Paint & Coating Industry May 2011

May 2011 VOLUME 27, NUMBER 5

INSIDE Manufacturing Equipment Wood Coating Technology

Paint

Coatings Industry

Outdoor vs. Laboratory Weathering Testing

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CONTENTS PA I N T & C O AT I N G S I N D U S T RY , V O L U M E 2 7 , N U M B E R 5

May 2011

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ONLINE FEATURES w w w. pcimag.com Groups Collaborate on Pioneering Anti-Freeze Program, Clariant New Waterborne Acrylic Resin for Bottle Labeling Adhesive Applications, DSM Coating Resins 100% VOC-Free Ceramic Coating – A GameChanger for Paint Contractors? EonCoat LLC

FEATURES 24 TiO2 Landscape Changing Rapidly, TZ Minerals International 30 What’s New in Pigment Technology? PCI Magazine

World Emulsion Polymer Demand to Reach 12.8 Million Metric Tons in 2014, The Freedonia Group, Inc. Application of Hollow Microspheres in Coatings, Missouri S&T Selling Your Company – The Optimum Time is Late 2011 or 2012, George Spilka and Associates

32 Is Calibration Really Necessary? BYK-Gardner USA 36 Outdoor Weathering Must Verify Accelerated Testing, Q-Lab Weathering Research Service 48 Novel Hybrid Technology Accelerates VOC Release from Wood Coatings, The Dow Chemical Company

BUSINESS TOOLS

DEPARTMENTS 6 8 12 18 64 66

Viewpoint Industry News Company News Equipment/Components/Media Classifieds Advertiser Index

22 Equipment Showcases

ON THE COVER: TiO2 photograph courtesy of DuPont.

31 Pigment Showcases 31 Supplier Showcases

PCI - PAINT & COATINGS INDUSTRY (ISSN 0884-3848) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: PCI - PAINT & COATINGS INDUSTRY, P.O. Box 2145, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to PCI - PAINT & COATINGS INDUSTRY, P.O. Box 2145, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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V I EWPOINT

Sustainability the Clear Focus at 2011 ECS The 2011 European Coatings Show and Congress wrapped up on March 31 after four days of presentations and exhibits on the latest developments and innovations in the global coatings market. Organizer Vincentz Network was certain that the number of attendees would surpass the drop in attendance that was seen back in 2009, but was unsure if they would exceed the record numbers of 2007. Preliminary reports show that over 26,000 visitors attended the event, which beats the previous record set in 2007. Exhibitors (887) from 45 countries presented their products and services on a record net display area of over 30,000 m² (322,917 square feet). The Congress reports 648 participants from 40 countries, with 150 papers in 25 sessions. The event had an international share of about 60% for both exhibitors and visitors. The European Coatings Award for the Best Conference Paper was presented to Dr. Marc Entenmann’s team from the Fraunhofer Institute for Manufacturing Engineering and Automation. The paper, entitled “Corrosion Protection with Nanoscale Anticorrosive Pigments in Coatings,” described the effects of reducing the particle size of corrosion protection pigments. The jury based its decision on the outstanding way in which the paper showed an approach to solving one of the industry’s biggest and most cost-intensive problems: the corrosion of steel.

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MAY 2011 | W W W . P C I M A G . C O M

If I had to sum up the focus of the event in one word it would be “sustainability”. After speaking with numerous industry suppliers, it is clear that sustainability is defined and achieved differently by everyone, whether it be through the use of bio-based raw materials, producing more environmentally friendly products, reducing the carbon footprint and that of customers, saving time and energy in production, recycling, or helping to create coatings that last longer and require fewer coats. Commenting on DSM’s recent reorganization, Patrick Niels, Business Unit Director of DSM Coating Resins, stated that the company wants to focus on building a portfolio focused on the most sustainable coating technologies including powder coatings, UV technology and sustainable liquid coatings. The best way to do this was to merge the DSM Powder Coating Resins and DSM NeoResins+ business units into a single new unit, DSM Coating Resins. Firmly believing that the only technology that will see real growth is sustainable technology, Niels has no interest in non-sustainable product lines. Among other things, his strategy is to invest heavily in converting China to water-based technology, and to increase the value, appreciation and profitability of DSM’s resins in the coatings industry in order to ensure that DSM can sustain its investments in R&D, which are necessary to support innovation in the industry. A few other companies spoke specifically with me about sustainability. Clariant discussed their recent Sustainability Report, which covers, in detail, the company’s focus on sustainable management and responsible action. Clariant discussed production economics and green technology when describing their additives and pigments designed to reduce production line complexity, improve efficiency and reduce the environmental impact. Perstorp’s approach to innovation is driven by sustainability on three fronts – through reducing emissions and energy consumption in raw material manufacturing; through the innovation of new products that enable customers to formulate low-impact solutions; and through high-performance additives that enable more durable and long-lasting end products. The European Coatings Congress featured a keynote lecture by Professor Matthias Beller from Rostock University, Germany. The winner of the first Sustainable Chemistry Award showed that sustainability in all aspects is the grand challenge of the 21st Century. Sustainability was also the central issue of the second keynote lecture by Dr. Erik Risberg, Jotun, Norway. As always, the ECS was a success, not only for its organizers, but for those who attended as well. For a roundup of what was exhibited at the show, check out PCI’s archived ECS daily e-newsletter at www.pcimag.com (click on E-Newsletter Archive in the left column). The next European Coatings Show will take place at the Exhibition Centre Nuremberg from March 19-21, 2013, and the Congress will start, as always, a day earlier on March 18, 2013.

By Kristin Johansson, Editor | PCI

Markets:

Architectural Coatings

Industrial Coatings

Container Automotive

Civil Aerospace Engineering

Coatings Technologies:

SolventBorne Coatings

WaterBorne Coatings

Powder Coatings

Surface/Substrate:

Wood

Brick

Concrete

Marine & Maintenance

UV Coatings

Metal

Stucco

High Solids Coatings

Vinyl

Plastic

Brenntag understands change is normal for the Coatings Industry. As the Coatings Industry has evolved through the years, Brenntag’s Paint and Coatings Team continues to provide our customers with the products and services to stay competitive in the marketplace. Whether you face different markets, technologies, or substrate applications, Brenntag’s Paint and Coatings Team can help you to adapt and make change work to your advantage.

Brenntag offers a complete specialty and industrial product portfolio, technical assistance with product development, formulations and applications know-how, superior logistics with versatile blending and re-packaging capabilities, and last, but not least, commitment to quality and safety. Change demands innovation and creativity. Brenntag Understands. Brenntag North America, Inc. (610) 926-6100 Ext: 3858 [email protected] brenntagnorthamerica.com

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Ask the Expert Charlie Hegedus Research Associate

Q

I am formulating waterborne alkyd coatings and need defoamer additives to improve my coating manufacturing, application and performance properties. What can you suggest?

Waterborne alkyd coatings are gaining popularity due to their enhanced properties, green chemistry and low VOCs. However, like most resins, waterborne alkyd coatings require specific defoamers to achieve optimal performance. Defoamers reduce or eliminate foam and help avoid production, application and applied coating problems. Our studies demonstrate that Surfy¯nol® DF-58 and DF-66 silicone defoamers (used at 0.05% to 0.5% of total formula) and Surfy¯nol DF-75 organic oil defoamer (used at 0.2% to 1%) provide excellent compatibility and defoaming. These additives enhance gloss of high-gloss coatings and provide excellent substrate coverage, appearance and protection. In wood coatings, such as clear varnishes and stains, they promote complete coverage, smooth finish, and excellent gloss, clarity and distinctness of image. In industrial coatings, such as metal primers, they eliminate defects such as pinholes, craters and other defects that can lead to corrosion, disbondment and other failures.

A

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I NDUSTRY NEWS

Report Looks at Brazilian Decorative Coatings Market SÃO PAULO – Research and consulting firm Frost & Sullivan has released a new report on the decorative segment in the Brazilian coatings market. According to the study, the Brazilian decorative coatings market was worth $2,077.3 million in 2010; with a compound annual growth rate of 5.8 percent, this is likely to increase to $3,262.6 million by 2017. The segment represents 63.8 percent in terms of revenue of the total coatings

market in 2010. The industrial segment held the second-largest position, with 21.4 percent, followed by the refinish and automotive sectors, with 14.8 percent combined. In 2009, the decorative segment was the least affected by the economic crisis, with a revenue loss of 2.4 percent, whereas the total market lost five percent.

Global Coatings Market to Reach $98 Billion by 2015 SAN JOSE, CA – The global market for coatings is forecast to reach $98.69 billion by 2015, led by rapid industrialization, economic activity, and demand from the automotive and construction sectors in developing countries. In addition, technological and product developments, a regulatory environment, and unique formulations will rekindle growth in the mature and developed markets of the United States and Europe. This and other information is found in a new report by Global Industry Analysts Inc. (GIA). Industrial growth in developing economies is a major growth driver for the coatings industry. Availability of cheap labor and an abundance of resources have companies focusing on Asia-Pacific and Latin America, and setting up production establishments in these regions. However, sustained demand from developed countries also contributes to the overall expansion of the coatings market. North America accounts for the majority of global coatings production, while China is considered the leading consumer of coating additives. Asia-Pacific, led by advances from high-growth markets including China,

MAY 2011 | W W W . P C I M A G . C O M

An insufficient supply of local raw materials, which meet approximately 40 percent of the total industry’s needs, is a major market restraint. Additionally, in Brazil, the per capita consumption of paint is about five liters; it is 15 liters per capita in the United States and more than 20 liters per capita in other developed countries. Fo r a d d i t i o n al information, e -ma i l Tat ia na B r u l l at t at i a n a . [email protected].

India, Indonesia and others, stands tall as the largest regional market. Europe and the United States trail closely behind other coatings markets worldwide. The Asian market is also forecast to surge ahead of other world regions at the overall fastest compounded annual growth rate of 4.2 percent through 2015. For additional information about the research report, titled “Coatings: A Global Strategic Business Report,” visit www.strategyr.com/Coatings_Market_Report.asp.

ASTM Publishes New Test Method W. CONSHOHOCKEN, PA – A new ASTM International standard now fulfills the need within the concrete surface preparation field for a means of measuring and permanently replicating the profile of a concrete-coated building surface. ASTM D 7682, Test Method for Replication and Measurement of Concrete Surface Profiles Using Replica Putty, was developed by Subcommittee D01.46 on Industrial Protective Coatings, part of ASTM International Committee D01 on Paint and Related Coatings, Materials and Applications. Coating inspectors can retain profile replicas that can be viewed or measured on site, prior to coating application, and used as a

I NDUSTRY NEWS pass/fail test of whether surface preparations meet specifications. Owners can retain replicas should a failure occur. Contractors can retain replicas for verification of adherence to the specification’s required anchor profile ranges. Coatings manufacturers can designate within the product data sheet the range requirements for the coating being used on the project, and engineers can write specifications utilizing the coating manufacturer’s product data sheets that designate a profile range for the required coating. Visit www.astm.org for additional information.

EPA Extends Greenhouse Gas Reporting Deadline WASHINGTON, DC – The U.S. Environmental Protection Agency has issued a final rule that extends the deadline for reporting 2010 data under the Greenhouse Gas (GHG) Reporting Program to September 30, 2011. Under the GHG Reporting Program, entities required to submit data must reg-

ister with the electronic GHG reporting tool (e-GGRT) no later than 60 days before the reporting deadline. With this reporting deadline extension, the new deadline for registering with e-GGRT is August 1, 2011.

Dean C. Webster to Receive Roy W. Tess Award in Coatings SOLON, OH – Dean C. Webster of North Dakota State University, Department of Coatings and Polymeric Materials, will receive the Roy W. Tess Award in Coatings for 2011. The officers and the Award Committee of the Division of Polymeric Materials: Science and Engineering (PMSE) of the American Chemical Society made Webster the announcement. Webster researches the synthesis and characterization of novel polymers. He has authored over 75 peer-reviewed papers and publications, and is credited

Coating Thickness Gages for

Non-Metal Substrates

with 11 patents (an additional 18 pending) on coatings-related topics.

ARB Discontinues Annual Architectural Coatings Reporting SACRAMENTO, CA – The California Air Resources Board (ARB) has decided to no longer require submission of the annual architectural coating reporting established by local districts adopting the ARB’s 2000 architectural coatings suggested control measure (SCM). Contact Jim Nyarady at [email protected] for additional information.

Cal Poly Offers Polymers and Coatings Short Course SAN LUIS OBISPO, CA – The Polymers and Coatings program at California Polytechnic State University, San Luis Obispo, CA, will offer a Polymers and Coatings Introductory Short Course during the week of July 18-22, 2011. The course will cover many aspects of coating technology including resin chemistry, pigments and fillers, additives, VOC testing, application aspects, and rheology; the emphasis will be on liquid coatings. The course includes daily laboratory sessions during which participants prepare and test polymers and coatings. For more information, visit www.polymerscoatings. calpoly.edu/ short%20courses.htm.

International Coatings Congress Issues Call for Papers SÃO PAULO – The 12th International Coatings Congress is taking place November 21-23, 2011, at the Transamerica Expo Center in São Paulo, Brazil, as part of ABRAFATI 2011. A call for papers has been issued for speakers interested in presenting at the event. Summaries should be posted through the Web site at www.abrafati2011.com.br.

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Photopolymerization Fundamentals Coming in June BRECKENRIDGE, CO – Photopolymerization Fundamentals 2011 is taking place June 26-29, 2011, in Breckenridge, CO. The event, presented by RadTech, the Photopolymerizations IUCRC and the University of Colorado, brings together international leaders from industry and academia to present and discuss the basic fundamentals of photopolymerization reactions as well as the most exciting future directions of this technology. For more information on the conference, visit http://radtech.org/pf2011. 

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C O M PANY NEWS

BYK-Gardner User Meeting Focuses on Color and Appearance Harmony DEARBORN, MI – BYKGardner hosted its sixth user meeting April 12-13 at the historical Henry Ford Museum in Dearborn, MI. Dr. Georg Schroeder, President, opened the meeting with an overview of BYK’s business structure and focus. The focus of the meeti ng was on color a nd app ea ra nc e ha r mony, with in-depth discussions on gloss, waviness, color match, effect and mottling. The meet i ng i ncluded

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MAY 2011 | W W W . P C I M A G . C O M

presentations from General Motors, Boeing, Akzo Nobel Ca r Ref inishes, Q-Lab, Wyle Integrated Science and Engineering Group, Eckart America, DuPont Performance Coatings, Office Color Science Co., BYK-Gardner and BYK-Chemie. At the conclusion of the first day, the 140+ attendees were treated to a sit-down dinner in the heart of the Henry Ford Museum, followed by a private tour of the facility.

Solvay Offers €3.4 Billion for Rhodia  BRUSSELS, Belgium – Solvay and Rhodia have signed a framework agreement in which Solvay will launch a friendly cash offer for 100 percent of the share capital of Rhodia. At €31.60 per share, the offer values the equity of Rhodia at €3.4 billion. The offer will be launched in France and extended to the United States. The Board of Directors of Rhodia has recommended the transaction unanimously. To facilitate a smooth and rapid integration of the two groups, Jean-Pierre Clamadieu, Chairman and CEO of Rhodia, will join Solvay’s Executive Committee in the role of Deputy CEO once the offer is closed. Clamadieu is also expected to succeed Solvay’s current CEO, Christian Jourquin, upon his retirement. In this context, Clamadieu will be proposed for appointment to the Board of Directors of Solvay at the AGM in May 2012. In addition, Gilles Auffret, COO of Rhodia, will be appointed CEO of Rhodia and member of the Executive Committee of Solvay.

Ashland Inc. and Flint Group Sign Agreement DUBLIN, OH – Coatings and adhesives from Ashland Performance Materials, a commercial unit of Ashland Inc., that are marketed to North American narrow web label, tag and wrapper converters, will now also be available from Flint Group. Ashland and Flint Group will begin a distribution and co-branding effort that calls for Flint Group to begin marketing Ashland products under a co-branded label that will carry the Flint Group trademark or trade name.

