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Wood effect powder coatings
F O C U S to act as distributor of Oxyplast for its range of powder coatings. In-house distribution of company products is a difficult operation, particularly in those areas that are remote from the manufacturing base and it is good commercial sense to utilise the services of companies who are familiar with those areas. I expect to see a greater use of such services in the highly competitive future growth of powder coatings. The growth of additives business in China is reported and a number of the major European suppliers are locating subsidiaries in mainland China. A cautionary note can be found on the internet, where a number of Chinese companies are now offering a wide range of low cost additives based on their equivalents to western products. The whole range of powder coating additives can now be supplied by Chinese duplicated technology. The Chinese have already captured a major part of the powder coatings production machinery market with competent low cost equivalents to the established European and US producers. The future of the Western coatings industries is dependent upon the continual improvement of products and processes and there are still sufficient technical barriers to be overcome, which will sustain the enthusiasm of formulators. Their efforts could provide the profitability to enable the industry to survive, and maintain the lead in the quality and performance of coatings. Sid Harris
TECHNICAL Wood effect powder coatings Wood effect powder coatings have seen growth over the years, particularly in Europe, as a real alternative to typical architectural materials such as wood, marble
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and granite. The powder coated finish provides the high weathering performance of aluminium coupled with the decorative effect of real wood. Decorative wood effects available from Rohm & Haas, Powder Coatings division, can be achieved in three ways: Sublichromy, Naturall, and Effecta. The Sublichromy Process produces a wood effect pattern onto aluminium profiles using a transferable media coated with special inks in a three-step process. When placed under a combination of heat and low pressure, the pattern is transferred onto a surface that has previously been coated with a specially formulated powder coating. The procedure for Sublichromy is: substrate pretreatment, basecoat powder application, and sublimation process. The pretreatment process is the key to ensuring that the initial powder coating layer achieves good adhesion to the surface and ensures good corrosion resistance. Pretreatments can include: hexavalent chrome systems and the more environmentally friendly, trivalent and chrome-free methods. A Qualicoat approved polyurethane, polyester/TGIC or polyester/TGIC free powder coating is applied to the substrate at a coating thickness of up to 60µm and then cured at 180°C to 200°C for approximately 20 minutes. This provides the base for the transfer of the ink design onto the surface in the next stage. In the sublimation process the coated aluminium profile is wrapped into a bag that has the transfer ink coated on one side and this is sealed at one end and along the topside. A vacuum is applied to the open end of the bag and the transfer ink is pulled into contact with the powder base coat. Sublimation, or ink transfer occurs in the oven at 150°C to 160°C, after which the bag is
C O AT I N G S removed and the profile is allowed to cool. There are several ways of assessing the quality of the process. One technique is to verify the degree of ink penetration into the powder coated base layer. This test can be performed using a metallographic microscope and inspecting the cross-section of a coated profile. It monitors the amount of ink that has penetrated into and through the base powder coating and good penetration improves the final performance of the coated product. Coating glass plates and inspecting the reverse side of the glass plate to determine the penetration of the transfer ink through the base coat is another method of visually inspecting ink penetration through the base coat. In order to achieve a high quality decorative finish, the base coat must have low opacity and conversion marks from the pretreatment should not be visible through the base coating. Film thickness should be even since a variable thickness will alter the hiding effect of the base coat and alter the appearance due to the uneven distribution of the ink through the film. Curing parameters of the basecoat should be strictly adhered to, and the transfer process must be performed in accordance with the manufacturers instructions. Basecoats that are the same colour, but formulated with powders of different chemical composition, will have similar weathering performance but may show different solvent resistant properties. The Naturall process is also known as the powder-on-powder coating system as it is a fivestage process using two applications of powder coatings. This is a patented process to obtain a wood effect finish on aluminium profiles and can be achieved by using TGIC-free polyester powder coatings. The first stage is surface pretreatment
