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Rohm & Haas powder coatings
F O C US demonstrated by its ready adaptation to powder coatings. This technology has effected significant reductions in both melting and curing temperatures. It is believed that much lower temperatures can be achieved and that supplementation with crosslinking agents will allow even more dramatic temperature reductions. Stability studies indicate that the particles possess a lengthy shelf life. The experience gained through the design of core-shell polymer particles for coatings, and the pliable nature of the particle, has motivated the team to examine other potential end use applications. They have successfully constructed a developing array of water-soluble core-shell polymer particles made of biodegradable molecules, and will pursue the targeting of cancer cells with tumour inhibiting compounds loaded into these particles. Article entitled “A Versatile Core-Shell Nanoparticle – A Solution to Coatings Challenges” by John Hartmann of ElizaNor Polymer LLC published in Paint & Coatings Industry, Oct 2003, 106-108
INDUSTRY NEWS Coating raw material suppliers struggle with costs Problems faced by the paints and coatings market during 2003 are discussed and include the rising cost of energy and raw materials combined with competition from Asia. BASF is retrofitting an existing manufacturing plant at Wyandotte, MI, US to produce high-quality, low-formaldehyde amino resins to sell under its Luwipal trade-name. Production is due to begin during 2Q 2004. During 2003 Dow Chemical merged its surfactants and polyglycols businesses. It will be known as Functional Solutions and Surfactants. New products introduced by the business 4
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include Tergitol L-Series ionic surfactants. During 2002 Ferro sold its European powder coatings operation to Rohm & Haas and its American powder coatings business to Akzo Nobel for a combined total of $160 M. North America has around 35 producers of powder coatings. Powder coatings are now being seen as commodity chemicals. Nubiola Pigments and Huber Engineered Materials are to provide sales, marketing and customer support for several nontoxic, anticorrosive, inhibitive products for coatings producers from 1 Jan 2004. Chemical Week, 19 Nov 2003, 165 (42)
Switzerland. Monopol acquires facade coatings activities from Vernicolor Swiss Monopol AG in Filisbach acquired the Swiss facade coatings activities (powder coatings, polyurethane and fluoropolymer coatings) from Valspar (Vernicolor) Corp AG. The product ranges of the companies complement each other. Monopol Colors is an established internationally-active family business and manufactures industrial coatings and anticorrosive paints.
C OAT I N G S a new production line for glycidyl methacrylate acrylic (GMA) powder coating resins plant at Vienna, Austria. The line can produce about 4 M lbs/year, and can be expanded as demand warrants. Reichhold previously only supplied GMA resins through its parent company Dainippon Ink and Chemicals (DIC). “Reichhold is now the largest producer of GMA in Europe and Reichhold/DIC is the only manufacturer with two plants in the world, allowing us to offer supply security to the automotive coatings market,” says Gary Krall, chairman and CEO of Reichhold. Demand for GMA resins is expected to grow “significantly” over the next decade, Krall says. GMA acrylic resins are used to produce high-durability powder coatings primarily for the automotive industry. Reichhold, Research Triangle Park, NC, USA. Tel: +1 919 990 7500. Website: http://www.reichhold.com
Eastman opened regional headquarters
German special effect pigments manufacturer Eckart will expand its range of aluminium, gold bronze and pearl lustre pigments with the construction of a Bonding Centre at the site in Velden. The advanced centre will ensure Eckart will be able to meet rising demand for bonded special effect pigments for powder coatings.
Eastman Chemical Company’s recently opened its newly constructed regional headquarters in Capelle aan den Ijssel, the Netherlands. The new facility near Rotterdam consolidates three Eastman offices, which were formerly located in The Hague and Rotterdam. Organizations occupying the new site include the company’s Europe, Middle East and Africa Customer Service Centre, shared Financial Service Centre as well as regional functions for human resources, information technology, sales and marketing. In total, about 170 Eastman employees representing some 18 different nationalities are working in the complex.
