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Functional fillers for powder coatings
FOCUS increased output per employee, and really significant reductions in energy costs are now genuine incentives to invest, for energy costs are not going to diminish in the foreseeable future. If I had a conventional thermosetting industrial coating line and operated as a job coater, then I would take advantage of the current bank borrowing facilities and invest in UV cure. The capital cost would be recovered within the first year, with higher levels of profitability. Unless trade coaters move with the times they will not survive in this postrecession business climate, which promises to be tough going for the traditionalist coater. I strongly believe in the future commercial prospects for powder coatings because they will always be less costly than wet paint industrial processes, and in many applications they will offer better film performance. Two major European powder producers appear to support my views. AkzoNobel believes that the main driver will be even stricter environmental legislation, supported by the positive issues of waste and energy savings. The research activities of major producers like AkzoNobel have provided the competitive edge and the capability to meet the special requirements of customers. Powder Coatings was the best performer in AkzoNobel’s performance coatings division in the first nine months of 2010 with a 36% rise in sales to $786 M but a significant part of this increase was due to the acquisition of the former Rohm and Haas powder coatings division of Dow Chemical. Nevertheless, if this contribution is discounted, the sales rise still amounted to 18% in the third quarter. While sales in Western Europe have only partially recovered, AkzoNobel has reported strong growth in powder coating sales in Eastern Europe with production growth at its
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plants in Russia, Turkey and the Czech Republic. The other progressive European producer of powder coatings, Jotun, confirms the growth of powder coating sales in Eastern Europe. Its sales policy is directed to expansion in the higher value markets with the development of low temperature curing powders for wood and plastic segments. Marketing products with the capability to cure at temperatures as low as 120°C without detriment to the aesthetic, mechanical and chemical resistance qualities are proving to be an attractive alternative to the use of laminates on MDF board. The future looks bright. Sid Harris
TECHNICAL Functional fillers for powder coatings A recent article describing the use of functional fillers in clear wood coatings has prompted this wider assessment of the beneficial effect that correct choice of filler, the particle size distribution and the percentage used, can impart in terms of improved film quality and genuine savings in the cost of high performance powder coatings. The article in question features the use of micronized nepheline syenite as an alternative to the much vaunted and high cost nano sized fillers. Nepheline is a naturally occurring filler with the following composition, 3(Na2O.K2O)4Al2O3.9SiO2, although this can vary slightly from source to source. The important qualities are very low opacity and extremely high Mohr hardness. It is commercially available in Europe from Sibelco and the article describes two grades, NS 10 and NS 12 with D50 average sizes of 2.1μm and 1.5μm respectively.
C O AT I N G S Opacity develops in a clear coating system when the filler has a high refractive index compared to that of the binder, promoting light scattering with the consequential milky visual effect. In the case of nano particles the scattering effect is greatly diminished. Poor wetting and air entrapment at the filler surface can also refract light; so smooth particles with low oil absorption are the most suitable grades for reduced opacity. Clarity in a clear coating is most important and this was determined by measuring the L* lightness value of the coating over the black portion of a Leneta sheet. The difference between this reading and the reading for an uncoated sheet was used as a measure of clarity with the smaller the difference indicating better film clarity. Both of the grades of nepheline had little effect upon film clarity but nano silica and nano alumina caused severe and moderate loss of clarity respectively. While gloss is less important than clarity, it is an aesthetic feature of clear coatings. In powder coating clear films, for example, the type of filler does not have a significant effect in adjusting the degree of gloss. Nano particles have variable effects on gloss levels. Nano alumina shows little or no effect on gloss reduction, while nano silica is a very effective matting agent. The effect shown by the two nepheline grades is comparable to that of the nano alumina and can be used in high gloss clear films. Incorporation of nepheline into clear wood coatings is an effective component in reducing blocking, or surface-to-surface adhesion when coated wooden panels are stacked, to avoid both sticking and marking of the film when separated. Nano alumina is reported in this article to cause a significant increase in blocking. The article makes a very good case for selection of micro-sized
