Antonio Merloni Pressure Vessels S.r.l. is a leading manufacturer specializing in cylinders and tanks for LPG (liquefied petroleum gas) storage. Serving over 1,200 customers across 48 countries, with two production sites located in Matelica and Sassoferrato, Italy, Antonio Merloni is recognized as one of the largest pressure vessel manufacturers in Europe.
Modernizing Production with Advanced Powder Coating Technology
In 2020, under the new leadership of Paolo Sparvoli and with the technical support of a PPG team based in Verbania, Antonio Merloni Pressure Vessels initiated a comprehensive plant renewal and modernization program.
A key focus of this program was transitioning from traditional liquid coatings to advanced powder coatings for their painting lines, applied to both above-ground and underground LPG tanks. These tanks range in capacity from 800 to 1,200 mm (31 to 47 inches) in diameter and can reach heights of up to 3 meters (9.8 feet).
To support this transition, Antonio Merloni invested in a fully automated chain painting system. This system enhances finish quality by enabling precise data control throughout the production flow, ensuring consistent application and superior coating performance.
Achieving a stable production flow in a large new coating plant requires time. Initial challenges can stem from both the plant’s operational conditions and the characteristics of the powder itself. To address these, PPG’s R&D powder coating laboratory conducted extensive testing to finalize product formulas that ensure optimal protection against environmental aggressors such as moisture, UV radiation and chemical exposure.
The Critical Role of Corrosion Protection in Pressure Vessel Safety
Corrosion protection is a vital safety consideration in the manufacturing of pressure vessels. Stringent industry standards mandate that the final tank finish must resist both soil and atmospheric corrosion to maintain structural integrity over time.
Both the sheet metal and the vessel structure welding provide resistance to pressure, but the tank must also resist corrosion to prevent metal thickness degrading and avoid compromising safety, and this is where the finishing makes a difference.
Valeria Tassotti, Technical Manager at Antonio Merloni Pressure Vessels, emphasizes, “Corrosion reduces the thickness of the sheet metal, weakening its ability to withstand pressure. Proper corrosion protection ensures the tank operates safely as designed throughout its service life.”
Upgrading Protection and Environmental Performance with Powder Coatings
For optimal protection of the above-ground LPG tanks, Antonio Merloni employs a double-coat system consisting of a PPG primer specifically formulated without zinc and a white polyester topcoat certified to Qualicoat Class 1 standards. This combination offers robust resistance to environmental factors such as UV exposure, rain and temperature fluctuations.
Underground tanks receive a single coat of PPG green epoxy powder coating with a thickness of 500 microns (µm), providing enhanced protection against soil moisture and corrosive elements.
The fully automated powder coating facility at the Matelica plant was inaugurated in spring 2022. Currently, Antonio Merloni Pressure Vessels produces over 40,000 tanks annually, with approximately 30,000 coated using PPG powder coatings.
Sustainability and Operational Benefits
The switch to PPG powder coatings has enabled Antonio Merloni Pressure Vessels to meet key objectives related to sustainability, productivity and quality. Powder coatings contribute to environmental sustainability by significantly reducing volatile organic compound (VOC) emissions compared to traditional liquid paints, lowering the plant’s overall environmental footprint.
Additionally, the powder coating process improves worker well-being by minimizing exposure to hazardous chemicals and enhancing workplace safety. The automated system also increases production efficiency and coating consistency, resulting in higher-quality, corrosion-resistant tanks that ensure long-term safety for end users.