MARCH 2006
F O C U S as previously described. This is followed by the first layer of base coat powder coating applied at 60 – 80µm film thickness. The next stage is a melting process at 100° to 120°C, followed by a second layer powder application – a flash coating of less than 10µm applied through a patterned silk screen. Process is concluded with a curing cycle of 180 to 200°C for twenty minutes. After the final curing process, the patterned second layer of powder has penetrated into the base coat, creating a compact and uniform layer of at least 60µm thickness. The final result is a powder-on-powder film with the look and feel of wood and high performance outdoor weathering characteristics. The most important advantage of the Naturall process compared to the Sublichromy system is the absence of ink. The Effecta process produces a wood effect finish on aluminium profiles using a specially designed roller application technique. The sequence is as follows: substrate pretreatment; first powder coatings application at 60 to 80µm; a melting process at 100° to 120°C; a second powder coating application; decorative effect applied using a special roller; melting process at 100° to 120°C; third application of powder coating if desired; use of special roller to obtain decorative effect if desired; and finally a curing process at 180° to 200°C for 35 minutes. After the curing process the second and third layers penetrate into the base coat giving a surface that has the look and feel of wood with outstanding weatherability and outdoor performance characteristics. Again the absence of the ink stage is a cost advantage. Article entitled “Finishing Touch – The Latest Powder Coatings Combine Function and Fashion to Offer End Users the Best of Both Worlds” by Eugenio Gomez, Rohm & Haas Powder Coatings, Castellon, Spain, published in Metal Finishing, Dec 2005, 103 (12), 3740
MARCH 2006
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POWDER
INDUSTRY NEWS New powder paint covers edges evenly The V-PET EC series is a new line of powder paint developed by Dai Nippon Toryo that offers improved rust resistance on end surfaces. The new paint provides a solution to the challenge of creating an even coating and appearance when covering the cut edges of steel plates and other substrates. It has been produced by optimizing the composition of a primary ingredient, pigments and additives, and regulating the curing speed during baking. The company is looking to develop markets for products ranging from road and construction materials, to distribution panels, dispenser, car parts, exhaust fans, space heaters, freezers and fuel tanks.
C O AT I N G S Investments has already made a bid worth A$ 3.25 /share (worth A$ 266 M in total) on Wattyl but AEP is unhappy with Wattyl’s management. Barloworld’s bid is worth A$ 3.8 /share (A$ 321 M in total). Ernst and Young has valued Wattyl at A$ 3.25-4.21 /share. However Barloworld’s offer raises problems of competition on the Australian market on which it already has a 7-9% share. Wattyl has a 17-19% share of the market. The market leader Orica has a 22-25% share. Akzo Nobel, which controls 3-6% of the Australian market might also be interested in acquiring Wattyl. By 2010 the value of the Australian paints market is expected to reach A$ 2.2 bn (compared with A$ 1.9 bn at present). Although Wattyl’s turnover fell from A$ 548 M to A$ 472 M between 20032005, in 2005 it made a return to profits after 2 years of making a loss. Chimie Pharma Hebdo, 20 Feb 2006, (330), 10 (in French)
Japan Chemical Week, 9 Feb 2006, 47 (2354), 2
Neopentyl glycol in short supply Bejing Red Lion buys back equity On 16 Jan 2006 Beijing Red Lion Coatings Co Ltd was permitted by Shanghai Fenghua (Group) Co Ltd to complete its RMB Yuan 96.76 M relocation plan. The company will also be permitted to buy back 25% equity currently held by Akzo-Nobel International Coatings Co Ltd in Red Lion Coatings International Co Ltd. China Chemical Reporter, 6/16 Feb 2006, 17 (4/5), 9
Paints: Barloworld aiming to become leading producer in Australia S African paints producer Barloworld is to launch a takeover bid on Wattyl, the second largest company on the Australian market. Barloworld may be seen as a white knight by Wattyl. Investment fund AEP Financial