MARCH 2011
FOCUS grades of fillers in clear coatings and it would seem the choice of filler could be equally effective in achieving the benefits that are claimed for nano materials. The author’s claims are completely in accordance with my own experiences in the formulation of powder coatings for wooden substrates, particularly the UV curable systems that are primarily based on semicrystalline polymers, which are characterized by greater film clarity, smoother surfaces and thinner films. I have found that certain grades of nepheline, incorporated at up to 20% of the total film loading, do not adversely affect gloss or clarity of the cured films. This clarity allows a significant reduction in the amount of expensive photoinitiator and because of the very low opacity of these fillers, pigmented powder coatings for wooden substrates can be formulated with lower amounts of the expensive organic colourants. Abrasion resistance at these levels of filler are found to be excellent. Article entitled “Functional Fillers for Clear Wood Coatings – Is Nano Necessary?” by Simon Bussell of Sibelco Europe published in PPCJ, Dec 2010, 200 (4555), 26-28
INDUSTRY NEWS Ferro unveils new tile coatings capacity Ferro Corp has finalized its acquisition of a newly built ceramic coatings facility in Fayoum, Egypt from principals of Pharaohs Ceramic Group. The facility will allow Ferro to more cost-effectively meet the needs of the expanding tile production markets in Egypt and other Middle East and North African countries. Ferro plans to outfit the Fayoum site with new equipment to raise capacity. The company expects the facility to have output MARCH 2011
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capacity of 200 M lbs for tile frit and glazes, after the initial expansion is completed. Ferro Tile Coating Systems is known globally for its tile design and technical skills and as a major distributor of decoration materials, including frits, fluxes, colours, glazes and inks for ceramic tile production. Asian Ceramics, Dec/Jan 2011, 18 (Website: http://www.asianceramics.com/)
Asian Paints to accelerate growth of its non-decorative coatings business On 24 Jan 2011, the Board of Asian Paints Ltd (APL) approved plans to enhance its fourteen year old relationship with PPG Industries Inc (PPG), one of the world’s leading coatings and speciality products companies, to accelerate growth of the nondecorative coatings businesses in India. As part of this arrangement, APL and PPG will enhance their existing non-decorative coatings presence in India by expanding their current 50-50 joint venture relationship, Asian PPG Industries Ltd (APPG), and also establish a second 50-50 joint venture. The modalities are being worked on. The arrangement is subject to regulatory approvals and it is expected to be completed during 2011. APPG currently services the Indian transportation coatings markets and this change will expand its scope to additionally service the industrial liquid, marine and consumer packaging markets. The proposed second joint venture will service the protective, industrial powder, industrial containers and light industrial coatings markets. “With PPG, we have had a successful collaboration and together, we will be able to take advantage of the rapidly developing Indian economy and serve all customers for nondecorative coatings in the Indian market,” said P M Murty, Managing Director and CEO, Asian Paints Ltd. He further
C O AT I N G S added that “Through this new approach, we will accelerate growth by leveraging PPG’s technology and global customer relationships while continuing to build on Asian Paints’ customer base, manufacturing footprint, distribution channels and local relationships.” APL and PPG have agreed that APL will take the lead in the second venture and PPG will take the lead in APPG in order to utilize their respective strengths to best capture the growth in infrastructure development and globally driven markets in India Press release from: Asian Paints Ltd, Asian Paints House, 6A Shantinagar, Santacruz (E), Mumbai 400 055, India, tel: +91 022 3981 8000, fax: +91 022 3981 8888, website: http://www.asianpaints.com/ (24 Jan 2011)
