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Beautiful inside and outArchitectural and decorative coatings in Asia Pacifi c

VOL 34 • NO 2MAY 2021

PRIMARY JOURNAL FOR THE COATINGS MARKET IN ASIA & THE PACIFIC RIM

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CONTENTS

1 APCJ • May 2021www.coatings-group.com

VOL 34 No 2 May 2021

FEATURES

MARKET REPORT11 INDONESIAIndonesia set for stable post-COVID growth

12 CHINAChina's robust recovery from the COVID-19 pandemic is allowing its paint market to develop sophistication

ARCHITECTURAL & DECORATIVE17 DECORATIVE COATINGS IN ASIA PACIFICDouglas Bohn, Orr & Boss, gives an overview of the market before, during and after COVID-19

19 ARCHITECTURAL FAçADE COATINGSColour solutions for durable exterior coatings

POWDER COATINGS21 A SILVER LININGHow the addition of a silver ion antimicrobial additive into UV cured powder coatings offers added protection for surfaces

23 RESTORING THE EARTHCourtney Jungjohann Deemer, PPG, speaks to APCJ about the sustainability benefits of powder coatings

MARINE COATINGS24 COUNTING THE HIDDEN COST OF BIOFOULINGHow shipping companies can reduce their carbon emissions

26 ANTI-FOULING COATINGS FOR THE FUTUREHow the reduction of cuprous oxide will make anti-fouling coatings ready for future environmental regulations

SMART COATINGS28 CHANGING THE REACTIVE COATINGS MARKETExpandable graphite solutions are enhancing the protection offered by fire retardant coatings

COMPANY PROFILE30 EVOLVING SUSTAINABLYInkmaker Group has rebranded to IM Group

PUMPING TECHNOLOGY31 OPTIMISING PERFORMANCEOptions for improving AODD pump protection when pumping TiO2

HIGH PERFORMANCE COATINGS32 REDUCING ENVIRONMENTAL FRICTIONHow high performance PVD coatings benefit the environment

RESINS34 CURING UNDER AMBIENT CONDITIONSAmbient curing resins for high heat and corrosion resistance

ADDITIVES37 NO MORE UPS AND DOWNSThe benefits of using levelling and substrate wetting agents

COVER IMAGE CREDIT: Image by Shutterstock

3 EDITOR’S PAGEComment from the Editor

4 NEWSA digest of news from the global paint and coatings industries

8 REGULATIONS UPDATE & EVENTS DIARYA round up of the latest regulation developments in Asia Pacific

14 BUSINESS REPORTDr Terry Knowles looks at how construction is continuing to drive coatings demand

15 INDUSTRY OUTLOOKDr Terry Knowles compares how PPG and AkzoNobel are faring so far this year

REGULARS

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EDITORIAL COMMENT


Side effects of a pandemic

Earth day took place on April 22 this year, with the theme ‘Restore Our Earth’. It seems a bit strange that there

is only one day dedicated to the planet, given its integral role in our lives, but it felt this year as though it got more attention than in years gone by. A side effect of the coronavirus pandemic has been that, with everyone remaining at home, pollution levels dropped, the air became cleaner and wildlife had more of a chance to thrive. Inevitably, as parts of the world come out of lockdown, pollution levels may return to pre-COVID levels – however, with less air traffi c predicted for the next couple of years at least and with a heightened sense of the impact we can have, hopefully some environmental benefi ts will stay with us.

As ever, sustainability is a key consideration in the coatings industry and innovation in this area is constantly evolving. Just as a snapshot, in this May issue of APCJ we speak to PPG’s Courtney Jungjohann Deemer about the sustainability benefi ts of powder coatings; Philip Chaabane, CEO of I-Tech AB, discusses how coatings can reduce carbon emissions; experts from Evonik focus on anti-fouling technology that will adhere to future environmental regulations; and Oerlikon Balzers demonstrates how high performance PVD coatings can benefi t the environment – and that’s all without a special focus on sustainability. That comes later in the year: we publish our annual Going Green supplement in the November issue of APCJ and already, we have some very interesting articles lined up for you.

n NEW DATES FOR COATINGS SHOWS

Another side effect of the coronavirus pandemic is that dates for exhibitions and

conferences have had to be rescheduled to allow for ongoing travel restrictions in place in different parts of the world.

The Coatings Group has also had to postpone its events but we are now pleased to announce that the Middle East Coatings Show will take place in Dubai on September 27-29, 2021 and Asia Paci� c Coatings Show will now take place in Jakarta on March 30-April 1, 2022. We have also postponed Coatings For Africa to May 4-6, 2022, in Johannesburg. We hope this means that as many people as possible will be able to travel and enjoy real-life, face-to-face meetings in safe surroundings.

n ZOOM FATIGUE

Perhaps the biggest side effect of the pandemic has been the sustained lack of human interaction, both personally and professionally. The proliferation of Zoom, Teams and Skype meetings over the pandemic has defi nitely taken its toll, with the CEO of Zoom himself recently admitting to suffering from ‘Zoom fatigue’.

Although it has been an effective way to keep in touch with colleagues and customers while house-bound, there’s no doubt that there’s a real desire to be able to interact normally with people again. Zoom has the double whammy of making you look at your own face, while also not being able to pick up facial clues from the person or people you are talking with. Being able to get back to meetings, exhibitions and conferences where you can have a real conversation with a customer, demonstrate your product and build a rapport without having to rely on the strength of your internet signal or accidentally talking over somebody, will be a real treat – and I, for one, am looking forward to seeing as many of you as possible at our events!

Sally GibsonEditor

EDITORIALSenior Editor: CHRISTINE MALTHOUSEEmail: [email protected]

Editor APCJ: SALLY GIBSONEmail: [email protected]

ADVERTISEMENT SALESEvent Director: PADDY O’NEILL Middle East (not including United Arab Emirates, North Africa, India)Tel: +971 4 445 3773Email: [email protected]

Senior Sales Manager: ANDY GATHERCOLEEurope (not including Italy, Russia & Spain), United Arab Emirates, The AmericasTel: +971 4 445 3712Email: [email protected]

KEZ CHENChina & Asia Pacifi cEmail: [email protected]

LUCA RICAGNIItaly, Russia & SpainTel: +39 333 282 9267Email: [email protected]

ADVERTISEMENT PRODUCTIONProduction Manager: MELANIE CHILESEmail: [email protected]

MARKETINGMarketing Manager: WINSTON PINTOTel: +971 4 445 3736Email: [email protected]

CORPORATESenior Consultant: IAN FAUXEmail: [email protected]

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ASIA PACIFIC COATINGS JOURNAL(ISSN 1468-1412) is published bydmg events LtdHeadquarters: Fifth Floor, The PalladiumCluster C, Jumeirah Lakes TowersP.O. Box 33817, Dubai, UAEWebsite: www.coatings-group.com

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NEWS


PPG opens China Application Innovation Center in ZhangjiagangPPG has opened its China Application Innovation Center (CAIC) in Zhangjiagang, Jiangsu Province, China. The facility is the company’s first cross-business research and development centre in the region, serving as a bridge between innovation and customer applications for its industrial, packaging and automotive refinish coatings businesses.

The CAIC is located in the Jiangsu Yangtze River International Chemical Industrial Park, which is adjacent to PPG’s Zhangjiagang manufacturing plant. The centre’s advanced, automated equipment and technologies enable PPG to simulate the diverse environments and climates where PPG paints and coatings may be applied. The CAIC location also will enable PPG to quickly move newly developed applications

to trial production at its Zhangjiagang plant, enabling increased speed to market for PPG innovations and accelerating product and service customisation.

NEWS IN BRIEFAzelis and BASF in Australia and NZAzelis has a new distribution agreement with BASF, effective immediately, for its dispersions, additives, and resins range in Australia and New Zealand (ANZ). These products are commonly used in CASE (coatings, adhesives, sealants and elastomers) and construction. This partnership strengthens Azelis’ lateral value chain, reinforcing its leading position in the ANZ CASE market.

Arkema in SingaporeArkema confirmed it is on track to begin production of Amino 11 and its flagship Rilsan® polyamide 11 high performance polymer at its new plant on Jurong Island, Singapore in the first half of next year. This plant, for which production will be 100% derived from renewable castor beans, represents a 50% increase in Arkema’s global polyamide 11 capacity.

BASF joins Digital Watermark InitiativeBASF has joined “HolyGrail 2.0 – Digital watermarks for accurate sorting and high-quality recycling”. The initiative aims to increase plastic recycling rates by adding imperceptible digital watermarks to product packaging. Under the auspices of AIM, the European Brands Association, BASF and more than 120 companies from the packaging value chain have joined forces to prove the viability of digital watermarking technologies for accurate sorting and the business case at large scale. Digital watermarks are imperceptible codes, the size of a postage stamp, covering the surface of consumer goods packaging.

Change of dates for Middle East Coatings Show and Asia Pacific Coatings Show, due to ongoing travel restrictionsThe Coatings Group, organiser of the internationally renowned Middle East Coatings Show, has announced that the exhibition will now take place on September 27-29, 2021, at the Dubai World Trade Centre.

The decision to postpone the event from June until September was reached because of ongoing travel restrictions in place across much of the world, which would prevent many of the show’s regular exhibitors and visitors from attending.

Paddy O’Neill, Event Director of the Coatings Group, said: “We are mindful that a significant number of our exhibitors and visitors travel to Dubai from overseas and at the moment, this isn’t straightforward or, in some instances, possible.

“Whilst Dubai is very much open for business and exhibitions have restarted successfully, we want to ensure that our exhibitors are fully confident in their participation with us. We believe the decision to further postpone the show to the

end of September hopefully gives everyone this assurance and, indeed, may come as a relief for some with concerns and reservations regarding making travel arrangements for June.”

The Middle East Coatings Show is the largest dedicated coatings event in the important Middle East and gulf region, regularly attracting a mix of exhibitors and visitors from more than 80 countries.

In light of ongoing COVID restrictions and the new dates for the Middle East Coatings Show, it has also been decided that the Asia Pacific Coatings Show, due to be held in Jakarta this September, will now be postponed until March 30-April 1, 2022.

More information can be found on the website: www.asiapacificcoatingsshow.com. For more information on how to book a stand or visit the Middle East Coatings Show this September in Dubai, visit: www.middleeastcoatingsshow.com

Siegwerk opens toluene-free ink blending centre in BangladeshSiegwerk, one of the leading global suppliers of printing inks, has inaugurated its new blending centre in the Dhaka region in Bangladesh.

Spread over 65,000ft2, the centre will host customised solutions for the Bangladesh market. The blending centre will generate direct and indirect employment for close to 50 people in Bangladesh and will significantly boost the

company’s domestic business in Bangladesh, while enhancing its market leadership position across the Asian region. The new blending centre will also reduce inventory costs to customers and allow Siegwerk to provide immediate technical support for local customers.

Siegwerk has been supplying printing ink in Bangladesh since the mid-nineties. The centre will

manufacture and supply toluene free inks, to ensure health and safety to consumers of packaged food. Toluene or any raw materials containing toluene, won’t be used as intentionally-added ingredients in the facility. The inks produced will be compliant with global regulatory and brand owner requirements to ensure products are safe for end-use packaging applications.


http://www.asiapacificcoatingsshow.com

http://www.middleeastcoatingsshow.com

NEWS


Covestro successfully completes acquisition of resins business from DSMOn April 1, 2021, Covestro successfully completed the acquisition of the Resins & Functional Materials business (RFM) from the Dutch company Royal DSM. The transaction received regulatory approval after Covestro and DSM signed an acquisition agreement in late September 2020. The transaction substantially expands Covestro’s portfolio of sustainable coating resins, making the Group one of the world’s leading providers in this growth market. The integration of RFM will expand the Group’s revenues by around €1bn and will add more than 20 sites to its global production network. “The acquisition of RFM significantly contributes to the

implementation of our new Group strategy. With this transaction, we are taking another important step towards sustainability, while at the same time generating sustainable growth,” said Dr Markus Steilemann, CEO of Covestro.

With the transaction, Covestro is expanding its business in several areas. The Group is already one of the leading global providers of water-based polyurethane dispersions. The acquisition of RFM adds a complete range of water-based polyacrylate resins, as well as strong brands in terms of sustainability, such as Niaga®, solutions for additive manufacturing and an advanced solar coatings business.

Retrofit buildings at Tokyo 2020 honour historyBehind the scenes of the Olympic Games Tokyo 2020, Dow’s materials science expertise helps power infrastructure technologies that insulate, seal, connect, coat, protect and deliver a sustainable legacy. More than half of the 43 Olympic venues are existing facilities, resulting in an estimated savings of 80,000t of CO2 equivalent emissions. Among the existing buildings, nine of those that are retrofitted deployed various Dow technologies to help elevate the performance and aesthetic of façades, building envelopes and electrical systems.

Dr Hirokazu Shibata, Technology & Sustainability Leader for Dow Sports Marketing Solutions, said: “It’s no secret that the construction industry is one of world’s largest consumers of both energy and resources and the decisions made today for the built environment will play a major role in the future of the industry. With technology solutions that exist today, like those incorporated throughout Tokyo’s retrofitted venues, we can improve the energy efficiency of structures, reduce embodied carbon and help leave a positive legacy backed by the power of sport and science.”

NEWS IN BRIEFPerstorp to set science-based emission targetsPerstorp Group has committed to setting science-based targets to reduce greenhouse gas emissions, in line with the Paris Climate Agreement. With ambitions to become the number one sustainable solutions provider within prioritised markets, Perstorp Group has already committed to becoming Finite Material Neutral. Now, the global chemical company has announced its commitment to emission reduction targets in line with the Paris Climate Agreement and the Science Based Targets initiative.

Covestro 3D printingCovestro has released its first material developed by the additive manufacturing business recently acquired from DSM: a glass-fibre filled recycled polyethylene terephthalate (rPET) for 3D pellet printing. Made from post-consumer PET waste, Arnite® AM2001 GF (G) rPET perfectly fits Covestro’s vision for a circular economy and illustrates how complementary the two organisations are in their approach to adding more value to additive manufacturing and industrial production overall.

Songwon establishes new entity in ChinaSongwon has established its new business entity in China, Songwon International-Qingdao Co, Ltd. The organisation will ensure Songwon remains well-positioned to continue providing customers in this important region with high quality products and service. The divestment of its shareholding in the Qingdao Long Fortune Songwon Chemical Co, Ltd joint venture has also been completed.

Hempel opens its new Campus Hempel has opened its new Campus, which features a newly constructed office building, a state-of-the- art R&D facility. meeting rooms, laboratories and test facilities, equivalent to more than 26,000m2 or three and a half football pitches of space. Located just north of Copenhagen, Denmark, Hempel Campus is the daily workplace for more than 350 Hempel employees. Construction of the new Campus began in 2017 and also includes an existing office building and test facility.

Both are scheduled for modernisation and rebuilding during 2021.

The entire Hempel Campus is expected to be finished in 2022 and has been designed by Årstidernes Arkitekter, now Sweco Architects. The design is inspired by the action of stirring a new colour into the centre of a can of paint, forming a pattern known as a spiral vertex. The new office building has been designed with a focus on sustainability and will be DGNB certified, with solar panels installed on the roof.

Sika acquires Hamatite adhesivesSika has agreed to acquire Hamatite, the adhesives business of The Yokohama Rubber Co Ltd. Hamatite is a market leader in Japan, offering adhesives and sealants to the automotive and construction industries. The acquisition will significantly strengthen Sika’s market position in Japan, increase market access to all major Japanese OEMs and notably extend the product offering for sealing and bonding applications in the Japanese construction industry. The product portfolio comprises various technologies, such as polyurethanes, hot melts and modified silicones.


NEWS


Clariant strengthens position in China with inauguration of One Clariant CampusClariant has opened its One Clariant Campus in Shanghai, China. Across a total floor space of approximately 24,000m2, the Campus will be home to Clariant’s Greater China Operational Headquarters, as well as the Innovation Center China. The Chinese market represented 10% of Clariant’s sales in 2020, totalling CHF402M. In order to increase its share of the Chinese market, the world’s largest chemicals market overall, as well as for speciality chemicals, the company is pursuing a dedicated strategy of becoming a true “China Insider” by fostering five key local elements: insight, competitiveness, empowerment, innovation and partnering.

To achieve this, Clariant is investing significantly in China. In addition to the CHF45M invested in the Campus, Clariant recently announced the construction of a new Catofin™

catalysts production facility in Jiaxing, Zhejiang Province and its joint venture facility with Tiangang Auxiliary in Cangzhou, Hebei Province, is opening soon.

New China office for The Shepherd Color CompanyThe Shepherd Color Company has opened its new Sales Office in Shenzhen, China. Shepherd Color Shenzhen will import, stock and sell The Shepherd Color Company and Shepherd Technologies products.

The main office will be in Shenzhen with three further

staff based in Shanghai. Shepherd Color will continue to use Eastway (Shanghai) as its preferred distributor in China for some customers. The Shepherd Color Company has been selling pigments in China through Eastway (Shanghai) for the past 14 years.

Purdue makes the whitest paintIn an effort to curb global warming, Purdue University engineers in the US have created the whitest paint yet. Coating buildings with this paint may one day cool them enough to reduce the need for air conditioning, researchers say.

In October, the team created an ultra-white paint that pushed limits on how white paint can be. Now, the newer paint not only is whiter but also can keep surfaces cooler than the formulation that the researchers had previously demonstrated. “If you were to use this paint to cover a roof area of about 1000ft2, we estimate that you could get a cooling power of 10kW. That’s more powerful than the central air conditioners used by most houses,” said Xiulin Ruan, a Purdue Professor of Mechanical Engineering.

The researchers believe that this white may be the closest equivalent of the blackest black, “Vantablack,” which absorbs up to 99.9% of visible light. The new whitest paint formulation reflects up to 98.1% of sunlight and sends infrared heat away from a surface at the same time. Typical commercial white paint gets warmer rather than cooler. Paints on the market that are designed to reject heat reflect only 80%-90% of sunlight and can’t make surfaces cooler than their surroundings. Two features give the paint its extreme whiteness. One is the paint’s very high concentration of a chemical compound called barium sulphate. The second feature is that the barium sulphate particles are all different sizes in the paint.

Innovation in AsiaBASF is strengthening its innovation capabilities in Asia by breaking ground for the third phase of its Innovation Campus Shanghai and by establishing an academic sounding board as part of the Network for Asian Open Research (NAO).

The expansion includes an additional R&D building and one R&D workshop building. Construction is expected to be completed by the end of 2022; by then, the total investment of BASF into its Innovation Campus Shanghai will sum up to around €280M.

