Low bake technologies for powder coatings: a technical up-date

2 JUNE 2013

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TECHNICALResearching new improved superdurable powder coatings using LifeCycle Analysis

A paper presented at the recentCoatings 2013 Congress byMomentive Speciality Chemicalsoutlines the application of LifeCycle Analysis (LCA)Methodology as a tool formeasuring the performance of itsnew extremely durable range ofsuper durable low thermal curingpolyester powder coatings, whichwill perform well in agriculture,transportation and architecturalend-use applications. Industrialcoatings applicators areincreasing demands uponcoatings suppliers to provide newproducts with reduced carbonfootprints, with the eventual aimof achieving zero emissions, andalso reducing the energyconsumed during application.Momentive hopes to achieve thisgoal by: increasing the lifespan ofthe finished coating; reducing theenergy consumed inmanufacturing; introducing theuse of LCA as a tool to measurethe environmental performance;and investing in technical-scientificcollaborations withresearch/technical institutions ableto support complex research.

Improving the durability ofpowder coatings is in highdemand for construction.agricultural and heavy-dutymachinery applications. In 2011,the demand for super durablepowder coatings was 10% of thetotal exterior powder coatingsmarket. This is predicted toincrease to 18% by 2017. Suchproducts must meet the long-lasting, high quality outdoor andmechanical performance requiredby the GSB and Qualicoatspecifications. All newimprovements must maintainexcellent flow, good storagestability and consistency frombatch to batch. Momentive claimsto have developed a complete

range of Low Temperature Curing(LTC) powder coatings, whichcure at temperatures as low as150°C. These resins are analysedby LCA to assess theenvironmental performance of allnew products in order to evaluateenergy and environmentalchanges to them, from design(ecodesign) throughoutmanufacture and use. Researchon new binders has focused onselecting resin backbones andraw materials to meet thedemanding specifications for lowercuring temperature, longer lifespan and decreased carbonfootprint. In 2011, Momentivecarried out a study on the eco-profiles of LTC powder resins anda bio-based system to identify thegains provided by the newtechnology. The company’s nextprogramme will be to apply anLCA specifically to identify thebenefits of LTC coatings withextended durability and combinedwith plasticizers that have beenfound to reduce the environmentalimpact of LTC coatings.

The future objective of the LCAanalysis is to study theenvironmental impacts in theproduction of the polyester resin,followed by a study of theimpacts occurring during powdercoatings manufacture byidentifying the role of sensitivecomponents, such aspigment/filler blends. The two finalstages will endeavour to quantifythe benefits of using Momentive’sLTC powder coating resins, andtheir role in extremely highoutdoor durability systems.

The paper describes the set-upthe researchers employed toevaluate the LCA powder coatingapplication process. One kilogramof steel balls, to simulate the highthermal inertia of large machineryparts. were covered with a 70μmthick layer of powder coating, andexamined at both standardtemperature curing and LTCconditions. The curing oven wasoperated at full load and acomplete recovery of over-sprayedpowder was carried out.

It has already been decided byMomentive that adipic acid shouldbe replaced to improve thecarbon footprint based on earlierassessments. The paperconcludes with the results of theLCA studies using threeconventional powder coatingresins: standard durable; LTCsuper durable; and flexible superdurable; together with two newlow thermal curing polyesterresins: LTC-A, a flexible andsuper durable resin curing at160°C for 15 minutes, using ß-HAA crosslinker in ratio 93:07;and LTC-B, the next generationwith replacement of adipic acid bymore sustainable materials.Momentive is still working tofurther improve the performanceof the LTC-B polyester resin.

Paper entitled “Using Life Cycle Analysis(LCA) to Validate New Horizons in theResearch of Sustainable Powder CoatingBinders: Low Thermal Curing PolyesterSuper Durable” by a team from MomentiveSpeciality Chemicals, Italy, presented at theEuropean Coating Show 2013 held inNuremberg, Germany, 18-19 Mar 2013, byThe Vincentz Network

Low bake technologies for powdercoatings: a technical up-date

This was a poster presentation byPriscilla Lips of DSM CoatingsResins during the Coatings 2013Show. It began with a brief reviewof low bake thermally curedpowder coating and thechallenges posed by lower baketemperatures or shorter curingtimes. In Europe the low bakepolyester powder coatings arerestricted to curing with ß-hydroxyalkylamide crosslinkersand these products give problemsof blooming when cured at160°C. This is because thiscrosslinker cannot be catalysedand it releases water during curecausing surface defects in thecured film. Hybrid powder coatingbased on polyester epoxysystems are also reviewed and itis concluded that these systemscould be catalyzed to give powdercoatings that can be cured at160°C for 10 minutes, that are

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free from blooming, with excellentfilm smoothness and goodstorage stability. The hybridpowder coatings are suitable forindoor applications only.

