January 2011 • Volume 18, Issue 1 • www.adhesivesmag.com
❯ Raw Materials ❯ Weather Durability Testing
A Simple Suggestion to Help You Squeeze More Profit Out of Every Cartridge
Get Rid of the Cartridge Poly-clip introduces a low-cost alternative to expensive cans and pre-formed single-use cartridges. The Poly-clip foil-pack tube for lubricants, adhesives and sealants. And, because one roll of film makes thousands of tubes it offers a consistently better seal with lower equipment, materials and maintenance costs than vertical tube forming systems and heat seal closures.
Environmentally conscious consumers will appreciate the fact that an empty tube is less than 8% the size of an empty cartridge
Poly-Clip System 1000 Tower Road, Mundelein, IL 60060 • Phone (847) 949-2800 • Fax (847) 949-2815 Email:
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INNOVATION = VALUE COATINGS: Go ‘green’ with innovative binder and additive technologies.
ADHESIVES & SEALANTS:
Conserve energy in production and product use.
ELASTOMERS:
Formulate with alternative raw materials, and do it competitively.
YOUR CUSTOMERS DEMAND ENVIRONMENTALLY-FRIENDLY PRODUCTS. LET UNIVAR SHOW YOU HOW YOU CAN GO GREEN. Univar supplies the CASE industry with much more than a comprehensive line of sustainable ingredients — we can provide you with an innovative approach to your green formulation challenges, offering you technical expertise from concept to production. Consider Univar your partner in sustainable product development. We connect you to the latest materials and technologies, and help you bring environmentally-friendly products to market. Innovation, sustainability, expertise — it all adds up to value.
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IN THIS ISSUE ADHESIVES & SEALANTS INDUSTRY, VOLUME 18, NUMBER 1
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DEPARTMENTS
ONE DAY OF SERENDIPITY, A LIFETIME OF ACHIEVEMENT Harry W. Coover has been awarded the National Medal for Technology and Innovation.
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Editor’s Memo
ADVANCEMENTS IN SINGLE-COMPONENT PRECISION DISPENSE AND SHOT METERING TECHNOLOGY
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Company News
10
People
12
Calendar
16
Focus On: Cray Valley
43
What’s New
44
Services Marketplace
45
Classifieds
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Ask Dr. Dave
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Ad Index
Technological developments offer additional control for metering and dispensing singlecomponent materials.
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NORDSON WINS 2010 GERMAN PACKAGING AWARD The MiniBlue® II adhesive applicator was recently honored at the FachPack International Trade Fair.
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SEARCHING FOR A BETTER NONPHTHALATE SOLUTION A new benzoate plasticizer product could satisfy the current needs of the adhesives industry.
28 31 34 36 37 40
CORPORATE COMPLIANCE CHALLENGES Chemical industry executives must be extremely attentive to compliance-related changes.
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WEATHER DURABILITY TESTING Testing long-term weather durability can be more accurate when done on a larger scale.
PACKAGING SUCCESS Changes in product packaging can lead to increased performance and reduced environmental impact.
PACKAGING SELLS Packaging technologies have evolved to enable manufacturers to enhance their brand’s standing in the marketplace.
January 2011 • Volume 18, Issue 1 • www.adhesivesmag.com
THE GLOBAL FORMULATED ADHESIVES MARKET Growth in emerging economies will be robust, while modest increases in the mature economies of Europe and North America are forecast, according to a new report.
MAXIMIZING THE R&D TAX CREDIT Much of what manufacturers do to keep their businesses profitable and growing also qualifies them for significant tax credit benefits.
❯ Raw Materials ❯ Weather Durability Testing
Cover.indd 1
12/14/10 11:17 AM
ON THE COVER: Photo courtesy of Graco Inc.
FOR SUBSCRIPTION INFORMATION OR QUESTIONS, CONTACT: Customer Service: (847) 763-9534 ADHESIVES & SEALANTS INDUSTRY (ISSN 1070-9592) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (Int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: ADHESIVES & SEALANTS INDUSTRY, P.O. Box 2148, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to ADHESIVES & SEALANTS INDUSTRY, P.O. Box 2148, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or
[email protected].