Coatex and Arkema Emulsion Systems Open Application Laboratory in China CHANGSHU, China – Coatex and Arkema Emulsion Systems have announced the opening of a new Asia-Pacific coatings application laboratory in Changshu, China, to provide technical support to their coatings customers in the region. Arkema Emulsion Systems focuses on latex binders, while Coatex is entirely dedicated to water-based rheology additives. Prod-

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C O M PANY NEWS ucts offered by the two businesses include EnVia® certified latex products from Arkema Emulsion Systems, as well as RHEOTECH™ and COAPUR™ thickeners and ECODIS™ dispersing agents from Coatex. On the same Changshu site, a waterbased rheology modifier plant will be

operational in the coming months, followed in 2012 by latex production lines for Arkema Emulsion Systems products.

ITW Consolidates Finishing Equipment Brands TOLEDO – ITW has announced the inte-

gration of its Binks, DeVilbiss, Ransburg and BGK brands into one new operating unit, ITW Finishing Equipment Americas. The consolidation was made to take advantage of the synergies between the four groups, all of which are involved in developing and manufacturing equipment for the finishing industry.

Algol Chemicals to Distribute for Celanese Emulsions NUREMBERG, Germany – Celanese Emulsions Polymers has appointed Algol Chemicals as its distributor in Russia and the Ukraine for all its water-based binders into all end-use applications. Representatives from both companies signed the agreement at the Celanese stand at the European Coatings Show to emphasize the commitment of both parties to the coatings industry in Russia.

“Algol Chemicals has a long history of doing business in Russia, and we are convinced they will assist us in reaching our growth goals by extending the reach of vinyl acetate/ethylene (VAE) emulsions in this region,” said Dr. Rolf Kuropka, Celanese Sales Director for EMEA. Celanese Emulsion Polymers will continue to handle international key accounts directly through its local sales manager in Moscow.

Univar Signs Distribution Agreement with Cytec Industries VANCOUVER, Canada – Univar has signed a non-exclusive distribution agreement with Cytec Industries Inc. to market and distribute its RADCURE® products to the coatings, adhesives, sealants and elastomers (CASE) industry in Canada.

DKSH and Kodak Specialty Chemicals Announce Distribution Agreement

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MAY 2011 | W W W . P C I M A G . C O M

ZURICH – DKSH, a Swiss-based market expansion services provider, and Eastman Kodak Co.’s Specialty Chemicals unit (KSC) have entered into an international distribution agreement to market high-value specialty chemicals produced by KSC. Under the arrangement, DKSH’s Business

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C O M PANY NEWS Unit Performance Materials will distribute KSC’s high-performance chemicals to the graphics, electronics, liquid crystal display, polymer and film coating industries.

DSM Partners With Kemrock Industries in India HEERLEN, The Netherlands – Royal DSM announced a partnership with Kemrock Industries in India for the production of specialty composite resins in India. DSM and Kemrock together will invest $25 million in the joint venture. DSM will focus on the supply of specialized composite resin solutions to the fast-growing Indian market, while Kemrock will concentrate on the production of high-end composite parts.

Dover to Expand Phosphite Facility DOVER, OH – Dover Chemical Corp., which doubled production capacity last year for its patented Doverphos S-9228 high-performance phosphite, announced a second expansion that will double it again by mid2011. The additive improves color and pro-

cessing stability in polymers used in automotive parts, household appliances, electronics, powder coatings and packaging.

OMNOVA Solutions Dedicates Chemical Facility in China SHANGHAI, China – OMNOVA Solutions announced the grand opening of its new specialty chemical plant at the Shanghai Chemical Industry Park (SCIP) in Caojing, China. The plant, which is part of a recent acquisition of ELIOKEM by OMNOVA Solutions, manufactures Pliocord® vinyl pyridine latex. In addition, production of OMNOVA’s complementary GenTac® vinyl pyridine latex is being evaluated for the site, as well as other specialty latices based on innovative styrene butadiene and acrylic emulsion polymerization technologies.

Oxea Increases Specialty Ester Capacity/Builds New Carboxylic Acids Unit OBERHAUSEN, Germany – Oxea has announced plans for significant capacity

expansion of its range of specialty esters. As of the second half of 2011, the capacity of the existing ester production unit in Oberhausen, Germany, will be extended by 40 percent. In order to further boost production capacity for a range of specialty esters, Oxea is evaluating the construction of an additional production unit in Oberhausen. The new unit is planned to come on stream in the second half of 2012. The company also announced it will build a new carboxylic acids unit in Oberhausen. The facility will come on stream by late 2012.

PPG Study Investigates Value of IR-Reflective Coatings PITTSBURGH – PPG Industries’ coil and extrusion coatings group has issued a white paper demonstrating the superior energy performance of buildings with infrared (IR)-reflective coatings on metal walls, window frames and roofs. The 12-page document, “Energy Savings in High-Rise Buildings Using High-Reflec-

tive Coatings,” summarizes an energy modeling study conducted by an independent energy and environmental analysis firm on prototype eight-story office buildings in 12 North American cities. Visit www.ppgideascapes.com to download the white paper.

Canadian Agency Approves Use of Fungitrol® 940 Dry Film Preservative WAYNE, NJ – ISP announced that the Pest Management Regulatory Agency of Health Canada has approved the use of Fungitrol 940 dry film preservative for the protection of paint, coatings and adhesive products. Fungitrol 940 is a zero-VOC, odor-free, water-based dispersion broadly compatible with latex coatings and emulsions. The highly concentrated (40 percent active) aqueous dispersion is designed to support the high performance and quality requirements of Canada’s product makers while contributing to sustainability and environmental goals.

ALTANA Buys Business Unit of Watson Standard Adhesives Co. WESEL, Germany – ALTANA has acquired the can end sealants business for the metal can packaging market of U.S.-based Watson Standard Adhesives Co. (WSAC). ALTANA primarily acquired customer relationships, products, knowhow and inventories. WSAC’s can end sealants business will be integrated into the ACTEGA Coatings & Sealants division. The former WSAC can end sealant products will be produced at ACTEGA’s existing site near Philadelphia and incorporated into ACTEGA Artística business.

Rhodia Completes Acquisition of Suzhou HiPro Polymers’ Guar Unit in China PARIS – Specialty chemical producer Rhodia, Paris, France, has completed the acquisition of the new guar derivatives production unit belonging to Suzhou HiPro Polymers, based at Zhangjiagang, Jiangsu Province, China. The acquisition

will enable Rhodia to meet the fast-growing demand for guar-based products in Asia-Pacific. Rhodia is also investing in its North American facility in Vernon, TX, to increase its guar derivatives production capacity and improve its competitiveness.

Cytec Completes Sale of Building Block Chemicals Business WOODLAND PARK, NJ – Cytec Industries Inc. has completed the previously announced sale of its Building Block Chemicals business to an affiliate of H.I.G. Capital LLC. The companies have also entered into long-term supply agreements for melamine and acrylonitrile. 

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Visit www.arkemaemulsionsystems.com/SNAP for more information about SNAP™ Structured Nano-Acrylic Polymers. At Arkema Emulsion Systems, we’re focused on your future.

SNAP™ is a trademark of Arkema Inc. ©2011 Arkema Inc.

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E QUIPMENT/COMPONENTS/MEDIA

Flow-Measurement Brochure KROHNE, INC.: This 58-page, color brochure for flow measurement products is designed to help customers choose the right flow device for their application, offering a chart that directs users to the most appropriate products. It includes information about KROHNE’s electromagnetic, variable, ultrasonic, mass and vortex flow meters, as well its flow controllers. Visit www.krohne-downloadcenter.com.

Pumps GRISWOLD™ PUMP CO.: Three new 17-inch 811 Series pump models are 100% compatible and interchangeable with many competitive B73.1 pump models. Features include: maximum flow rates to 7000 gpm; maximum heads to 310 ft; epoxy-coated oil sump; oil-level sight glass; SKF® bearings; and Inpro/Seal® bearing isolators. Mechanical or packing seal options are available. Visit www.griswoldpump.com.

efficiency mill designed for processing ceramics, paints, coatings, metal oxides, and numerous other materials. The mill has been engineered with a swivel head, which allows for easy access to the top of the grinding chamber. It also comes equipped with a 60 hp variable-frequency drive, tangential inlet assembly, media charging port and media discharge plug. E-mail [email protected].

discharger has an integral hopper and flexible spiral conveyor that feeds the contents from the bag either by volume or by weight to process or packaging machinery. E-mail [email protected].

Flow Meters PARKER FLUID CONTROL DIVISION: A new line of Vortex Shedding Flow Meters offers meters that monitor the flow of cooling fluid for resistance welders, slurry pump seal water, machine coolant and steam boiler feed water. With no moving parts to clog or wear out,

Flow Switch Three-Roll Mill BUHLER AG: The redesigned Trias™ enables constant and reproducible quality, independent of the operator. All parameters and production values are displayed with trending and can be saved according to the respective orders. Reliability, high raw-material yield, and gentle dispersion of contamination- and temperature-sensitive products are key properties of this three-roll mill. Different roll materials and concepts permit clean-room production in accordance with international standards. E-mail [email protected].

Heat Transfer Fluid System MOKON: The HTF ST Series, a new line of stationary heat transfer fluid systems, offers energy-efficient performance and reduced space requirements for applications requiring higher heating capacities. Designed and built to customer specifications, features include a low-watt density electric heater mounted in a structural steel frame. These systems are completely pre-wired and available in single- and multiple-zone configurations with pumping capacities up to 120 gpm. Visit www.mokon.com.

Continuous Attritor Mill UNION PROCESS, INC.: The “C” Series Continuous Attritor is a work-horse machine that uses 1/8 - 3/8” grinding media. It is designed for applications that require continuous production of large quantities of material. It is a low-maintenance, high18



SOR: The 1520 is a vertically mounted, vane-operated flow switch suitable for plant and OEM applications where open or closed contacts are required to signal flow or no-flow conditions. The vane extension arm moves a magnet that actuates (deactuates) a hermetically sealed reed switch. Visit www.sorinc.com.

Bulk Bag Discharger SPIROFLOW SYSTEMS, Multi-discharger INC.: Model T7 is a versatile emptying system that allows processors to discharge materials from bulk bags, rigid bins, Octabins or sacks. The multi-discharger employs a controllable discharger and a subframe. A bulk bag or rigid container is placed on the subframe, which has fork channels to allow loading on to the discharger. The

meters are well suited to monitor media with small particulates with uncompromised accuracy. Meters operate with NPT ports ranging from ¼”-2” in size and can handle flows from 4-200 gpm, with occasional over-ranging up to 125% of capacity without damaging the meter. Visit www.parkerfluidcontrol.com.

Oven GRIEVE: No. 1002 is an electrically heated, 500 ºF (~260 º C) cabinet oven currently used for various test procedures. Workspace dimensions measure 20”W x 20”D x 20”H. Features include: 4” insulated walls throughout; type-304, 2B stainless-steel interior with continuously back-welded seam construction; stainless-steel exterior with #4 brushed finish; heavy-duty door and door frame; three nickel-plated wire shelves; and adjustable patented opposed louvers on full coverage supply and return ductwork. E-mail: [email protected].

Air-Operated Double-Diaphragm Pump WILDEN®: The Advanced™ Metal Series of AODD pumps are available in a bolted design, which provides superior containment of products during the manufacturing and transfer of coatings. The bolted configuration delivers better leak resistance at higher pressures than traditional clamp-banded designs. Pumps include a variety of elastomer options, as well as the Pro-Flo X™ air-distribution system, which allows the pump user to control the flow rate and maximize efficiency to reduce processing costs. Visit www.wildenpump.com.

MAY 2011 | W W W . P C I M A G . C O M

Fan-tastic! COLORTREND® 808 No-VOC High Performance Colorants Introducing COLORTREND® 808HP No-VOC colorants and Vivid Expressions™, the newest color collection offering 460 of the brightest, cleanest colors in the coatings industry. Vivid Expressions™ provides the flexibility to expand an existing COLORTREND® system or be used as a stand alone point-of-sale color system. Now you will experience broader color space for brighter colors, plus high performance solutions for better durability, superior fade resistance and improved opacity. By utilizing this latest No-VOC colorant technology you will also meet growing market demands and exceed environmental regulations. As the largest independent colorant manufacturer and a global leader in specialty chemicals, Evonik continues to deliver eco-friendly, innovative, color system solutions. Just one more step to making our world safer, brighter, better – inside and out! colored by colortrend

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For more information, please contact your local Account Manager. Colortrend USA LLC 2 Turner Place P. O. Box 677 Piscataway, NJ 08854 USA phone +1 732 981 5343 www.evonik.com/colortrend

E QUIPMENT/COMPONENTS/MEDIA Progressing Cavity Pump

Agitator

MOYNO, INC.: The Moyno® 2000 Model

CHEMINEER, INC.: The Chemineer HT and HTM high-torque agitators offer proven, reliable performance in demanding processes such as chemical reactors, fermentations, gas dispersion, polymer reactors, flue gas desulfurization, mining and waste treatment. Features include: spiral bevel and helical gearing, oversized solid internal shafting to extend gear and bearing life, dry well seal to eliminate oil leakage, factory-assembled agitator drives, and a right-angle drive that provides a balanced design and reduces headroom requirements. Visit www.chemineer.com.

G3 progressing cavity pump is suited for handling semi-dry, high solids content or caked substances. It features a series of finger mechanisms mounted on two counter-rotating shafts, which prevents the accumulation of material in the throat of the pump. With Moyno’s crown geartype universal joint, it is capable of accommodating exceptionally high torsional and thrust loads. Patented joint seals effectively protect the gear joints from pumpage contamination. The pump offers flow rates to 400 gpm and pressure capabilities to 350 psi. Visit www.moyno.com.

reducing minimum height requirements. The design also allows vertical alignment of the top inlet and bottom outlet, allowing the smallest fraction to descend through the screener in a straight-through path at high rates. Visit www.kason.com.

Classifier KASON CORP.: Vibroscreen® Flo-Thru low-profile screener classifies bulk material into three fractions at high rates. It employs two screening decks and two unbalanced-weight gyratory motors mounted on opposing exterior sidewalls of the unit, instead of one motor positioned beneath the screening chamber,

Sliding Vane Pump BLACKMER: The four-inch model of NP Series sliding vane pumps now offers optional electric heating. The option may be used in place of jacketed heads in order to provide pump heating for applications that normally require jackets, such as handling asphalt, bitumen and

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We are thinking about the same thing you are… How to make your products greener and their performance pure gold. Our customers come to us to help them stay ahead of competitive pressures by helping to re-formulate existing products and innovate new ones – meeting “green” goals while preserving and even enhancing performance. We call it Greenability. You’ll call it genius. 2 Another fine result of the Innovation Principle – . Let us help you work through the formula for Greenability.

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E QUIPMENT/COMPONENTS/MEDIA lube oils. Blackmer will continue to offer jacketed heads for customers who need NP pumps with steam and hot-oil capabilities. Visit www.blackmer.com.

Grinding Media

for processing viscous formulations. The mixer design is composed of three independently driven agitators working in tandem. The high-speed disperser quickly draws powders into the liquid batch through a powerful vortex. The

SIGMUND LINDNER: New SiLibeads Type ZY Premium Quality ceramic beads offer extremely low wear and tear due to the use of fine crystalline and pure raw materials in the production process. The exact roundness as well as the smooth and polished surface of the beads contributes to this low wear rate. This means there is nearly no contamination of the grinding product. This applies particularly to materials and products within the nano-particle range. The beads show excellent performance in low-viscosity suspensions, especially in water-based systems in high-speed mills. Visit www.sigmund-lindner.com.

Flow Meters BADGER METER: The Model IOG line is designed for a variety of applications including petroleum-based fluids, water solutions and other highly viscous fluids. Flow meters are available in aluminum with liquid crystal polymer gears, for petroleum, non-acids, oil, paint and ink applications. Designed to withstand extreme conditions where conventional meters fail, Model IOG is ideal for high-viscosity liquid and provides extremely high accuracy, even in low-flow environments. With an accuracy rate of ±.5 percent, it meets or exceeds industry accuracy requirements. Visit www.badgermeter.com. 