Farbe und Lack, Nov 2003, 109 (11), 71 (in German)
Coatings Flash, 1 Dec 2003. Website: http://www.coatings.de
Reichhold completes powder coating resins plant
Rohm & Haas powder coatings
Farbe und Lack, Nov 2003, 109 (11), 16 (in German)
Effect pigments. Eckart establishes pigment bonding centre
Reichhold says it has completed
Following the successful integration of Morton Powder DECEMBER 2003
F O C U S Coatings, Pulverlac, and the Ferro European powder business; Rohm & Haas Powder Coatings unveiled its new title at the recent Surface World 2003 Exhibition. The new company launched the ‘Pulverlac’ range of RAL colours for general industry and architectural use; ‘Corvel’ zinc rich primer; ‘Sparklite, a conductive powder coating, and the new enhanced anti-graffiti coating ‘Graffaway’. Surface World, Oct 2003, 14
MARKETS Assessing industrial coatings technologies There are many differences between solvent-borne, waterborne and powder coatings and their usefulness varies by situation. The technologies also continue to change. Bob McElroy of The Sherwin Williams Company conveys this message in an unbiased comparison that provides an up-to-date evaluation of the three major industrial coatings technologies. While many assume that solvent-borne coating systems are on the way out, it is still a fact that the $6.5 billion finishing market in North America is still largely dominated by solventborne finishes, despite the regulatory pressures to reduce VOC and HAP emissions. A new ultra-low-VOC polyester baking enamel containing VOC-exempt solvents that emit less than one pound of VOCs per gallon, will assist manufacturers to comply with regulations. There are further new technologies under development that are likely to halt the demise of this proven technology. This will bring some relief to finishers who have relied upon solvent-borne coatings for many years and have no desire to adopt new working practices. Regulations have restricted the use of many solvents classified as HAPs because they are DECEMBER 2003
O N
POWDER
considered to be toxic. These include xylol, toluol and MEK, while other solvents such as MAK and isopropanol are high in VOCs. Some solvents are not classified in either category but their use is limited by high evaporation rates. Solvent-borne coatings offer a wide range of choice to metal finishers in many fields and they also find applications in the coating of plastics and other types of manufactured products that cannot tolerate high temperature curing conditions. These finishes still set the industry standards for overall performance and high solids solvent-borne systems are sufficiently low in VOCs to satisfy current regulations. In the coating of large surfaces requiring a full gloss range of finishes with little or no orange peel, excellent colour, gloss retention and chemical resistance in exterior exposure, solvent-borne coatings offer a wider choice than alternative systems. In some situations the choice of water-borne finishes is a better alternative to solvent-borne finishes, particularly in high production facilities facing strict regulatory requirements and wherever finishers want to reduce fire risks and the costs of solvent clean up and disposal. Waterborne finishes offer quick and easy clean up with water. They can be formulated with very low VOCs and no HAPs. The use of resins designed for water-borne formulations is required and water takes the place of most organic solvents. Resins are chosen to determine the final properties of the coating system, and are usually synthetic polymers that may be dissolved in water or dispersed and stabilized by emulsifiers, or some combination of both. A number of drawbacks to the use of water-borne coatings have been overcome. These include longer drying times and poor adhesion to plastics. Water-borne acrylic latex coatings
C OAT I N G S can dry in as little as five minutes, while the problems of adhesion, due to different surface tensions, have been resolved by matching surface energy profiles of the coatings and substrates. The dry times of water-borne acrylic air-drying coatings are affected by relative humidity, and a temperature and humidity controlled environment is desirable. Optimal drying conditions occur at 30 to 70% relative humidity and good air movement is essential for proper drying. Water-borne acrylic latex enamels are quick setting, but they can be limited in their range of gloss levels, and substrates must be capable of exposure to baking temperatures in the range 130 to 180°F, a range that is below the deformation