This further expansion demonstrates BASF’s continued commitment to further build up innovation capacities in China and the whole Asia Pacific region. With this expansion, BASF will strengthen its R&D capabilities for advanced materials and systems, as well as for chemical engineering in order to serve the needs of growing industries, such as automotive, construction and coatings.

NEWS IN BRIEFPPG acquires CetelonPPG has acquired Cetelon Lackfabrik GmbH, a manufacturer of coatings for automotive and light truck wheel applications. Financial details of the transaction were not disclosed. Cetelon develops and manufactures a wide range of coating systems for the wheel industry, including certain proprietary technologies.

Coatings to help with greener air travelA materials expert at the UK’s University of Nottingham has secured more than £2.1M to develop new coatings for use in aerospace that could cut jet plane CO2 emissions and help spacecraft built for humans venture further into our solar system. Dr Tanvir Hussain has received the five-year fellowship – funded by the Engineering and Physical Sciences Research Council – to find new modelling and processing techniques that will overhaul the design and manufacture of advanced ceramic materials for the next-generation of air and space travel.

Nippon Paint wins green technology awardNippon Paint Marine Coatings ships’ hull coating AquaTerras has won the ‘Green4Sea Technology Award’ in an online event. The paint system, currently the world’s first and only completely biocide free, self-polishing (SPC) antifouling paint, came top in a global poll for making a “significant technological breakthrough” in marine environmental sustainability. Other companies shortlisted in the category included Alpha Ori Technologies, Filtersafe, Solvang and Jotun.


NEWS


Philippine NGO discovers more spray paints with dangerously high lead contentA toxics watchdog group from the Philippines has found more spray paints in the market that are contaminated with dangerously high concentrations of lead, a chemical forbidden in the manufacture of paints under the country’s law. In a statement, the EcoWaste Coalition revealed that 13 spray paints with lead content ranging from 4500 to 56,100 parts per million (ppm) are being sold to uninformed consumers by offline and online retailers in brazen violation of the country’s lead paint regulation limiting lead to a maximum of 90ppm. This brings the total number of lead-containing aerosol paints uncovered by the group to 50, including its discovery of 37 violative products last year that were subsequently banned by the authorities. None of these 50

leaded spray paints was produced by companies affiliated to the Philippine Association of Paint Manufacturers (PAPM).

The EcoWaste Coalition has notified the authorities about its latest findings and has also requested retail stores to take the violative products off the shelves. Lead compounds were used before in paint formulations to add colour, quicken the drying process, inhibit rust and increase durability. Exposure to lead can affect a child’s developing brain and cause reduced intelligence and attention span, as well as increased risk of behavioural problems.

A full report can be found here: https://ipen.org/documents/lead-spray-paints-consumer-use-philippines

Hempel acquires Wattyl Australia and New ZealandWattyl Australia and New Zealand is now officially part of world leading coatings manufacturer Hempel. With the acquisition of Wattyl, Hempel is strengthening its footprint in Australia and New Zealand significantly.

On February 18, 2021, Hempel A/S signed an agreement to acquire leading paint and coatings manufacturer Wattyl Australia and New Zealand from The Sherwin-Williams Company, the world’s largest paint

and coatings company, headquartered in the USA. Hempel received formal customary approval from the relevant authorities in Australia and New Zealand and Wattyl is now officially a part of the Hempel Group. The acquisition is part of Hempel’s ambition to double its revenue to €3bn by 2025 as outlined in its Double Impact strategy.

“We have taken the first major step on our growth journey, which will see us build leadership positions

in chosen geographies and segments. With Wattyl as part of the Hempel Group, we are gaining a strong footprint in Australia and New Zealand, while pursuing our strategic ambitions for the Decorative, Infrastructure and Energy segments in our South & East Asia region,” said Lars Petersson, CEO of Hempel.

Wattyl has an annual turnover of €150M and has been a household name in Australia and New Zealand for more than 100 years.

NEWS IN BRIEFAkzoNobel invests in Qlayers startupQlayers’ coating technology offers a fully automated solution that is safer, more consistent and faster than the manual coating processes used now in the industry. By eliminating overspray, it’s a sustainable solution that saves costs. Qlayers is part of AkzoNobel’s Paint the Future collaborative innovation ecosystem.

Siegwerk and Kotkamills join forcesSiegwerk, one of the leading global providers of printing inks, and Kotkamills, a Finnish paper and paperboard manufacturer, have joined forces to create solutions for printers and producers of fibre-based packaging to further drive packaging circularity. The collaboration is based on the potential of water-based dispersion barrier coated paperboard to replace traditional polyethylene (PE) coated board. Thus, the switch in coating not only offers an economic driver to collectors and recyclers, it also reduces the environmental impact of the packaging.

Multi-ship referenceTurkey’s Iskenderun Ship Management has provided a first reference for Nippon Paint Marine’s self-polishing antifouling paint FASTAR, following an agreement to apply the novel coating to five bulk carriers scheduled to drydock in China this year. FASTAR, developed to reduce the volume of paint required without detriment to performance, was officially introduced to the market in January. It is designed to deliver an approximate 8% reduction in fuel consumption and CO2.

Covestro co-operates with AkzoNobel and MINE TechnologiesIn the growing market for consumer electronics, manufacturers are looking for new aesthetic and functional solutions. To meet their needs, Covestro worked with paints and coatings manufacturer AkzoNobel to develop a new type of waterborne coating system with adjustable haptics and a matte optics effect. It simultaneously meets the high demands on the quality and durability of today’s electronic products.

One current example is the functional Smart Mirror from the Chinese manufacturer MINE Technologies. The mirror cover is coated with AkzoNobel’s waterborne soft-touch coating. It is highly resistant to abrasion and scratching and is based on the polyurethane raw materials Bayhydrol® and Bayhydur® from Covestro.

The water-based coating is characterised by only low emission of volatile organic compounds (VOCs), contributing to a more sustainable

manufacturing process. The mirror also features compelling new electronic functions. If you swipe its edge, it begins to glow. The brightness can also be adjusted via swiping. The Smart Mirror can also connect to WiFi networks and is capable of recharging wirelessly.

With pilot projects like this, Covestro is positioning itself in the growing consumer electronics devices market.

https://ipen


DIARY | REGULATIONS


REGULATORY ROUND UP — ASIA PACIFIC By Kathryn Wortley in Tokyo; Raghavendra Verma in New Delhi; Jens Kastner and Poorna Rodrigo - International News Services

DIARYMAY 18-19Global Coatings & PaintInnovation SummitAmsterdam, The Netherlandswww.evnoiagroup.com

MAY 26-28Coating Korea 2021Songdo Convensia, Incheon, Koreawww.coatingkorea.com

JUNE 23-25Paint & Coating JapanOsaka, Japanwww.coating-japan.jp

JULY 26-28ICIE & Coatings Raw Material Procurement ConferenceGuangzhou, PR Chinawww.coatexpo.cn

AUGUST 6-8China Coatings Show SNIEC, Shanghai, PR Chinawww.coatshow.cn

AUGUST 26-28Coatings Expo VietnamSECC, Ho Chi Minh City, Vietnamwww.coatings-vietnam.com

SEPTEMBER 14-16European Coatings ShowNuremberg, Germanywww.european-coatings-show.com

SEPTEMBER 27-29Middle East Coatings ShowDWTC, Dubai, UAEwww.middleeastcoatingsshow.com

NOVEMBER 16-18ChinaCoatSNIEC, Shanghai, PR Chinawww.chinacoat.net

MARCH 10-12, 2022PAINTINDIABombay Exhibition Centre, Indiawww.paintindia.in

MARCH 30-APRIL 1, 2022Asia Pacific Coatings ShowJI Expo, Jakarta, Indonesiawww.asiapacificcoatingsshow.com

MAY 4-6, 2022Coatings For AfricaJohannesburg, South Africa www.coatingsforafrica.com

SOUTH KOREAAn Act on the Punishment for Serious Accidents passed South Korea’s legislature on January 8, angering the country’s coatings sector. Coming into force one year after its promulgation, the law will strengthen punishment for companies and managers involved in industrial accidents. The act has been criticised by South Korea’s coatings sector. In online forums, companies said that they should not be penalised for an accident given that pigments, resins and additives contain many petrochemicals, such as benzene, toluene and xylene, and so fires or leaks are an inevitable risk. One user said: “Companies already have to spend billions of billions of dollars a year investing in and maintaining environment and safety related facilities but due to the nature of chemical products, no matter how closely the facilities and processes are managed, the negligence of workers and the possibility of accidents in the transportation process cannot be excluded.” See: www.m.stock.naver.com; www.hani.co.kr/arti/politics/assembly/977786.html

JAPANThe Japan Paint Manufacturers Association has released its 2021 list of safe household paints, designed to provide “peace of mind” for general consumers. As of January 31, hundreds of paints from 16 companies have been listed in two main categories: for indoor and for outdoor use. The products are further subcategorised into water-based, solvent-type and aerosol-type paints. The public is asked to check the respective manufacturing company for details on each product’s use, quality performance and other information. See: www.toryo.or.jp

INDIAIndia has scrapped an anti-dumping duty on Japanese exports of phthalic anhydride, a dye additive that is also used as a plasticiser and to make resins. However, the Indian Directorate General of Trade Remedies recommended continuing an anti-dumping duty on imports of this chemical from Russia for another five years, as “there is likelihood of dumping and consequent injury to the domestic industry.” Exports from Japan have been attracting US$126.17/t and from Russia US$159.43/t, with the duties set in US$ rather than Indian Rupees. These duties were first imposed in December 2015. See: www.gov.in

CHINAThe China National Coatings Industry Association (CNCIA) – a state backed body – on February 4 unveiled Technical Specifications

for Titanium Dioxide (T/CPCIF 0088-2021, T/CNCIA 02008-2021) and Green Design Product Evaluation Technical Specifications for Iron Oxide Pigments (T/CPCIF 0089-2021, T/CNCIA 02009-2021). These standards will be implemented from May 3. They resulted from NCIA mandates during the 13th Five-Year Plan period (2016-2020), which encouraged the creation of a green manufacturing system for the coatings industry, which has spawned a series of new standards for the industry. See: www.chinacoatingnet.com

TAIWANTaiwan’s Environmental Protection Administration (EPA) has said that it will prioritise the implementation of the island’s Standard for Volatile Organic Compounds in Building and Industrial Maintenance Paints, limiting volatile organic compounds in building paint products. From October 2019 to March 2020, for instance, EPA inspections across Taiwan found 47 violations of emission standards for VOCs in coatings. The EPA said it would review specific industry-specific emission standards for printing and coatings consuming sectors, such as automotive manufacturing. See: www.epa.gov.tw

THE PHILIPPINESThe Philippines’ Maritime Industry Authority (MARINA) has issued (in January 2021) new rules and regulations on the application of anti-fouling paints and coatings on ships to prevent the use of environmentally-harmful substances. MARINA Memorandum Circular No. SR-2020-04 aims to minimise, if not completely eliminate, the environmental effects of organotin compounds in anti-fouling systems (AFS) that prevent the attachment of unwanted organisms on ship hulls. “Failure to comply with the anti-fouling system controlled under the International Convention on the Control of Harmful Anti-Fouling Systems in Ships (AFS Convention) shall [necessitate] repair or replacements to completely comply with the said convention,” MARINA said. See: www.marina.gov.ph/wp-content/uploads/2021/01/MC-SR-2020-04.pdf

VIETNAMVietnam’s Ministry for Industry and Trade has promulgated a new National Technical Regulation on Safety in the Production, Trading, Use, Storage and Transport of Dangerous Chemicals. It will take effect from January 1, 2022. It stipulates a set of chemical incident response procedures and includes the obligation for businesses that handle hazardous chemicals to have a list that must contain information on chemical names, trade names, classifications, warning images, maximum storage levels at a


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DIARY | REGULATIONS

REGULATORY ROUND UP — ASIA PACIFIC

Axalta gives new impulses to architectural and design applicationsAxalta is expanding its range of highly weather-resistant metallic effect powder coatings from the Alesta® SD SuperDurable product line with “The SuprAnodic Collection”. The new collection provides the advantage of an environmentally friendly powder coating. It combines ecological responsibility and creative freedom. The SuprAnodic Collection offers the look of high-quality anodised finishes and portrays current and future trends in architecture and design. Additionally, the QUALICOAT Class 2 and GSB Florida 3 (Master) certified powder coatings have excellent UV and weather resistance and easy application, making them ideal for outdoor architectural

applications and exterior design. “At Axalta, we are intensively engaged with both the developments that influence architecture and the requirements of the coating industry,” says Ludovic Béal, Product & Marketing Leader Architecture & Furniture at Axalta Powder Coatings in EMEA. “This includes ensuring that our metallic products are manufactured using the latest bonding technology giving them their low gloss, optical depth and fascinating metallic effect, which, in combination with the new colours, enable architects and designers to set extraordinary accents on buildings and objects”.www.axalta.com/supranodic

New Bismuth Vanadate YellowShepherd Color has launched its new Bismuth Vanadate (BV) Yellow, product code 30C133.

Bismuth Vanadate, also known as C.I. Pigment Yellow 184, is widely used in high-performance yellow colour matches and has wide regulatory approvals and inclusion in chemical registries around the world. Shepherd Color’s Yellow 30C133 is only available in its Dynamix® brand, which removes the time consuming, energy-intensive and variable pigment grinding step in laboratory development, scale-up, and full production.

Yellow 30C133 is all inorganic and doesn’t have any organic dispersion aids or resins included that might compromise the performance of systems incorporating Yellow 30C133.

Common uses for Yellow 30C133 are high-performance coatings, such as coil & extrusion spray, automotive, industrial, architectural, powder and other coatings. It can also be used in plastics and engineering polymers, especially in thin films and fibres. The pigment is optimised for easy dispersion.www.shepherdcolor.com

location and rules on designated storage areas. It also contains detailed technical requirements for equipment and pipes containing corrosive chemicals. See: www.luatvietnam.vn

AUSTRALIAThe Australian government’s Department of Health has announced that 2-Butyloctanoic acid, used as an emollient for polymers, paper coating and solvents among other uses, has been added to the Australian Inventory of Industrial Chemicals, following an assessment of its potential environmental health impact. Manufacturers and importers of this chemical must inform the department within 28 days if there any potential breaches of Australian government guidance regarding this chemical. See: www.industrialchemicals.gov.au

INDONESIAIndonesia has opened up investments to construction services based in the country, including paint and coating services, that had previous foreign

ownership restrictions. Effective March 4, 2021, Indonesia’s Presidential Regulation 10 of 2021, dubbed “the positive list”, replaces Presidential Decree No. 36/2010, known as “the negative list”, which was far more restrictive. As part of the government’s ongoing economic reforms and Omnibus Law (No. 11/2020 on Job Creation), the regulation presents one of the greatest liberalisations in Indonesia’s foreign ownership limitations since the negative list was first introduced in the 1980s. However, the manufacturing of ozone-depleting substances and industrial chemicals remain closed for private investments both domestic and foreign. See: www.kemlu.go.id/portal/id

MALAYSIAAnalysis of trade data released by Malaysia’s Ministry of International Trade and Industry (MITI) for January (2021) has shown significant recent export growth has been driven by strong shipments of manufactured goods (Jan: +11.7%; Dec: +12.4%), particularly rubber products, chemicals and chemical products,

including key ingredients for paints, coatings, resins and adhesives. United Overseas Bank (UOB) Group’s Senior Economist Julia Goh and Economist Loke Siew Ting said that this growth happened despite Malaysia reinstating a Movement Control Order (2.0) in mid-January to fight COVID-19. See: www.miti.gov.my/miti/resources/MITI Weekly Bulletin/MITI_Weekly_Bulletin_Volume_627_02_March_2021.pdf

THAILANDThailand is scheduled to unveil fresh tax incentives and relaxed regulations for foreign direct investment in late March 2021, which should help Thai paint and coating manufacturers relocating production to their home country. Deputy Prime Minister Supattanapong Punmeechaow said the stimulus measures aim to raise the country’s competitiveness for foreign investment and that, “Thailand will become more attractive for foreign investment, especially among investors that want to relocate their production bases.” See: www.boi.go.th

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http://www.industrialchemicals.gov.au

http://www.kemlu.go.id/portal/id

http://www.miti.gov.my/

http://www.boi.go.th

MARKET REPORT


INDONESIA

Ahmad Pathoni reports from Jakarta on Indonesia’s paint and coatings sector

Indonesia set for stable growth post COVID-19

The paint and coatings industry in Indonesia still has ample room for growth amid booming

infrastructure development, although it has had to struggle with the ongoing COVID-19 pandemic, say offi cials and industry experts.

With the property sector being the primary growth driver of Indonesian paint and coating sales, the high demand for new housing and the repainting cycle assures a steady demand for paint and coating products, said Mahendra Chahar, Senior Consultant at Frost & Sullivan.

The Indonesian government is also planning to spend nearly US$40bn on new metro railway lines for the Jakarta region, which will boost paint and coating demand and plans to construct a new national capital in Borneo, costing US$400bn, which will do the same.

“The paint and coatings industry has a bright prospect in line with the increasing national paint consumption and the rate of physical development,” said Muhammad Taufi k, Director of Upstream Chemical and Pharmacy Industries at Indonesia’s Industry Ministry. “The opportunity for growth in the paint industry is still very large. The government’s infrastructure programmes and the continued high growth in the property sector are among factors driving the increase in demand for paint,” he said. Noting that the government boosted its budget allocation for infrastructure development to Indonesian Rupiah IDR417.8trn (US$29bn) for 2021 up from IDR281trn in 2020, partly to boost the economy during the COVID-19 pandemic, he commented: “It is hoped that domestic paint and coating industry players can make the best of this.”

Infrastructure projects planned for the next few years include 53 dams (43 units are being built and 10 new dams); sanitation and solid waste facilities for 1.65M families; an irrigation network

stretching 600km; 965.4km of roads; 26.9km of bridges; 446.56km of railway lines and 10 airports, according to the National Development Planning Agency.

Taufi k hopes this will cause the country’s paint and coatings industry to increase production. He also hopes a strengthened paint sector could boost the country’s competitiveness to “compete in local and global markets.”

n THE IMPACT OF THE PANDEMIC

Farid Muhammad, a former Director at Pt Sigma Utama Paint, Bogor, West Java, however, said some construction projects have been suspended or cancelled during the pandemic: “Everyone is suffering and has to tighten their belts. We have been forced to review our spending and this results in a business downturn. For big companies, they can still survive even with smaller margins. But small companies are lucky to reach a break-even point.”