Mixer CHARLES ROSS & SON CO.: The VersaMix multi-shaft mixer is well proven

EQUIPMENT SHOWCASES 22

rotor/stator carries out a number of tasks depending on the product being mixed: it can break down agglomerates, accelerate homogenization or prepare fine droplets in an emulsion. A low-speed anchor promotes bulk flow and uniform batch temperature while scraping the vessel sidewalls and bottom. Visit www.mixers.com.

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MAY 2011 | W W W . P C I M A G . C O M

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concrete loves exposure Keep your patio looking fresh and new. The wet-look of Joncryl® 2970 in your formulated coating resists whitening even after weeks of continuous water exposure. At BASF, we create chemistry. basf.us/dpsolutions

T

he landscape of the TiO2 industry is changing rapidly and there is no guarantee that the market fundamentals of the last 20 years will return during the next five years. On the demand side, emerging economies are stretching the supply chain to the breaking point, forcing rapid price escalation for those customers able to source the material. On the supply side, the industry has been in a clear “retrenchment” over the past 20 years, with suppliers rationalizing high-cost capacity during industry downturns and only adding incremental capacity through brownfield additions, while attempting to grow with the market and maintain market share. TZMI does not expect any significant capacity expansions outside of China over the next two years, but expects global demand to grow more than 4% over the same period. China producers will add significant capacity over the next decade, with this capacity to run at very low utilization rates. The ability of China’s producers to procure adequate feedstocks to support the additional capacity is in question.

Supply/Demand TiO2 demand is driven by demand for durable products (Figure 1). Many of the applications are directly tied to building and construction activity. High-quality coated paper and non-durable plastics are the major non-durable applications for TiO2. Rubber, ceramics, inks and specialty applications account for approximately 10% of total demand. We estimate that demand grew at a 12% pace yearon-year in 2010 as the world recovered from the global financial crisis and customers restocked depleted inventories. Titanium dioxide producers noted the rapid increase in demand in mid-2009, but were unable to re-start idled capacity quickly enough and were forced to deplete inventories in order to meet demand. The end result in 2009 was that year-end inventories were at very low seasonal levels, with the paint season quickly approaching (March to October).

FIGURE 1 | 2010 major market segments for TiO2. 2010 Demand ~5.3 million tonnes

Architectural Coatings Industrial Coatings PVC & Polyolefins Other Plastics Paper Inks Rubber Other Source: TZMI Database

By Eric Bender, Senior Consultant | TZ Minerals International, Australia 24



MAY 2011 | W W W . P C I M A G . C O M

By the onset of the paint season in 2010, inventories had fallen further, and only continued to deplete during the 2010 paint season. We believe that producers ended the year at near historical low inventory levels of 30-35 days’ sales. Most producers consider inventory of less than 35 days “sold out,” since they generally operate on monthly planning cycles and maintain numerous finished product warehouses in sales regions. Looking ahead, TZMI expects the emerging economies to drive demand for several years into the future, accounting for as much as 80% of cumulative demand growth over the next five years. We expect the mature economies (notably Western Europe and North America) to continue in a slow growth trajectory, as sovereign debt burdens and household debt levels must be unwound. North America will likely surge forward at some point in the future, but we believe this is likely to occur after 2015. In 2010, North America remained more than 250,000 tonnes (20%+) below peak demand levels of 2006. Overall, global growth rates are expected to exceed global GDP growth in the short term. Two pieces of evidence support our bullish forecast. The first is the rise of the middle class in emerging economies – particularly China, Brazil and India – which most economists expect to continue. As the middle class grows in number, the growth in disposable income, a key indicator for TiO2, is likely to outpace GDP in these countries. Second, TiO2 demand is still behind cumulative global GDP growth rates over the past decade, so the industry has some “pent up” demand that is likely to spur growth at greater than GDP rates. Figure 2 provides an “S Curve” function that indicates the steep curve for demand growth as emerging economies increase disposable income levels

likely to add less than 50,000 tpa of near-term capacity at a time when global demand is expected to increase by more than 200,000 tonnes. China’s producers will likely add a considerable amount of capacity in the next two years. Historically, new capacity added in China operates at much lower utilization rates – as low as 40-50% of nameplate in the initial years of operation. The significant near-term concern for China’s producers, however, is feedstock availability. The feedstock of choice for Chinese producers, sulfate ilmenite, will be in substantial shortage for several years. In practicality, sulfate producers in China will likely be limited by feedstock availability and will face significant price pressure for the material. The net effect is a cap on the amount of exports that China can provide to other emerging regions. Non-Chinese producers can fill part of this gap, but not all. Globally, we expect a continuation in shift in trade and rising TiO2 pigment prices, both of which have been ongoing since late 2010.

Saturation Level, % 100

2020

FIGURE 2 | TiO2 demand growth. 2010 2015

and are able to purchase more “quality of life” products like TiO2. Figure 3 provides a historical comparison of global GDP growth and TiO2 demand growth. On the supply side, the TiO2 industry has historically been considered an oligopoly. The industry has five major global suppliers that maintain more than 60% cumulative market share. E. I. du Pont de Nemours and Company (DuPont) is by far the largest with more than 20% market share, all of which is chlorideprocess. The balance is split among the following four global producers, in order of market share: Cristal Global, Kronos Worldwide Inc. (Kronos), Huntsman Corporation (Huntsman), and Tronox Inc. Two significant regional producers add about 7% market share: Ishihara Sangyo Kogyo (ISK) of Japan and Sachtleben Chemie GmbH (a joint venture between Rockwood Inc. of the United States and Kemira Oyj of Finland). China’s producers together represent more than 20% of global supply. The remaining producers are regional in nature and are mostly confined to Eastern Europe and India. As stated previously, supply has not kept up with demand since mid-2009, and 2011 is developing into the same headline (Figure 4). None of the global producers are expected to add significant capacity in the next two years due to the lead-time required for internal and external approvals. In 2010, Tronox and Exxaro added 43,000 tpa of chloride technology capacity to the Tiwest Joint Venture in Western Australia, following approximately 160,000 tpa capacity permanently shut down in 2009 (Savannah, GA, and Baltimore, MD, plants operated by Tronox and Cristal Global, respectively). Huntsman also “swapped” some of its UK-based sulfate capacity to chloride through the closure of Grimsby while at the same time expanding Greatham. TZMI expects the global producers to add capacity through de-bottlenecking activities, innovation and small capital investments, but these activities seem

80 60

Transition in emerging economies is transforming the industry

40 20

0

Sources: Rio Tinto TZMI Conference (Singapore), TZMI Database, Consensus Economics

0

10,000

20,000 30,000 40,000 GDP per capita 2005 US$ PPP

50,000

FIGURE 3 | Historical global GDP growth index versus TiO2 demand growth index. 1.30 1.25 1.20 1.15 1.10 1.05

GDP Ti02 Demand

1.00 0.95

0.90 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Source: TZMI Database

PA I N T & C O A T I N G S I N D U S T R Y



25

TiO2 Landscape Changing Rapidly

FIGURE 4 | Historical price index and capacity changes. ‘000 tonnes 2010=100 Overcapacity coinciding with ‘91/92 global recession. Price collapses and purchasing 200 250 power moves to customers. Period of “treading water” while Chinese180 200 led commodity boom occurs. Rising cost base is leading to margin squeeze for 160 -4.6% 150 TiO2 producers. 140 100 +0.9% 120 50 100 0 -50 80 Result of ‘84-89‘ global supply shock PLUS licensing of technology by Kerr60 -100 TiO2 Real Price Index Closures McGee (Tronox). All global producers -150 40 added a greenfields site. Greenfields plants -200 20 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 Source: TZMI Database

Feedstock Market The term “feedstock” in the TiO2 context refers to TiO2containing minerals that can range from 40-95% TiO2 content. Generally, sulfate operations use lower TiO2 feedstocks, while chloride feedstocks are generally higher in TiO2. TiO2 feedstocks are mined materials, with the majority of minerals historically provided from Australia, South Africa, Canada, the United States, Norway and a number of African countries. Australia, Canada and South Africa have historically been the major producing countries, accounting for around 56% of global supply. Feedstocks represent a significant cost for TiO2 producers, and TiO2 represents a significant cost for coat-

ings and plastics producers. The industry structural issues associated with these facts have been one of the primary causes of shrinking profitability in both the TiO2 and feedstock sectors. As a result, feedstock producers have also curtailed investment in the sector; in fact, many feedstock producers are mining companies with other investment options that were more attractive over the past decade. The issue with feedstocks is principally that investment today results in feedstock sales in 8-10 years, on average. As such, the feedstock supply landscape is mostly written for the next four to five years. Almost nothing can be done to remedy the situation that is evolving. As such, TZMI expects pricing in the feedstock sector to rise dramatically, with the undersupply situation to reach a crescendo in 2014 or 2015. For TiO2 pigment producers, there is almost nowhere to hide. We expect the cost curve to shift upwards in subsequent years through 2015. With pricing power clearly now upstream of the coatings sector, these increases in titanium feedstock pricing will ultimately be passed on down the supply chain.

Substitutes TiO2 substitutes have been around for decades. Two major substitutes are most pervasive: hollow sphere polymers and inorganic extenders. While the price for

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MAY 2011 | W W W . P C I M A G . C O M

2011 PCI

WACKER Improving efficiency, sparing resources AND reducing costs: what may sound like a vision of the future has long been part and parcel of everyday life for some companies. Take Wacker Chemie AG,

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for example: the Group offers customers of all sizes individually tailored e-solutions – from its webshop for secure and simple ordering, to paperless invoicing and integrated system solutions. As well as ensuring flawless standard processes and reducing the mountain of paper, they also leave staff to fully concentrate on the thing that matters: personal customer support.

Optimizing Processes. Cutting Costs! WHETHER IN A SMALL BUSINESS OR A LARGE COMPANY, ESOLUTIONS NOT ONLY BOOST EFFICIENCY, THEY ARE ALSO SUSTAINABLE AND USERFRIENDLY.

Customer Portals and Webshops: the Secure and Simple Way to Proceed Customer portals benefit SMEs and global players alike. Provided, of course, that they are consistently user-friendly and offer clear added value. Portals such as WACKER’s Login4more are all about service. Each customer is given a secure login, enabling them to access a wealth of tailored information and personalized services – from the ability to view the status of orders to the chance to receive information on a range of products, tailored to individual customers. Online ordering not only frees up staff, it also eliminates traditional sources of error. There’s even an added bonus: less stress, greater efficiency.

Paperless Invoicing On request, invoices can be sent out as a PDF document. A small innovation with a big impact: Swiss payments service provider, Billentis, has calculated that it costs an average of €2.20 just to archive a single paper invoice – and that goes for both the sender as well as the recipient.

What’s more, e-invoicing saves on natural resources. An important consideration for companies committed to protecting the environment: around twelve million trees are felled annually for paper invoices in Europe alone.

Automated Ordering – Using your Own System Integrated system solutions are an attractive prospect for larger companies. Wacker Chemie AG uses Elemica – the global network solution – to transfer data fast and securely between business partners. Elemica understands the customer’s system language and translates it for WACKER’s own SAP system. Customers place orders in the normal way using their own systems. Orders are automatically placed and an order confirmation sent out. WACKER customers even have the chance to amend an order once it has been placed. On request, the system can issue an Advanced Shipping Notice telling the customer when the goods have left the factory. What’s more, paperless invoices can be issued.

The Future Is Now: Topping Up Stocks Automatically Our Vendor Managed Inventory system, or VMI for short, offers yet more possibilities. VMI checks customer stock levels at agreed intervals. If, say, a silo’s contents fall below a certain limit, a sales order is automatically triggered. By being notified in real time, the customer enjoys certain benefits: extra costs caused by inflated stocks and costly express deliveries become a thing of the past. Errors are avoided and the administrative costs are considerably reduced. “It’s not the large challenges which sap the most energy in the workplace, it’s the daily routine,” confirms Sabine Brosch, WACKER’s director of Online Services. “That’s why we have been investing in e-solutions for a long time now, helping to ease the burden on our customers.” What’s more, she adds, customers tell us that they can see the benefits for themselves – which is why e-solutions are welcomed by such a high number of decision-makers and users. “The most important thing we have learnt is that our e-solutions are consistently geared to user needs. Plus, they bring partners even closer together.”

Greater customer proximity: by offering pioneering e-solutions, Wacker Chemie AG defines itself as a supplier consistently focused on the needs of its customers.

www.wacker.com/e-business PA I N T & C O AT I N G S I N D U S T RY



TiO2 Landscape Changing Rapidly

TiO2 was in decline and supply was abundant, users of TiO2 pigment did not need to pay close attention to substitutes since formulating these products required more effort than generated savings. Most likely these products are getting a second look by formulators looking for ways to

offset increased costs without compromising the performance of products. TZMI believes that the ability of substitutes to play a major role in curbing TiO2 demand is limited in the short-term. Extenders are generally inexpensive, but have limited ability to replace the

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functional attributes that TiO2 provides (opacity and brightness). Hollow spheres can probably replace 10-15% of TiO2 in targeted formulations, but the functional change to the attributes of the end products to accommodate these alternatives often limits the use to a minority of formulations. As TiO2 prices continue the march up, the substitute products will gain more favor, but TZMI believes the net impact to demand is probably limited to 1% in the next two or three years.

TiO2 Outlook TiO2 prices have been rising dramatically since mid-2010. The fundamentals supporting the rapid increases are low inventory, high capacity utilization levels at producers, rising costs and a persistent under-supply situation. Prices are likely to continue the upward march as fundamentals are not likely to change in 2011 or 2012. Already, TiO2 producers have announced increases of $300 per tonne in most regions. We believe the price increase announcements will continue through 2011 and 2012. We also predict that the supply of feedstocks is in question – more so for sulfate producers in the short term, with all feedstocks impacted over the next five years. The impact is not limited to costs for TiO2 producers; security of supply and potential disruptions to TiO2 pigment customers are also serious concerns. Some pigment customers may experience supply disruptions, some of them significant. Historically, there are two to three significant production disruptions (e.g., hurricanes, earthquakes, accident, equipment failure, etc) per year. Already in 2011, Sakai Chemical’s plant in Onahama, Japan has been temporarily idled due to the impact from the massive earthquake on the northeastern coast of the country. This site’s status for the remainder of 2011 is uncertain. Further disruptions in 2011 could result in significant impact on pigment prices. TZMI believes the TiO2 pigment undersupply situation will persist until at least 2013. The global producers are developing capacity addition plans and will be deploying capital for smaller brownfield expansions prior to 2013, but significant capacity is likely to come on after this period. Given the poor financial history of the industry, global producers are likely to be more disciplined in adding capacity during this growth phase of the industry. 

E-mail Eric Bender at [email protected] for more information.