Asian Paints consolidated sales for the quarter increase by 29.6% For its 3Q 2010 (period ends 31 Dec 2010), Asian Paints Ltd has reported consolidated net sales of Rupees 2099.6 crores (+29.6% on its 3Q 2009), PBDIT of Rupees 344.9 crores (+8.5%), and net profit of Rupees 220.3 crores (+11%). For the first nine months of its fiscal 2010, the company has reported consolidated net sales of Rupees 5740.6 crores (+19.5% on its 3Q 200(), PBDIT of Rupees 1023.5 crores (+11.7%), and net profit of Rupees 657.2 crores (Rupees 643.1 crores). Asian Paints is India’s largest paint company and ranked among the top ten decorative coatings companies in the world with a turnover of Rupees 66.81 bn. Asian Paints along with its subsidiaries has operations in 17 countries across the world with 23 paint manufacturing facilities, servicing consumers in 65 countries through Berger International, SCIB Paints – Egypt, Asian Paints, Apco Coatings and Taubmans. Asian Paints Results 3Q 2010, 28 Jan 2011, 1-2 (Asian Paints Ltd, Asian Paints House, 6A Shanti Nagar, Vakola Pipeline, Santacruz (E), Mumbai 400055, India, tel: +91 22 398 18600, fax: +91 22 398 18805, website: http://www.asianpaints.com)
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plants in Russia, Turkey and the Czech Republic. The other progressive European producer of powder coatings, Jotun, confirms the growth of powder coating sales in Eastern Europe. Its sales policy is directed to expansion in the higher value markets with the development of low temperature curing powders for wood and plastic segments. Marketing products with the capability to cure at temperatures as low as 120°C without detriment to the aesthetic, mechanical and chemical resistance qualities are proving to be an attractive alternative to the use of laminates on MDF board. The future looks bright. Sid Harris
TECHNICAL Functional fillers for powder coatings A recent article describing the use of functional fillers in clear wood coatings has prompted this wider assessment of the beneficial effect that correct choice of filler, the particle size distribution and the percentage used, can impart in terms of improved film quality and genuine savings in the cost of high performance powder coatings. The article in question features the use of micronized nepheline syenite as an alternative to the much vaunted and high cost nano sized fillers. Nepheline is a naturally occurring filler with the following composition, 3(Na2O.K2O)4Al2O3.9SiO2, although this can vary slightly from source to source. The important qualities are very low opacity and extremely high Mohr hardness. It is commercially available in Europe from Sibelco and the article describes two grades, NS 10 and NS 12 with D50 average sizes of 2.1μm and 1.5μm respectively.
C O AT I N G S Opacity develops in a clear coating system when the filler has a high refractive index compared to that of the binder, promoting light scattering with the consequential milky visual effect. In the case of nano particles the scattering effect is greatly diminished. Poor wetting and air entrapment at the filler surface can also refract light; so smooth particles with low oil absorption are the most suitable grades for reduced opacity. Clarity in a clear coating is most important and this was determined by measuring the L* lightness value of the coating over the black portion of a Leneta sheet. The difference between this reading and the reading for an uncoated sheet was used as a measure of clarity with the smaller the difference indicating better film clarity. Both of the grades of nepheline had little effect upon film clarity but nano silica and nano alumina caused severe and moderate loss of clarity respectively. While gloss is less important than clarity, it is an aesthetic feature of clear coatings. In powder coating clear films, for example, the type of filler does not have a significant effect in adjusting the degree of gloss. Nano particles have variable effects on gloss levels. Nano alumina shows little or no effect on gloss reduction, while nano silica is a very effective matting agent. The effect shown by the two nepheline grades is comparable to that of the nano alumina and can be used in high gloss clear films. Incorporation of nepheline into clear wood coatings is an effective component in reducing blocking, or surface-to-surface adhesion when coated wooden panels are stacked, to avoid both sticking and marking of the film when separated. Nano alumina is reported in this article to cause a significant increase in blocking. The article makes a very good case for selection of micro-sized
MARCH 2011