He said economic stimuli offered by the government had yet to benefi t many paint and coatings companies. He added that direct government COVID-19 support had often been slow to arrive, causing further disruption: “We can only hope that vaccinations can be done faster and the economy runs again. If that happens, demand will increase and our business can fl ourish again.” He expects a revival in general demand during July: “The paint business is likely to stabilise next year,” he said.

Haryawan, Secretary General of the Indonesian Coatings Association (Ascoatindo), was more optimistic: “We still don’t know the impact of the pandemic but when people are at home, they have little to do. They start painting their houses. At the domestic level, the impact seems to be insignifi cant,” said Haryawan, who has just one name. He said infrastructure projects are also still running, generating demand

for coatings and galvanising agents. The government has also increasingly used local products rather than imported ones for its construction schemes: “Local products and brands can compete with imported products and the quality is not inferior to those foreign products,” he said.

Factories have continued to operate during the pandemic, especially those outside of Indonesia’s central (and most populous) Java island, although offi ce staff have generally worked from home, Taufi k said.

With its population of 270M, it is unsurprising that Indonesia is the largest paint and coatings market in south east Asia. But what makes the paint and coatings sector special in this 17,500-island archipelago is that it is one of the few business sectors in Indonesia with strong domestic players and once the pandemic is over, the Indonesian paints and coatings market is expected to post robust annual growth of 6.5% over the next fi ve years, according to Mumbai, India-based Inkwood Research.

Indonesia’s growing population (up 1.1% yr-on-yr in 2019), rapid urbanisation (56% in 2019), the growing construction industry and the swiftly expanding middle class are among contributors to growth, Inkwood said. This currently comprises more than 150 companies – consisting of small, medium and large enterprises – with a total capacity of 1.5Mt/yr, with production per factory varying from 4000-75,000t/yr, Taufi k said.

Four paint companies, PT Propan Raya, PT Avia Avian, PT ICI Paints Indonesia – subsidiary of Dutch multinational AkzoNobel – and Japan’s Nippon Paint Holdings have 65% to 75% of the market share in Indonesia. The remainder of the paint market is held by other international players and smaller local manufacturers.

Because of this, the country has a relatively low level of imports – 83,140t (worth US$354M) in 2019, up from 74,700t (worth US$283.57M) in 2015, >13


MARKET REPORT


CHINA

Mark Godfrey reports on how China’s robust recovery from the COVID-19 pandemic is allowing its paint market to develop sophistication and its industry to expand exports

China: A tale of two price-points

China’s embrace of Scandinavian style is propelling sales of innovative decorative paints among young

homeowners in China. “Simplicity” and “high quality lifestyle” are the watchwords of the Nordic style being marketed by Jotun, whose focus on the premium part of the Chinese market appears to have paid dividends.

n EXTERNAL INFLUENCES

The Norway-based fi rm recorded a record year in 2020 in China in terms of sales, profi t and market share. China’s economy recovered quickly from COVID-19 in Q2, 2020, said Jinn Yep Chan, Business Director for decorative paints at Jotun China. While the broader paint market in the country grew by 6-7% yr-on-yr during 2020, Jotun grew its overall sales in China by double fi gures, said Chan.

“We did that by increasing its distribution network through a franchise-type dealer network. And by focusing on the premium end of the market.” By premium he means young middle-class homebuyers whose travel and trips to giant IKEA stores in Beijing have made them amenable to Nordic decorative fashion tastes.

Now Jotun wants to double its own distribution network by opening more concept stores through its dealers: it wants to double the number of such stores to 200 in 2021, focusing on larger “fi rst and second tier” cities, said Chan.

A new Nordic ‘Premium Paints’ concept store opened by Jotun in a Beijing mall “allows clients to browse beautiful panels [in various paint colours] which can inspire [customers] to choose colour schemes,” said Chan. He explained how the Nordic aesthetic differs from the American (represented in China by PPG and other players). “There’s been an evolution in paint tastes in China: in China 10 years ago, the majority of paint was in white or light yellows or blues. More exposure to European styles through travel has changed Chinese tastes.” The American aesthetic is “bright and shiny”, but the Nordic aesthetic is more “minimalist and cosy”.

n DOMESTIC FACTORS

China remains reliant on imports at the high end of the market. While its exports are increasing, these are of a lower price point to internationally branded products.

There has also been a boom in domestic spending – a Chinese government 2020 stimulus designed to keep the economy afl oat during the COVID-19 pandemic has been a boon for local paint makers, such as San Ke Shu Paint Co, based in Fujian, which is projecting that 2020 revenues rose 39% yr-on-yr, alongside a 23.3% jump in profi t.

The company’s performance was driven by demand for its water proofi ng and insulation paints, explained Zhan Zhi Yang, an analyst at Fuzhou-based Xing Ye Securities, who monitors the paint manufacturer. San Ke Shu promotes itself to consumers – it runs adverts on China National Radio targeted specifi cally at new homeowners, he noted.

San Ke Shu is well placed geographically, said Zhan, with manufacturing facilities in Anhui, Fujian, Hebei and Henan. Zhan sees the main risks to continued growth as a slowdown in China’s real estate market and increased competition in the paints sector.

China’s spending on infrastructure grew sharply in the second half of 2020, backed by Chinese Yuan Renminbi CN¥4.7trn (US$752bn) of special local government and national government bonds. Whereas

China’s embrace of Scandinavian style is propelling sales of decorative paints in China


MARKET REPORT


western countries paid COVID payments to their citizens, such as the UK’s furlough scheme, China focused on its fiscal stimulus, explained HSBC’s Chief China Economist Qu Hongbin in a paper.

While this has been good for the construction industry, it has not given a direct boost to private consumption (which accounts for 39% of China’s GDP, compared to 65% in the USA), which in turn makes for a slower recovery in retail sales.

Yet China’s focus on bricks-and-mortar projects to drive economic growth is the main growth strategy of another leading local player, Oriental Yuhong Waterproof Technology Co Ltd (Dong Fang Yu Hong in Mandarin), which is based in Beijing. Its marketing slogan, ‘Less leaking, better life’ is hardly the most reassuring slogan but may have its origins in the quality issues facing Chinese construction – and the country’s diverse climate.

Oriental Yuhong has flagged profits for Q4, 2020 of at least CN¥969M (US$150M) - an increase of 93.7% on the same period in 2019. The company’s profitability is down to increased real estate finishings and stagnant raw material costs, according to Zhao Jun Sheng, an Analyst at Beijing-based DongXing Securities. Yuhong’s 28 manufacturing bases give it geographic reach, said Zhao.

Beijing-based Oriental Yuhong has used its 2016 investment in German firm DAW (Deutsche Amphibolin-Werke SE) to increase its consumer facing business: its ‘De Ai’ brand (the name is a play on the Chinese characters for ‘Germany’ and ‘love’), was named on a list of 500 top suppliers to the Chinese real estate development sector collated in 2020 – the ‘Best 500 of China Real Estate Developers Preferred Brand’ award.

n PRICE DISPARITIES

It is clear that there’s a major gap in the pricing power of Chinese paint and coatings manufacturers and international peers. China’s coatings import and exports are both increasing, according to data from the General Administration of Customs of China, yet while exports are larger in volume terms they are lower in value per unit compared to imports. China exported 211,378t of paint and coatings in 2019 said China Customs, up 10.9% yr-on-yr, and the export value was US$679M, an increase of 8.2% yr-on-yr. China imported 180,840t, worth US$1.37bn in 2019, a yr-on-yr increase of 32.5%.

However, the average import price of Chinese coatings was US$7229/t, whereas the average export price was US$3217/t, according to the China Customs. Its data shows imports coming especially from Germany, South Korea and Japan – 19.8%, 19.5% and 14.4% respectively of China’s coatings imports in 2019. The top three destinations for Chinese exports were Hong Kong, Vietnam and Panama, with export volume accounting for 16.9%, 8.9% and 6.2% respectively. Exports are

made up largely of “acrylic- and polyester-based paints”, according to a China Customs note.

With the country’s highly fragmented paint and coatings manufacturing scene long encouraging cut-throat competition on price, it is hard to see how Chinese paint production will move up the value chain in its international market offerings in the short term.

Overall, paint and coatings production is expected to expand from 22Mt to 25Mt between 2020 and 2025, according to the China National Coatings Industry Association (CNCIA). Yet there are real risks to this scenario materialising – and those risks include a falloff in the Chinese and wider Asian real estate markets.

Meanwhile, it appears that the premium end of the domestic market will remain the preserve of international brands.

One curious thing also seems to be constant: the Chinese aversion to DIY, which continues to distinguish this market from Europe, where COVID-19 lockdowns prompted a surge in paint sales to homeowners. While there are growing numbers of Chinese willing to paint, the figure is “not significant” and the bulk of painting is done by decoration companies, explained Jinn Yep Chan. Jotun, for example, co-operates with the large Jia.com, an interior design platform that allows homeowners to pick their paints and price the job online. n

For more information, contact: Keith Nuthall, International News ServicesWebsite: www.internationalnewsservices.comTel: +44 (0)207 193 4888

For more information, contact: Keith Nuthall, International News ServicesWebsite: www.internationalnewsservices.comTel: +44 (0)207 193 4888

according to Indonesia Trade Ministry data. During the pandemic, from January to October last year, imports slowed to 62,270t (worth US$236.25M), it said. Exports have been stable over the past five years from 41,000t (US$74.8M) in 2015 to 36,000t (US$86.92M) in 2019, the ministry added. From January to October 2020, exports were 28,000t (US$63.27M). South Korea, China and Malaysia are the key exporters to Indonesia, while Singapore is the main export destination, the ministry said.

The pandemic has increased demand for antimicrobial paint, with Nippon Paint leading in this sector. Taufik said that Indonesia is also moving ahead with antimicrobial products. Nippon Paint Indonesia has been applying silver-ion technology to Nippon Vinilex Fresh since 2005, which is used in hospitals. Then in

2018, this technology was introduced to the retail business through Nippon Spot-Less Plus – a premium segment interior paint with anti-stain and anti-germ functions, he added. Nippon Paint Indonesia last April (2020) integrated its silver-ion antimicrobial technology into Vinilex Anti-Kuman, a medium segment interior wall paint, said Chahar of Frost & Sullivan. Also, despite the pandemic, PT Mowilex Indonesia, a subsidiary of Asia Coatings Enterprises Pte Ltd, is set to open a new IDR500bn (US$34M) plant this year, the company’s Finance Director Esther Sugiono told the state-run Antara news agency.

So, as Haryawan said, innovations in the Indonesian coatings sector have grown rapidly, with Norwegian major Jotun recently launching its Global 2021 Colour Trends in Indonesia and its ColourDesign app and companies developing coatings

that work as insulators to withstand heat and electricity, although he admitted that ensuring such high-tech coatings follow international standards remains a problem in Indonesia.

“Local companies like Siba Utama, Novalux and ICI have begun producing good quality coatings and also exporting them,” although some other companies, while producing these functional lines, “have a long way to go to achieve desired quality,” he said. n

<11

“It is clear that there’s a major

gap in the pricing power of Chinese paint and coatings manufacturers and international peers.

”


http://www.internationalnewsservices.com

http://www.internationalnewsservices.com


MARKET REPORT

After some time away from coatings-related topics, The Freedonia Group has recently published

two new global studies of interest to the coatings sector and its suppliers: Global Paint & Coatings – 7th Edition and Global Thermoplastic Elastomers – Adhesives, Sealants and Coatings. A third global study, which is from Grand View Research, is also included in this column and it covers the demand for iron oxide pigments.

In Freedonia’s global paint and coatings study, the main trends that will shape short-term growth in the global paint and coatings market until 2024 are as follows:

• Improving living and housing standards in the Asia Pacific region;

• Interest in the rapidly developing countries of south east Asia – including Indonesia, Thailand, the Philippines and Vietnam which are benefiting from investment from North American and Western European companies;

• Increasing infrastructure expenditure in developing countries, particularly in areas such as roads and bridges;

• Growing DIY activity in mature economies, including the USA;

• Recovery of the automotive sector following the collapse during the pandemic period, thereby increasing OEM coatings demand but also with emphasis on the refinish segment, which may reflect affordability struggles in household spending, post-pandemic.

Overall growth in the market is envisioned at an average rate of 2.7%/yr for the period 2019-2024. The split of the entire market places architectural coatings at 54% of the total, as seen in Figure 1.

The top six companies in the paint and coatings sector (Sherwin-Williams, PPG Industries, AkzoNobel, Axalta Coatings Systems, BASF and Nippon Paint) are deemed to account for just more than a quarter of all sales of paints and coatings globally.

In the company’s study for thermoplastic elastomers that delves into the adhesive, sealant and coatings segments, the collective outline for growth has some similarities. They are:

• Growth in the construction sector around the world;

• Greater penetration of thermoplastic elastomers in the Asia Pacific region for use in tapes and labels;

• Rising demand for personal hygiene products in China and India;

• Above-average growth for polyolefin elastomers (POEs) and thermoplastic polyurethanes (TPUs) (Figure 2).

Almost all of the regions that the report covers are expected to witness slower growth over the period 2019-2024 when compared to 2014-2019. Eastern Europe is the exception, where growth of just more than 3%/yr is anticipated in the near term. Central and South America, the Asia Pacific and MEA regions are all expected to show faster growth than this (typically 3-4.5%/yr) and North America and Western Europe slower growth in comparison. In fact, Western Europe offers the slowest growth of all.

n IRON OXIDE PIGMENTS

In April, Grand View Research published a new report on the global market for iron oxide pigments and it values said market at US$2.2bn in 2020. It is expected to expand at a CAGR of 4.7% across the forecast period 2021-28. The rapidly growing construction industry in emerging nations will be the key growth factor for the sector. Moreover, the growing utilisation of iron oxide pigments in the coatings industry owing to their excellent dispersibility and high strength, which make them suitable for use in formulations for extreme atmospheric and weather conditions, is expected to propel their consumption even further.

The synthetic iron oxide pigment segment leads the market and

Dr Terry Knowles looks at three reports that all highlight how construction is driving growth in the coatings industry

Construction continues to drive demand

>16

Author bio: Dr Terry Knowles has been writing and editing information for the paint, coatings and ink industries for 23 years and is now the editor of The Palette Newsletter – a brand-new monthly publication with a business slant, serving all parts of the coatings chain. For more information and a free trial, email Terry at [email protected] or contact/follow on Twitter: @newspal2 Email: [email protected]

Figure 1. Source: Freedonia Group Figure 2. Source: Freedonia Group Figure 3. Source: Grand View Research





INDUSTRY OUTLOOK

Two of the world’s top three paintmakers have released their first-quarter results for 2021 as I write this, those being PPG

Industries and AkzoNobel. This May issue of APCJ is therefore a good opportunity to highlight their very latest figures and outlooks but before I do that, a short comparison of how they both fared overall in 2020.

n PPG INDUSTRIES IN 2020

PPG Industries’ calendar year sales for 2020 reached in excess of US$13.8bn, which is down by about 9% on 2019, including unfavourable foreign currency impacts of about 1%, or approximately US$150M. Acquisitions added 1% to sales but sales growth on the organic, continuing bases were down by nearly 8% over 2019.

PPG stopped short of detailing the cumulative outcomes over the year by coatings segment, other than providing the most basic sales and income data (Table 1).

n AKZONOBEL IN 2020

At AkzoNobel, the Asia Pacific region performed the least favourably in 2020 as far as decorative paints were concerned, with a 15% decline in

revenues in the segment. With actual growth in the EMEA region for decorative paints, particularly as the DIY sector benefited from the stay-at-home spur, Asian sales of decorative

Dr Terry Knowles outlines the Q1 results from industry titans AkzoNobel and PPG

Giants step forward again

Author bio: Dr Terry Knowles has been writing and editing information for the paint, coatings and ink industries for 23 years and is now the editor of The Palette Newsletter – a brand-new monthly publication with a business slant, serving all parts of the coatings chain. For more information and a free trial, email Terry at [email protected] or contact/follow on Twitter: @newspal2 Email: [email protected]

2019 2020 Δ

Net Sales

Performance Coatings 9034 8495 -6%

Industrial Coatings 6112 5339 -13%

Total 15,146 13,834 -9%

Segment Income

Performance Coatings 1409 1359 -4%

Industrial Coatings 862 750 -13%

Total 2271 2109 -7%

Region 2019 2020 Change (%)

EMEA 2129 2246 +5

South America 457 396 -13

Asia 1084 916 -15

Total 3670 3558 -3

Table 1. Annual sales and income in 2020 at PPG Industries (US$M)

Table 2. AkzoNobel’s Decorative Paints business revenues in 2020, by Region (€M)

Table 4. Comparison of PPG and AkzoNobel for Q1, 2021

PPG Industries in Q1 2021 Segment AkzoNobel in Q1 2021

High single-digit percentage growth Decorative/Architectural Asia Serial quarterly recovery in place for India, Pakistan and Malaysia; Asian sales up by 33%

Approximately 20% increase in sales as DIY demand continued

Decorative/Architectural EMEA EMEA sales up by 21%, with good demand in the DIY segment

Strong performance in professional and DIY in USA, good growth through concessionaires in Mexico

Decorative/Architectural Americas 14% increase in sales in South America, following pricing initiatives

Robust demand for appliances among other end-uses

Powder coatings 13% growth to sales of €318M. Good growth in Asia

10% collective increase in sales for automotive, packaging and general industrial coatings

Industrial coatings Sales up by 8% as coil and packaging coatings demand remain strong everywhere

Up by a low percentage overall. Demand from China offset weakness in the USA.

Marine and protective coatings Revenues 7% lower at €270M due to postponement of projects in the oil & gas sector

Aerospace coatings segment down by 30% but aftermarket expected to pick up in second half of 2021

Aerospace coatings Demonstrating early signs of recovery

Refinishes benefit from re-stocking in the USA

Comments on other segments Strong growth in the yacht coatings market




INDUSTRY OUTLOOK

paints fell from nearly 30% in 2019 to just under 26% in 2020 (Table 2). A similar level of sales collapse was also experienced in South America, where a variety of industry tensions have wreaked havoc on business results.