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olor was everywhere at the 2011 European Coatings Show. Following is a report of just some of the pigment technology that was on display. Merck KGaA showcased fascinating application examples of its effect pigments. Mannequins wore a Uvex helmet glittering with the intense color effects of the Pyrisma® range. These interference pigments are based on natural mica and stand out due to their exceptional color saturation. The Merck stand’s painted wood floor was coated with Colorstream®, an effect pigment with a fascinating color travel effect depending on the angle of viewing. Merck also presented an Audi A7 Sportback painted with “Daytona Gray Pearl Effect”. The intense sparkle of a silver-white pigment of the Xirallic® range made this coating an eye catcher. Clariant launched three new Easily Dispersible (ED) pigments for water-based decorative pigment dispersions. This EDW range is a major step towards completion of the whole color circle from yellow to blue for decorative applications. Clariant aims to achieve this target by the beginning of 2012 to offer a full pigment range that includes highperformance organic pigments as well as economic grades. EDW pigments offer a unique approach to simplifying the pigment dispersion process by removing the need for an expensive and time-consuming bead milling step. Heubach featured HEUCO®FIT, an innovative pigment preparation concept that utilizes the synergies of inorganic and organic pigments, combining high tinting strength, saturation and a broad color range with the highest durability and hiding power. Heubach also introduced VANADUR® 1030, a non-encapsulated grade, green-shade Bismuth Vanadate pigment. HEUCODUR® IR 945 is the new star in Heubach’s IR-reflecting pigments product line. It combines jetness and a neutral color shade in reductions with an extraordinary IR-reflecting ability. Sudarshan, the largest pigment producer in India, featured its range of organic pigments for the automotive, industrial and decorative coatings markets. Just some of the brands featured included: Sudaperm™, a premium range of the highest performance organic pigments, with technical benefits for the most demanding plastics and coatings applications; Sudafast™, a high-quality range of mediumperformance organic pigments; Sudacolor™, a range of organic pigments that provides a combination of quality, value and ease of use; and Sudadur™, a range of traditional inorganic pigments that impart excellent color, durability and coverage for the most demanding applications. BASF presented Firemist® Velvet Pearl EH 921 (9P130I), a new effect pigment that offers an antique, matte pearl By Kristin Johansson, Editor | PCI Magazine 30



MAY 2011 | W W W . P C I M A G . C O M

surface, yet with a sharp, clear sparkle that appears only when light hits it at a certain angle. The company also launched new inorganic grades for Luconyl® NG aqueous pigment preparations for architectural coatings. The labelfree Luconyl NG range is both VOC- and APEO-free, while also conforming to the GHS 2015 standard. It covers a wide color space and features excellent durability for waterbased and solar heat management facade coating systems. Burgess Pigment featured its OPTIWHITE ® calcined aluminum silicate product line. OPTIWHITE is a premium whiteness, flash calcined extender for TiO2, exhibiting excellent GE brightness used extensively in first-line interior/exterior flat or low-sheen waterbased and alkyd paint systems. CPS Color Group Oy announced at the ECS the acquisition of LENTEQ Industries B.V., a specialist provider of dispensing and mixing equipment based in Lisserbroek, the Netherlands. LENTEQ’s strengths in innovative piston pump technology are set to enhance and complete CPS Color’s product portfolio. CPS Color showcased the latest in tinting technology, including its VOC-free colorants. The company’s portfolio also includes waterborne, solvent and low-VOC options. Nubiola showcased a non-hazardous greenish yellow Bismuth Vanadate and NUBIFER Y-7050, a new heatresistant yellow iron oxide. In addition, the company featured its range of ultramarines, iron oxides, zinc ferrites, chrome oxide greens, chrome yellows, molybdate oranges and corrosion inhibitors. The Shepherd Color Co. featured its Arctic® line of infrared-reflecting pigments and Dynamix® stir-in pigments. Arctic infrared-reflective pigments allow for the design of products that remain cool under the sun, without sacrificing color. Dynamix stir-in pigment technology requires only simple mixing. The time it takes to reach complete dispersion will depend upon the intensity of the mixing equipment, but it can be achieved in as little as five minutes. ECKART presented the next generation of its high-end metal and pearlescent pigments, including IReflex, which contributes to the reduction of heating energy when mixed with conventional interior wall colors due to the heat-reflecting effect of the special off-white aluminum pigment. ECKART also introduced a new quality of silver dollars – SILVERSHINE S-1500. Its fine and homogeneous composition offers bright and chrome-like effects. From the pearlescent pigment series, LUXAN CFX offers robust resistance against weather and condensation, in addition to providing a fascinating sparkle effect. Four pigments have already been launched in the LUXAN CFX series: two silver-white shades, one interference blue tone and a brilliant gold color. 

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PERFORMANCE COLORS Sudarshan Chemical Industries is a prominent producer of performance colors, manufacturing an extensive range of organic pigments and mica-based effect pigments. The company has more than 50 years of manufacturing experience. Sudarshan products are available worldwide and meet international quality, environmental and safety standards.

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31

Is Calibration Really Necessary?

D

eciding how and when to calibrate color, gloss and haze instruments can be a difficult decision. How often should the instrument be checked? Do you use the local calibration house that is already taking care of the basic test equipment? Should the instrument be sent to the manufacturer for calibration? Or should one forgo recalibration and use it as is? This article will look at the factors that affect this decision and the impact it may have on your measurement system. With modern electronics, calibration seems like an unnecessary expense. But several factors are involved and must be considered to make the correct decision. • Is the instrument maintained in good condition, free from dirt, mishandling, temperature extremes and impact damage? • Has the instrument been checked on a secondary standard on a regular basis? • How critical is the measurement to the process?

BYK-Gardner’s technicians have the advantage of factory training, full parts support and computer-based calibration software to bring instruments back to as-new performance.

• How much tolerance is allowed in the measurement? Let’s take a closer look at each factor. • Many instruments lead a rough life. Even with the rugged construction of modern electronic equipment, instruments used on the production floor usually get very dirty inside. Optical instruments utilize a light source, lenses and other optics along with a detection system to make accurate measurements of products. Dust or fingerprints on the lenses will reduce light throughput. Rough handling or dropping the instrument can lead to misalignment, cracked lenses and loose optical components. On the other hand, meters used in a clean, laboratory environment stay clean and are generally handled with greater care. • It is important to have a good standards program in place and to use secondary standards on a regular basis to verify the operation of the meter. • The appearance of a product is often a significant factor in the overall quality of the product. An out-of-spec instrument can result in a variable or incorrect product sent to your customers. • What is the allowable tolerance within a given production process? If it is only a few units, it becomes critical to verify that the instrument used to check that process is operating to specification. Once you have evaluated your specific situation, a decision on how often the calibration check should occur can be made. Generally, the recertification interval is set at one year. If the environment is clean and no out-of-tolerance condition is noted following certification checks, then think about increasing the interval to two years. But if every year the instrument is found out-of-tolerance, then it is time to shorten the interval to every six months. Who should perform the recertification? There are many certification labs that are perfectly equipped for certification of multimeters, thermometers, calipers and other popular test equipment. But for glossmeter, hazemeter and spectrophotometer calibrations, there are very few that bother to invest in more than just a few test

By Rick Trawick, Development Engineer | BYK-Gardner USA, Columbia, MD 32



MAY 2011 | W W W . P C I M A G . C O M

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Is Calibration Really Necessary?

MINEX ® delivers unique physical and photochemical properties ideally suited for clear coats. Its low refractive index is best utilized in transparent wood and furniture coatings, where MINEX can be loaded up to 20% without excessive haze to improve hardness, light stability and moisture resistance.

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It is difficult to believe this much dust accumulated in less than three weeks. The service technician did not have the information needed to disassemble and properly clean this glossmeter.

tiles. In essence, these labs are doing nothing more than reading a checking standard and printing a calibration certificate if the instrument reads within whatever tolerance they choose. This is nothing more than can easily be done in-house with the purchase of your own checking standard. As a manufacturer of precision appearance measurement equipment, BYK-Gardner’s service center is fully equipped to perform a complete calibration. Factory-trained technicians disassemble each instrument, check for loose or damaged components, then thoroughly clean and reassemble them. Each instrument is then checked against a full range of standards and run with proprietary software that adjusts the instrument to optimum operation. Calibrations are performed in an environmentally controlled area to assure consistent results. These tools are not used by third-party calibration companies due to their cost and complexity.

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MAY 2011 | W W W . P C I M A G . C O M

A BYK-Gardner micro-tri-gloss was recently received for service. The user was concerned that he had just had the instrument “calibrated” by a third-party company, but he suspected the readings were not correct. Our customer sent us the instrument less than three weeks after the third-party calibration. Note the amount of dirt on the lenses. The haziness observed in the photo is light reflecting off of the dust layer behind the lenses. This can only be removed by disassembling the glossmeter. We also found the glossmeter had a cracked 85° lens. Correcting these issues required several hours of disassembly and cleaning to restore it to functionality. Without the proper training and experience, the third-party company was unable to correctly service the glossmeter. Having the meter checked and certified by the manufacturer would have saved this customer hundreds of dollars and eliminated the need to recheck thousands of dollars worth of questionable material tested while the glossmeter was not working correctly. Calibration on a regular interval assures consistent measurements and consistent results. By staying with the original manufacturer for calibration services, the highest quality of performance can be expected throughout the instrument’s lifetime. 

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Outdoor Weathering Must Verify Accelerated Testing

C

urrently, all weathering testing is done using either an outdoor exposure location or indoor accelerated testing equipment. These two major test types are not the same. Accelerated tests are made with controlled, artificial light sources in the laboratory, whereas natural weathering is performed in large outdoor fields with real sunlight but where all the exposure parameters are not controlled. Table 1 gives a comparison of outdoor and accelerated tests. The choices that are laid before us are whether to use the fast, controlled exposure that uses simulated conditions, or the slow, noncontrolled test that is known for its realism. For many, the choice has been to pick speed over substance. When making the decision about which type of testing program to follow, there may be a number of “psychological” factors that unintentionally affect the outcome. In order to make a more informed and reliable choice about testing, we need to understand those biases, or what we might call Weathering Myths. Note: A myth is an unproven legend, a story that has been around for so long that it takes on a truth of its own.

Weathering Myths Myth #1: Accelerated tests are 100% repeatable. The truth is that accelerated tests are as variable as any other test. In fact, accelerated weathering, even in the most controlled test, can produce a great deal of variability in the results. Repeat tests in the same device and reproducible tests in different laboratories may have high differences. A major round-robin was performed by ASTM Committee

TABLE 1 | Comparison of accelerated and outdoor tests. Accelerated Tests

Outdoor Tests

Testing chamber Controlled conditions Artificial light source Simulated weather conditions

Racks in large fields Uncontrolled conditions Natural sunlight Real weather conditions

G031 in the 1990s and found that there could be as much as 30% difference in results from several devices. This difference is reduced with correct operation. Myth #2: Any degradation is good. The truth is that the wrong degradation mode is a bad result. If the failure mode in the real world or outdoor test is not reproduced by the accelerated test, then the accelerated test should not be used. For example, if a coating normally exhibits moderate chalking outdoors but displays severe cracking in the accelerated test, this shows that a different failure mechanism is occurring and the results are therefore meaningless. The accelerated test chamber must create the same failure type as the outdoors. Myth #3: Outdoor weathering requires five years to provide useful data. The truth is that outdoor testing can yield useful data in 12 months. While it may be necessary to wait five years to find out five years of degradation, there is much useful information that can be obtained in the first 12 months of exposure, such as the distinction between good and bad material. The truth is that with the correct experimental design and plentiful evaluations, meaningful data can be obtained that will greatly increase the confidence of the accelerated data. Myth #4: Weathering test data is absolute. The truth is that no single test will yield perfect correlation. There are a number of material specifications that require a single test specimen to be exposed and where a pass/fail threshold is set. For example, if a color difference of 3.0 ΔE units is the criteria, then a value of 2.9 passes, but 3.1 fails. Yet we know the variability of the color measuring equipment is such that any comparison where the color difference is less than 1 ΔE unit is meaningless. The limit of human perception is also no better than 1.0 ΔE. Myth #5: Ranked data is weak data. The truth is that ranked data can be powerful if correctly applied. There is a thought that non-parametric statistics, such as ranking, cannot be of any use because they are based on less powerful techniques. When properly applied, ranked data can be used to prove many of the hypotheses we test

By Michael Crewdson, Managing Director | Q-Lab Weathering Research Service, Homestead, FL 36



MAY 2011 | W W W . P C I M A G . C O M

in weathering. Ranked data works well with numerical data produced in subjective evaluations.2

Unforeseen Problems The problem we are facing as a testing industry is that many companies perform only accelerated weathering tests on their materials. The outdoor testing is either given second-class status, or is just simply ignored. The time-related pressure of moving a new material to market has forced a reduction in the development cycle, and this affects the durability testing. Most product development now is done with only the results from accelerated testing, and many material specifications will accept a material with only accelerated test results. Using ONLY accelerated testing can have unforeseen problems. The main consequence is that the material is formulated for resistance to an artificial climate. As the cycle of testing, reformulation and retesting continues, the end result is a material that can withstand exposures to a simulated and controlled environment. This can lead to field failures when the material that has passed testing in the laboratory then fails in the end-use environment. Accelerated tests are not 100% reliable in predicting what will happen outdoors. The search for a universal test method with perfect correlation is our industry’s equivalent of the quest for the Holy Grail. Correlation factors are not transferable from one material to any other or for the agreement to a different outdoor climate. If we could be sure of complete agreement in an accelerated test, the only need to conduct weathering outdoors again would be if we were comparing to a new climate. But even repeat tests where nothing has supposedly changed will give different results. Using only accelerated testing means taking a big risk when trying to determine the true reliability of the material.

Correlation For the purposes of weathering testing, correlation is defined in ASTM G 113 as follows:3 “The agreement of results between outdoor and accelerated tests.” Therefore, the results from the accelerated test are supposed to match the results from the outdoor test. Most research effort into this elusive target has focused on accelerated tests, but it is apparent that the key to correlation is the outdoor test. Without outdoor weathering as a baseline, there is nothing to provide a fixed comparison for the accelerated test.

Cost It is surprising that one of the major excuses for not doing the outdoor test is the cost factor. This should be the least of any worries, and while it may not be a technical issue, we do recognize that many important technical concerns are not being addressed because of the misconception that weathering testing is expensive. What should be considered is the cost of not testing. Table 2 compares the cost of a typical outdoor test to the cost of not doing a test. For the up-front saving of up to $1,000 per year you could be risking your company’s reputation as well as the potential for millions in warranty replacements, and potential litigation. The small investment in outdoor weathering tests should be compared to the potential cost of not testing.

Note: These figures are representative and do not reflect any particular charges. Testing costs may differ amongst different commercial providers of these services, as well as between commercial services and conducting the testing yourself.

Cyclic Conditions One of the reasons we see many reports indicating poor correlation is because the factors of weathering are different in the weathering chamber than in the outdoor environment. The conditions within the chamber can cycle between any of the conditions in Table 3, but there are many factors missing. Table 3 shows that the three basic factors of weathering are included in most accelerated weathering test devices. The right-side column shows that there are many more factors that can influence outdoor weathering. Each new factor gives the possibility for many more related interactions.

Cycle Times Compared Even when we look at only those factors that occur in both the outdoor and the accelerated test, there is a difference in the cycle timing. For outdoor testing we are dealing with one complex cycle per day, whereas in the accelerated device, we are dealing with multiple, complex, repeating cycles per day. A summary of the differences in the cyclic conditions can be found in Table 4.

Cycle Rate Comparison Compared to the outdoor environment where there is only one cycle per day, there may be as many as 12 complete cycles in the accelerated test. We have known for some time that cyclic exposures tend to be more severe than steady-state exposures. It is the changeover from one steady-state condi-

TABLE 2 | Cost comparison of testing. Factor

Testing

Not Testing

Cost of test Downside Customer service Image

$500 to $1,000 per test None Happy customers Great reputation

$0 per test Potentially millions of $ Unhappy customers Loss of reputation

TABLE 3 | Factors of weathering comparison. Accelerated Test

Outdoor Test

Artificial light Temperature Water spray

Sunlight Temperature Rain Condensation Humidity Biological Acid deposits Dirt and contaminants

TABLE 4 | Comparison of cyclic effects. Average cycle time Cycles per day Dark period Cycle consistency

Accelerated Tests

Outdoor Tests

2 - 4 hours 6 -10 cycles Possible Same every time

24 hours 1 cycle Always Different every time

PA I N T & C O A T I N G S I N D U S T R Y



37

Outdoor Weathering Must Verify Accelerated Testing

tion to another that puts the material under stress and causes degradation. Therefore, faster turnaround in the cycles should increase the degradation of the material because it is being subjected to more of the conditions that may cause degradation. In reality, this may or may not be true. As conditions change, the exposed material will be attempting to equilibrate to its surroundings. For example, if the material is wet and the atmosphere is dry, the material will become drier, or if a cold material is placed in a warm environment it will begin to warm up. The environment contains the possibility of changing faster than the material. If the material does not equilibrate to the conditions before the conditions change, the materials will never reach a steady state (Figure 1). All materials have a different rate at which they can adapt to the changing conditions around them. So it is quite possible that in the same exposure, some materials will equilibrate and some will not. Some materials will not completely attain the steady state. If the material under test does not attain steady-state equilibrium with the surrounding atmosphere, the effects

Action and Response

FIGURE 1 | Environment and material equilibration. 10 Accelerated Conditions

5

Accelerated Material

0 -5 -10

Cycles

FIGURE 2 | Comparison of cycle effects on material.