January 2011
Adhesives & Sealants Industry
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GUEST EDITORIAL
HAPPY NEW YEAR! I would like to introduce myself as the new publisher of Adhesives & Sealants Industry. I’m looking forward to learning more about you and would like to tell you a little more about myself. Originally from Cleveland, OH, I graduated from the University of Toledo with a bachelor’s degree in communications. I currently live in Houston, TX. I’ve worked in the media industry for nine years and have been with ASI for five years as the regional sales manger for the Midwest, Southwest, and West. ASI is focused on bringing you information that will help your business succeed in 2011 and beyond. To that end, I believe it’s important to hear about your challenges and successes, and I look forward to visiting you and meeting you at key industry tradeshows and seminars to better understand the industry. New for 2011, I am pleased to announce that ASI is introducing a green-focused e-newsletter. The quarterly Green Opportunities e-newsletter, set to launch next month, will provide a roundup of adhesives and sealants news and issues related to renewable energy, sustainability, and all things green. To sign up for the new e-newsletter, visit the ASI website at www. adhesivesmag.com and scroll down to ASI eNews. Clicking the Subscribe button will give you the opportunity to request Green Opportunities, as well as our popular weekly ASI E-News. We have an exciting year planned for ASI, with new editorial topics on composites and coatings, as well as expanded coverage of topics such as the packaging of adhesives and testing/ quality control. We will continue to provide top-quality content through multiple platforms—including print and digital editions, websites, e-newsletters, and various social media drivers—so you can receive the information you need in the format you prefer. The rebounding economy should provide many new opportunities for our industry, and we at ASI are optimistic for the future. Please feel free to contact me at (614) 554-0035 or vallancea@ bnpmedia.com with your questions, comments or suggestions.
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CONTRIBUTING EDITORS Dave Dunn, bms North America Dan Murad, The ChemQuest Group Inc. David P. Nick, DPNA International Inc.
EDITORIAL ADVISORY BOARD Steven Gailbreath, Arizona Chemical Richard P. Muny, Chemsultants International Network Larry Owen, Franklin International Lex Reynolds, Reynolds Glue Deborah Chrzanowski, Intertape Polymer Group and
Amy Vallance is publisher of Adhesives & Sealants Industry and Ceramic Industry magazines. She can be reached at (614) 554-0035 or vallancea@ bnpmedia.com.
PSTC Technical Steering Committee Chair
AUDIENCE DEVELOPMENT Jill Buchowski, Audience Development Manager Kelly Carlson, Multimedia Specialist Carolyn M. Alexander, Audience Audit Coordinator
THIS MONTH ON www.adhesivesmag.com... Online Exclusive: How to Manage Volatile Raw Material Prices More than 250 European managers from the chemical, construction, and base material industries reveal how they address higher costs, inflation, and collapsing margins.
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CORPORATE DIRECTORS Publishing: Timothy A. Fausch
Finance: Lisa L. Paulus
Publishing: John R. Schrei
Creative: Michael T. Powell
Online Exclusive: COMPOSITES 2011 We take an inside look at the upcoming COMPOSITES 2011 convention and exhibition.
Corporate Strategy: Rita M. Foumia
Directories: Nikki Smith
Information Technology: Scott Kesler
Human Resources: Marlene J. Witthoft
Marketing: Ariane Claire
Conferences & Events: Emily Patten
Digital Edition ASI’s digital editions are easy to read, search and download. This month’s edition is sponsored by Merlin Packaging Technologies Inc.