As with all companies exposed to the harsh climate for industrial coatings in 2020, every reported segment revealed a yearly downturn. In common with many of its competitors, AkzoNobel witnessed the greatest decline in its protective coatings operations. The automotive sector was also impacted quite badly in 2020, although AkzoNobel is not exposed to the maxi-scale OEM activities that PPG, Axalta and BASF compete in. Table 3 provides all of the figures.

n ENTERING 2021

With the start of 2020 having been a difficult time for industry and supplies on all levels, recovery through the winter has automatically created favourable

comparisons for most segments in Q1. PPG and AkzoNobel have similar activities and a good comparison of how they have fared and the state of play as industry recovers across different segments and geographies is shown in Table 4. n

2019 2020 Change (%)

Powder coatings 1229 1128 -8

Marine & Protective

1290 1068 -17

Automotive & Specialty

1318 1127 -14

Industrial coatings 1707 1634 -4

Others 5 - -

Total 5549 4957 -11

Table 3. AkzoNobel’s Performance Coatings business revenues in 2020, by Segment (€M)

accounted for more than 69% share of the global revenue in 2020.

This greater popularity and preference over natural iron oxide pigments is explained by their superior strength and stability. They possess resistance to UV rays and all kinds of atmospheric conditions and are mainly used in coatings, plastics, paper and construction (Figure 3).

The coatings industry is a major end-user of synthetic iron oxide pigments and accounts for a quarter of all consumption, particularly for exterior and industrial coatings where durability, stability and anti-corrosive properties are crucial.

Rising demand for coatings from various industries, such as building & construction and oil & gas, is expected to have a positive impact on the demand for synthetic iron oxide pigments over the forecast period.

Natural iron oxide pigments are less commonly used, owing to their lower tinting strength and the presence of contaminants that minimise their working efficiency.

Natural iron oxide pigments are used in many applications, including house and

barn paints, primers, building paints and other building materials.

• Red iron oxide pigments lead the market and accounted for more than 42% share of the global revenue in 2020. This is attributed to their pure hue, tinting strength, light fastness and consistent properties, which make them highly suitable for several applications, such as paints and coatings, paper, rubber, ceramic, linoleum, wallpaper, polishing rouge, plastic asphalt, mosaic tiles, and flooring. The pigments are commercially available as a fine dry powder made by heat processing ferrous sulphate or grinding ore material.

• Yellow iron oxide pigments are widely used in scagliola, paints and concrete owing to their pure and bright colour, high opacity, excellent dimensional stability and good weatherproof properties. They offer a dull buff shade that is opaque to visible light with low near-infrared (NIR) reflectance. Yellow iron oxide pigments are widely used as colourants in various end-use industries, such as rubber, construction and paper.

• In geographical terms, the Asia Pacific region dominates the market and accounted for more than 39% of world sales in 2020. Rising construction activities are expected to boost the demand for iron oxide pigments in the region significantly.

The industrial and manufacturing sectors in Asia Pacific have been attracting significant investments from multinational companies.

Cheap labour and proximity to raw material suppliers are further luring investors to the region and China and India will fuel the regional market growth in the coming years in a big way.

The industry is fragmented in nature and the prominent players are Huntsman, Venator Materials, Applied Minerals, Cathay Industries, Lanxess, BASF, KRONOS, Hunan Sanhuan Pigment Co and Titan Kogyo Ltd. Integration throughout the value chain secures continuous raw material supply, as well as low manufacturing costs.

R&D initiatives by a few companies to enhance their product specifications and expand their market penetration will help to satisfy the markets in the coming years. n

<14

“We expect overall global coatings demand growth to be broad-based across most of the end-use markets

that we supply. In addition... an increase in domestic flight activity in various parts of the world... should

support the gradual recovery in aftermarket aerospace coatings

demand in the second half of 2021.”Michael H McGarry

PPG Chairman and CEO

“Ongoing challenges related to raw materials are an industry-wide issue and require our continued attention...

We’ll remain focused on offsetting higher raw material costs with pricing initiatives and cost discipline, to ride out the wave and build on our strong

foundation for growth.”Thierry Vanlancker

AkzoNobel CEO


ARCHITECTURAL & DECORATIVE


The Asia Pacific decorative coatings market is a large, diverse market that covers more than 50% of the

world’s population and a third of global GDP. With a value of US$26bn in 2020, the Asian decorative coatings market is the largest geographic-segment in the global coatings industry. Asia has also been the fastest growing decorative coatings region in the world. Given the wide geographic expanse of Asia, there is lot of diversity in this segment with different countries and markets with different needs. The large size, fast growth rate and diversity results in this market being attractive to paint and coatings manufacturers.

n OVERVIEW OF THE ASIAN DECORATIVE COATINGS MARKET

The Asian decorative coatings market is estimated to have a value of US$26bn and 11.7bn litres. Orr & Boss segments the market into five major sub-regions within Asia: Greater China; Japan & Korea; South Asia; South East Asia; and Australia & New Zealand. Each of these five sub-regions could be sub-divided further into their various country segments.

The five sub-regions are defined as:• Greater China, which includes mainland

China, Taiwan, Hong Kong and Macau;• Japan & Korea includes Japan

and Korea;• South Asia, which includes India,

Pakistan, Bangladesh, Sri Lanka, Nepal, Bhutan, Afghanistan and the Maldives;

• South East Asia, which includes Indonesia, Malaysia, Thailand, Vietnam, the Philippines, Singapore, Myanmar, Cambodia, Laos, Brunei and Timor-Leste;

• ANZ includes Australia, New Zealand and the Pacific islands.

Of the five sub-regions, Greater China is the largest, with just more than half of the Asian market. South Asia is then the next largest segment. A summary of each of these markets is given in Figures 1 & 2.

n SEGMENTS OF THE MARKET

The DIY portion of the Asian decorative coatings market is about 15%. This is smaller than other regions like North America and Europe, where DIY is 40-50% of the decorative coatings market. The amount of DIY in the markets varies widely, with China and India and some of the South East Asian countries having less than 10% of the market as DIY. In Japan & Korea, DIY is closer to 20% of the market. In Australia & New Zealand, the percentage of DIY is similar to that found in Europe and North America, at close to 50% of the market being DIY.

Within the professional market, most of the paint is sold for residential applications. Some of the markets do have a significant amount of commercial building which drives a significant amount of paint in these segments but overall, the market is such that about 70% of the of the market is residential.

n IMPACT OF COVID-19 ON ASIA’S DECORATIVE MARKETS

Like all markets in the paint and coatings industry, the COVID-19 pandemic had a significant impact on the Asian decorative coatings market. The impact varied by market sub-region. Figure 3 shows figures for 2019, 2020 and our expected or forecasted 2021 growth.

The estimated size of each of the sub-region markets is given in Table 1 for 2019-2021 and a summary of each region’s sub-regional market is given below:

Greater ChinaIn 2020, the Chinese decorative market had an up and down year. The year started off with lots of optimism but by the end of January, it became clear that the COVID-19 pandemic was going to be a significant event.

As lockdown began, Q1 saw the strongest decline in the market in recent memory. As the lockdowns ended, however, demand surged in Q3 and Q4. We estimate the Chinese decorative market ended up about +3.5% in value terms in 2020. We expect that in 2021, the Greater China decorative coatings market will increase by about 8% in value terms.

South AsiaSouth Asia is the second largest decorative coatings market within Asia at an estimated US$6 bn. India and the other countries of South Asia had a very tough lockdown and decorative coatings sales declined dramatically, but they came back strong in the second half of the year. For the full year 2020, decorative coatings sales were down 4%.

In 2021, we expect that the pent-up demand will be strong and that sales growth will return to its pre-pandemic rate of above 10% per year. One trend that we have noticed, however, is that the market is converting more and more to economic or lower-priced paints due to the recession and the economic hardship caused by the pandemic.

Douglas Bohn, Orr & Boss Consulting Incorporated, gives an overview of the decorative coatings market in Asia Pacific

Decorative coatings in Asia Pacific: Before, during and after COVID-19

Figure 1.Breakdown by region

Figure 2. DIY versus professional




Japan & KoreaJapan & Korea is the highest priced market within the Asian decorative coatings market. Traditionally, it has not been a fast growing market but its relatively high prices and the fact that it is worth US$2.4bn, makes it interesting. The market was down about 3% in 2020 but we expect it to bounce back this year, as GDP growth is expected to be strong.

South East AsiaThe decorative coatings market here was down 6% in 2020 but we expect a strong recovery in 2021 – overall, we expect sales to be up 10%. Similar to South Asia, the markets fell significantly in Q2 and then came back up in the second half of the year and pent-up demand from 2020 is being fulfilled in these markets. Also, similar to South Asia, we saw a shift to economic or lower-priced paints in these markets, due to the economic hardship created by the COVID-19 pandemic.

Australia and New ZealandThe decorative paint market in Australia and New Zealand increased by more than 4% in 2020. This was mainly the result of strong DIY growth in the region. As homeowners stayed home and did not travel, they focused on fixing up their homes and DIY paint sales benefited.

We saw a similar effect in North America and Europe.

n MARKET TRENDS

There are several key trends occurring within the market. First, there is certainly interest and strong demand for antimicrobial and antiviral paints. This is occurring across all segments of the paint and coatings market but is especially prevalent in the decorative market. Commercial buildings, where a large number of people occupy the building during the day, are especially good places for antimicrobial and antiviral coatings. We are also seeing a significant uptick in demand in residential applications for antimicrobial and antiviral paints.

Another interesting trend is the increased interest in special effect or artisan paints for interior applications. As people are spending more time at home, they are looking for ways to differentiate their interior living spaces, so distinctive artisan paints with a slightly different colour, special effect or faux finish are starting to become popular.

The final trend that we have noticed is the increase in DIY. As noted above, DIY is not as large in Asia as in the United States or Europe, but it does have its place. As homeowners have been staying home

more than usual, they have been focusing more on upgrading their home and this has led to a surge in DIY paint sales in the countries with a strong DIY market, most notably Australia and New Zealand.

n RAW MATERIALS

Overall, sales of Asian decorative coatings should be relatively strong this year but like other parts of the world, raw materials are in short supply and prices are increasing. The main factor driving this is the significant turnaround in demand. In 2020, as sales declined some raw material suppliers decreased their inventories and curtailed production. Then with demand turning around so quickly, the supply chain needed to be restocked and this has led to shortages and price increases. We do expect the availability and price situation to moderate in the coming months and are hopeful that by Q3 and into Q4, the raw material shortages and price increases that the industry is facing now will moderate themselves.

n FINAL THOUGHTS

The Asian decorative coatings market is a large and diverse market. It is the single largest geographic-segment in the global coatings industry. Due to its size and its diversity, there are many opportunities for coatings companies. Large markets like China, India and Japan present opportunities but there are many other countries that still have sizable markets, such as Vietnam, Indonesia, Malaysia, Bangladesh and others. Also, the overall Asian decorative coatings market has been growing faster than the global average, with the markets of South Asia and South East Asia growing especially quickly. All these factors lead to the Asian decorative coatings market being considered one of the most attractive markets in the global paint and coatings industry. n

Author: Douglas Bohn, Orr & Boss Consulting Incorporated Email: [email protected]: www.orrandboss.com

Greater China Japan & Korea South Asia SE Asia ANZ Total Asia

Volume (Mlit)

Value (US$M)

Volume (Mlit)

Value (US$M)

Volume (Mlit)

Value (US$M)

Volume (Mlit)

Value (US$M)

Volume (Mlit)

Value (US$M)

Volume (Mlit)

Value (US$M)

2019 4642 13,477 546 2499 4181 6239 2134 2956 169 803 11,672 25,973

2020 4806 3952 524 2423 4062 5990 1963 2779 175 839 11,530 25,983

2021 5094 15,068 550 2593 4469 6709 2120 3056 179 873 12,411 28,299

Table 1. Note: Volume in the table is provided in millions of litres and value is provided in millions of US dollars

Figure 3. A breakdown of growth rates for the five sub-segments of the market



http://www.orrandboss.com



The performance of a coating is rated on its ability to preserve, protect and decorate. Paints not only provide aesthetics but

also protect the façade from deterioration. Coatings today largely focus on improved service life and durability1. Recent innovations have been directed on improving this parameter as a differentiator among competitive products2. Large paint companies are challenging one another about the warranty for the service life of the coating3. Coatings that offer superior durability are also economical in the long run, as application and maintenance costs are much higher than the paint cost. The other significant aspect is on the overall sustainability of the value chain.

The durability of architectural coatings is dependent on many factors (Figure 1) that are not always in the scope of the coating. Environmental stresses like sunlight, rainfall and acidity of the atmosphere impact the coating

to a large extent, as well as building stressors. However, a coating forms the first line of defence for the building from external stressors.

n APPROACHES TO ADDRESS DURABILITY

In recent years, innovations have largely focused on addressing the durability issues by honing the chemistry of the coating in the form of binder or resin4. The importance of a binder in a paint has been well studied by many researchers5. The majority of the trends have focused on making binders that replace the carbon content with other molecules. It is a well known fact that the bond energies of C-C bonds are lower than C-Si or Si-O-Si linkages. It has been a steady progress on these lines from lowering aromaticity to increasing heterogeneity in polymers (Figure 2).

In this context, binders that provide differing crosslinking groups that provide not just heterogeneity of atoms but also different particle morphology are being extensively studied for superior performance properties. While binders provide a base for improving the coating performance, they cannot be the sole contributors to durability aspects of a coating. The binder content would depend largely on the pigment volume concentration (PVC) of the coating. In many geographical areas, exterior coatings are especially applied as textured finishes that have low binder contribution in the paint. Therefore, there is a requirement for pigment dispersions to be used in façade coatings that provide superior durability.

n COLOUR AS AN INTEGRAL COMPONENT TO ADDRESS DURABILITY

Pigment dispersions are widely used in the tinting of paints. These are often sold as point of sale colourants that are added into the base to provide the required shades. Pigment dispersions have also undergone innovations to provide durability and are classified into interior grade and exterior grade pigments, depending on their light and weather fastness.

In general, the colour from an organic pigment is due to chromophore groups present in the molecule, while the lattice structure is responsible for the colour of an inorganic pigment. The colour

Kamakshi Christopher, Soujanya Color, discusses the need for colour, as well as durability, in architectural façade coatings

Façade colourants: Colour solutions for highly durable exterior coatings

AbstractRecent trends in architectural coatings show a preference for specially formulated, highly durable exteriors for façades. While most research is focused on special polymers to enhance durability, an aspect that most customers would prefer is a wide choice of colour offerings. Colour brings visual appeal to coatings and therefore, needs to be specially formulated with an enhanced focus on durability. Pigment dispersions have evolved over generations at a steady pace with respect to market requirements. We present a range of high performance weather resistant pigment dispersions that offer solutions for highly durable exterior coatings. Our special range of colourants are VOC free, machine dispensable and may be used across different high durable coating finishes.

Figure 1. Factors impacting durability of a façade




strength of an organic pigment is always higher than that of the inorganics. However, inorganic pigments are less susceptible to heat, light and other weathering agents. Furthermore, there are certain high performance organic pigments that provide high durability as stand-alone or in shades.

n UV DURABILITY OF SMARTINT FAÇADE COLOURANTS

The pigment systems in Table 1 were studied for their durability.

The UV durability of the façade pigment dispersions were studied in silicate plaster paints. The colourant was added at a concentration of 2% to the plaster base. The coating was applied on panels and allowed to cure for seven days. The panels were exposed to the UV-B light of 315nm under a 4hr condensation cycle. Figure 4 shows the shade difference that is observed after 500, 1000 and 1500hr of QUV exposure. It is found that the

plasters are found to retain their colour and appearance as denoted by the DE values after 1500hr.

n FADE RESISTANCE OF SMARTINT FAÇADE COLOURANTS

The colour strength on the exposed area of the panels is similar to the unexposed section of panels. Façade colourants are found to display fade resistance as shown in Figure 5.

n SMARTINT ADVANTAGE

The advantage of the façade colourants is that these are compatible with paints made with a wide variety of binder systems, such as PVDF, acrylic silicones, polyurethanes, acrylics, styrene acrylics and vinyl acetate.

• Available as low VOC colourants;• Alkaline resistant, weather resistant and

have superior light fastness;• Completely flowable with superior

rheology properties.

n SUMMARY AND CONCLUSION

Trends show that the performance and durability of coatings is of utmost importance. The durability of exterior coatings is affected by both the nature of the coating and the environment. Approaches for addressing durability should include colour as an integral component of durability. Façade colourants are effective across different chemistries. Façade colourants are low to zero VOC and can be glycol free, depending on applications. They can also be suited for speciality effects and textures. n

Shade name Pigment CI no

% Pigment Solids(±5%)

Viscosity(±15KU)

Specific gravity (±0.025)

Tinting strength(±2%)

White PW6 63 75 75 2.07 100

Iron oxide black PB11 55 72 75 2.05 100

Bismuth vanadate PY 184 63 72 75 2.25 100

Chromium oxide green

PG 17 65 80 75 2.18 100

Ultramarine blue PB 29 50 60 75 1.55 100

Yellow oxide Y PY 42 59 78 75 1.75 100

Iron oxide orange PY 42 + PR 101

55 70 75 1.96 100

Red oxide B PR 101 58 76 75 1.9 100

References1. Cynthia Challener, CoatingsTech Vol 16 No 6,

June 2019.2. Kamakshi Christopher et al, Progress in

Organic Coatings, 77(6):1063–1068.3. Joshua Taylor et al, Asia Pacific Coatings

Journal, October 2020.4. Makoto Nakao, CoatingsTech, Vol 16 No 2,

February 2019. 5. Markus Vogel et al, Asia Pacific Coatings

Journal, June 2020.

Author: Kamakshi Christopher, Soujanya Color, C35-36, TTC Industrial Area, MIDC Pawane, Navi Mumbai 400705, IndiaEmail: [email protected]: www.soujanya.com

Figure 2. Innovations in binder systems to address durability

Figure 4. Difference in colour change (DE) after UV exposure

Table 1. Smartint façade series colourants

Figure 5. Panels showing fade resistance after exposure to UV for 1500hr

Figure 3. Innovation in pigment dispersions to address durability



http://www.soujanya.com

POWDER COATINGS


What was – is no more. COVID-19 has changed everything from how we live, socialise, work, go

to school, shop and entertain. We have become much more aware of the spaces and environments we pass through and the objects we encounter each day. We think twice before turning a doorknob, placing purchases on the checkout counter, or working at a desk, asking ourselves “is it safe?” or “will I get sick?” Proper cleaning and disinfection have never been more at the front of our minds. What we took for granted, we no longer do. Our expectation for safety and safe products has drastically increased.