There is a need for even lowerbake powder coating systems foruse on heat sensitive substratessuch as wood and plastic. TheDSM approach to this problem isto produce a powder coatingformulation that can be processedin an extruder and cured attemperatures ranging from 100°Cto 130°C for 20 to 5 minutesrespectively. This system consistsof an unsaturated polyester resincombined with a semi-crystallinevinyl ether based co-agent(Uracross P 3307) that reacts byradical initiated polymerization.The selected organic peroxidesare dilauroyl peroxide, dibenzoylperoxide from the group of diacylperoxides, and tert-butylperoxybenzoate, which ischemically a peroxyester.

DSM believes that this systemcan be finely tuned to coat arange of heat sensitive substrates,and its development work willcontinue along these lines foryears to come.

Paper entitled “Low Bake Technologies forPowder Coatings: A Technical Up-date” byPriscilla Lips of DSM Coatings Resins, TheNetherlands, presented as a posterpresentation at the European Coatings Show2013 held in Nuremberg, Germany, 18-19Mar 2013, by The Vincentz Network

INDUSTRYNEWS

PPG completes acquisition ofAkzoNobel’s N American coatingsbusiness

AkzoNobel has completed thesale of its N American decorativepaint and coatings division toPPG at a cost of $1.05 bn(around €820 M). Thisstrengthens PPG’s lead on themarket. According to AkzoNobel,the business had a turnover of

€1.19 bn ($1.5 bn) and an ebitdaof €19 M. This was animprovement on 2011 when theactivity had a loss of €69 M onsales of €1.09 bn. PPG hasrestructured its activities, withcoatings accounting for 85% oftotal turnover ($15.2 bn) in 2012compared with 57% of total salesof $11 bn in 2006. The groupsold its commodity chemicalsdivision to Georgia Gulf in 2012.A table gives world market for 7coatings sectors and the positionon each of the sectors for PPG,AkzoNobel, Sherwin-Williams,DuPont, Valspar and BASF. Theworld market was split as follows:decorative $43 bn, industrialcoatings $25 bn, marine coatings$12 bn, automotive originalequipment manufacturer $7 bn,repair $6 bn, packaging $3 bnand aerospace $2 bn. PPG isworld leader for automotive OEMand repair and aerospacecoatings as well as being worldleader overall. AkzoNobel ismarket leader for industrial andmarine coatings. Sherwin-Williamsleads on the decorative paintssector. Valspar is market leaderfor packaging coatings. PPG isranked second in the US fordecorative paints.

Original Source: Chimie Pharma Hebdo, 8 Apr 2013, (629), (Website:http://www.industrie.com/chimie) (in French)© ETAI Information 2013

Higher net profit but lowerturnover forecast for AkzoNobel in1Q 2013

Analysts are on averagepredicting a net profit of €102 Mfor AkzoNobel in 1Q 2013,compared with €85 M in 1Q2012. Turnover is expected to fallfrom €3.97 bn to €3.64 bn. Thecompany itself is forecasting a20% increase in net profit, thanksto cost savings and lower rawmaterial prices, but a fall inturnover.

Original Source: Het Financieele Dagblad, 17 Apr 2013, (Website: http://www.fd.nl/) (inDutch) © Het Financieele Dagbad 2013

AkzoNobel expects continuingweak demand, improvementprogramme to save €500 M/y

AkzoNobel’s chief financial officerbelieves that end markets willremain weak, especially inEurope, though positive seasonaleffects are expected in 2Q and3Q 2013. Turnover was down 7%and operating profit down 8% in1Q 2013. AkzoNobel is currentlyworking on efficiencyimprovements which should boostoperating results up to the newtarget for 2015. An importantelement in the restructuring is thecentralization of office functions.Processes and methods will bestandardized, thus reducingcomplexity and increasinguniformity. The improvementprogramme should lead to savingsof €500 M/y by the end of 2013.

AkzoNobel reported anoperating result of €217 M for 1Q2013, compared with €236 M for1Q 2012, the decrease beingmainly due to weak marketconditions and problems in theproduction of speciality chemicals.Turnover was down from €3.71 bnto €3.47 bn, primarily because ofweak demand in Europe anddisinvestment, particularly inPakistani operations. Analysts hadpredicted €3.64 bn. Turnover fellin all 3 divisions, with DecorativePaints recording a 5% decreaseto €925 M, Performance Coatingsdown 3% to €1.33 bn, andSpeciality Chemicals down 11%to €1.24 bn.

Original Source: Het Financieele Dagblad, 18 Apr 2013, (Website: http://www.fd.nl/) (inDutch) © Het Financieele Dagblad 2013

Asian Paints 3Q 2012 net profit atRup 335 crore

Asian Paints registered a netprofit of Rup 335 crore in 3Qended 31 Dec 2012, up 30% fromRup 256 crore in the same year-ago period. The positive resultcould be attributed to the firm’simproved distribution, renewedfocus in brand building andmarketing activities. Consolidated