Response

10 5 0 -5 -10

will not penetrate into the depths of material. Short cycles will only have an effect on the surface layers. To reach the interior of a specimen, it is necessary to lengthen the cycle times in order for the whole of the material to be under the influences of the exposure conditions (Figure 2). This difference can be summed up by the term “Chamber Factor”. This implies immediately that the changing conditions inside the weathering device cannot match the outdoors unless the cycle times and the ramping rates are identical to the outdoors. If the changing conditions do not match the outdoors, the effect on the material will be different. We can draw the following inferences from this. First, it is clear that weathering chambers cannot match the complexity of the outdoors. There are more variables in the outdoors, and the cycle timings are significantly different. Second, as a consequence, enclosed chambers and open spaces may not yield the same results

Accelerated Test Design Once we comprehend the shortcomings of accelerated testing, we can plan our approach to creating an accelerated weathering test program. This is a bigger commitment than simply slipping some specimens into the first accelerated weathering device we find with some extra space. The following is the basic outline of a plan that can be followed to get the best possible test cycle. 1. Accelerated test conditions and cycles should be developed using a plan of simulate first, then accelerate. 2. Determine the extremes in the weathering factors, for example, highest and lowest temperatures, maximum irradiance, relative humidity ranges, etc. 3. Determine the response rates of the material. What is the rate of change in moisture content when moving from a 50% to a 100% RH atmosphere (and in the reverse direction)? 4. Determine the minimum cycle time based on the material reaching the steady-state condition. 5. Consider an unbalanced cycle (such as the SAE J2527) in lieu of the same, old repetition (such as the 102/18 cycle). 6. Once a test method is demonstrating some promise, the test can be repeated to prove repeatability. 7. Ruggedness testing, by increasing one parameter at a time, can be used to determine the limits of acceleration.

Time (one day)

How Much Acceleration? Accelerated Conditions Outdoor Conditions

Accelerated Material Outdoor Material

FIGURE 3 | Simulation, acceleration and correlation. 100%

Degree

80% 60%

Acceleration Correlation Idealized

40%

Correlation Typical

20% 0% 1

2

3

4

5

6

7

8

9 10 11

Steps 38



MAY 2011 | W W W . P C I M A G . C O M

When you have zero acceleration in the simulated test, you can expect to get close to 100% agreement. As the degree of acceleration increases, the obvious reaction is that there will be a corresponding decrease in agreement. In an ideal test there will be a direct relationship between agreement and acceleration, but the typical situation is that there are thresholds. This is where the agreement remains pretty good for a certain amount of acceleration, but then drops off dramatically (Figure 3). This is due to one of the influencing factors exceeding a critical point.

Outdoor Weathering How do you make sure that you get good data in a meaningful time frame? The design of the outdoor test must be done correctly before the test is started. Your outdoor weathering program also requires some advance planning. Test objec-

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Outdoor Weathering Must Verify Accelerated Testing

tives must be determined before you begin your exposures. The following is a list of good practices to follow in order to maximize the success chances from the correlation. • Begin testing as soon as possible. • Use many replicates. • Evaluate regularly and often. • At least five evaluation intervals per test.

• Use control or reference specimens. • Establish a baseline of material degradation. • Typically 12 to 24 months sufficient.

Specimen Matrix The typical experimental material variable array is unbalanced. This will cause problems, as large amounts of raw data need

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to be reduced into groups in order to see patterns develop. For many years we have heard that the right way to do an exterior exposure test is to expose as many specimens as possible, as quickly as possible. If not planned correctly though, the excessive amounts of data collected by the end of the test can make all the results appear random. Our desired evaluation of a new test method might look like the following example for an automotive paint.



MAY 2011 | W W W . P C I M A G . C O M

r

TM

Red, Blue, Green, Yellow, Black, White, Gray (7) Substrate: Steel, Aluminum, Plastic (3) Binder: Binder A, Binder B (2) Color Coat: Reflective, Matte, Glossy (3) Topcoat: Polyester, Silicone (2) Number of specimens is the multiple of all the variables and in this case is 7 x 3 x 2 x 3 x 2 = 252. The total of 252 is considered to be an average test for an outdoor exposure test, but for many studies this is too big of a sample set to expose in the accelerated test. We could then consider a partial sample set, which reduces the quantity of specimens. A smaller matrix extracted from the above plan might look like this. Colors 3, Substrates 2, Binder 1, Color Coat 1, Topcoat 2 for a total number of variables of 3 x 2 x 1 x 1 x 2 = 12. This set can be tested and if the results are promising, the rest of the matrix can then be evaluated.

Balanced Design The specimen matrix must be balanced so that meaningful comparisons can be made. In order to get meaningful conclusions, individual results need to be grouped, and in order to do this properly, all specimen types must be represented in all the tests. • Every variable must be in every test. • Use an equal number of specimens in each test. • Use the same number of exposure periods in each test. • Use the same evaluation techniques throughout. The schedule of evaluations does not have to be evenly distributed. It is acceptable to schedule more evaluations in the early periods of the test. This is likely to be the time when the greater amount of change is achieved. The use of replicates is most important. Too many tests are conducted with only a single specimen representing each variable. The end of the test, when it is time to analyze the data, is not the time to find out that not enough specimens were exposed. • More specimens lead to better data analysis.

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Outdoor Weathering Must Verify Accelerated Testing

• At least three of each kind allows mean, median and standard deviation calculation. • More specimens permit a conclusion with smaller difference between results.

Reference Materials Reference materials, which are also known

as control materials, are a valuable tool in comparing accelerated and outdoor tests. A reference, or control, material is one with known performance, and this can be used to verify that the accelerated test is yielding the correct failure types. Use the reference material to compare different tests or different exposures. The accelerated test is only

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useful if it produces the same type of degradation as the outdoor exposure. By basing the end point of any test on the amount of degradation on the control material, we can make judgments as to whether the other materials are better or worse. The results from the reference materials can be used to “normalize” the results. If we know that we get a certain amount of degradation on the control material in a set time frame outdoors, we can use that to determine the amount of time in the accelerated device that is equal to the time outdoors. When the amount of time to reach this point changes from one test to another or from one exposure to another, we can always use the response of the reference material to reset the time scale. Another “best practice” method is to always expose one good and one bad “control” material. When only one control material is included in the test, it should have a degradation end point somewhere in the middle of the pack. That is to say, the control material should not be the best performer nor should it be the worst performer. This is sometimes very difficult to predict, so a more reliable approach is to include two control materials. If you incorporate one relatively good and one relatively bad control material, it is easier to make sure their results fall somewhere in the group, and this also has the advantage of always knowing the “difference” between the two controls. When we talk about control or reference materials for accelerated or outdoor weathering, this material is one of your own products. This material is not one of those standard reference materials such as blue wool, or a polystyrene chip. Your reference material should have been tested often, or there should be a large amount of data on its known performance in the end-use environment.

Repeat the Test

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MAY 2011 | W W W . P C I M A G . C O M

It is most important and often overlooked, but you must repeat the tests. This will prove the test method is correct by ensuring repeatability. We need the data from repeat tests to show the inherent variability in the testing. The difference in the performance of two materials must be more than the inherent variability of the test before it is possible to say with any certainty that there is a real difference. The second step in developing a standard test is to prove it can be done again. Lastly, it would be good practice to see if the test can be reproduced by another lab or by another technician.

Outdoor Weathering Must Verify Accelerated Testing

Unknowns Determine and measure the unknown factors that will appear when testing. It is a fact of weathering testing that we should expect the unexpected. Therefore when unexpected events happen, make notes and store the data. There may be a time when the odd data reveals a pattern. If something happens differently in one test versus another or between the outdoor and accelerated tests, this might mean there is a different failure mechanism.

Gather the Data To correctly examine the testing, our recommendation is to ensure there are at least five evaluation intervals during the extent of the test. If the initial condition is one of these intervals, that means we need four other sets of results. In the opinion of this author, this is the minimum quantity of data sets needed to properly track the degradation. The following three rules should be followed. 1. Know your degradation mode. This will ensure that when the results are forthcoming, only the correct type of degradation will be acceptable. 2. The degradation result must be the same in all tests. The test is invalid if you get different failure modes in the different tests. If cracking is found outdoors, and blistering occurs in the accelerated test, the wrong failure mode is being recreated. 3. Evaluate for all known degradation modes. It is not good practice to only judge a test by one failure mode. In most cases there are typically multiple degradation symptoms. Testing for only one failure mode may prevent us from seeing if we have a problem as per rule

TABLE 5 | Comparison of evaluation groups. Non-Destructive

Increases specimen quantity Looks at internal properties Objective Variable

Reduces specimen quantity Only gives surface data Subjective Consistent

TABLE 6 | Weathering evaluation methods. Non-Destructive (Surface Properties)

Tensile Impact Bend Hardness Abrasion

Gloss Color Visual appearance

FIGURE 4 | Time degradation curve accelerated test.

Gloss Loss %

100 80

1

60

2 3

40

4

20

Acceleration factors are the most widely requested information. We are often asked “How many hours in a weathering chamber equals one year in Florida?” or “How many years in Europe equals one year in Florida?” We cannot answer these questions, but we can provide instructions on how those numbers can be determined for a particular specimen in a specific test. The following list is a guide for how to determine your own acceleration factors. An example of how to calculate acceleration factors can be found in the section on time degradation curves. Summary of steps to create Acceleration Factor: 1. Use Time versus Degradation curves; 2. Compare the accelerated and outdoor; 3. Check for time to reach same amount of degradation; 4. Verify by ranking or compare means; 5. If results are the same, calculate acceleration factor (AF); 6. AF = Time outdoor/Time in accelerated.

In the general field of weathering, there are two good practices for examining data.

Time Degradation Curves As described above, this technique requires nothing more than to track the degradation results over time. By plotting the points on a graph we can see the shape of the curve. Not all degradation is linear. In fact, most degradation curves show a stable period, followed at some point by a marked increase in degradation. By comparing the degradation curves of the same group of materials in both the accelerated and outdoor test we can determine such things as: • Is the shape of the curve similar? This tells us whether the failure mechanism is the same. • Does the relative performance of the specimens change during the test? This tells us that we must be careful about when we perform the determination about the comparison of the tests. • Is the overall duration of the test correct? The most favorable point in the test for determining performance differences is where there is the greatest separation. The greater the difference between the specimens means we can more easily and confidently conclude relative performance rankings.

5

0

6

0

250

500

750

1000 1500 2000 2500 3000 Hours

44

Acceleration Factor

Data Analysis

Destructive

Destructive (Inherent Properties)

number 2 above. Keep all original data, especially if testing for instrumental color difference. Choose a type of evaluation that most closely meets your needs. Table 5 compares advantages of the different evaluation types. The measurement techniques described in Table 6 are a sample of the type of analyses that can be performed on weathered specimens. Non-destructive testing can be used to rate surface properties and have the advantage of requiring fewer specimens. Destructive testing will determine inherent properties of materials, but as the specimens are destroyed during the evaluation process, more specimens are needed initially.



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7

The time degradation graphs in Figures 4 and 5 can be used to generate the acceleration factor calculation in Figure 6. The data shown in Figures 4, 5 and 6 is only

Statistical Analysis All testing results should be reviewed by some form of statistical analysis. The right statistics will tell you all the important things you need to know from a test. • Is the test method realistic? • Are the test results reliable? • What is the acceleration factor? Although there are many statistical methods available, two simple, yet powerful statistics are recommended. These recommendations are based on many years of application to weathering data.4 Comparison of Means (Student t) see Eq. 1, and Rank Correlation (Spearman’s rho) see Eq. 2, are recommended by ASTM Committee G03 and can be found in ASTM G 169.5 Comparison of Means • Directly compare two sets of data Is one test different from another? Did two specimens perform differently?

FIGURE 5 | Time degradation curve outdoor test. 100 Gloss Loss %

an example of how this type of calculation can be made. One other indication that the test comparisons are good is that all the individual specimens have approximately the same acceleration factor. If the factors are different, this will show that the accelerated test is not a good simulation of outdoor exposure.

1

80

2

60

3

40

4

20

5 6

0 0

6

12

18

24

30

36

42

48

54

60

7

Months

FIGURE 6 | Acceleration factor creation. Xenon Arc Exposure 50% Gloss Loss 1 = 1800 hours, Rank 2 2 = 1250 hours, Rank 1 3 = 3000 hours, Rank 7 4 = 2250 hours, Rank 5 5 = 2100 hours, Rank 4 6 = 2500 hours, Rank 6 7 = 1900 hours, Rank 3

Outdoor Florida Exposures 50% Gloss Loss 1 = 30 months, Rank 2, AF 12:1 2 = 24 months, Rank 1, AF 14:1 3 = 45 months, Rank 7, AF 11:1 4 = 40 months, Rank 5, AF 13:1 5 = 36 months, Rank 4, AF 13:1 6 = 42 months, Rank 6, AF 12:1 7 = 33 months, Rank 3, AF 13:1

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45

Outdoor Weathering Must Verify Accelerated Testing

TABLE 7 | Testing opportunities. Outdoor Location

Accelerated Test

Hot, wet, UV Very hot, dry, UV Temperate Pollution Seashore Very cold

Xenon Fluorescent UV Solar concentrator Combined UV/salt

In this statistic, equal rankings are allowed but must be accounted for by using half values. This statistic may only be applied if the exact same number of specimens were exposed in both tests. This statistic is best when used to evaluate various colors, or multiple materials, in two tests.

Best Practice Testing

TABLE 8 | Testing program example. Exposure location Light source Duration Intervals Evaluations Specimen size

Outdoor

Accelerated

Florida 5 degrees South 60 months duration Measure at 3 months Color, gloss, visual 300 x 150 mm panels

Xenon arc Daylight filters 3,000 hours Measure at 250 hrs Color, gloss, visual 75 x 50 mm panels

• Compare experimental to production Is the new product better than the old? Is there a significant improvement? Student t Test • Determine the two means X1, X2 • Determine the two standard deviations S1, S2 • Count the specimens N1, N2

X1- X2

t=

(N1-1)S21+(N2-1)S22 (N1+N2-2)

1

1

Putting it all Together

+

N1 N2

When it is time to start your weathering test, you have many options to choose from. The best practice is to run several outdoor and several accelerated tests and use the statistics above to determine which test method gives you the most realistic results. Table 7 is a list of the current technical possibilities for both outdoor and accelerated testing. The different outdoor locations are used to ensure that all potential failure modes are examined. When you have found which test method is most suitable, you can conduct future testing with that procedure. Note: You should re-verify the test exposure conditions if there are any changes to the formulation of the material. When the material changes, so does its response to the exposure conditions. Use a control specimen and re-expose along with the new material. Table 8 shows one possible consolidated outdoor and accelerated test program. In this case the following assumptions have been made. The material is an automotive exterior paint that exhibits gloss loss and color change. The manufacturer wishes to have a five-year warranty on the performance of the material. Early examination of the material has shown that the failure modes can be recreated in a modified SAE J2527 test. There is a new directive to reduce the cost of producing the coating, and the testing laboratory is to determine if the newer and cheaper formulation has the same durability as the existing product.

(1)

One major advantage of this statistic is that it can be applied independent of specimen quantity, so that there does not need to be an equal number of specimens in each test.6 This statistic is best when used to compare one material, or one color, or one type in each test. Rank Data • Rank the specimens in order of performance. • Use measurable targets. Time to 50% gloss (example) Ranking at greatest differentiation Ranking at end of test • Can be used to determine if an accelerated test is a good predictor of real time.

Outdoor testing is essential for the validation of the accelerated testing. The outdoor testing can be done simultaneously with the accelerated exposures, and with the use of correct evaluations and statistical analysis will increase the confidence of conclusions taken from the accelerated tests. Laboratory-accelerated tests are one of the most useful tools available to researchers in developing new products, but in order to minimize the risk of wrong conclusions, realistic baseline data is required. Nobody wants to be surprised when specimens don’t perform as predicted by the accelerated test. Outdoor testing must verify the accelerated weathering.  This paper was presented at the 2010 Coatings Trends & Technologies Conference sponsored by PCI Magazine and the Chicago Society for Coatings Technology.