FOCUS grades of fillers in clear coatings and it would seem the choice of filler could be equally effective in achieving the benefits that are claimed for nano materials. The author’s claims are completely in accordance with my own experiences in the formulation of powder coatings for wooden substrates, particularly the UV curable systems that are primarily based on semicrystalline polymers, which are characterized by greater film clarity, smoother surfaces and thinner films. I have found that certain grades of nepheline, incorporated at up to 20% of the total film loading, do not adversely affect gloss or clarity of the cured films. This clarity allows a significant reduction in the amount of expensive photoinitiator and because of the very low opacity of these fillers, pigmented powder coatings for wooden substrates can be formulated with lower amounts of the expensive organic colourants. Abrasion resistance at these levels of filler are found to be excellent. Article entitled “Functional Fillers for Clear Wood Coatings – Is Nano Necessary?” by Simon Bussell of Sibelco Europe published in PPCJ, Dec 2010, 200 (4555), 26-28
INDUSTRY NEWS Ferro unveils new tile coatings capacity Ferro Corp has finalized its acquisition of a newly built ceramic coatings facility in Fayoum, Egypt from principals of Pharaohs Ceramic Group. The facility will allow Ferro to more cost-effectively meet the needs of the expanding tile production markets in Egypt and other Middle East and North African countries. Ferro plans to outfit the Fayoum site with new equipment to raise capacity. The company expects the facility to have output MARCH 2011
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POWDER
capacity of 200 M lbs for tile frit and glazes, after the initial expansion is completed. Ferro Tile Coating Systems is known globally for its tile design and technical skills and as a major distributor of decoration materials, including frits, fluxes, colours, glazes and inks for ceramic tile production. Asian Ceramics, Dec/Jan 2011, 18 (Website: http://www.asianceramics.com/)
Asian Paints to accelerate growth of its non-decorative coatings business On 24 Jan 2011, the Board of Asian Paints Ltd (APL) approved plans to enhance its fourteen year old relationship with PPG Industries Inc (PPG), one of the world’s leading coatings and speciality products companies, to accelerate growth of the nondecorative coatings businesses in India. As part of this arrangement, APL and PPG will enhance their existing non-decorative coatings presence in India by expanding their current 50-50 joint venture relationship, Asian PPG Industries Ltd (APPG), and also establish a second 50-50 joint venture. The modalities are being worked on. The arrangement is subject to regulatory approvals and it is expected to be completed during 2011. APPG currently services the Indian transportation coatings markets and this change will expand its scope to additionally service the industrial liquid, marine and consumer packaging markets. The proposed second joint venture will service the protective, industrial powder, industrial containers and light industrial coatings markets. “With PPG, we have had a successful collaboration and together, we will be able to take advantage of the rapidly developing Indian economy and serve all customers for nondecorative coatings in the Indian market,” said P M Murty, Managing Director and CEO, Asian Paints Ltd. He further
C O AT I N G S added that “Through this new approach, we will accelerate growth by leveraging PPG’s technology and global customer relationships while continuing to build on Asian Paints’ customer base, manufacturing footprint, distribution channels and local relationships.” APL and PPG have agreed that APL will take the lead in the second venture and PPG will take the lead in APPG in order to utilize their respective strengths to best capture the growth in infrastructure development and globally driven markets in India Press release from: Asian Paints Ltd, Asian Paints House, 6A Shantinagar, Santacruz (E), Mumbai 400 055, India, tel: +91 022 3981 8000, fax: +91 022 3981 8888, website: http://www.asianpaints.com/ (24 Jan 2011)
Asian Paints consolidated sales for the quarter increase by 29.6% For its 3Q 2010 (period ends 31 Dec 2010), Asian Paints Ltd has reported consolidated net sales of Rupees 2099.6 crores (+29.6% on its 3Q 2009), PBDIT of Rupees 344.9 crores (+8.5%), and net profit of Rupees 220.3 crores (+11%). For the first nine months of its fiscal 2010, the company has reported consolidated net sales of Rupees 5740.6 crores (+19.5% on its 3Q 200(), PBDIT of Rupees 1023.5 crores (+11.7%), and net profit of Rupees 657.2 crores (Rupees 643.1 crores). Asian Paints is India’s largest paint company and ranked among the top ten decorative coatings companies in the world with a turnover of Rupees 66.81 bn. Asian Paints along with its subsidiaries has operations in 17 countries across the world with 23 paint manufacturing facilities, servicing consumers in 65 countries through Berger International, SCIB Paints – Egypt, Asian Paints, Apco Coatings and Taubmans. Asian Paints Results 3Q 2010, 28 Jan 2011, 1-2 (Asian Paints Ltd, Asian Paints House, 6A Shanti Nagar, Vakola Pipeline, Santacruz (E), Mumbai 400055, India, tel: +91 22 398 18600, fax: +91 22 398 18805, website: http://www.asianpaints.com)
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