continues to grow, exploring liquid coating solutions for complex gas tank designs. Leveraging technical expertise, KANSAI HELIOS delivers powder and liquid solutions that meet Merloni’s performance and environmental standards. Our joint know-how “tank” is well filled and ready for further development in the future.