In China, neopentyl glycol (NPG) capacity totals 57,000 tonne/y, and there are four major producers: BASF JCIC Neopentyl Glycol Co Ltd (25,000 tonne /y); Shandong Linzi Yongliu Chemical Industry Co Ltd (20,000 tonne/y); Shandong Dongying Dongchen Group Co Ltd (10,000 tonne/y) and Shandong Guanghe Fine Chemical Co Ltd (5000 tonne/y). In 2006, Shandong Guanghe intends to raise capacity to 10,000 tonne/y. NPG output rose by 55.6% to 28,000 tonnes in 2004, and consumption increased by 10.8% to 57,000 tonnes. Imports rose by 3.6% to 29,000 tonnes. A graph shows output, consumption and import data for NPG in China, 2001-2004 inclusive. By 2008, Chinese NPG demand is expected to rise to 90,000 tonne/y. The main end uses for NPG include applications in the automotive, textile,
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TECHNICAL Wood effect powder coatings Wood effect powder coatings have seen growth over the years, particularly in Europe, as a real alternative to typical architectural materials such as wood, marble
2
ON
POWDER
and granite. The powder coated finish provides the high weathering performance of aluminium coupled with the decorative effect of real wood. Decorative wood effects available from Rohm & Haas, Powder Coatings division, can be achieved in three ways: Sublichromy, Naturall, and Effecta. The Sublichromy Process produces a wood effect pattern onto aluminium profiles using a transferable media coated with special inks in a three-step process. When placed under a combination of heat and low pressure, the pattern is transferred onto a surface that has previously been coated with a specially formulated powder coating. The procedure for Sublichromy is: substrate pretreatment, basecoat powder application, and sublimation process. The pretreatment process is the key to ensuring that the initial powder coating layer achieves good adhesion to the surface and ensures good corrosion resistance. Pretreatments can include: hexavalent chrome systems and the more environmentally friendly, trivalent and chrome-free methods. A Qualicoat approved polyurethane, polyester/TGIC or polyester/TGIC free powder coating is applied to the substrate at a coating thickness of up to 60µm and then cured at 180°C to 200°C for approximately 20 minutes. This provides the base for the transfer of the ink design onto the surface in the next stage. In the sublimation process the coated aluminium profile is wrapped into a bag that has the transfer ink coated on one side and this is sealed at one end and along the topside. A vacuum is applied to the open end of the bag and the transfer ink is pulled into contact with the powder base coat. Sublimation, or ink transfer occurs in the oven at 150°C to 160°C, after which the bag is
C O AT I N G S removed and the profile is allowed to cool. There are several ways of assessing the quality of the process. One technique is to verify the degree of ink penetration into the powder coated base layer. This test can be performed using a metallographic microscope and inspecting the cross-section of a coated profile. It monitors the amount of ink that has penetrated into and through the base powder coating and good penetration improves the final performance of the coated product. Coating glass plates and inspecting the reverse side of the glass plate to determine the penetration of the transfer ink through the base coat is another method of visually inspecting ink penetration through the base coat. In order to achieve a high quality decorative finish, the base coat must have low opacity and conversion marks from the pretreatment should not be visible through the base coating. Film thickness should be even since a variable thickness will alter the hiding effect of the base coat and alter the appearance due to the uneven distribution of the ink through the film. Curing parameters of the basecoat should be strictly adhered to, and the transfer process must be performed in accordance with the manufacturers instructions. Basecoats that are the same colour, but formulated with powders of different chemical composition, will have similar weathering performance but may show different solvent resistant properties. The Naturall process is also known as the powder-on-powder coating system as it is a fivestage process using two applications of powder coatings. This is a patented process to obtain a wood effect finish on aluminium profiles and can be achieved by using TGIC-free polyester powder coatings. The first stage is surface pretreatment
MARCH 2006