References 1

2

Spearman Rank Correlation • Determine the difference • Sum the square of differences ΣD2 • Count the specimens N1, N2

3

4

rs = 1 –

46



5

6 (∑ D2) N(N2 – 1) MAY 2011 | W W W . P C I M A G . C O M

(2)

6

ASTM Committee G03 round robin data can be found in the Precision and Bias section of standards G 152, G 153, G 154, and G 155. ASTM Book of Standards; ASTM International: Philadelphia, PA; 2007; Volume 14.04. Asher, Louis B. The Use of Ranked versus Rated Data in the Evaluation of Weathered Specimens or Material. In Durability Testing of Nonmetallic Materials, Robert J. Herling ed. ASTM STP 1294, 1996. ASTM G 113 Definitions of Terms used in Durability Testing of Nonmetallic Materials. ASTM Book of Standards; ASTM International: Philadelphia, PA; 2007; Volume 14.04. Fischer, Richard M. Results of Round Robin studies of Light and Water Exposure Standard Practices. Accelerated and Outdoor Durability Testing of Organic Materials, Ketola/Grossman eds., ASTM STP 1202, 1994. ASTM G 169 Standard Guide for Application of Basic Statistical Methods to Weathering Tests. ASTM Book of Standards; ASTM International; Philadelphia, PA; 2007; Volume 14.04. Freund, John E. Modern Elementary Statistics, 4th Edition; Prentice Hall, 1974.

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Novel Hybrid Technology Accelerates VOC Release from

Wood Coatings

M

any market segments within the coatings industry are under pressure emanating from governmental regulations and consumer concerns to reduce their environmental impact. Examples include the reduction of HAPs and VOCs released from a coating, the desire to use raw materials with higher renewable content, and use of less hazardous chemistries for improved worker and end-user safety. The industrial wood coatings market is no stranger to these concerns, and the reduction of HAPs, VOCs and hazardous chemical species such as formaldehyde has driven reformulation and the use of new technologies such as UV cure and waterborne coatings. As an example, the current dominant technologies used in North America are solventborne nitrocellulose lacquers for wood furniture, and acid-catalyzed alkyd-aminoplast conversion varnishes for kitchen and bath cabinets.1 Reformulation of these solventborne coatings to lower VOC and HAPs levels has allowed their continued use in those markets, but the use of even lower VOC technologies should be expected to grow in the future. In particular, UV-cure technology has grown significantly in the kitchen cabinet market, where flat stock can be finished before assembly.1 Waterborne technologies are also available, and waterborne systems based on acrylic latex, polyurethane dispersions and other polymer technologies have been increasingly utilized as regulatory pressures lead coating manufacturers and wood finishers to look for more environmentally advanced coatings. Wood coatings end users such as furniture and cabinet manufacturers are also looking for solutions to regulations and specifications that limit emissions of chemical species from finished products. Regulatory pressure is partly the result of consumer demand for living and working space with better air quality, and partly based on the knowledge that building materials and products such as finished wood can affect indoor air quality by emitting volatile components long after their manufacture. Examples include limits on individual species such as formaldehyde or certain other aldehydes, as well as on total VOC (TVOC), an estimation of the total volatile organic content that is emitted from a wooden coated part after it has been

TABLE 1 | Clear formulation based on acrylic binder AC-1. Material Name

Totals => Levels w/o additives Volume solids Density Weight solids VOC (g/L) Levels with additives Volume solids Weight solids



MAY 2011 | W W W . P C I M A G . C O M

865.44

Gallons 75.22

2.06 1.89 1.29 1.22 11.40 17.86 0.51 0.25 0.33 2.08 3.64 99.89

27.99% 8.66 31.03% 138 30.46% 33.42%

dried for a certain amount of time and is then packaged for shipment. Manufacturers don’t want consumers to be exposed to volatile emissions when items are unpacked, or for their products to be emitting VOCs during use and contributing to poor indoor air quality. There are several certification and specification programs underway that limit volatile emissions, such as those from Greenguard2 and BIFMA (Business and Institutional Furniture Manufacturers Association).3 Both the Greenguard and BIFMA standards measure volatile emissions using a dynamic chamber method designed to simulate emissions occurring in a model environment, such as a business office or residential bedroom.3,4

By Leo Procopio, Laura Vielhauer and Eric Greyson | The Dow Chemical Company, Spring House, PA 48

Pounds

AC-1 663.08 Slowly add the following blend of coalescents: Premix DOWANOL® PnB 15.23 DOWANOL® DPM 15.01 DOWANOL® DPnB 9.85 PARAPLEX® WP-1 10.25 Water 95.13 Premix Sub-total 145.47 Tego Foamex® 805 4.33 TegoGlide® 410 2.08 Surfynol® 104DPM 2.77 Michem® Emulsion 39235 17.35 Water 30.36

TABLE 2 | Clear formulation based on acrylic/polyurethane binder PUA-1.

Material Name

Pounds

Gallons

PUA-1 704.00 Slowly add the following blend of coalescents: Premix DOWANOL® PnB 7.50 DOWANOL® DPM 7.50 DOWANOL® DPnB 5.00 PARAPLEX® WP-1 5.00 Water 75.00 Premix Sub-total 100.00

79.91

Tego Foamex® 805 TegoGlide® 410 Surfynol® 104DPM Michem® Emulsion 39235 Water Totals => Levels w/o additives Volume solids Density Weight solids VOC (g/L) Levels with additives Volume solids Weight solids

1.02 0.94 0.66 0.59 8.99 12.19

4.40 2.00 2.75 17.50 39.50

0.52 0.24 0.33 2.10 4.73

870.15

100.02

28.49% 8.70 31.58% 145 30.33% 33.35%

The purpose of this article is to describe a new waterborne technology for wood coatings that will impact both the VOC content and rate of emission from finished wood products. A unique combination of acrylic latex and polyurethane dispersion (PUD) polymers leads to a coating that has lower VOC demand and offers a mechanism for the accelerated release of coalescing solvents compared to a waterborne acrylic by itself. Performance improvements in hardness development are significant, as well as in properties that are related to hardness such as block, print, scratch and mar resistance. The effect of the technology on the measurement of volatile emissions will be described. A comparison of the new acrylic/PUD blends with waterborne acrylics and commercial waterborne and solventborne wood coating systems will be made using test protocols designed for wood furniture and kitchen cabinet applications.

Experimental The acrylic/polyurethane binder based on the new technology that was used in the evaluations is designated as PUA-1. It is a blend of a hard acrylic latex and a soft polyurethane dispersion, and contains self-crosslinking functionality that cures by oxidative and photolytic mechanisms at ambient temperatures. PUA-1 was prepared at 39.0% weight solids and pH 7.6, and has a minimum film formation temperature (MFFT) of less than 0 °C. PUA-1 contains some solvent (dipropylene glycol dimethyl ether,

DMM), which comes from the manufacturing process of the PUD. PUA-1 contains approximately 2.9% DMM on total, and has a calculated VOC content of approximately 84 g/L. DMM does act as a coalescent and aids in film formation for the acrylic/urethane blends. A commercially available waterborne acrylic, AC-1, is used for comparison. AC-1 is a self-crosslinking, hard acrylic latex polymer (Tg = 43 °C) that is currently being used for wood coating applications such as furniture and kitchen cabinets. It is similar in hardness properties to the acrylic latex that is used in the preparation of PUA-1. AC-1 is supplied at 40.5% weight solids and pH 7.0. PUA-1 and AC-1 were tested in various experimental formulations. Tables 1 and 2 show the main formulations used as both sealer and topcoat for testing over wood substrates, and detail the coalescent packages and additives. All coatings tested were clears. Commercial coating systems designed for use in wood furniture and cabinet applications were obtained from their manufacturers and are described briefly in Table 3. The systems consisted of both a sealer and topcoat. The commercial waterborne system (COM-1) consisted of sealer (WB-1) and acrylic topcoat (WB-2) formulations. The binder chemistry is not disclosed for WB-1, but is assumed to be acrylic latex. Solventborne system COM-2 consisted of a fast-drying, vinyl-modified nitrocellulose sealer (SB-1) and a cellulose acetate butyrate (CAB)/acrylic topcoat (SB-2). The second solventborne system (COM-3) uses both sanding sealer and lacquer based on nitrocellulose technology. Sealer and topcoat combinations were chosen based on manufacturer system recommendations.

Panel Preparation For most tests, coating systems were applied to maple panels (10 cm x 30 cm) by conventional air spray. Coatings were applied at approximately 1 mil (25 μm) dry film thickness per coat, with one coat of sealer and two coats of topcoat. Maple panels were sanded with 220 grit sandpaper prior to use, with sanding dust removed by compressed air spray and wiping with a clean, lint-free cloth. For each coat applied, the coating was dried at ambient temperature for 10 min and then placed in a 60 °C oven for an additional 10 min. The sealer was sanded with 280 grit sandpaper prior to application of the topcoat. After sealer and topcoats were applied, the maple panel was placed in a constant temperature and humidity room (75 °F and 50% RH) for 2 weeks prior to testing. For hardness, scratch/mar, and block and print resistance tests, coatings were applied by drawdown bar to a treated aluminum panel (Q Panel Type AL-412 chromate pretreated aluminum, 10 cm x 30 cm) to yield approximately 1.5 mil (40 μm) dry film thickness. Panels were placed in a constant temperature and humidity room (75 °F and 50% RH) for the amount of time listed below for each test prior to testing.

Testing Procedures Coatings were evaluated according to the test methods for kitchen and vanity cabinet coatings outlined in the Kitchen Cabinet Manufacturers Association (KCMA) standard.5 PA I N T & C O A T I N G S I N D U S T R Y



49

Novel Hybrid Technology Accelerates VOC Release from Wood Coatings

TABLE 3 | Description of commercial wood coatings. Coating System # Description Coating#

COM-1

COM-2

COM-3

Waterborne

Solventborne SB-1 SB-2 SB vinyl-modified SB CAB/ nitrocellulose sealer acrylic (uncatalyzed) lacquer Vinyl-modified CAB/acrylic nitrocellulose

Solventborne SB-3 SB-4 SB SB nitrocellulose nitrocellulose sealer lacquer

WB-1

WB-2

Coating type

Water-reducible sanding sealer

Water-reducible acrylic lacquer

Polymer type

Unknown

Acrylic latex

Coating used as: sealer topcoat Recommended for: wood furniture kitchen cabinets Coating Properties: %Volume solids %Weight solids Viscosity, sec (Zahn#2) VOC (g/L)

X

X X



Nitrocellulose

X X

X

X X

X X

X X

X X

X X

X X

28.0 31.0

26.5 32.0

15.0

19.0

17.0 24.5

17.5 25.0

25

30

22

29

17

18

< 240

< 240

< 550

< 700

< 600

< 600

A) Detergent and Water Resistance (edge soak) – For this test, all six sides of the maple panels were coated as described previously. A #8 cellulose sponge was soaked in a 0.5% Palmolive dish detergent solution, and the panel edge was placed on the sponge for 24 h. Panels were rated for delamination, swelling, color change, checking and other forms of film failure. A pass is reported for no change in the film and panel. B) Hot and Cold Check Resistance – This test cycled the panel between hot (49 °C), ambient (25 °C) and cold (-21 °C) temperatures, and was run as described in the KCMA standard using a Thermotron environmental chamber model S-8S-SL. A pass is reported for no change in the panel or coating. C) Shrinkage and Heat Resistance – This test placed the panel at 49 °C and 70% relative humidity for 24 h and was run using a Hotpak Environmental Chamber model 417532. A pass is reported for no change in the condition of the coating. D) Chemical Resistance – The coating was subjected to a variety of household chemicals to determine its resistance to staining and discoloration. The chemicals include lemon, orange and grape juices, vinegar, ketchup, coffee, olive oil, 50% ethanol, 0.5% Palmolive dish detergent, and mustard. Chemicals were applied to the panel in a vertical position, and allowed to stand for 24 h before cleaning and rating of the panel. In the case of mustard, cleaning was performed after a 1 h exposure. The exposed coating was evaluated for discoloration, staining and other obvious changes, and rated on a 1 to 10 scale, with 10 equal to no change. Other tests were run on maple substrates to evaluate the systems as viable coatings for wood furniture and general wood application. These include the following: E) Clarity – A visual observation of the coating clarity. F) Adhesion – an “X” scribe was cut into the coating using a razor blade. Adhesion was tested by the tape pull method (ASTM D 3359) using Permacel 99 tape. Ratings use a scale of 0A to 5A, with 5A being no adhesion loss. 50

Nitrocellulose

MAY 2011 | W W W . P C I M A G . C O M

G) Chemical Spot Resistance – Resistance to common chemicals was evaluated by applying spots of the chemical to the coated panel for a specified time, then cleaning the panel with clean water and a sponge, and drying prior to rating. Chemicals were applied to the surface by saturating a 2.3 cm, grade 3 Whatman filter and covering with a watchglass to prevent evaporation. One hour spot tests were done using ethanol, isopropyl alcohol, butyl acetate and acetone. Overnight exposures for 16 h were done with water, hot coffee, 50% ethanol, Formula 409 cleaner, isopropyl alcohol, 7% ammonia, Scheaffer brand red ink, and grape juice. Rating of film damage and discoloration/staining was done on a 1 to 10 scale, with 10 being no change. Several tests were performed on just the topcoat, including hardness, scratch/mar, block and print resistance, and gloss and color retention. These tests were evaluated for topcoats applied to treated aluminum panels. H) Koenig Hardness – evaluated according to ASTM D 4366 using a TQC SP0500 Pendulum Hardness Tester, and reported in seconds. Measurements were taken at various intervals over the course of 2 weeks. I) Block Resistance – Panels were dried for 1 or 7 days, and then two 4 cm wide strips were cut from the aluminum panel, and placed face-to-face forming a cross. A #8 rubber stopper was placed on the cross-section of the strips, and a 1 kg weight placed on top of the rubber stopper. Block resistance was rated under two conditions, 1) after 24 h at room temperature, and 2) after 30 min at 60 °C. The following 0 to 10 scale was used to rate the coatings for tack and film damage: 10, no tack/perfect; 9, trace tack/excellent; 8, slight tack/very good; 7, slight tack/good; 6, moderate tack/good; 5, moderate tack/ fair; 4, severe tack, no seal/ fair; 3, 5-25% seal/ poor; 2, 25-50% seal/ poor; 1, 50-75% seal/ poor; 0, complete seal/ very poor. J) Scratch/Mar Resistance – Scratch and mar resistance can be measured by several methods. A new method

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Novel Hybrid Technology Accelerates VOC Release from Wood Coatings

was employed in this study, which insults the film with a combination of scratch, mar and impact damage. Coatings were applied to a treated aluminum panel and dried for 12 days prior to testing. A section of the panel was placed on the bottom of a quart container with the film facing up. Various types of impact media were placed on top of the film, the container sealed and placed on a paint shaker. The container was agitated for two min, and then the sample was removed and evaluated visually. Different types of impact media can lead to different types of damage, corresponding to differing real-world insults. This study used three different sets of impact media, a) 10 smooth, spherical, 1/4 inch diameter steel shot beads, b) two 1/2 inch diameter hexagonal steel nuts, or c) one metal lid from a two ounce paint can. In general, impact media with more corners and with corners having smaller radii of curvature lead to more damage on most films. More massive media also tend to produce greater damage. The type of damage also changes with media shape – for example, ball bearings create mainly impacting-type damage, metal lids create mainly marring-type of damage, and sharper objects (such as screws) can create mainly gouging-type damage. K) Gloss and Color Retention – Topcoats were applied in one coat at approximately 1.5 mils (40 μm) dry film thickness to the white portion of a metal Leneta chart T12-10. Panels were dried for 2 weeks prior to testing. Panels (7.5 cm x 12.5 cm) were exposed in a QUV accelerated weathering cabinet using UV-A bulbs (340 nm) and a cycle consisting of 8 h light and 4 h condensation. Gloss (20°/60°) and color (L*a*b*) were measured initially and at various time intervals during the exposure.