This expectation is contributing to the increased use of antimicrobial additives in everyday products. Pre-COVID-19, antimicrobials were primarily used in healthcare materials and related products where there is a perceived risk of infection. Product manufacturers are now using these additives in paints and coatings, in articles of clothing, cleaning products and anywhere there is risk of the transmission of infection. The Grand View Research Report values the 2019 global antimicrobial coatings market at US$7.1bn and predicts a compound annual growth rate (CAGR) of 12.8% from 2020 to 2027.

Antimicrobial additive materials carry an important caveat: they only inhibit the reproduction of potentially harmful bacteria and micro-organisms. They do not kill bacteria and micro-organisms and are not a replacement for regular cleaning and environmental hygiene. Antimicrobial coatings used along with standard and regular cleaning practices of a product or in an environment can help stop the growth and spread of these harmful micro-organisms on surfaces. This article will discuss the addition of a silver ion antimicrobial additive into the formulation of

UV cured powder coatings and the product applications and benefits.

Powder coating began in the late 1960s and is an economical and environmentally friendly finishing solution. When first introduced, powder coatings were electrostatically applied as a dry powder and then melted and cured with heat. Powder coating is most widely known for its use on metal substrates, however advancements in cure technology have enabled the use of powder coating on heat sensitive substrates, such as wood, plastics, composites and more. There are two main types of powder coatings, thermally cured and UV cured. Thermally cured coatings use only heat energy to cure the coating. UV cured powder coatings use ultraviolet light energy to cure. UV cured powder coating can be used on a variety of products including worksurfaces, doors, retail store fixtures and other ‘high touch’ products.

n USING SILVER FOR ADDED PROTECTION

The silver ion in the antimicrobial coating attaches to the cell walls of a microbe, interrupting enzyme production and DNA replication. Silver is widely used as an antimicrobial agent and was even used by the oldest civilisations (Romans, Greeks and Egyptians) for centuries, achieving a reduction of micro-organisms, preventing infections or preserving water and food. Over the years, technology has evolved but the antimicrobial properties of silver have remained. Formulators add the antimicrobial additive during the powder manufacturing process, completely dispersing it in the coating. The antimicrobial agent persists for the entire lifetime of the coating. This gives the finished surface 24/7 antimicrobial

Michael Knoblauch, Keyland Polymer UV Powder, LLC, looks at how the addition of a silver ion antimicrobial additive into UV cured powder coatings offers added protection for surfaces

A silver lining


POWDER COATINGS


protection and repeated cleanings do not diminish or degrade the efficacy of the coating.

Independent third-party testing using ISO 22196 standards was performed on surfaces coated with a UV cured powder coating containing a silver ion antimicrobial additive. After 24hr, the test confirmed E coli and Staphylococcus bacterial reproduction was reduced by more than 99.99%. It is important to restate that antimicrobial powder coatings do not eliminate the potential of harmful microbes nor do they replace normal cleaning practices. However, when used with standard cleaning practices antimicrobial coatings help prevent the growth and the buildup of microbes that can cause staining, odours and illness.

With an increased use in cleaning products and frequency of cleanings, it is important to evaluate the performance and durability of these surface coatings in their perspective environments. UV cured powder coatings on MDF were tested to

determine the robustness of the surface when regularly cleaned using common household or commercial liquid cleaning products. This test is a modification of the NEMA LD 3-2000 method 3.4 Cleanability/Stain Resistance, 3.4.5 and 25 cycles are considered one cleaning for the purpose of this test procedure (Table 1).

The test results confirmed that the use of the cited cleaning products causes no observable or measurable change in surface properties, colour fastness, pencil hardness, film build, or gloss loss for the UV powder coated MDF surface. These results only further demonstrate the durability and longevity of powder coated MDF components.

The use of antimicrobial UV cured powder coating on many commercial, industrial and household products along with normal cleaning practices may help stop the spread of harmful microbes. Antimicrobial powder coating offers protection for surfaces against harmful micro-organisms, stains and discolouration,

which can lead to premature product replacement. The effectiveness of the antimicrobial properties and the durability of the finish will ensure the continued demand for these coatings for years to come, relieving concerns about safety and answering the ever-important question: “is it safe to touch?” n

Table 1. Active Ingredients - 2: N/A; 3: Sodium Hypochlorite; 4: Isopropyl Alcohol; 5: n-Alkyl (40% C12, 50% C14, 10% C16) dimethyl benzyl ammonium chloride - (Quaternary Ammonium); 6: Ethyl Alcohol; 7: Alkyl (60% C14, 30% C16, 5% C12, 5% C18) dimethyl benzyl ammonium chloride & Alkyl (68% C12, 32% C14) dimethyl ethyl benzyl ammonium chloride - (Quaternary Ammonium). *Clorox Commercial Solutions® Formula 409® and Troy Chemical Incorporated, Troy 1609® are registered trademarks in the US and other countries

Author: Michael Knoblauch, President Keyland Polymer UV Powder, LLCTel: +1 216 741 7915Email: [email protected]: www.keylandpolymer.com

Keyland Polymer is a global leader in the development, manufacturing and application of solid materials cured with UV (ultraviolet) light energy.

Website: www.graphicalresearch.com/industry-insights/1553/asia-pacific-powder-coating-market

Reagent Water2 Bleach Solution(2% v/v)3

Isopropanol Solution(70% v/v)4

Clorox CommercialSolutions®

Formula 409®5

Ethanol Solution(70% v/v)6

Troy ChemicalIncorporated,Troy 1609®7

*Initial film thickness, mils 3-3.5 3-3.5 3-3.5 3-3.5 3-3.5 3-3.5

*Final film thickness, mils 3-3.5 3-3.5 3-3.5 3-3.5 3-3.5 3-3.5

*Initial gloss, 60° GU 85-90 86-90 88-90 86-90 88-90 86-90

*Final gloss, 60° GU 86-90 86-90 88-90 85-90 89-90 86-90

*Initial pencil hardness H H H H H H

*Final pencil hardness H H H H H H

Colour transfer to cotton cloth Yes/No

No No No No No No

Coating appearance comments after testing

No observable change






Asia Pacific’s powder coatings market due to reach US$8bn by 2026A new report from Graphical Research details how revenue from Asia Pacific’s powder coatings market reached US$4.5bn in 2019 and is predicted to grow at a rate of 8.6% between 2020-2026, reaching a value of US$8bn.

The Asia Pacific powder coating industry is poised to experience a major transformation in the near future, with rapid expansion of numerous end-use verticals. Powder coatings find application in automotive, transportation, construction, agriculture and the oil & gas sectors. Ongoing developments in the automotive and construction sectors, mainly driven

by people’s increased income levels and improved living standards, will certainly bolster the industry outlook.

Based on the type of resin, powder coatings can be classified into thermoset, thermoplastic and fusion bonded epoxy coatings. Thermoset powder coatings mainly find use in construction and home furnishing applications, while fusion bonded epoxy powder coatings are preferable for application in concrete reinforcement bars, pipeline construction and petrochemical refineries.

The region is one of the world’s largest automotive manufacturers. The next few

years are likely to witness an increased production of passenger and commercial vehicles. These trends can be attributed to the rise in people’s household incomes and the demand for premium vehicles. In addition, factors such as increasing globalisation will lead to a rapid expansion of the transportation infrastructure, creating promising opportunities for regional powder coating manufacturers. n



http://www.keylandpolymer.com

http://www.graphicalresearch.com/

POWDER COATINGS


How is PPG taking part in Earth Day this year?PPG launched its 2020 Sustainability Report right before Earth Day, highlighting the company’s strong, continued progress against key environmental, social and governance (ESG) areas. Our unwavering commitment to ‘protect and beautify the world’ guides our more than 46,000 employees to further advance our sustainability progress each day. We continue to innovate, invest and develop sustainable products and processes that our customers and other stakeholders count on to create a more sustainable future. As highlighted in our latest Sustainability Report, we have made significant progress within our many ESG-related initiatives, and we continue to drive our ambitious targets forward.

Internally, we focus on Earth Day by showcasing a variety of different stories and successful innovations around sustainability. Externally, we also highlighted PPG’s commitment to sustainability and protecting and beautifying the world to celebrate Earth Day on our digital platforms, including social media.

What sustainability benefits do powder coatings achieve compared to liquid coatings?Powder coatings offer advantages over liquid coatings at every point in the lifecycle. Powder coatings have enhanced durability and exceptional chip and abrasion resistance. They are specifically formulated without VOCs and are also cost efficient due to high transfer efficiency and reclaimability. From an applicator perspective, powder coatings offer low cost-of-entry to the market, low PPE requirements, do not use solvent for clean up and have minimal impact on the environment. In addition, there

are no special storage or transportation requirements and no hazardous waste is generated in the powder coating process.

What broader sustainability benefits are there to powder coatings in general?In addition to powder coatings being specifically formulated without VOCs, non-flammable and extremely reclaimable, a huge sustainability benefit being recognised is within our innovations, such as powder for heat sensitive substrates that replace multi-layer liquid systems. PPG Envirocron® Heatsense low bake technology provides the sustainability benefits of powder coatings while producing goods with a greater toughness and durability than powder coatings typically provide.

PPG has also developed a proprietary polyester resin, which contains up to 33% post-industrial recycled plastic (rPET). As first to the market, we have been implementing the resin for more than five years, which has a major impact on our sustainability efforts and will be used for continued innovation in this space.

Adhering to environmental regulations across the globe is a constant challenge for the coatings industry. Is this as prevalent in the powder coatings segment, or is it less of an issue?In powder, we are constantly watching and forecasting regulations around various components in a powder coating and we work with our regional and product stewardship experts to stay ahead of these changes. However, we continue to see customers moving from traditional liquid systems to powder coatings, due to the ever-changing environmental regulation landscape and the benefits of powder. I think we will continue to see this trend play out, especially as powder approaches a

liquid-like finish and continues to have a lower cure.

What innovations in powder coatings is PPG currently working on and what do you believe you will be able to achieve in the future? Through insight from our major OEMs and customers, we identified that although other products claimed to have edge and corrosion protection for the last decade, the quality and performance of those coatings did not meet customers’ expectations. So, in 2019, PPG launched Envirocron® Extreme Protection Edge, which delivers exceptional edge corrosion protection in one coat. Specially formulated to cover sharp edges, it has patented proprietary additives to ensure edges are covered before going into the oven that went beyond just flow restriction. It was not previously realised that with other formulas, edges were not covered before going into the oven, thus impacting protection of the substrate. PPG also developed fast techniques to determine edges are covered, backed by SEM images and corrosion testing without taping edges. The coating delivers film build coverage of greater than 20μm on edges, far surpassing standard one-coat and two-coat powder systems and providing exceptional edge corrosion performance. A one-coat edge solution offers the applicator significant cost savings.

Further innovations in antimicrobial-protected coatings is expected. With our March 2020 acquisition of Alpha Coating Technologies, we have expanded our powder coatings offering. This acquisition also has enabled us to launch our quick-ship programme for SilverSanTM antibacterial-protected powder coatings. Our customers can receive SilverSan powder coatings with two-day shipping orders in the top 30 RAL

This year, PPG released its 2020 Sustainability Report to coincide with Earth Day. APCJ spoke to Courtney Jungjohann Deemer, to discover the sustainability benefits of powder coatings

Restoring the earth

>25


MARINE COATINGS


What does your next pint of beer have to do with barnacles? At the time of writing, Heineken has

become the first global brewer to advocate for full carbon neutrality across its full value chain — aiming to cut emissions by 30% from a 2018 baseline. With this goal, Heineken joins cargo-moving heavyweights like Unilever in setting ambitious net zero targets for their products. These, in turn, are driving ambitious carbon targets for the shipping industry to decarbonise, which could well go beyond the recently set goals by the UN regulatory body, the IMO.

Reducing shipping’s carbon emissions is an uphill struggle – and one that isn’t getting any easier. It’s also one where coatings play a crucial role through fuel consumption reduction. Hard biofouling — caused by barnacles — creates some of the highest levels of hydrodynamic drag on a vessel hull. In fact, a 2011 study conducted by Michael P Schultz quantified that a navy vessel with 10% barnacle fouling coverage on the hull requires 36% more power to maintain the same speed.

A 2020 study conducted by I-Tech and independent marine coatings consultant, Safinah Group examined the scale of the issue and indicated that biofouling, in particular hard fouling, could account for as much as 110M tons of excess carbon emissions across the global fleet. Spread across a variety of vessel types, hard fouling was found on nearly every vessel studied. Even more alarmingly, it was found that 44% of vessels had more than 10% hard fouling coverage, a level that is deemed ‘unacceptable’ by industry standards.

We can conservatively estimate that hard biofouling adds some US$6bn to the shipping industry’s annual bunker bill — largely due to this vessel drag and the resulting fuel consumption rates. More worryingly, current trends suggest that this issue will only escalate and accelerate if not tackled head-on in the immediate future. As the effects of COVID-19 meant many businesses have been forced to down tools and their vessels been left idle,

sometimes for weeks or months at a time, we’ve seen increased time spent idle for most vessels, giving barnacles a chance to thrive. This is compounded by the phenomenon of rising water temperatures caused by global warming, creating a prime environment for biofouling, expanding areas already deemed ‘hotspots’ or ‘red zones’ for the likes of barnacles and other types of biofouling.

n NICHE AREAS

Hull biofouling is not only a carbon issue — it also poses a significant biosecurity threat to marine ecosystems as a vector for invasive aquatic species.

There is an increasing amount of regionally focused legislation that aim to preserve local marine ecosystems. In California, for example, port authorities estimate that 60% of invasive marine species are transferred by fouled hulls.

Further data gathered and analysed by Safinah and I-Tech shows that nearly every vessel poses a biosecurity threat, even if its hull is otherwise clean, as fouling can be found within niche areas spread throughout a vessel’s submerged structure.

Although the data is difficult to obtain, niche areas, such as boot tops, sea chests,

gratings and dry dock support strips could account for as much as 10% of the total underwater hull surface of the global shipping fleet1. Consequently, we cannot ignore these parts of the hull’s submerged structure when it comes to biofouling. However, some signs suggest the global shipping community is doing just that.

We found that while flat underwater hull surfaces vary in their hard fouling coverage, at least 95% of the global commercial fleet has heavily fouled niche areas. There are a number of reasons why these areas all too frequently become biofouling ‘hotspots’ — an ideal environment for barnacles and other forms of fouling. For one, restricted water flow in these areas limits the action of biocidal antifouling coatings that require a flow of water to remove the top coating layer, resulting in a thick ‘leach layer’ of depleted biocides and minimising the efficacy of coatings.

Due to the complex and oftentimes dangerous nature of niche areas, they’re also not only susceptible to poorer, inadequate coatings but can be more difficult to maintain, and sustain damage in the everyday operation of a vessel faster than in other smooth hull areas.

Comparatively, efforts to prevent biofouling on niche areas have historically been much less than that for the overall flat surface of the hull, since the primary goal of hull cleaning is to reduce hydrodynamic drag and in turn, fuel consumption. However, given the high risk to maintenance costs and other effects, barnacle fouling in niche areas needs to be higher on the agenda.

n SOLVING THE PROBLEM

As with most challenges in the shipping industry — or any industry for that matter — there’s no single solution to decarbonisation or the threat of invasive species. However, when it comes to hard fouling, it’s clear that owners should be expecting more from their coatings. A key area to examine is the idle period guarantee for coatings. Most antifouling

With more multinational companies pledging to become carbon neutral across their entire supply chain, Philip Chaabane, I-Tech AB, looks at how shipping companies can reduce their carbon emissions

Counting the hidden cost of biofouling

“What does your next pint of beer have to do with barnacles?”


MARINE COATINGS


agents added to marine coatings will only offer idle day period guarantees of between 14-21 days. However, given the unexpected static periods we’ve seen so far, owners need to be considering whether this works for them, especially if they are going to be frequenting the expanding areas of warmer waters and ‘biofouling hotspots’. Some owners could be benefiting from idle guarantees of 30 days — coatings containing barnacle antifouling agents, such as Selektope® have been found to achieve this.

Antifouling active agent, Selektope, for example, is designed to cope with even the toughest fouling conditions, including areas in which biofouling is more heavily concentrated. However, atypical of most biocides, it has a low concentration in the coating formulations, meaning it reduces the biocidal load. It also works in a unique mode of action: repelling the organism, rather than killing it. So, in essence, Selektope delivers efficacy in nano molar concentrations, achieving the same effect as competitor biocides but in significantly lower quantities.

As for niche areas, choosing the right coating is essential – and there are options available. Owners can specify with yards the use of premium coatings with higher polishing rates for niche areas, which are more conducive to fouling prevention in low water-flow areas. Primarily, using an effective antifouling coating — such as one with a high concentration active agent, as with Selektope — with a higher polishing rate in low-water flow conditions will improve the overall performance of a vessel and reduce fouling in these complex areas. The fouling control solutions used for the hull might not be the ideal choice for niche areas. Fouling control solutions, which work under different hydrodynamic conditions in the niche areas, should be used. This can be higher polishing paints that have been designed to work at lower vessel speeds and for longer idling periods.

Often, niche areas do not get the attention they deserve so greater time and attention should be paid when coating niche areas to ensure thorough and long-lasting protection in otherwise difficult to maintain environments. The best antifouling

coatings will not give satisfying results if the application is not completed properly.

There’s no silver bullet that will magically reduce shipping’s carbon emissions or solve problem with invasive species. But with global brands increasingly joining the fray of aspired net zero carbon operations, the way we approach biofouling is a key composite of that journey. As we’ve found out, there’s a lot more that the industry could do to make sure that its coatings are performing as efficiently as they can to make carbon-neutral pints (and many other things) a reality. n

References1. Moser, C S; Wier, T P; First, M R et al,

Quantifying the extent of niche areas in the global fleet of commercial ships: the potential for “super-hot spots” of biofouling. Biol Invasions 19, 1745–1759 (2017). https://doi.org/10.1007/s10530-017-1386-4

Author: Philip Chaabane, CEO, I-Tech ABWebsite: www.i-tech.se/www.seloktape.com

colours that weigh up to 200lb (91kg). We are offering five-day shipping on orders for SilverSan coating in 170 alternative RAL colours, or on shipments that weigh more than 200lb.

We also just launched PPG Envirocron® HeatSense. Engineered to complement the latest advances in low-bake cure technology, these coatings — coupled with a perfected, strictly regimented application and curing process — overcome the traditional barriers to powder coated wood. The result is a tough, durable coating that delivers clear advantages over competing finishing technologies in sustainability, aesthetics and functionality.

You can also anticipate advancements in powder coatings in the extrusion market. We will be announcing a new, exciting coating for building products in Q2 called Coraflon® Platinum that meets AAMA 2605 standards.