Production: Vincent M. Miconi
Clear Seas Research: Beth A. Surowiec
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January 2011
COMPANY NEWS ACQUISITIONS AMERICAN SECURITIES LLC, a New Yorkbased middle-market private equity firm, has completed its acquisition of a controlling interest in ARIZONA CHEMICAL. Management and current investors will continue to own a meaningful equity position. Headquartered in Jacksonville, FL, and Almere, the Netherlands, Arizona Chemical has more than 1,000 employees and stateof-the-art refineries located in six countries. Equity was provided by American Securities Partners V, L.P., a $2.3 billion private equity partnership. For additional details, visit www. arizonachemical.com or www.americansecurities.com. AMETEK INC. has acquired ATLAS MATERIAL TESTING TECHNOLOGY LLC from Industrial Growth Partners for approximately $159 million in cash. Headquartered in Chicago, Atlas has additional manufacturing operations in Germany and a global network of outdoor and laboratory testing facilities. Atlas will become part of AMETEK Measurement & Calibration Technologies (M&CT), a division of the company’s Electronic Instruments Group (EIG). AMETEK M&CT designs, manufactures and distributes material test instruments for applications such as tensile, hardness and force testing; instruments for high-accuracy temperature, pressure and signal calibration; and a line of sensors for pressure, level, position and temperature measurement. For more information, visit www.ame tek.com or www.atlas-mts.com. ARSENAL CAPITAL PARTNERS, a New Yorkbased private equity firm, has announced the acquisition of ROYAL ADHESIVES & SEALANTS LLC from Quad-C Management Inc. Royal Adhesives & Sealants is a leading producer of high-performance adhesives and sealants headquartered in South Bend, IN. “Royal has industry-leading capabilities that provide proprietary, value-added solutions for its customers,” said John Televantos, partner, Arsenal Capital. “We are impressed by the accomplishments of the Royal team and we look forward to working with management to continue the company’s focus on customer service and to drive growth through innovation.” “We are delighted to partner with Arsenal Capital,” said Ted Clark, CEO of Royal. “Arsenal has a successful track record of build8
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ANNOUNCEMENT ASI CO-SPONSORS VIRTUAL MANUFACTURING EXPO Tech ManufactureXPO, an educational virtual event covering trends in manufacturing—from design to delivery—is scheduled to take place May 4. This online event, co-sponsored by ASI, will feature webinars, how-to podcasts and a virtual trade show. In addition, a keynote address will be given by Harry Moser, chairman emeritus of machine tool company GF AgieCharmilles. Moser is founder and leader of the Reshoring Initiative, a nonprofit organization dedicated to persuading U.S. manufacturers to bring work back from overseas by educating them about the true costs of outsourcing. He was recently inducted into Industry Week magazine’s Manufacturing Hall of Fame. For more information or to register, visit www.techmanufacturexpo.com.
ing similar companies in the middle-market specialty industrials sector, and their experience will better enable us to take our company to the next level of growth and innovation.” For additional details, visit www.arsenal capital.com or www.royaladhesives.com.
The acquired business will be integrated into Nordson’s Advanced Technology Systems segment. Additional details are available at www.nordson.com.
Ashland Inc. announced it has signed a definitive agreement to sell its global distribution business, ASHLAND DISTRIBUTION, to TPG CAPITAL for $930 million. “This divestiture reflects Ashland’s strategic direction and completes a major step in our multi-year transformation into a high-performing specialty chemicals company,” said James J. O’Brien, chairman and CEO. “Our overall goal remains to return maximum long-term value to our shareholders. For TPG, the purchase of Ashland Distribution represents an opportunity to acquire an industry-leading distributor with an established network of suppliers. I believe the outlook for the distribution business and its employees will be much stronger as part of an organization targeting growth within the distribution marketplace.” Visit www.ashland.com for more information.