Results and Discussion Once film formation has occurred, coalescents and cosolvents are no longer needed in the film, and it is desirable for them to leave the dry coating film to enhance properties such as hardness. Some slow coalescents [e.g., 2,2,4-tri-

FIGURE 1 | Mechanism of accelerated coalescent release from new acrylic/polyurethane blend technology.

Water Evaporation

Particle Deformation

Polymer Diffusion

Coalescent Transfer to Soft Polyurethane Phase

Accelerated Evaporation

Hard, high Tg acrylic Soft polyurethane Coalescent molecule

52



MAY 2011 | W W W . P C I M A G . C O M

methyl-1,3-pentanediol monoisobutyrate (IBT)] remain in acrylic coating films for many weeks or longer. Acrylic/ urethane blends based on the new technology offer a novel mechanism for the faster release of volatiles, such as coalescents and co-solvents, from the drying film. The result is a dry film that offers faster hardness development and improvement in other film properties that rely on hardness such as block, print and mar resistance, and dirt pickup resistance. The mechanistic details of the new acrylic/urethane blend technology have been described previously,6 but a short description will be given here to aid the reader in understanding the results of the current study. The technology depends on the presence of two polymer phases. The major or dominant phase is a hydrophobic, hard acrylic polymer. Rapid hardness development works best with an acrylic having a glass transition temperature (Tg) greater than 25 °C. The second, minor phase is a soft polyurethane, which in the wet state is more hydrophilic than the acrylic due to its swollen, hydroplasticized state. In the wet state of the formulated hybrid polymer, the coalescent partitions mainly to the more hydrophobic acrylic phase, where it is most needed and aids in lowering the MFFT. This partitioning of coalescent has been demonstrated through computer modeling studies and experimentally using NMR techniques.6 After coating application, water evaporates and polymer particles begin to deform as film formation proceeds (Figure 1). When most of the water has left the film, the polyurethane phase changes from being hydrophilic to hydrophobic, and this shift acts as a trigger for the coalescent to diffuse from the acrylic phase to the polyurethane phase. Changes in how small molecules partition between polymer phases of different composition after film formation have been previously demonstrated in related acrylic latex systems, where the small molecules were non-volatile, low-molecularweight acrylic oligomers.7 In the present study, the small molecules are volatile coalescents. It is known that small molecules, such as coalescents, will diffuse more rapidly through a soft polymer phase due to the effect of greater free volume; thus the coalescent will diffuse out of the film via the soft polyurethane phase more rapidly than if the hard acrylic phase were by itself. One requirement of the mechanism shown in Figure 1 is that the polyurethane phase must form a continuous network through which the coalescent can diffuse. The amount of polyurethane needed to form this “percolation network” depends on the relative particle sizes of the polyurethane dispersion and acrylic latex employed and the geometry of particle packing. In general a minimum of about 20 - 30% by weight of total polymer is required to be polyurethane. The described mechanism results in faster coalescent release from a drying film, and impacts properties such as early hardness development, block and print resistance, and scratch/mar resistance. The faster coalescent release also presents the possibility for lowering the TVOC of a factory-applied wood coating. Early water resistance can be improved by removing hygroscopic materials such as hydrophilic coalescents and co-solvents from the drying film before the dry film comes into contact with water. The presence of a polyurethane phase also tends to improve

Novel Hybrid Technology Accelerates VOC Release from Wood Coatings

FIGURE 2 | Comparison of hardness development for acrylic/polyurethane PUA-1 and hard acrylic AC-1 in clear formulations with various coalescent packages. (Coalescents in each case were present at 20% on total polymer solids.) 140 120

Koenig Hardness (sec)

100 PUA-1/EB AC-1/EB

80

PUA-1/DPnB AC-1/DPnB

60

PUA-1/IBT AC-1/IBT

40 20 0 0

1

2

3 4 5 6 7 8 Time (days) TABLE 4 | Block resistance of clear formulations, comparing acrylic/polyurethane PUA-1 with hard acrylic AC-1.

1 Day Dry 7 Day Dry 24 h @ RT 30 min at 60 °C 24 h @ RT 30 min at 60 °C

Block Conditions Coalesced with 20% IBT AC-1 PUA-1 Coalesced with 20% EB AC-1 PUA-1

3 5

6 4

9 10

9 8

6 8

3 8

10 10

9 9

Note: Coalescents added at 20% on total polymer solids. Block resistance rated on a 1 - 10 scale, 10 = best. Coatings dried for either 1 or 7 days before being subjected to the room temperature or 60 °C block resistance test.

TABLE 5 | TVOC measured by a static chamber method after drying for 7 days at 23 °C and 50% relative humidity. Coating System Polymer

Acrylic/Polyurethane PUA-2

Hard Acrylic AC-1

TVOC (mg/m3)

2

21

toughness, as measured by pencil hardness and scratch/ mar resistance, compared to an all-acrylic composition. The improved hardness development is demonstrated in Figure 2, which plots Koenig pendulum hardness versus drying time at room temperature for acrylic/polyurethane PUA-1 and hard acrylic AC-1. For this experiment, the clear formulations were fairly simple, including only binder, water, coalescent at 20% on polymer solids, wetting aid and thickener. A single coalescent was used in each case, including the slow coalescent IBT, dipropylene glycol butyl ether (DPnB) and the fast coalescent ethylene glycol butyl ether (EB). For a particular coalescent, it is observed that PUA-1 develops Koenig hardness much more quickly. For example, Koenig hardness of the PUA-1 formula containing IBT is approximately 70 s after 7 days dry, whereas the acrylic AC-1 is only at approximately 50 s. Clearly neither has reached their ultimate hardness, which is measured after baking the panel to drive off all volatiles, and is close to 130 s. This demonstrates an important point regarding 54



MAY 2011 | W W W . P C I M A G . C O M

the new technology presented here. The presence of the polyurethane polymer phase in the dry film only provides a pathway for the coalescent to diffuse from the film more rapidly than through the acrylic phase. The ultimate hardness of the system (i.e., hardness achieved after all volatile materials have been driven off) relies mainly on the hardness (and Tg) of the acrylic phase. The rate of release is also dependent on the volatility of the coalescent. Thus, when a non-volatile coalescent or plasticizer is used, such as dibutylphthalate, the polyurethane-based pathway is ineffective at improving hardness development or related properties, because the plasticizer never leaves the film. However, when a more volatile coalescent such as EB is utilized, hardness development can be greatly accelerated. In Figure 2, the PUA-1 film containing EB has reached its ultimate hardness in less than 3 days, compared to the acrylic AC-1, which is still not there after seven days. Figure 2 shows significant acceleration is also observed with a coalescent of more moderate volatility, such as DPnB. The accelerated coalescent release also improves block resistance for the acrylic/polyurethane blends compared to the hard acrylic. Table 4 shows results of block resistance testing for clear formulations based on acrylic/ polyurethane PUA-1 and hard acrylic AC-1. The formulas contained only binder, water, coalescent, wetting aid and thickener. No waxes or mar/slip aids were included in order to see the polymer effect on block resistance. Coatings were coalesced with either a slow coalescent (IBT) or a fast coalescent (EB) at 20% on polymer solids. The coatings were dried at room temperature for 1 or 7 days before running both 24 h room temperature and 30 min oven (60 °C) block tests. The data shows an advantage for the acrylic/polyurethane blend technology, especially at early dry times. Block resistance is an important property for factory-applied coatings as it should develop before coated items are stacked or packaged to prevent damage to the new film. Scratch and mar resistance are also improved by the faster coalescent release. Figure 3 shows damage inflicted on clear coatings based on acrylic/polyurethane PUA-1 and hard acrylic AC-1 and tested according to the new method described above. The formulas in this case are those shown in Tables 1 and 2, and the test was also run for formulations without the mar aid and wax. Figure 3 demonstrates the enhanced mechanical durability of PUA-1 over AC-1 using this scratch/mar test. Using a metal lid as the impact media leads to a marring type of damage, and results in more and deeper scratches in the all-acrylic AC-1 than it does in PUA-1 (photos on left). The formulations pictured on the left side of Figure 3 were made with no mar or slip additives to show the inherent properties of the resins. If mar and slip additives are included in the formulations they both perform much better, but PUA-1 still creates a more resilient film. Using steel hex nuts as the impact media leads to small, roughly spherical gouges, but mar and slip additives can largely mitigate these gouges. Even with mar and slip aids, however, the impact of these collisions causes flakes of film to chip off in some locations for acrylic polymer AC-1, whereas the film made from PUA-1 is free of these defects (photos on right). Similar testing was done with spherical

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Novel Hybrid Technology Accelerates VOC Release from Wood Coatings

FIGURE 3 | Photos of films showing damage from the scratch/mar test. (All four panels display an area of 4 inch x 1.75 inch, and insets are at 3x magnification.)

P UA-1

P UA-1

AC-1

AC-1

steel shot. Steel shot leads to less visible damage, but there is still a clear advantage to using PUA-1 over AC-1. The accelerated development of hardness, block and scratch resistance correlates well with the mechanism proposed above for the faster release of volatile coalescent from the drying film. To provide more mechanistic evidence, drying films were examined by GC/MS to determine the level of coalescent remaining in the film at various dry times. Results are shown in Figure 4 for clear coatings based on acrylic/polyurethane PUA-1 and hard acrylic AC-1. Formulations used in this test are shown in Tables 1 and 2, and contained a mixture of volatile coalescents and a non-volatile plasticizer. Figure 4 reports the amount of volatiles measured using a GC/MS technique as a percent of the total film weight. Clearly, after only 1

day drying at room temperature, the film based on PUA-1 has only about half as much coalescent remaining as the hard acrylic AC-1. It takes 7 days for AC-1 to reach a similar level, at which point the film based on PUA-1 has released nearly all of its volatile coalescent as measured by this method. At more than 7 days, the amount of volatiles in the PUA-1 film was below the detection limit for this method. At 2 weeks, there was still a significant amount of coalescent present in the film based on AC-1. The release of volatiles from the films was also measured using GC analysis of the headspace in a static chamber method. Aluminum panels were coated by drawdown with the same two coatings based on AC-1 and PUA-1. After drying for 7 days in an environmental chamber at 23 °C and 50% relative humidity, the panel was placed in a chamber that provided a surface area to volume ratio of 1 m2/m3. The panel sat overnight in the chamber, and the headspace was then sampled and analyzed by GC. Results are shown in Table 5. The TVOC measured for the coatings is 21 mg/m3 for the hard acrylic AC-1, and a significantly lower value of 2 mg/m3 for the acrylic/polyurethane PUA-1. Although the static chamber method used here does not correlate with the dynamic chamber measurements used in some specifications such as Greenguard and BIFMA,3,4 the results should give a worst case scenario as there are no air changes in the static method, and provides positive evidence that the acrylic/polyurethane technology holds promise for helping formulators meet such TVOC limits. The main benefits of the new acrylic/polyurethane blend technology are in properties related to the release

TABLE 6 | Results for coating systems tested according to the KCMA standard for kitchen cabinets on maple substrate. Coating System

Acrylic/Polyurethane

Hard Acrylic



COM-2

COM-3 SB-3 SB nitrocellulose sealer

Sealer

PUA-1

AC-1

WB-1 Water-reducible sanding sealer

SB-1 SB vinyl-modified nitrocellulose sealer (uncatalyzed)

Topcoat

PUA-1

AC-1

WB-2 Water-reducible acrylic lacquer

SB-2 SB CAB/acrylic lacquer

SB-4 SB nitrocellulose lacquer

< 240 < 240

< 550 < 700

< 600 < 600

pass

slight cracking, whitening

pass

10 10 10 10 10 10 10 10 10 5

10 10 10 10 10 10 10 5 10 8

10 9 10 10 10 10 10 5 10 8

pass

pass

pass

pass

pass

pass

VOC (g/L) Sealer < 150 < 150 Topcoat < 150 < 150 Edge Soak - Detergent and Water Resistance pass pass Chemical Resistance (24 h exposure except where noted) Vinegar 10 10 Lemon juice 10 10 Orange juice 10 10 Grape juice 10 10 Ketchup 10 10 Coffee 10 10 Olive oil 10 10 Ethanol 10 10 0.5% Palmolive 10 10 Mustard (1 h) 3 9 Hot and Cold Check Resistance pass pass Shrinkage and Heat Resistance pass pass 56

COM-1

MAY 2011 | W W W . P C I M A G . C O M

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Novel Hybrid Technology Accelerates VOC Release from Wood Coatings

of the coalescent, such as hardness, block, scratch/mar and TVOC. Other properties important for industrial wood coatings, such as chemical resistance and flexibility, remain largely unchanged by the presence of the polyure-

FIGURE 4 | Measurement of the amount of coalescent remaining in the drying film (weight % coalescent) as a function of drying time, for clear coatings based on acrylic/polyurethane PUA-1 and hard acrylic AC-1. 7 6

Wt. % Coalescent

5 4 3

AC-1 PUA-1

2 1 0

0

2

4

6

8

10

12

14

16

Time (days)

thane phase. Water resistance is generally improved by the more rapid release of coalescent from the hybrid film. Another key feature of PUA-1 is the ability to self-crosslink at ambient temperatures and still maintain true onepackage stability. The functional groups present in the polymer will crosslink via both oxidative and photolytic curing mechanisms. Formulations based on the resin will begin to crosslink as soon as they are applied, and may require about 2 to 4 weeks until some properties have reached their maximum performance level. The crosslinking offers enhancements to properties such as dirt pickup resistance, chemical and solvent resistance, and durability. Because PUA-1 combines both hard acrylic and soft polyurethane phases, and the soft PUD phase contributes to lowering the MFFT of the blend, it can also be formulated at lower coalescent demand than the corresponding acrylic phase by itself. This manifests itself in the ability to formulate at lower VOC, while giving a coating that has better hardness development – a combination that is sought after in a variety of applications. Coatings based on the acrylic/polyurethane blend technology were also evaluated over wood according to test methods used for kitchen and bath cabinets and wood furniture. Table 6 shows results of testing in self-sealed coating systems over maple according to the KCMA standards.5 The new technology represented by PUA-1 is compared to AC-1, a commercial hard acrylic latex that exhibits excellent performance in wood coatings. The

TABLE 7 | Results for coating systems tested according to wood furniture and general wood coatings methods on maple substrate. Coating System

Acrylic/Polyurethane

Hard Acrylic



COM-2

COM-3

Sealer

PUA-1

AC-1

WB-1 Water-reducible sanding sealer

Topcoat

PUA-1

AC-1

WB-2 Water-reducible acrylic lacquer

SB-1 SB vinyl-modified nitrocellulose sealer (uncatalyzed) SB-2 SB CAB/acrylic lacquer

< 240 < 240 11 / 58 good

< 550 < 700 7 / 40 good

< 600 < 600 25 / 81 good

5A

5A

5A

3 3 1 1

1 1 1 1

1 3 1 1

10 9 9 5 1 5 3 9

10 10 10 10 1 10 10 10

10 10 10 10 3 7 10 10

VOC (g/L) Sealer < 150 < 150 Topcoat < 150 < 150 Gloss (20° / 60°) 24 / 74 32 / 81 Clarity good good Adhesion (X-scribe and tape pull) 5A 5A Chemical Spot Resistance (rated 1 - 10, 10 = best) 1 h exposure Ethanol 8 8 Isopropyl alcohol 8 7 Butyl acetate 8 6 Acetone 10 7 16 h exposure Water 10 10 Hot coffee 7 9 50% Ethanol 9 9 409 Cleaner 6 5 Isopropyl alcohol 9 9 7% Ammonia 5 5 Red ink 5 5 Grape juice 6 10 58

COM-1

MAY 2011 | W W W . P C I M A G . C O M

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Novel Hybrid Technology Accelerates VOC Release from Wood Coatings

FIGURE 5 | Gloss retention for clear topcoats on UV-A exposure. 100 90 80

60º Gloss

70 AC-1 PUA-1 PUD WB-2 (COM-1 topcoat) SB-4 (COM-3 topcoat) SB-2 (COM-2 topcoat)

60 50 40 30 20 10 0 0

200

400 600 Time of Exposure (h)

800

1000

binders were formulated into the clear formulations given in Tables 1 and 2. Also included in the testing were two solventborne systems that are commercially available, based on nitrocellulose sealers, and acrylic (COM-2) or nitrocellulose (COM-3) topcoats. A commercially avail-

able waterborne system (COM-1) using an acrylic topcoat was also used for comparison. Overall, PUA-1 performed very well versus the much higher VOC commercial systems, only showing some staining in the mustard spot resistance. Similar testing typical for furniture coatings was also done for self-sealed systems over a maple substrate. Comparisons with AC-1 and the solventborne and waterborne commercial systems are included in Table 7. Overall, PUA-1 performed very well, with excellent solvent resistance compared to the industry standards. Figure 5 shows gloss retention results for the topcoats only, applied to metal panels, and exposed to UV-A light in a QUV accelerated weathering cabinet. Also included in the test was a clear coating based on the polyester PUD used to make PUA-1. Although the PUD does not have excellent gloss retention by itself, blending it with an acrylic to form PUA-1 does not hurt the gloss retention of the blend. In fact, all of the acrylic-based materials shown in Figure 5 performed well in UV-A exposure, including AC-1, and the commercial waterborne and solventborne acrylic topcoats used in the commercial systems COM-1 and COM-2. Of the five wood systems tested, only the nitrocellulose topcoat from COM-3 did poorly in UV-A exposure, showing a large drop in gloss after only 300 h. The nitrocellulose topcoat also yellowed significantly on exposure. In contrast, the acrylic systems maintained their gloss and color even after more than 900 hours. This

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Novel Hybrid Technology Accelerates VOC Release from Wood Coatings

result is perhaps not too surprising given the well known UV stability of acrylic polymers, but demonstrates a main benefit that an acrylic wood finish could provide.