Which application areas can powder coatings currently not be used for?Powder coatings have long been renowned for their toughness, durability and sustainability when used over metal but the technology has worked less reliably over wood. Thanks to recent advancements in low-bake technology, PPG recently announced our PPG Envirocron® HeatSense powder coatings for heat sensitive wood and wood-composite substrates. Additionally, very thick substrates can be a challenge due to powder cure but I believe there will continue to be innovations as cure

windows for powder continue to go lower. There are so many additional areas powder can be expanded into in the future, and we will continue to see the transition from liquid to powder due to advancements in the technology.

As well as sustainability, how does PPG use its powder coatings technology to improve people’s health and wellness?Certainly, customers’ desire for performance and key features will remain the same with an additional emphasis on personal health and protection. Our focus will remain on asset protection, sustainability, innovation and supplying products that enable lower total cost solutions in the powder segment. In addition, we will continue to see a focus on environmental legislation. This will continue to increase the demand for powder coatings, since they are specifically formulated without VOCs.

Additionally, consumers will pivot and demand products to protect their health and safety everywhere, from home offices to public transportation and retail spaces. For example, PPG supplied SilverSan antibacterial-protected powder coatings to the McCormick Center in Chicago for medical furniture to support COVID-19 patients in the retrofitted spaces.

How has the COVID-19 pandemic affected innovation and R&D at PPG?While nothing will take the place of face-to-face interactions that often lead to creativity

and innovation, PPG is focused on virtual platforms for daily communications, customer interactions and e-learning opportunities. Additionally, we are launching a new, ecommerce powder platform in the second half of 2021 to continue to expand our digital offerings.

Our customers are interested in assurances of supply. As businesses restart, the full supply chain needs to be primed and ready to support. PPG continues to utilise our vast manufacturing footprint in the US and across the world to meet our customers’ demand and find solutions to supply chain issues due to COVID, storms and beyond.

PPG is proud to be dedicated to R&D. In fact, in 2020, we invested US$466M in R&D efforts. R&D fuels our new products and we plan to continue to invest in solving the biggest coatings challenges.

At PPG, we believe we have the best talent in the industry and offer our customers’ continued innovation through our global powder research and development and technology centres. There are many exciting innovations from PPG on the horizon. Keep an eye out for all the things to come! n

<23

Author: Courtney Jungjohann DeemerPPG Business DirectorPowder Coatings, Global Website: www.sustainability.ppg.com.


https://doi

http://www.i-tech.se/www.seloktape.com

http://www.sustainability.ppg.com

MARINE COATINGS


Maritime transport is the first preference for cargo; nearly 90% of all goods transported worldwide

are carried by more than 50,000 ships1. The commercial viability of the global merchant fleet depends heavily on the shell of the vessels. Biofouling, caused by plant and animal growth on the hull under the waterline, is a particular cause for concern. Besides the aesthetic and damaging impacts on the coatings, it tremendously increases the drag and therewith, the energy need. Higher CO2 output is the consequence. Even a thin biofilm gives rise to CO2 emissions of more than 270Mt/yr (million tonnes per year). The most effective method known so far for protecting the hull is a biocide-containing coating and cuprous oxide (Cu2O) is the main biocide in the market. This toxic substance leaches out of the coating matrix to form a kind of ‘biocide cloud’ around the ship, thereby killing micro-organisms before they are able to settle on the hull. Estimating four tonnes of coating material per vessel containing approx. 40% Cu2O, considering a five-year service life of the coating on the fleet of ~50,000 ships, about 16,000t of cuprous oxide is released to the oceans annually. This results in vast damaging of marine life and the sinking of invaluable resources to the bottom of the sea.

n FUTURE PROBLEMS

Experts from the University of Sydney warn that the peak of copper production

will be reached in 2040. In 2020, an extreme increase of demand was observed in China2. More and more traders and analysts believe that dwindling supplies could trigger a further price explosion. The copper price reached a two-year high of US$6800/t in September 20203.

There are increasingly critical voices as to the environmental impact of this biocide – especially, the very high loadings of copper oxide (50 weight-% or more for full performance), is a cause of concern.

In addition, new regulations are established regionally and the future will even bring more restrictions to the use of biocides in the marine environment. For instance, according to K BPR in Korea, from January 2020 onwards, biocidal products and treated articles containing active substances must be fully approved before being imported and made available on the market. The deadline for antifoulants is June 30, 2026.

Sweden regulates the use of biocides for leisure boats. In parts of the Baltic Sea, the use of products with a reduced amount of cuprous oxide is allowed4.

n FUTURE SOLUTIONS

A solution to decrease the amount of cuprous oxide in a formulation is to incorporate a novel structure modified, nanostructured synthetic silica, without weakening the longed-for anti-fouling properties. Coating properties, such as hardness, viscosity and storage stability

were tested. It was proven that an addition of 4-6% VP 4200 by weight led to an increased hardness of the coating layer film, thus, the resistance of the surface is improved. The influence of VP 4200 on the rheology is low compared to fumed silica, see Figure 1, whereas regarding the storage stability and sagging of pigments and fillers, it improves the performance.

As up to 40% Cu2O is replaced by only 4-6% silica in the formulation, the question of compensation is very important. Missing Cu2O can be compensated with solvents, an additional amount of fillers and a slight increase in binder content.

To prove the performance of the structure modified silica, seawater exposures were done both in cold and warm waters. VP 4200 was formulated in different types of antifouling coatings. However, the same anti-fouling performance was achieved employing only one third of the biocide. Figure 2 shows an example after 10 months immersion in Singapore. A silyl acrylic formulation was immersed with Cu2O as the main biocide and copper pyrithione as co-biocide. The standard formulation containing 32% Cu2O shows good performance with slight slime formation (left). The formulation with only 12% Cu2O but 4% VP 4200 shows very good performance, even slightly better than the standard. The blank (right) is highly fouled.

In Figure 3, an exposure in the North Sea is illustrated over several months. Fouling rate is calculated according to

Dr Katrin Roland and Julia Foth, Evonik, discuss how the reduction of cuprous oxide in anti-fouling coatings makes them ready for future environmental regulations

Making anti-fouling coatings ready for the future

Figure 1. Impact of silica types on rheology Figure 2. Sea water exposures, Singapore, after 10 months


MARINE COATINGS


ASTM D 6990-03. A low rating stands for high fouling on the surface.

The formulations tested show the importance to find the right ratio between VP 4200 and Cu2O for sufficient performance.

Generally, anti-fouling coatings are formulated by dry-volume parameters with a 3:1:1 ratio of Cu2O: ZnO: co-biocide as the standard starting point. For formulations with VP 4200, a ratio of approx. 1:1:1:1 proved beneficial.

From SEM pictures (Figures 4 & 5), the structure modified silica gathers on the surface of the Cu2O particles. It forms a

protecting layer and reduces the amount of Cu2O released at a time.

A TEM image of a coating with 5% VP 4200 and 10% Cu2O (Figure 6) shows that the silica is strongly attached to the Cu2O surface, although attachment to other surfaces like pigments or fillers would be possible.

In rosin-based formulations, the action mechanism is considered, as shown in Figure 7. Without silica, high amounts of Cu2O leach out of the film and the matrix is depleted but mostly preserved. When adding VP 4200, a protection layer is formed around the cuprous oxide. The biocide is leaching out of the matrix more slowly. However, the matrix is not only depleted but also polished. The film thickness is reduced.

n CONCLUSION

In conclusion, VP 4200 offers a new way of formulating marine anti-fouling coatings with dramatically reduced biocide content without compromising their properties. Lowering the environmental impact of these performant coatings makes them ready for the future. n

Authors: Dr Katrin Roland and Julia Foth Evonik CorporationWebsite: www.evonik.com

Figure 3. Fouling rate of a rosin-based formulation

Figure 4. Cu2O disp. without VP 4200

Figure 7. Hypothesis for mode of action

Figure 5. Cu2O disp. with VP 4200

Figure 6. TEM image of a coating

References1. Elements, October 2017 #60. 2. www.spektrum.de/magazin/wann-wird-kupfer-

knapp/1322085, abgerufen am 09.03.2021.3. www.pressebox.de/pressemitteilung/

goldinvest-consulting-gmbh/Kupfer-wird-knapp-Steigt-der-Preis-weiter/boxid/1021632 (Hamburg, 04.09.20), abgerufen am 09.03.2021.

4. Hintergrund//juni 2018 Sind kupferhaltige Antifouling-Anstriche ein Problem für unsere Gewässer? Umweltbundesamt.

Background reading5. ‘The use of copper as a biocide in marine

antifouling paints’, S Brooks, NIVA, Norway and M Waldock, Cefas Weymouth Laboratory, UK.

6. Katranitsas, A; Castritsi-Catharios, J; Persoone, G. (2003). ‘The effects of a copper-based antifouling paint on mortality and enzymatic activity of a non-target marine organism’, Mar. Pollut. Bull. 46(11): 1491-1494.


http://www.evonik.com

http://www.spektrum.de/magazin/wann-wird-kupfer-knapp/1322085



http://www.pressebox.de/pressemitteilung/

SMART COATINGS


The reactive coatings market has become an integral part of society. Chemists, engineers and product

designers have taken notice as consumers expect superior product performance and appreciate value added features to ensure their safety. Fire retardant coatings are delivering more protection from fi re, as well as protection for the substrates they cover.

GrafGuard® is an intumescent reactive material, an expandable graphite from NeoGraf Solutions in Lakewood, Ohio USA. GrafGuard materials have been used as a reliable and high performing intumescent material for fl ame retardant applications for nearly 30 years.

Fire suppression coatings are very diverse and they vary based on application; from structural steel support members to engineered wood beams to polymer water supply tubing to drop down ceiling tiles. The substrates that need to be protected are as varied as the applications; therefore, the reactive coatings need to be compatible with many polymeric coating systems.

The result of these coatings is to maximise the safe-exit-time for the affected people in the path of a fi re, while adhering to all the regulations and requirements of the geographical region. The reactive coatings can also reduce loss of property due to fi re and smoke damage.

Reactive coatings are often a composite of materials that have very specifi c functions individually and provide improved functionality due to their synergistic interactions. Expandable graphite fl akes can be used in multiple layers of the composite, or simply as the reactive substance in the fi re protective layer.

The versatility of these materials is attested by the various polymeric coating systems in which it has been incorporated. Nearly all existing premier coatings solutions have used this graphite-based intumescent coating including epoxies, latex, silicones, siloxanes, bitumen mixes, polyurethanes and many hybrid structures as well.

n CHARACTERISTICS OF EXPANDABLE GRAPHITE:

The nomenclature for the GrafGuard expandable graphite products is descriptive. For example: GrafGuard 160-50N. This is a representative name describing the on-set temperature (°C) – particle size (US mesh) – and surface chemistry (A, N or B, corresponding to acidic, neutral or basic).

On-set temperature is defi ned as the temperature at which the graphite material begins to expand in an irreversible form. All aspects of processing including curing or post-curing of the coating must be considered when choosing the appropriate grade of materials for the application, to prevent expansion of the graphite fl ake during the processing. The on-set temperatures can be controlled from 160°C to around 280°C, depending upon the grade of the material. The on-set

temperature is measured using a thermal mechanical analyser with a neat sample. This on-set temperature will be different in the polymer matrix, as the pressure of the surrounding polymer may slow or delay the expansion of the fl akes if the polymer is not soft enough to allow the materials to expand. In the case of a high glass transition temperature epoxy, the GrafGuard may build up pressure until the surrounding temperature reaches the glass transition temperature of the epoxy, then the fl akes will expand forming the char layer.

The expansion volume of the GrafGuard grade is the primary distinguishing factor when it comes to the height and density of the char layer formed. The typical expansion volumes vary from grade to grade, but are well characterised at different expansion temperatures from 200°C to 1000°C. It is key to note that bigger expansion may not always be better. While the larger expansion volumes dictate a higher amount of char, the density of the char may be very low and can be blown away if there is a high velocity wind at the surface. Figure 3 depicts the typical expansion volume for many of the grades of materials.

Flake size is the next specifi ed feature of GrafGuard expandable graphite. In general, the larger the fl ake the more expansion can be expected. Flake size is an important characteristic to consider when making a coating since the fl akes may be visible and possibly alter the texture of the coating. Application techniques will also affect the texture of the coating by aligning the fl akes to the substrate, allowing for the thinnest possible coating. The application method of the coating may also contribute to the decision of the grade of material. If the coating is applied by a roll-to-roll system, the particle size may not have an effect, but if the coating is being applied by a spraying system the particle size of the material is a critical parameter to observe. The particles must be small enough to fi t through the fi nal spray nozzle, as well as any fi lters inside the system. For this reason, the GG 210-200N,

David Stuart, NeoGraf Solutions, describes how expandable graphite solutions are enhancing the protection offered by � re retardant coatings

Changing the reactive coatings market with graphite

Figure 1. Textured fire retardant coating on sheet plywood

Figure 2. Photograph of a reactive epoxy coating incorporating GrafGuard® expandable graphite on a steel substrate before and after exposure to a propane torch. (Photo by Xiaoyi Chen, Case Western University, Cleveland, OH, USA)


SMART COATINGS


GG 200-100N or GG 160-80N products would be a typical recommendation. The particle sizes of the grades are well known and can be compared with the orifice sizes of the equipment to be used.

Surface treatment of the flakes is used to make the flakes more miscible in the polymer system. Depending upon the system, the acidic active sites on the surface of the material may allow for ionic suspension of the flakes, while the same groups could cause the polymer to aggregate around the flakes, causing a non-homogeneous system. The flakes are typically neutralised to a pH of around seven but can be altered to have a lower or higher pH, depending upon the sensitivity and characteristics of the coating system.

n HOW EXPANDABLE GRAPHITE WORKS

Upon exposure to high temperatures, GrafGuard materials expand and form a graphite char that is more fire resistant than other carbon chars that are formed from typical chemical intumescent materials. A char layer is a protective layer that effectively shields the “fuel” from the fire. The fact that graphite does not burn also reduces the total amount of combustible material in the matrix. GrafGuard expandable graphite contains no halogenated additives and is manufactured without hazardous heavy metals like lead or chromium, which may be found in other expandable graphite flakes.

Through a proprietary processing technique, GrafGuard materials are manufactured by placing an intercalant between the layers of the graphite flake. When exposed to elevated temperatures as low as 160°C, the intercalant decomposes

to a gas which forcefully expands the graphite flake in the “Z” direction, separating the graphite layer planes apart and forming a highly effective char layer. This resulting char protects the reactive coated substrate from the heat of the fire and minimises the smoke generated from the burning of the polymeric coating protecting the substrate.

A typical fire protection reactive coating may consist of a single component or the coating may be more efficient with multiple different fire-retardant materials. The coating may have several layers of the different activated groups or be combined into one thicker homogenous layer with several different reactive materials acting synergistically. The synergistic effects of expandable graphite combined with metal hydroxides, minor intumescent materials, organophosphates and char promoters have been observed. A minor intumescent is a material that expands utilising a blowing agent and a carbon donor to generate a char layer like ammonium polyphosphate, melamine polyphosphate, red phosphorous and zinc borate. Using GrafGuard synergistically with a minor intumescent

will allow the formulator to greatly reduce or eliminate the blowing agents and carbon donor. The schematic in Figure 4 depicts the simplified actions of the reactive coating to the stimulus of a fire or radiant heat source.

n EFFECTIVE USE OF EXPANDABLE GRAPHITE

As a rough rule of thumb, it is recommended that the minimum thickness for the layer containing GrafGuard materials to be around 200µm. This is due to the fact that the graphite flakes have a nominal thickness of around 35µm and to be most effective, multiple flakes need to be incorporated into the graphite char layer that is formed. This will allow the expanded graphite to knit together as the char layer is formed and generate a barrier-effect that keeps the heat away from the rest of the system and the substrate being protected. Figure 5 depicts the char formation from the reactive coating containing GrafGuard expandable graphite.

The layering effect of the material as it is dispersed throughout the coating allows for self-repairing of the char layer as the expanded graphite sublimates off from the surface. As the heat penetrates deeper into the coating the material that is heated to the on-set temperature expands, densifying the char and continuing the protection of the substrate.

The breadth of applications for expandable graphite extends beyond coatings. GrafGuard materials have been incorporated into polyurethane, latex (natural and synthetic), ethylene propylene diene monomer rubber, polystyrene and high impact polystyrene in the forms of sheets and moulded foams. In addition to film coatings, expandable graphite can be used in foam coatings, insulation foams, packaging foams, mastic adhesive materials, bituminous roofing & sealing products, epoxy adhesives, polypropylene, polyethylene (low, medium and high density), silicones, siloxanes, thermoplastic polyurethanes and polyvinyl chloride. The higher on-set GrafGuard materials are now being incorporated into thermoplastic injection moulded parts and thermoformed panels. The products may also be introduced directly into some building materials, such as oriented strand-board, particle board, sheet rock and cement board. n

Figure 3. Different grades of GrafGuard® materials expanded in a closed cylinder under nominal pressure at the same temperature

Figure 4. Simplified stages of GrafGuard® reactive fire-retardant coating

Figure 5. Schematic of the reactive coating char layer formation when activated by a fire, separating the polymer fuel from the fire

Author: David Stuart, Research Scientist - NeoGraf SolutionsWebsite: www.neograf.com


http://www.neograf.com

COMPANY NEWS


The company Inkmaker was founded in 1987 by Carlo Musso, Luciano Longobardi and Giuliano Cigna,

focusing on dispensing systems for the paint, coatings and ink industries. Since then, the group has evolved on many fronts – both internally, in terms of its systems and processes, software, technology and global teams around the world, as well as a spate of recent acquisitions that further broadened the Group’s technology and expertise in colour systems. Following on from these acquisitions, the decision was taken to rebrand this existing Inkmaker Group into IM Group, to create a distinct identity that can better compete in the marketplace as a complete-solutions provider.