ARCH CHEMICALS INC. has announced the formation of a new subsidiary in India, Arch Protection Chemicals Pvt. Ltd. (APCPL). Capitalizing on the indigenous availability of raw materials and cost-effective production, APCPL will offer biocide products and services tailored to meet the needs of Indian customers and climatic conditions. “Arch is already supplying major international accounts in India with biocide products and our popular antidandruff agent, and we see tremendous opportunities here for further growth,” said Saravana Kumar, India country manager. “APCPL has been formed to serve the biocides needs of esteemed customers in varied segments, including coatings, emulsions, adhesives, metalworking fluids, textiles and auxiliaries, disinfectant, and hygiene applications, as well as personal-care products and cosmetics. To be successful in India, it is essential to establish a local operation to access the highly skilled workforce and diverse raw material resources.” For more information, visit www.arch biocides.com.
NORDSON CORP. has announced the completion of its acquisition of St. Paul, MN-based MICROMEDICS INC., a leader in applying and dispensing biomaterials for controlling bleeding, healing wounds and other related medical procedures. “Micromedics extends Nordson’s expertise in precision dispensing technology and adds to our growing suite of applications in the expanding medical device and life sciences market,” said Michael F. Hilton, president and CEO of Nordson. “The company is an ideal fit with Nordson’s strategy of acquiring high-performing market leaders with differentiated technology and significant recurring revenue.”
COMPANY NEWS
BASF has earned Strategic Supplier status for the second time from Donaldson Co. Inc. for polyurethane systems. The award recognizes suppliers for having the best performance in technology, customer support and value. Donaldson provides air and liquid filtration systems and replacement parts. BASF supplies polyurethane systems to Donaldson North American sites and supports product technology transfers to other regions, including China, Brazil, Europe, Australia, and India. BASF products go into applications January 2011
such as filters for medium- and heavy-duty trucks, off-road vehicles, and aerospace and defense and industrial systems. For additional details, visit www.basf.com.
“We needed the reassurance that our multi-component adhesives were going to be packaged without any problems. APS delivered.”
CLARIANT has opened its new Greater China headquarters in Shanghai. The facility also includes a new technical application center for pigments. In addition, Clariant has announced the startup of its new Quinacridon pigment joint venture in Hangzhou. A new ethoxylation facility in Dayabay, the industrial hub in southern China, is currently under construction and scheduled to open in mid-2011. Additional details are available at www. clariant.com. DOW CORNING CORP. and WACKER CHEMIE AG have officially inaugurated their joint, integrated silicone manufacturing site in Zhangjiagang, Jiangsu province, China. The facility will serve the fast-growing demand for silicone materials in China, India and Asia. According to the companies, the facility is among the world’s biggest and most advanced integrated silicone production sites and, at 1 million square meters, is the largest facility of its kind in China. The $1.8 billion combined investment by Dow Corning and WACKER includes a jointly owned siloxane and pyrogenic silica plant, in addition to finished silicone production plants owned and operated independently by each company. Production at the Zhangjiagang site is intended to increase the global supply of silicone materials by providing the additional capacity needed to support rapidly growing industries in China and Asia, and by freeing up capacity and resources in the Americas and Europe to stabilize supply to customers in those regions. For more information, visit www.dow corning.com or www.wacker.com. ELLSWORTH ADHESIVES announced it is an authorized distributor of 3M products in the UK, Spain and Sweden. “The 3M distribution agreement is a key business partnership allowing us to strategically meet our European sales and business growth objectives,” said Mike McCourt, global president, Ellsworth Adhesives, Specialty Chemical Distribution. For additional details, phone (800) 888-0698, or visit www.ellsworth.com or www.3m.com. EXXONMOBIL CHEMICAL is expanding the capacity of its hydrocarbon fluids plant in January 2011
If you have an epoxy, acrylic, silicone, polyurethane, polysulfide, or any polymer system that needs high quality custom packaging, then you need the experience of APS. For over 30 years, APS has established itself as a world-class leader in the adhesive industry. APS has the ability and a proven track record in providing cost-effective solutions from one gram to a thousand grams. Its ability to provide worldwide drop shipments to meet delivery schedules is unmatched. In addition, our JIT program for multiple locations assures you that your project will meet its destination on time and safely. Is it any wonder why our customers say...”APS delivered.”
Call today for a free sample using your supplied material.