temperature of most plastics. Water-borne epoxies can offer chemical resistant and mechanical properties equal to or better than solvent-borne epoxies. They contain modified resins and additives to improve their resistance to corrosion and foaming during application. New water-borne epoxies containing emulsion polymers have overcome the problem of unreacted co-reactant in the paint film, and give coatings with high hardness and chemical resistance. They perform well in salt spray corrosion and resist synthetic cutting oils. Faster cure times, longer pot-life, improved resistance to yellowing and better gloss stability are other advantages. Water reducible polyurethane dispersions and polyurethane acrylic hybrids give good performance and ease of application. These finishes are tough and durable and require little or no heat to cure, although a drawback can be a lack of chemical resistance. They are often ideal for coating structural foam or injection moulded plastic, such as polycarbonate, acrylic, ABS and high impact polystyrene in applications for medical equipment and electronic enclosures. Water-borne finishes 5
INDUSTRY NEWS Coating raw material suppliers struggle with costs Problems faced by the paints and coatings market during 2003 are discussed and include the rising cost of energy and raw materials combined with competition from Asia. BASF is retrofitting an existing manufacturing plant at Wyandotte, MI, US to produce high-quality, low-formaldehyde amino resins to sell under its Luwipal trade-name. Production is due to begin during 2Q 2004. During 2003 Dow Chemical merged its surfactants and polyglycols businesses. It will be known as Functional Solutions and Surfactants. New products introduced by the business 4
O N
POWDER
include Tergitol L-Series ionic surfactants. During 2002 Ferro sold its European powder coatings operation to Rohm & Haas and its American powder coatings business to Akzo Nobel for a combined total of $160 M. North America has around 35 producers of powder coatings. Powder coatings are now being seen as commodity chemicals. Nubiola Pigments and Huber Engineered Materials are to provide sales, marketing and customer support for several nontoxic, anticorrosive, inhibitive products for coatings producers from 1 Jan 2004. Chemical Week, 19 Nov 2003, 165 (42)
Switzerland. Monopol acquires facade coatings activities from Vernicolor Swiss Monopol AG in Filisbach acquired the Swiss facade coatings activities (powder coatings, polyurethane and fluoropolymer coatings) from Valspar (Vernicolor) Corp AG. The product ranges of the companies complement each other. Monopol Colors is an established internationally-active family business and manufactures industrial coatings and anticorrosive paints.
C OAT I N G S a new production line for glycidyl methacrylate acrylic (GMA) powder coating resins plant at Vienna, Austria. The line can produce about 4 M lbs/year, and can be expanded as demand warrants. Reichhold previously only supplied GMA resins through its parent company Dainippon Ink and Chemicals (DIC). “Reichhold is now the largest producer of GMA in Europe and Reichhold/DIC is the only manufacturer with two plants in the world, allowing us to offer supply security to the automotive coatings market,” says Gary Krall, chairman and CEO of Reichhold. Demand for GMA resins is expected to grow “significantly” over the next decade, Krall says. GMA acrylic resins are used to produce high-durability powder coatings primarily for the automotive industry. Reichhold, Research Triangle Park, NC, USA. Tel: +1 919 990 7500. Website: http://www.reichhold.com
Eastman opened regional headquarters
German special effect pigments manufacturer Eckart will expand its range of aluminium, gold bronze and pearl lustre pigments with the construction of a Bonding Centre at the site in Velden. The advanced centre will ensure Eckart will be able to meet rising demand for bonded special effect pigments for powder coatings.
Eastman Chemical Company’s recently opened its newly constructed regional headquarters in Capelle aan den Ijssel, the Netherlands. The new facility near Rotterdam consolidates three Eastman offices, which were formerly located in The Hague and Rotterdam. Organizations occupying the new site include the company’s Europe, Middle East and Africa Customer Service Centre, shared Financial Service Centre as well as regional functions for human resources, information technology, sales and marketing. In total, about 170 Eastman employees representing some 18 different nationalities are working in the complex.