The new logo displays a symbol of a face created from a series of triangles, that, like the many brands and skills of the group, converge to form a strong whole – a distinct ‘human identity’, depicting a technological engineering leader with a ‘human touch’. The face is embellished with a crown, representing the Group’s determination to maintain its leading position in the industries it serves, such as paint, coatings, ink, speciality chemicals, adhesives and more. Gianluca Incerti, Global Commercial Director, IM Group, said: “Our strategy is to create ‘areas of excellence’, dedicating each of our brands to a specific expertise, that can come together – like our logo – to form a strong force. Each brand can still work individually with its existing clients in its own markets and when required, share their expertise, offering total solutions, for example, on large turn-key plant engineering projects. With the restructure of our brands, Inkmaker will focus on ink dispensing and software design; Rexson will be predominantly for paint, as well as liquid ink; Vale-Tech will focus on narrow-web and paste-ink dispensing, so UV flexo ink and offset inks; Swesa is mainly for food, pharmaceutical, corrugated packaging, cosmetics and more; Teko will remain in POS Tinting and R&D Training; and Tecnopails for filling solutions.”

n SOFTWARE AND AUTOMATION

Key to the Group’s development is its software. Francesco Nesti, Global

Director of Software & Automation, noted: “Inkmaker’s software – now known as “IMAESTRO” – was designed inhouse by our Software team and has always defined us as a leader amongst our competitors and therefore, it plays a major role in the operational execution of IM Group’s global strategy. We have since expanded our software line to another one, called IMPRIMO, which we recently released with our ink-transfer/supply system, Inktrasyt, and another three are under development, planned for release by next year.”

Enrico Mattiazzi, Global Director of Engineering, Production and Supply Chain, also commented: “Our global strategy is to offer ‘Total Process-Engineering’ to our clients, worldwide. With my technical team, we have been studying the various machines of our brands, their capabilities and performances and their related market positionings. In order to meet this market segment distribution, several machines were removed and others have been re-designed. One such example is that we are integrating and upgrading the whole Rexson and Vale-tech product range to improved versions.

Others are planned for upgrades throughout the year. The most important feature of this re-engineered and integrated range of machines is the synergy with our IMAESTRO software that, as Francesco explained, will greatly benefit our clients.”

n A FOCUS ON ASIA

IM Group is evolving on all fronts and in all our locations globally but perhaps with an emphasis on Asia. Roberto Guerra, CEO Asia Pacific, says: “We have expanded our premises in Malaysia to house our Tinting and Engineering brand, Teko, together with Inkmaker. We will be opening an office in Thailand. We are gaining market share in the Philippines. The big one, of course, is China and suffice to say, that due to our larger premises we can now double the number of standard machines we ship monthly – from an average of five or six units to 10 to 12 units. More importantly, the real added value for us is the capability to build more complex units, which is where Inkmaker R&D is investing a lot of resources. Smart factory and Industry 4.0 are driving our growth.”

Lua Kar Seng, General Manager, Inkmaker Shanghai, agrees that China is an area of special interest: “In Shanghai, we have already brought forward our IM Group expansion plans. In April 2020, we expanded our facilities to double the size of our previous production area. At the time it was at the height of the COVID-19 pandemic but we had to do it, to meet the escalation in demand. The move has resulted in being hugely beneficial to us. Having bigger premises means we can manufacture more machines and can now offer a greater variety. So, for us, the new IM Group brand will certainly impact business positively in China. It creates a platform for us to promote all our brands individually, or working in unison, as a total solutions provider.” n

On April 22, Earth Day, Inkmaker Group changed its name to become IM Group. The official launch, which was in the planning stages for approximately two years, was filmed on location at the Group’s headquarters in Turin, Italy. Here, key figures from IM Group explain the strategy, positioning and strength of the new brand

Evolving sustainably

Author: Silvio Cimenti, Global Director of Branding and Marcom, IM GroupEmail: [email protected]: www.im-group.com

Above: Roberto Guerra and below: Lua Kar Seng



http://www.im-group.com

PUMPING TECHNOLOGY


There is scarcely a painted surface in the world – be it a house, portrait or child’s toy – that has not been

covered by a paint containing titanium dioxide, or TiO2, which is a fine white powder that is produced most often through the mining of the mineral ilmenite. The reason that TiO2 is used as a white pigment in most of the world’s paints and coatings is simple: it possesses the highest refractive index of any material in the world. In other words, because TiO2 does not absorb visible light, any paint containing it has a high level of opacity, or hiding power, which is a much needed characteristic for a high-performing paint or coating.

Because of its indispensability as a paint and coating component, the global TiO2 market is a robust one, buoyed by the fact that it is also commonly used in the production of plastics, paper, pharmaceuticals, inks, food colourings and cosmetics, among many others. In fact, according to market-research firm Research And Markets and its Global Titanium Dioxide (TiO2) Market 2019-2023 report, the TiO2 market will experience a compound annual growth rate (CAGR) of 4% through to the year 2023.

The size and importance of the global TiO2 market make it imperative that paint and coatings manufacturers identify and deploy a pumping technology that can reliably introduce it to the production process and then transfer the finished paints and coatings in the high volumes that are required to meet the demands of strict composition characteristics and production schedules. This white paper

will illustrate how positive displacement air-operated double-diaphragm (AODD) pumps have risen to the fore as a first-choice technology for TiO2 pumping, with a new generation of diaphragm designs adding to their ability to deliver optimised TiO2-handling performance.

n THE CHALLENGE

In paint and coatings plants, TiO2 is introduced to the production process as a high-viscosity slurry. AODD pumps have become an obvious choice for TiO2 transfer because they can handle abrasive liquids of higher viscosities that may also contain large solid particles. Their method of operation also gives them the ability to self-prime, deadhead and run dry with low shear, which enables them to quickly reach and maintain desired flow rates throughout the entire duration of the product run, while also being able to reliably handle shear-sensitive materials.

While AODD pumps can capably handle the general challenges of transferring TiO2, there is one specific challenge that must be overcome – though TiO2 appears to be a very fine powder, it is very abrasive in slurry form, which poses a threat to the longevity of the AODD pump’s diaphragms. Specifically, the high level of abrasiveness of TiO2 slurry exacerbates a phenomenon known as “outer piston abrasion,” which is a primary failure mode for AODD pumps. Outer piston abrasion happens with all standard diaphragm designs that rely on an inner and outer piston to hold the diaphragm in place. During its

operation, the diaphragm flexes around the outer piston causing normal wear of the diaphragm at the point where they touch. Add a highly abrasive slurry like TiO2 and the touching acts like sandpaper on the diaphragm, dramatically impacting its service life. This abrasion, if left unchecked, will cause the diaphragms to fail prematurely. The result of diaphragm failure is increased pump downtime and higher maintenance, repair and replacement costs – and you can add cleanup costs to the equation if a product leak occurs. In these days, where reliable throughput and product containment are at a premium as manufacturing facilities look to optimise their operating costs, any interruption in the production schedule, or costs associated with a product leak, can be deleterious to the manufacturer’s bottom line.

n THE SOLUTION

The operating principle of AODD pumps was invented by Jim Wilden 65 years ago and today, the company offers a full range of diaphragm pumps that are equipped for efficient, effective and safe use in paint and coatings production. The Pro-Flo® SHIFT Series of bolted and clamped, metal and plastic pumps are outfitted with the Pro-Flo SHIFT Air Distribution System (ADS) and, in my opinion, operate with world-class efficiency in paint applications.

While Wilden® AODD Pumps have earned their stripes over the years, it is a recent advancement in diaphragm technology that further differentiates the TiO2 pumps from the competition –

TiO2 is a critical component in paint and coatings production and can be challenging to handle.

Erik Solfelt, Wilden, discusses options for improving AODD pump protection

Optimising diaphragm performance when pumping titanium dioxide

AODD pumps are widely used in paint applications TiO2 is very abrasive in slurry form The Chem-Fuse Integral Piston Diaphragm

>33


HIGH PERFORMANCE COATINGS


Specialised physical vapour deposition (PVD) coatings are widely recognised for the critical role they perform in

enhancing operational performance and extending the life of parts across countless manufacturing and industrial sectors. Less understood is the value that these coatings provide in reducing the environmental impact of the industrial processes where they are used.

It starts with one of the primary reasons to use PVD coatings in the first place, which is to reduce friction between mated parts to improve performance. This can result in direct energy savings and, by extension, reduced CO2 emissions. Because these coatings extend the life of component parts that require frequent replacement, the raw materials, metals and energy that are required to manufacture a replacement part, are also saved.

In fact, some specialised coatings manufacturers are making a strong case that coatings are a significant contributor to improving the environment. They not only point to these environmental benefits but also to the enhancements they have made in their own coating equipment to operate more efficiently. In addition, continued advancements in specialised PVD coatings are also playing an important role in the design of components for new and emerging green technologies.

n REDUCING FRICTION WITH SPECIALISED COATINGS

Reducing friction when mated components are in contact with each other is critical, particularly in punishing environments where there are high loads and high wear. Bearings, gears, rollers and other precision components suffer from excessive wear, surface fatigue, pitting, galling and corrosion, which can also cause failure especially in high-load applications.

To prevent these issues from occurring, specialised PVD coatings are applied in thicknesses of typically only a few micrometers to further harden the surface of these parts and through mechanisms,

such as altering the surface chemistry they can also lower the coefficient of friction. As a result, less energy is used and less emissions are generated.

Carbon-based coatings, such as Diamond-Like Carbon coatings (DLC) are even more durable. Produced mainly through Plasma-Assisted Chemical Vapor Deposition (PACVD), these well adhering coatings provide a unique combination of high hardness and low friction coefficients.

Such coated components are utilised for a variety of applications including wind turbine shaft bearings and planetary gears; stainless steel cutting blades and piston pumps; and sliding components across many industries. The coatings are also a proven technique for upgrading critical rotating parts in hydraulic drives, pumps and valves.

Advanced, hydrogen-free DLC coatings provide even higher hardness along with a very low coefficient of friction. These coatings can be applied in the most demanding environments for high friction, wear and contact areas, such as in hydraulic pump parts, mechanical seals and high-pressure valve components. Today, they are also playing an increasingly important role in e-mobility applications.

n SMALL EFFICIENCIES ADD UP

Even small percentage gains in energy savings can really add up in large scale industrial environments. “Consider that a single percent gain in efficiency for a 200-megawatt gas turbine represents the equivalent power needed for 1500 homes,” said Alessandro Zedda, of specialised coatings formulator Oerlikon Balzers.

Seemingly minor factors such as a smoother surface finish can improve fuel efficiency. In the aerospace and energy sectors, for example, PVD erosion coatings are applied to compressor blades to protect polished surfaces from degrading over time. This can reduce fuel usage by up to 0.5% while promoting component longevity. These fuel reductions translate into comparable CO2 reductions.

Mobility, energy and general engineering operations benefit from lower energy consumption, reduced CO2

emissions and longer equipment operating life when high performance PVD coatings are used

Reducing environmental friction


HIGH PERFORMANCE COATINGS


Similarly, in the automotive sector, DLC-coated valve and power train components can reduce the friction mean effective pressure (FMEP) by 10%. This translates to a 2% reduction in fuel. A 20% reduction in FMEP will generate a 5% fuel consumption reduction.

More stringent environmental regulations and standards worldwide are also causing industry to focus on reducing its carbon footprint and design greener products.

Take large cargo ships as an example. Today, operators need to reduce the sulphur content of their fuel in order to be compliant with current sulphur cap requirements. With a cleaner fuel mandate, marine engine manufacturers required a new fuel injection technology because clean fuels typically do not lubricate as effectively as those with a higher sulphur content.

As a result, the coatings used in diesel marine engines also needed to be redesigned to ensure the new clean fuels will work well. Coatings that meet this new requirement have become an enabler of more efficient, higher performance, cleaner and smoother running machinery.

n EXTENDING THE LIFE OF PARTS SAVES ENERGY

The environmental benefit of high-performance coatings is also realised by how they extend the life of parts and tools. When parts last longer they are replaced less frequently, which reduces the raw materials, metals and energy it takes to manufacture them.

In the automotive sector, forming tools are made from multi-tonne pieces of steel in the negative shape of a car. Used to make millions of cars, the forming

tools will degrade over time and require reworking. To ensure optimal performance and long life, they require polishing and a PVD coating application. In addition to saving energy by keeping the forming tool in optimal condition, additional energy is saved by less frequently moving equipment of this size and weight to a separate location to be repaired.

In the energy sector, applying a DLC coating to roller bearings in wind turbines extends their life and lowers maintenance expenses. Consider that changing one main shaft bearing costs between US$200-300,000 in addition to the disruption caused by taking the turbine off of the grid.

n ENABLING GREEN TECHNOLOGY DEVELOPMENT

Beyond improving the efficiency and carbon emissions of existing systems, PVD coatings can be an enabler of new green technologies in categories like fuel cells and high-power energy density batteries.

“Within the fuel cell sector, we are working with a client who manufactures bipolar plates, a key component in fuel cells,” said Alessandro. “Here, the role for a PVD coating will be to promote conductivity while at the same time resisting corrosion. Together these attributes will promote the longevity of the fuel cells, extending their environmental benefits.”

Alessandro adds: “We are also working with clients to apply PVD coatings on some exciting and highly innovative projects in high power energy density batteries. As industry continues to develop environmentally friendly innovations, there will be more opportunities for coatings to be engineered to support their performance and overall life span.”

n GENERATING AN ENVIRONMENTAL ROI

Further up the specialised coatings supply chain, coatings manufacturers themselves have examined their processes for applying coatings as it consumes both materials and energy.

When the energy consumed to produce coatings is compared to the energy savings they generated in their application, either through the improved efficiency and longevity of an engine or a cutting tool, an ‘energy payback’ or return on investment is generated.

“We are constantly striving to reduce the energy consumption of our coating equipment,” said Alessandro. “Our new coaters consume 40% less energy by using new more efficient plasma sources. Multiply this saving on every batch at all our coating centres around the world and the environmental benefit is huge.” He adds, “While the impetus to explore a new source was environmentally-driven, it is also in our customers’ economic best interests because it reduces their coating cost and shortens our manufacturing cycle.”

Specialised coatings have an important role to play in reducing our environmental impact. Energy consumption and carbon emissions of manufacturing and operations processes can be reduced significantly. So, while industry continues to use specialised coatings for their ability to enhance operating performance, the environmental impact is an important value-add that should not to be overlooked. n

Company: Oerlikon Balzers Email: [email protected]: www.oerlikon.com/balzers

Chem-Fuse Diaphragm. The design of the Chem-Fuse diaphragm aims to make outer-piston abrasion irrelevant. Specifically, Chem-Fuse diaphragms feature a one-piece Integral Piston Diaphragm (IPD) design that encases the outer piston within the diaphragm material itself. The elimination of the outer piston means that failure-causing abrasion can no longer occur. Moreover, it also eliminates a potential leak point around the outer piston, further improving pump reliability. The result of this is that Chem-Fuse diaphragms can deliver improvement in service life when compared to traditional diaphragms that are used in AODD pumps that handle TiO2. The extension of service life in typical instances is usually two to three times that of old-school diaphragms, though Chem-Fuse life spans that can be up to 10

times more than normal have also been observed. Finally, the encapsulation of the outer piston in the diaphragm material allows Chem-Fuse diaphragms to handle higher inlet pressures than standard two-piece diaphragms.

n CONCLUSION

It’s inherently obvious that the highest-performing paint and coatings feature titanium dioxide in their ingredient mix. Because of its highly abrasive nature, TiO2 can put traditional two-piece diaphragms under extreme stress, leading to costly leak points, failure and downtime. Chem-Fuse diaphragms aim to solve this conundrum through the integral-piston design, which eliminates abrasion points, leading to a safer, cleaner, more reliable and more

efficient pumping process. By extending diaphragm service life, Chem-Fuse allows for optimisation of TiO2-based paint and coating production. n

Author: Erik Solfelt, Diaphragm Pump Product Director for Wilden®, a leading manufacturer of air-operated double-diaphragm (AODD) pumpsGrand Terrace, CA, USATel: +1 (909) 422 1741 Email: [email protected]: www.wildenpump.com; www.psgdover.com.

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http://www.oerlikon.com/balzers


http://www.wildenpump.com

http://www.psgdover.com

RESINS


One of the common characteristics of silicone resins is their capacity to provide heat resistance on

substrates that are exposed to high temperatures, due to their inorganic character. Depending on the contained type and amount of organic modification,

they can resist temperatures up to 650°C. Silicone resins are modified with methyl and/or phenyl groups. Given their inorganic character and low organic modification, they provide permanent resistance against oxidation to metallic structures that are exposed to temperatures above 250°C,

such as exhaust mufflers, chimneys or industrial stoves.

Today, there are different grades of commercially available options of methyl/phenyl modified silicone resins, which typically cure at approximately 250°C in 30min. This type of curing limits their application on large structures like heat exchangers, distillation columns or industrial vessels.

Due to the mentioned limitations, a new generation of methyl/phenyl silicone-based resins has been developed that cure under ambient conditions. They comprise a relatively high content of alkoxy functionals and oligomeric character. The resulting coating will be then cured by a hydrolysis-condensation mechanism.

n CHEMISTRY

Chemistry of ambient cure methyl/phenyl silicone resinsSilicones are organic silicon compounds known as polyorganosiloxanes. This product group can be defined simply as follows:

• They are polymers• Silicon is directly bonded to carbon• There is at least one oxygen atom

connected to the siliconThe silicones occupy a hybrid

position between inorganic and organic compounds, specifically between silicates and organic polymers. The siloxane link (Si-O-Si), also found in silicates, is responsible for the “inorganic” character. The organic properties arise from the direct link between silicon and carbon1.

Usually, methyl/phenyl silicone resins contain up to 95% of siloxanes within their framework. In the case of the typical oven cured silicone resins, the siloxanes have a low to no alkoxy functionality and thus, polymer structures of high molecular weight. The few remaining alkoxy functionalities, crosslink at approximately 250°C and 30min of curing time.

Francisco Cortes Baledon, Markus Hallack and Jim Reader, Evonik, discuss a new generation of methyl alkoxy silicone resins that can cure under ambient conditions while maintaining corrosion protection, enabling application on large industrial structures

Ambient curing resins for high heat and corrosion resistance

AbstractMethyl/phenyl silicone resins are a well-known technology for excellent corrosion protection and heat resistance up to 650°C. Currently, these coatings require curing at elevated temperatures, which limits their application on large objects, reducing their scope to smaller pieces like exhaust mufflers, chimney and oven components and small industrial stoves. A new generation of methyl alkoxy silicone resins has been developed that cure under ambient conditions, while maintaining corrosion protection at permanent high temperatures. The high content of alkoxy functional groups, in combination with specific tin-free and heavy metal free catalysts, allows the hydrolysis-condensation reaction and therefore, cross-linking of the system, at ambient temperature. These new, low VOC resins represent a novel technology that enables application on large industrial structures, such as heat exchangers, distillation columns or industrial vessels, mostly without interrupting operations. This paper also reviews some specific considerations when formulating these coating systems, such as curing conditions and application methods. Performance application data is also presented.