Conclusions A unique acrylic/polyurethane technology has been described that offers a new

mechanism for the faster release of coalescent from industrial wood coatings. The combination of a hard acrylic phase and a soft polyurethane phase results in polymers that offer faster hardness development compared to the hard acrylic by itself. In addition, other properties that correlate with hardness, such as block, print and mar

resistance, are improved. The key is the formation of a “percolation network” of the soft polyurethane throughout the dry coating. Volatile coalescents will diffuse faster through the soft polyurethane phase due to free volume effects, and the continuous network provides a pathway for the coalescent to escape more quickly. In addition to property improvements, the faster coalescent release shows promise for wood coating formulations with lower TVOC emissions, a characteristic sought by manufacturers of wood products such as furniture, cabinets and building materials, as well as their coatings suppliers. For example, the ability of a coating to release the majority of its volatile materials prior to the packaging and use of a piece of furniture should eventually lead to better indoor air quality for the consumer and a competitive advantage for the furniture manufacturer. The new acrylic/polyurethane technology described here offers those qualities in an environmentally advanced, one-component, lowVOC waterborne coating, and provides the coatings industry with a powerful tool for industrial wood coatings. 

Acknowledgements The authors would like to thank Dr. Lawrence Mink and Dr. Wei Xie from the Dow Analytical Sciences group for their assistance in the GC/MS analysis of residual coalescent and static chamber TVOC measurements. This paper was presented at the 38th Annual Waterborne Symposium, February 2011 in New Orleans.

References 1

2

3

4

5

6

7

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3/27/09 4:12:19 PM

U.S. Paint & Coatings Market Analysis (2004 – 2009), National Paint and Coatings Association, October 2005. Greenguard Indoor Air Quality (IAQ) Standard for Building Materials, Finishes and Furnishings, Standard GGPS.001, Greenguard Environmental Institute, 2009. ANSI/BIFMA M7.1-2007, Standard Test Method for Determining VOC Emissions from Office Furniture Systems, Components and Seating, BIFMA International, 2007. Standard Method for Measuring and Evaluating Chemical Emissions from Building Materials, Finishes and Furnishings Using Dynamic Environmental Chambers, Standard GGTM. P066, Greenguard Environmental Institute, 2008. ANS/KCMA A161.1-2000, Performance and Construction Standard for Kitchen and Vanity Cabinets, Kitchen Cabinet Manufacturers Association, 2001. Fu, Z.; Hejl, A.; and Swartz, A. Designed Diffusion Technology: A Paradigm Shift in Film Formation, Eur. Coat. J. 2009, July, 26 - 33. Fasano, D. M.; Fitzwater, S.J.; Lau,W.; and Sheppard, A.S. Diffusion of Oligomers in Latex Systems – A Route to Low Volatile Organic Compound (VOC) Coatings, Can. J. Chem. 2010, 88, 500-513.

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www.mixers.com [email protected]

• Experience managing a team • BS in chemistry or chemical engineering • A minimum of 5 years of “in plant” experience in the paint and coatings industry • Experience formulating with epoxy and polyurethane chemistry • Trouble shoot product / production issues • Ability to write material safety data sheets (MSDS) and technical data sheets • Knowledge of environmental and safety regulations • Good documentation skills • Prior experience with Sage PFW (Batch Master) a plus

Competitive salary and benefits.

www.grindingmediadepot.biz

Send resume to Arizona Polymer Flooring, Inc. Glendale, Arizona Fax: 623-435-8585 [email protected]

www.bladedepot.biz

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800-726-1366 [email protected]

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MAY 2011 | W W W . P C I M A G . C O M

(814) 723-7980

To place your classified ad, contact Andrea Kropp Ph: (810) 688-4847 Fax: (248) 502-1048 Email: [email protected]

www.pcimag.com/classifieds

Coatings Trends & Technologies provides a global, resource-rich environment where attendees can engage with industry experts to learn about new products and developments that will improve coatings formulation.

www.coatingsconference.com

This affordable, 1-1/2 day, live event allows formulators to customize their educational and networking experience through concurrent technical sessions and an interactive exhibit hall.

REGISTRATION IS OPEN 2010 Sold Out Early Register Online Today!

SPONSORSHIPS ARE AVAILABLE Contact Your PCI Magazine Rep Today!

EARLY-BIRD DISCOUNT Register by July 1 and SAVE $100

SEPTEMBER 13-14, 2011 ■ OAK BROOK, IL SESSION TOPICS Additives Resins and polymers Pigments Solvents Nanotechnology Renewable raw materials Low-VOC technology UV-curing technology Powder coatings Waterborne systems Solventborne systems Green technology Improvements in adhesion Legislation and regulatory issues Test methods, materials characterization and performance evaluation Accelerated weathering PRODUCERS

CURRENT EXHIBITORS

WHO ATTENDS – Coatings formulators – Chemists – Technical managers – R&D personnel – Applicators/raw material suppliers – Quality control personnel – Analytical testing personnel – Technicians – Technical directors – Purchasing directors

C LASSIFIEDS RECRUITMENT SERVICES

CONSULTING & TESTING

Specializing in paint/coatings industry. Seeking passionate, high-impact professionals for nationwide positions. Send your resume in confidence to: Spencer M. Hermann

SEARCHLIGHT PARTNERS 28052 Camino Capistrano, Suite 209 Laguna Niguel, CA 92677 (949)429-8813 • [email protected]

Paint & Coatings Industry Executive Search Recruitment & Org. Consulting

Need Help With Your Color Dispersions and Color Matching Software? I have over 30 yrs. exp. matching colors & milling: Epoxies, Urethanes, Alkyds, and Polyesters. I will help with your dispersions and matching databases including: Datacolor Match Pigment/Paint and X-Rite.

Contact Tim Pastick – 651-261-8915 [email protected]

CUSTOM MANUFACTURING

Toll Converting & Packaging • ISO 9001:2008, FDA-EPA-ATF Reg. Facility • 2 plants in N. Texas • Epoxy, urethane, solvent, water-based • High speed dispersion, vacuum processing • Adductions, advancements, prepolymer • Small, medium and large batch • Packaging: tankwagon, totes, drums, pails, gallons, quarts, pints and smaller

www.thomasbrooke.com THOMAS BROOKE INTERNATIONAL

Contact Nicola James [email protected]

888-896-3330 ext. 22

www.quadrantchemical.com [email protected] 200 Industrial Blvd., McKinney, TX 75069 972-864-0865 x 25 / 972-542-0072

AD INDEX 3M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Evonik Degussa . . . . . . . . . . . . . . . .15, 19

www.3Mpurification.com

Abrafati Show 2011 . . . . . . . . . . . . . . . 63

www.evonik.com/Butterfly www.evonik.com/colortrend

www.abrafati2011.com/br

Eye Lighting International . . . . . . . . . 26

Air Products . . . . . . . . . . . . . . . . . . . .8, 11

www.eyesolarlux.com

www.airproducts.com/zeta1 www.airproducts.com/surfactants

Paul N. Gardner Company, Inc. . . . . . 22

Alberdingk Boley, Inc. . . . . . . . . . . . . . 31

Glen Mills Inc. . . . . . . . . . . . . . . . . . . . . 12

www.gardco.com

www.Alberdingkusa.com

www.glenmills.com

AllCoat . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Heubach. . . . . . . . . . . . . . . . . . . . . . .31, 35

www.allcoattech.com

www.heubachcolor.com

Arch Chemicals . . . . . . . . . . . . . . . . . . . 31

HOCKMEYER . . . . . . . . . . . . . . . . 22, 45

www.archbiocides.com/proxelbzplus

www.hockmeyer.com

Arkema Emulsion Systems . . . . . . 16-17

Hoover Color Corporation . . . . . . . . . 55

www.arkemaemulsionsystems.com

www.hoovercolor.com

Asia Pacific Coatings Show 2011 . . . 59

ISP Performance Chemicals . . . . . . . . 13

www.coatingsgroup.com

BASF Corporation . . . . . . . . . . . . . . . . . 23 www.basf.us/dpsolutions

Brenntag North America. . . . . . . . . . . . 7 www.brenntagnorthamerica.com

Buhler Inc. . . . . . . . . . . . . . . . . . . . . . . . 42 www.buhlergroup.com

Burgess Pigment . . . . . . . . . . . . . . . . . . 53 www.burgesspigment.com

BYK USA Inc. . . . . . . . . . . . . . . . . . .21, 31 www.byk.com

CINIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 www.cinic.com

Classifier Milling Systems . . . . . . . . . . 20 www.cms-can.com

Coating Trends & Technologies . . . . . 65 www.coatingsconference.com

Conn and Co. . . . . . . . . . . . . . . . . . . . . . 40 www.connblade.com

CPS Color. . . . . . . . . . . . . . . . . . . . . . . . . 47

www.ispcoatings.com/water

Jiangxi Tikon Titanium . . . . . . . . . . . . 4 www.tikon.com.cn

Jyoti Ceramic Industries. . . . . . . . . . . . . 3 www.jyoticeramic.com

KW Container. . . . . . . . . . . . . . . . . . . . . 39 www.kwcontainer.com

Mason Color Works, Inc. . . . . . . . . . . . 41 www.masoncolorpigments.com

Michelman . . . . . . . . . . . . . . . . . . . . . . . 14 www.michelman.com

Micro Powders, Inc. . . . . . . . . . . . . . . . 67 www.micropowders.com

MYERS Engineering, Inc . . . . . . . . . . 62 www.myersmixer.com

Nexeo Solutions, LLC . . . . . . . . . . . . . . 33 www.nexeosolutions.com

Nubiola. . . . . . . . . . . . . . . . . . . . . . . . . . . 43 www.nubiola.com

Pan Technology, Inc. . . . . . . . . . . . . . . 31 www.pantechnology.com

www.cpscolor.com

Powder Coatings Forum. . . . . . . . . . . . 57

DeFelsko Corp. . . . . . . . . . . . . . . . . . . . . 10

www.powdercoatingsforum.com

www.defelsko.com

Q-Lab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Dow Coating Materials . . . . . . . . . . . . . . . . . . . . . . . . . 68

www.q-lab.com

www.dow.com/hiding

www.reitechcorporation.com

Reitech Corporation . . . . . . . . . . . . . . . . 6

Dynamix . . . . . . . . . . . . . . . . . . . . . . . . . 22

Ross, Charles & Son. . . . . . . . . . . . . . . . 29

www.dynamixinc.com

www.mixers.com

Elcometer . . . . . . . . . . . . . . . . . . . . . . . . 60

Sudarshan . . . . . . . . . . . . . . . . . . . . . .2, 31

www.elcometer.com

www.sudarshan.com

EMD Chemicals Inc. . . . . . . . . . . . .31, 51

Unimin Corp. . . . . . . . . . . . . . . . . . . . . . 34

www.emdpigments.com

www.BrilliantAdditions.com

Eurasia Coatings Show. . . . . . . . . . . . . 61

Wacker Chemical Corporation. . . . . . 27

www.turkcoat.com

www.wacker.com/e-business.com

Visit ads.pcimag.com 66



MAY 2011 | W W W . P C I M A G . C O M

P U B L I S H I N G / S A L E S S TA F F Publisher/ Donna M. Campbell East Coast Sales Tel: 610/650.4050 • Fax: 248/502.1091 E-mail: [email protected] Midwest/ Lisa Guldan West Coast Sales Tel: 630/882.8491 E-mail: [email protected] China Media Rep. Arlen Luo Tel: 0086-10-88579899 E-mail: [email protected] Europe Regional Uwe Riemeyer Manager Tel: 40 (0)202-271690 E-mail: [email protected] Inside Sales Manager Andrea Kropp Tel: 810/688.4847 E-mail: [email protected] Production Manager Brian Biddle Tel: 248/244.6434 • Fax: 248/244.3915 E-mail: [email protected]

E D I T O R I A L S TA F F Editor Kristin Johansson Tel: 248/641.0592 • Fax: 248/502.2094 E-mail: [email protected] Technical Editor Darlene R. Brezinski, Ph.D. E-mail: [email protected] Associate Editor Karen Parker Tel: 248/229.2681 E-mail: [email protected] Art Director Clare L. Johnson

O P E R AT I O N S S TA F F Single Copy Sales Ann Kalb E-mail: [email protected] Reprint Manager Jill L. DeVries 248/244.1726 E-mail: [email protected] For subscription information or service, please contact Customer Service at: Tel: 847/763.9534 or Fax: 847/763.9538 or e-mail [email protected]

MICRO POWDERS WAX ADDITIVES. FOR SUPERIOR SOLUTIONS ALL OVER THE HOUSE.

There are very few places in today's home where Micro Powders wax additives aren’t at work enhancing performance. From window frames to appliances to floors and furniture, our unique waxes make coatings function better. They’re used in wood coatings to aid sanding, prevent marring and provide a smooth feel. They increase scratch resistance in the coatings for refrigerators, stoves and washing machines that are used every day. They also provide textured surfaces on phones, televisions, computers, CD and DVD players. Micro Powders waxes help decks bead water. On window shutters and frames, they contribute to mar resistance and dirt release. They enable front doors to resist impact, and add texture to walkways and poolsides for excellent traction. Even two and three-piece food and beverage cans benefit from our additives for easy interior release and exterior scratch resistance. For better solutions all over the house, just check us out at www.micropowders.com or contact our worldwide network of agents and distributors today.

MICRO POWDERS, INC. Certified to ISO 9001:2000

580 White Plains Road, Tarrytown, New York 10591 TEL: 914-793-4058 FAX: 914-472-7098 WEB: www.micropowders.com

THINK NEW DIRECTiONS 2

The old paths to hiding have run their course. At Dow, we can help you Rethink Hiding—with flexible technology choices that can stretch your TiO2 supplies, reduce your raw material costs and deliver equal or better levels of hiding and performance. Let’s get your experts talking to our experts about EVOQUETM Pre-Composite Polymer Technology, our breakthrough in emulsion polymers that improves TiO2 particle distribution and light scattering efficiency. Or consider our industry-leading ROPAQUETM Opaque Polymers for your new formulations. Better yet, add both technologies and take advantage of the combined results. The point is, when you’re working with Dow Coating Materials, you’ve got OPTiO2NS. And in today’s competitive coatings world, that’s a smart place to be.

It’s time to rethink hiding. www.dow.com/hiding