Farbe und Lack, Nov 2003, 109 (11), 71 (in German)
Coatings Flash, 1 Dec 2003. Website: http://www.coatings.de
Reichhold completes powder coating resins plant
Rohm & Haas powder coatings
Farbe und Lack, Nov 2003, 109 (11), 16 (in German)
Effect pigments. Eckart establishes pigment bonding centre
Reichhold says it has completed
Following the successful integration of Morton Powder DECEMBER 2003
F O C U S Coatings, Pulverlac, and the Ferro European powder business; Rohm & Haas Powder Coatings unveiled its new title at the recent Surface World 2003 Exhibition. The new company launched the ‘Pulverlac’ range of RAL colours for general industry and architectural use; ‘Corvel’ zinc rich primer; ‘Sparklite, a conductive powder coating, and the new enhanced anti-graffiti coating ‘Graffaway’. Surface World, Oct 2003, 14
MARKETS Assessing industrial coatings technologies There are many differences between solvent-borne, waterborne and powder coatings and their usefulness varies by situation. The technologies also continue to change. Bob McElroy of The Sherwin Williams Company conveys this message in an unbiased comparison that provides an up-to-date evaluation of the three major industrial coatings technologies. While many assume that solvent-borne coating systems are on the way out, it is still a fact that the $6.5 billion finishing market in North America is still largely dominated by solventborne finishes, despite the regulatory pressures to reduce VOC and HAP emissions. A new ultra-low-VOC polyester baking enamel containing VOC-exempt solvents that emit less than one pound of VOCs per gallon, will assist manufacturers to comply with regulations. There are further new technologies under development that are likely to halt the demise of this proven technology. This will bring some relief to finishers who have relied upon solvent-borne coatings for many years and have no desire to adopt new working practices. Regulations have restricted the use of many solvents classified as HAPs because they are DECEMBER 2003
O N
POWDER
considered to be toxic. These include xylol, toluol and MEK, while other solvents such as MAK and isopropanol are high in VOCs. Some solvents are not classified in either category but their use is limited by high evaporation rates. Solvent-borne coatings offer a wide range of choice to metal finishers in many fields and they also find applications in the coating of plastics and other types of manufactured products that cannot tolerate high temperature curing conditions. These finishes still set the industry standards for overall performance and high solids solvent-borne systems are sufficiently low in VOCs to satisfy current regulations. In the coating of large surfaces requiring a full gloss range of finishes with little or no orange peel, excellent colour, gloss retention and chemical resistance in exterior exposure, solvent-borne coatings offer a wider choice than alternative systems. In some situations the choice of water-borne finishes is a better alternative to solvent-borne finishes, particularly in high production facilities facing strict regulatory requirements and wherever finishers want to reduce fire risks and the costs of solvent clean up and disposal. Waterborne finishes offer quick and easy clean up with water. They can be formulated with very low VOCs and no HAPs. The use of resins designed for water-borne formulations is required and water takes the place of most organic solvents. Resins are chosen to determine the final properties of the coating system, and are usually synthetic polymers that may be dissolved in water or dispersed and stabilized by emulsifiers, or some combination of both. A number of drawbacks to the use of water-borne coatings have been overcome. These include longer drying times and poor adhesion to plastics. Water-borne acrylic latex coatings
C OAT I N G S can dry in as little as five minutes, while the problems of adhesion, due to different surface tensions, have been resolved by matching surface energy profiles of the coatings and substrates. The dry times of water-borne acrylic air-drying coatings are affected by relative humidity, and a temperature and humidity controlled environment is desirable. Optimal drying conditions occur at 30 to 70% relative humidity and good air movement is essential for proper drying. Water-borne acrylic latex enamels are quick setting, but they can be limited in their range of gloss levels, and substrates must be capable of exposure to baking temperatures in the range 130 to 180°F, a range that is below the deformation temperature of most plastics. Water-borne epoxies can offer chemical resistant and mechanical properties equal to or better than solvent-borne epoxies. They contain modified resins and additives to improve their resistance to corrosion and foaming during application. New water-borne epoxies containing emulsion polymers have overcome the problem of unreacted co-reactant in the paint film, and give coatings with high hardness and chemical resistance. They perform well in salt spray corrosion and resist synthetic cutting oils. Faster cure times, longer pot-life, improved resistance to yellowing and better gloss stability are other advantages. Water reducible polyurethane dispersions and polyurethane acrylic hybrids give good performance and ease of application. These finishes are tough and durable and require little or no heat to cure, although a drawback can be a lack of chemical resistance. They are often ideal for coating structural foam or injection moulded plastic, such as polycarbonate, acrylic, ABS and high impact polystyrene in applications for medical equipment and electronic enclosures. Water-borne finishes 5