Figure 1. Curing mechanism of oven cure methyl/phenyl silicone resins

Figure 2. Curing mechanism of ambient cure methyl/phenyl silicone resins


RESINS


The new ambient curing silicone resins are different from the previous generation, primarily because of the oligomeric character, which is to say, they contain low molecular weight siloxane structures and higher alkoxy functionality. This characteristic also allows them to have a high solid content (up to 100%) and low viscosity (see Table 1). The functional groups available within the resins are methoxy, ethoxy or combinations of both. In order to crosslink and achieve further resin polymerisation by condensation, such functionals must be hydrolysed, in

a first reaction mechanism, leading to the formation of silanol groups. Then, these silanol groups will react between each other, in an alcoholic condensation reaction mechanism. Once this step is finalised, the resin achieves its polysiloxane character and liberates alcohols as a reaction by-product. Reaction mechanisms for both silicone resin types are shown in Figures 1 & 2. The influence of the organic methyl and/or phenyl groups is reflected mainly on the thermal stability and hardness of the coating but also in the compatibility of the resin with pigments and fillers. Figure 3

shows the influence of the methyl or phenyl groups on the resin’s mechanical properties.

n FORMULATION

Formulation of high heat resistant anti-corrosive coatings with ambient cure silicone resinsThe property profile of coatings based on silicone resins is strongly dependent on the formulation. Inorganic pigments and fillers with a high heat resistance, such as oxides and spinels or inverse spinels, are mandatory (see Table 2). Lamellar metallic and mica effect pigments increase the heat stability additionally, up to 650°C. Moreover, the pigment volume concentration plays an important role for the performance. The coating should be formulated like a primer, hence with a high PVC.

Also very important, is the use of laminar fillers as, for example, mica. This will provide flexibility and barrier properties on thermal expansion while alternating temperatures. Figure 4 shows a clear example of the coating brittleness when such a type of filler is underutilised (or too sparsely used) in the formulation.

At temperatures above 400°C, the organic components of the resin are almost completely burned off. At 650°C, frits can be sintered and inorganic composites are formed, which are very hard and chemically inert but at the same time very brittle.

As mentioned previously, the reactivity of these silicone resins allows catalytic curing at ambient temperature. Catalysts, such as titanium compounds are recommended as first choices.

AC 900 needs the use of the catalyst TMG (tetramethylguanidine), a strong base, to accelerate the reaction speed. The recommended mixing ratio of the titanate with the TMG is preferably 1:1.

The recommended dosages of both catalysts are 0.5-2.0%, depending on the formulation. Higher relative humidity levels will lead to faster reaction. The addition of a catalyst is recommended just before the application (2-pack).

Table 1. Chemical and performance properties of methyl/phenyl silicone resins. Comparison between ambient cure (AC 1000 & AC 900) and oven cure resins (P50/X and P80/X)

Table 2. Heat stability of some inorganic pigments

Figure 3. Influence of methyl and phenyl groups on the mechanical properties of silicone resins

Figure 4. Coating after heat stress and cool down - temperature exposure 4hr at 400°C


RESINS


n PERFORMANCE HIGHLIGHTS

When formulated and fully cured, the applied silicone-based coating can provide the following performance properties:Coating performance

• Excellent corrosion resistance• Early resistance against chemicals (see Figure 6)• Permanent resistance against oxidation and weather resistance

Heat stability• Outstanding long-term heat stability • High hardness under heat (low thermoplasticity)• Superb resistance against yellowing at permanent heat stress

Both grades of AC silicone resins can be used to formulate heat resistant coatings. However, there are differences in their technical profile. AC 900 has better pigment wetting properties and better

compatibility with other resins. With this resin it is possible to formulate more flexible coatings – an especially important property in the stages of heating up and cooling down.

AC 1000 is average in wetting of pigments but the stability of bright colours under heat stress is better, due to the low tendency for yellowing. This resin shows extremely low smoke formation during the first heating.

n SUMMARY AND CONCLUSIONS

The use of ambient curing silicone resins shows a good alternate option to formulate high heat resistant coatings, compared to the traditional oven curing or ambient drying silicone resins. Their high solid content and low viscosity enables the formulation of significantly lower VOC coatings. Beside this, a lower smoke and odour development. is characteristic for these resins. When formulated and properly cured, the resulting heat resistant coating can provide excellent corrosion and early chemical resistance, along with long term heat stability. This set of performance attributes enables their application on chemical plants, power generation and waste incineration equipment, along with other large industrial structures, without the need of increasing down time due to coating operations and reducing the amount of energy consumption while curing. n

References1. Technical Background_Silicone Resins, TEGO Journal, Evonik Degussa. 2nd

Edition, 2013.2. Silikophen AC Formulation Manual, Evonik Corporation, April 2014.

Authors: Francisco Cortes Baledon, Markus Hallack and Jim Reader, Evonik CorporationWebsite: www.evonik.com

Figure 5. Schematic representation of the catalyst adding process

Figure 6. Xylene rubs resistance of high heat resistant coatings, based on oven cure (top) and ambient cure (bottom) silicone resins


http://www.evonik.com

ADDITIVES


During the drying of waterborne coatings and especially after high speed applications, such as spraying, some

irregularities or marked textures can arise on the surface finish. This leads to surface coating defects, such as craters, fish-eyes, pinholes, waving effect, etc. And the point is that a perfect surface aspect derives from good substrate wetting and good levelling properties of the liquid coating. These characteristics are all the more important as they provide a continuous and homogeneous film during drying, which enables better mechanical performances. These properties are directly related to surface tension issues and especially at the two interfaces liquid-air and liquid-substrate.

n MASTERING SURFACE TENSION PHENOMENA

Surface imperfectionsSurface defects are usually caused by heterogeneities of surface tension at the liquid-air interface, where the liquid tends to reduce its surface area to be less energetic. For instance, because of these heterogeneities and during the drying stage, the water evaporates and thus, activates localised rising of surface tension at the place of the volatile component. The fluid tends to these areas and this causes waves and irregularities. This can also occur at the interface with a contaminant that has a low surface energy (Figures 1 & 2).

The most common surface defects that can appear may be, for example, craters or fish-eyes. Due to areas with higher surface tension, they appear under the shape of small points (1 to 5mm for craters and up to 20mm for fish eyes), and worsen the surface appearance. Besides, if the liquid has not formed an homogeneous layer, solvent molecules can remain after the drying stage, forming pressure pots. These are called pinholes or popping, appearing as small points on the dried surface (less than 1mm). There is also the orange peel effect, arising from a structured and wavy surface topography. Orange peel effect may lead to an improper distinctness

of image (DOI), which designates the quality of an image that is reflected by the surface of the coating. This data is a useful complement of the gloss measurement to characterise the smooth and the appearance of a surface. It can also be worsened with the haziness of the liquid.

LevellingOur surface additives are surfactant-like polymers. Because of their chemical structure, they migrate and position themselves at the liquid-air interface. These polymers can be organically modified to adjust other properties when necessary (flow, slip, etc) and to bring more or less compatibility with the medium.

The chemical structure of the additive must be slightly incompatible with the media, so it can migrate towards the interface and act on reducing short waves. On the other hand, it has to be sufficiently compatible with the media to avoid clearcoats showing haziness.

Thus, levelling agents concentrate at the liquid-air interface and homogenise the surface

Whether it is to do with decorative paints or industrial coatings, waterborne finishes need to get a perfect surface appearance and optimal mechanical properties. Levelling and substrate wetting agents can be a valuable aid for this

purpose. It is now consistently noted that the continuing expansion of waterborne coatings is crucial for health and ecological reasons. Within this context, better adapted surface additives are constantly developed. Here, experts from Group Protex

International describe an experimental study that highlights the benefits of using levelling and substrate wetting agents

No more ups and downs: Mastering levelling of waterborne coatings

Figure 1.

Figure 2.

Figure 3.


ADDITIVES


tension of the coating. Equalising the surface tension at this interface helps to reduce significantly the short waves and, as a consequence, improves the levelling and prevents surface defects.

Substrate wettingA proper substrate wetting is essential to achieve a good flow and levelling. A good substrate wetting is promoted through a low contact angle between the liquid and the substrate (Figure 3). A low contact angle (q< 90°) is possible when the liquid has a lower surface tension than the surface energy of the substrate. Thus, the substrate wetting can be improved either by reducing the surface tension of the liquid or by increasing the surface energy of the substrate. Surface additives act on the first parameter, by reducing the surface tension of the liquid coating.

Water is a liquid with a high surface tension (73mN.m-1 at 20°C) compared to solvents usually used in coatings (from 20 to 70mN.m-1). Thus, it is even more challenging to obtain a good substrate wetting with waterborne coatings.

Then surface additives need to be developed with the better compromise: If the surface tension provided by the additive is too low, the substrate wetting will be improved but it would be more difficult to avoid the waving effect at the surface. If the surface tension is too high, substrate wetting issues may happen.

Others powers of levelling agentsAccording to their chemical structure, some surface-active additives may also have other positive or negative impacts on the formulation. For example, they can act on the flow of the liquid, slightly modify the rheology or, more annoyingly, stabilise the foam. Or else, once the system is dried, they may change slip properties of the surface, the haze, the intercoat adhesion, etc. They may even have an impact on the open time or drying time of the liquid coating. During the application, a longer open time can be interesting, as it allows a better workability of the coating. It also extends the available time for the levelling agent to adjust the surface tension at the air interface, providing a better levelling

of the coating. Therefore, it is important that when choosing an efficient levelling or substrate wetting agent, other parameters are considered as well.

Two families of chemistryTwo different chemistries are generally employed to produce levelling agents for waterbornes. There are first polysiloxane-based additives, which strongly reduce the surface tension of the liquid. They particularly give a good flow, are quite efficient at reducing the waving effect and thus, the orange peel. But sometimes they may degrade the inter-coat adhesion in the case of multi-layers systems. Then, there are polyacrylate-based levelling agents (homopolymers or copolymers). These are less efficient in decreasing the surface tension of the liquid, but their chemical structure allows them to be very efficient in decreasing craters or pinholes. They are also very helpful to reduce orange peel. Their compatibility with the medium is worked up to get efficiency while avoiding haziness.

n PRESENTATION OF MODAREZ PW RANGE

Several efficient levelling and substrate wetting agents are present in the Synthron’s Modarez® PW range. Table 1 gives basic data about four of these additives.

Modarez® PW 336 is an acrylic-based additive with free hydroxyl functional groups, particularly effective in improving flow and levelling. Its action is immediately visible as it reduces craters and orange peel. As its viscosity is relatively high, a diluted version, Modarez® FA 365, is also proposed for easier handling. Modarez® PW 363 is also an acrylic-based additive with good performances in surface levelling. This product has the particularity to improve the open time during the drying stage of the protective finish, without negatively impacting on the total drying time. Finally, Modarez® PW 677 is also a levelling agent that significantly enhances surface appearance of coatings, with the added value of having high substrate wetting performances. Therefore, this

additive is particularly convenient for low surface energy substrates, such as plastics, intended to be coated with waterborne systems.

Regarding environmental regulations, all these additives are VOC-free and comply with EU Ecolabel (2014/312/UE), which may be helpful to reduce other solvent-containing components of the formulation. Furthermore, Modarez PW 336 and Modarez FA 365 are FDA 175-300 compliant.

n EXPERIMENTAL STUDY

FormulationsThe levelling agents are evaluated in classical white waterborne architectural paints. The formulas of these paint bases defined to test their performances are detailed in Tables 2 & 3.

Levelling agents are added at the end of the process and homogenised to the system under automatic stirring. For these experiments, the dosages used are 2.5%. For each product, a sample of the paint base without additive is kept as a reference.

Testing procedureLevelling and substrate wetting testSo as to better observe the surface coating aspect, the application is made on smooth glass panels that have been previously degreased with ethanol. Paint samples are deposited using a K-coater bar at a wet film thickness of 100µm. A second application on aluminium Q-panels A-35 is also carried out to complete the test. Drying processes at ambient temperature (23°C). For each test, paint with and without levelling agents are applied simultaneously.

For testing substrate wetting, coatings were applied on polypropylene and polyethylene panels. These materials have a low surface energy of 30dynes/

cm-1, making them difficult to recover with traditional coatings and even more with waterborne coatings. In order to accentuate the differences of substrate wetting for the testing, substrates have not been surface-treated before application (eg plasma technology). Plastic panels were simply cleaned with ethanol before application.

Product Chemistry Recommended dosage

Dry content (%)

Viscosity (mPa.s) – 20°C

More than a levelling agent…

Modarez PW 336 Acrylic polymer 0.5-3% 48 30000 Flow improvement

Modarez FA 365 Acrylic polymer 0.8-3.5% 31 <1500 Low viscosity for easy handling

Modarez PW 363 Acrylic polymer 0.5-3% (up to 5%) 48 25000 Increasing of the open time

Modarez PW 677 Modified polysiloxane polyacrylate

1-3% 52 9000 Substrate wetting and flow improvement

Table 1. Levelling and wetting agents of the Modarez® PW range


ADDITIVES


Paint samples are applied in thin layers using a wet and squeezed brush. Within the next few seconds, a mark is drawn on the wet film using a small wooden stick. This helps to observe an eventual de-wetting effect. Indeed, when the coating doesn’t properly wet the substrate it can tend to retract, making plastic pores appear and sometimes forming droplets (crawling effect). The coating wetting ability is visible immediately after application.

Open time measurementOpen time and drying times are measured by using a drying time recorder that operates according to the Beck Koller method (ISO9117-4:2012). Paint samples are applied at 120µm wet thickness on 300x25mm glass strips, using a cube applicator. Coated strips are positioned on the device and hemispherical needles carried by a mobile rack travel the length of the strips after 6hr. After the testing is finished, drying time stages can be read as shown in Figure 4. In practice, all these stages are not always apparent. More often, we can easily observe the hard dry time (which we call drying time) and the tack-free time (which we call open time).

Experimental resultsThe addition of the Modarez PW additives significantly improves the flow and levelling of the tested paints. Table 4 summarises their evaluation results. By acting on the surface tension of the liquid coating, these levelling agents for waterborne systems can help to eliminate numerous surface defects, such as pinholes, craters or orange peel. Among the different experiments carried out in the laboratory, some examples of levelling improvement have been highlighted, as described below.

The application on glass panels of the paint A, which contains Modarez PW 677, demonstrated that the additive can eliminate pinholes on the surface coating (Figure 5), and therefore, significantly improve the appearance of the dried paint film. Moreover, the application on aluminium Q-panels A-35 showed that Modarez PW 336 improved the flow and the levelling of the paint B. As illustrated in Figure 6, the non-additivated paint B presents some marks induced by the application (in this case, the K-coater), whereas any relief on the surface appears with the paint containing the additive.

Experiments also proved that Modarez PW 677 enhances better substrate wetting. The paint A, in fact, retracts and a lot of de-wetted areas appeared on the polypropylene and polyethylene panels, immediately after being applicated. However, when the paint contains the

Raw Materials Supplier Description Parts by weight (%)

Water 6.2

Synthro-Pon W 578 Synthron Dispersing agent 1.6

Moussex S 8044 Synthron Defoamer 0.1

Kathon WT Dow Chemical Preservative 0.0

Kronos 2064 Kronos Inc TiO2 Pigment 18.6

Grinding

Water 7.3

Synthro-Thix 608 Synthron Thickening agent 1.3

"Alberdingk U 475 (paint A) or PROX R 908 (paint B)"

"Alberdingk Boley or Synthron"

Polyurethane binder 56.7


Luzenac 20 MOOS Imerys Talc 2.4

Durcal 5 Omya CaCO3 4.0


Prox AM 162 S Synthron Thickening agent 0.4

DMEA pH neutraliser 0.6

Total 100.0

Table 2. Formula of the waterborne white paints A and B

Table 3. Formula of the waterborne white paint C

Figure 4.

Raw Materials Supplier Description Parts by weight (%)

Water 4.9


Moussex 9092 SE Synthron Defoamer 0.1

Kathon WT Dow Chemical Preservative 0.0

Kronos 2064 Kronos Inc TiO2 Pigment 14.5

Grinding

Acronal Eco 6716 BASF Styrene acrylic binder 33.2

Luzenac 20 MOOS Imerys Talc 2.9

Durcal 5 Omya CaCO3 20.7


Propylene glycol Coalescent 5.0


Synthro-Thix 618 Synthron Thickening agent 0.7

Water 12.4

DMEA pH neutraliser 0.3

Prox AM 162 S Synthron Thickening agent 0.7

Dowanol DPnB Dow Chemical Coalescent 2.4

Total supplier 100.0


ADDITIVES


additive, the surface tension of the liquid coating is sufficiently modified to spread properly on the substrate and obtain a good wetting. This is noticeable in Figure 7. Besides, inter-coat adhesion of this paint has been tested and it demonstrated that Modarez PW 677 doesn’t have a negative impact on this parameter.

Regarding the open time measurement, experiments have revealed a positive effect generated by the additive Modarez PW 363 (Figure 8). Indeed, when the additive is introduced in the acrylic waterborne paint C at a dosage of 2.5%, the open time is evaluated at 17min against 8min for the non-additivated paint, an increase of 9min. And the total drying time (30min) is not increased, as it is the same for both samples, with and without additive.

n CONCLUSION

Modarez PW products are key additives for waterborne coatings. As it is their main purpose, they provide very good performances in flow and levelling to the liquid system. Their full compatibility with numerous waterborne binders prevents a ghosting and clouding effect, while they act to eliminate surface defects, such as craters, fish-eyes or pinholes. They reduce orange peel effect as well, which helps to improve gloss and DOI.

Thanks to their chemical structure, they have no negative impact on water resistance or inter-coat adhesion for multilayer systems. Furthermore, they are all VOC-free additives.

Finally, Modarez PW additives have their own specificity, such as the open time improvement for Modarez PW 363, flow and levelling properties enhanced with Modarez PW 336 or the excellent substrate wetting property for the Modarez PW 677. n

Author: Group Protex International, Levallois-Paris, FranceTel: + 33 1 41 34 14 00Email: [email protected] Website: www.protex-international.com

Product Substrate wetting Levelling effect Surface tension reduction

Open time improvement

Modarez PW 336 + +++ ++ +

Modarez FA 365 + ++ ++ +

Modarez PW 363 + +++ ++ +++

Modarez PW 677 +++ +++ +++ +

Table 4. Main characteristics of the Modarez® PW range

Figure 5. Paint A - glass substrate

Figure 6. Paint B - glass substrate

Figure 7. Paint A - polypropylene substrate

Figure 8.



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