F O C U S as previously described. This is followed by the first layer of base coat powder coating applied at 60 – 80µm film thickness. The next stage is a melting process at 100° to 120°C, followed by a second layer powder application – a flash coating of less than 10µm applied through a patterned silk screen. Process is concluded with a curing cycle of 180 to 200°C for twenty minutes. After the final curing process, the patterned second layer of powder has penetrated into the base coat, creating a compact and uniform layer of at least 60µm thickness. The final result is a powder-on-powder film with the look and feel of wood and high performance outdoor weathering characteristics. The most important advantage of the Naturall process compared to the Sublichromy system is the absence of ink. The Effecta process produces a wood effect finish on aluminium profiles using a specially designed roller application technique. The sequence is as follows: substrate pretreatment; first powder coatings application at 60 to 80µm; a melting process at 100° to 120°C; a second powder coating application; decorative effect applied using a special roller; melting process at 100° to 120°C; third application of powder coating if desired; use of special roller to obtain decorative effect if desired; and finally a curing process at 180° to 200°C for 35 minutes. After the curing process the second and third layers penetrate into the base coat giving a surface that has the look and feel of wood with outstanding weatherability and outdoor performance characteristics. Again the absence of the ink stage is a cost advantage. Article entitled “Finishing Touch – The Latest Powder Coatings Combine Function and Fashion to Offer End Users the Best of Both Worlds” by Eugenio Gomez, Rohm & Haas Powder Coatings, Castellon, Spain, published in Metal Finishing, Dec 2005, 103 (12), 3740
MARCH 2006
ON
POWDER
INDUSTRY NEWS New powder paint covers edges evenly The V-PET EC series is a new line of powder paint developed by Dai Nippon Toryo that offers improved rust resistance on end surfaces. The new paint provides a solution to the challenge of creating an even coating and appearance when covering the cut edges of steel plates and other substrates. It has been produced by optimizing the composition of a primary ingredient, pigments and additives, and regulating the curing speed during baking. The company is looking to develop markets for products ranging from road and construction materials, to distribution panels, dispenser, car parts, exhaust fans, space heaters, freezers and fuel tanks.
C O AT I N G S Investments has already made a bid worth A$ 3.25 /share (worth A$ 266 M in total) on Wattyl but AEP is unhappy with Wattyl’s management. Barloworld’s bid is worth A$ 3.8 /share (A$ 321 M in total). Ernst and Young has valued Wattyl at A$ 3.25-4.21 /share. However Barloworld’s offer raises problems of competition on the Australian market on which it already has a 7-9% share. Wattyl has a 17-19% share of the market. The market leader Orica has a 22-25% share. Akzo Nobel, which controls 3-6% of the Australian market might also be interested in acquiring Wattyl. By 2010 the value of the Australian paints market is expected to reach A$ 2.2 bn (compared with A$ 1.9 bn at present). Although Wattyl’s turnover fell from A$ 548 M to A$ 472 M between 20032005, in 2005 it made a return to profits after 2 years of making a loss. Chimie Pharma Hebdo, 20 Feb 2006, (330), 10 (in French)
Japan Chemical Week, 9 Feb 2006, 47 (2354), 2
Neopentyl glycol in short supply Bejing Red Lion buys back equity On 16 Jan 2006 Beijing Red Lion Coatings Co Ltd was permitted by Shanghai Fenghua (Group) Co Ltd to complete its RMB Yuan 96.76 M relocation plan. The company will also be permitted to buy back 25% equity currently held by Akzo-Nobel International Coatings Co Ltd in Red Lion Coatings International Co Ltd. China Chemical Reporter, 6/16 Feb 2006, 17 (4/5), 9
Paints: Barloworld aiming to become leading producer in Australia S African paints producer Barloworld is to launch a takeover bid on Wattyl, the second largest company on the Australian market. Barloworld may be seen as a white knight by Wattyl. Investment fund AEP Financial
In China, neopentyl glycol (NPG) capacity totals 57,000 tonne/y, and there are four major producers: BASF JCIC Neopentyl Glycol Co Ltd (25,000 tonne /y); Shandong Linzi Yongliu Chemical Industry Co Ltd (20,000 tonne/y); Shandong Dongying Dongchen Group Co Ltd (10,000 tonne/y) and Shandong Guanghe Fine Chemical Co Ltd (5000 tonne/y). In 2006, Shandong Guanghe intends to raise capacity to 10,000 tonne/y. NPG output rose by 55.6% to 28,000 tonnes in 2004, and consumption increased by 10.8% to 57,000 tonnes. Imports rose by 3.6% to 29,000 tonnes. A graph shows output, consumption and import data for NPG in China, 2001-2004 inclusive. By 2008, Chinese NPG demand is expected to rise to 90,000 tonne/y. The main end uses for NPG include applications in the automotive, textile,
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