APS...custom packaging to reach a global market.
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Adhesives & Sealants Industry
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COMPANY NEWS ANNOUNCEMENT ADHESIVE AND SEALANT PAVILION TO DEBUT AT COMPOSITES 2011 The Adhesive and Sealant Council, Inc. (ASC) has announced that it is partnering with the American Composites Manufacturer’s Association (ACMA) to provide the first-ever Adhesive and Sealant Pavilion at ACMA’s COMPOSITES event. COMPOSITES 2011, which takes place February 2-4 in Ft. Lauderdale, FL, will feature a dedicated pavilion area organized by the ASC in the exhibit hall. Adhesive and sealant manufacturers, suppliers, and consultants will showcase fastening and sealing solutions offered to the many market segments that use composites. In addition, the ASC will also host an education session for conference attendees to broaden their knowledge of adhesives and sealants. Several ASC member companies have committed to exhibit either in the pavilion or elsewhere on the exhibit floor, including Albion Engineering Co., Arkema Inc., Ashland Inc., Bayer MaterialScience LLC; The ChemQuest Group Inc., Eastman Chemical Co., Graco Inc., Hexion Specialty Chemicals, ITW, Kenrich Petrochemicals Inc. and Sika Corp. For additional details, visit www.acmashow.org or www.ascouncil.org.
Antwerp, Belgium. This expansion will focus on high-performance Exxsol™ fluids, including Exxsol D, Pentane and Hexane fluids. The project, which will increase capacity at the plant by 10% and strengthen supply reliability, is expected to be complete in mid-2011. Visit www.exxonmobilchemical.com for more information. H.B. FULLER CO. has begun construction of a $12 million manufacturing facility to support the expansion of business into India. The plant, to be located near the city of Pune, approximately 100 km south of Mumbai, is expected to be operational by August. “India is one of the largest countries in the world, with one of the fastest growing economies,” said Steve Kenny, senior vice president, EIMEA (Europe, India, Middle East and Africa). “As such, it represents a huge market for H.B. Fuller and our customers. This expansion reflects our commitment to the market and to our global customers, many of whom have an active presence in India. This investment is another key component of our five-year strategic plan and is the latest in a series of moves designed to drive growth at H.B. Fuller while strengthening our competitive presence.” For additional details, visit www. hbfuller.com.
In the third quarter of 2010, HENKEL posted sales of @3,961 million (~ $5,528 million), which represents an increase of 13.7% compared to the prior-year quarter. After adjusting for foreign exchange, sales improved by 6.4%. Organically (after adjusting for foreign exchange, acquisitions and divestments), the increase was 6.5%. 10
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Operating profit (EBIT) rose by 73%, from @290 million (~ $404 million) to @501 million (~ $699 million). This is primarily due to the substantial improvement attained by Adhesive Technologies, which was able to maintain a significant rate of increase in earnings. The Adhesive Technologies business sector generated further profitable growth in the third quarter. Sales exceeded the level of the still crisis-affected prior-year quarter by 19.3%, reaching @1,945 million (~ $2,714 million) and outpacing market growth in all regions. Organic sales rose by 9.7%. Additional details are available at www. henkel.com. HUNTSMAN CORP. has reported revenues of $2,401 million for the third quarter of 2010, an increase of 16% compared to $2,075 million for the same period in 2009 and an increase of 2% compared to $2,343 million for the second quarter of 2010. Adjusted net income for the third quarter of 2010 was $83 million, compared to adjusted net loss of $48 million for the same period in 2009. For more information, visit www. huntsman.com. NORDSON ASYMTEK announced that it has been selected by LG Display Co. Ltd. as the exclusive provider of dispensing equipment for LG Display’s LED BLU manufacturing operations in Nanjing and Guangzhou, China. The company’s automated dispensing equipment installations at both sites are part of an ongoing relationship between the companies in which Nordson ASYMTEK will also provide process development and on-site service support. Visit www.nordsonasymtek.com or www.lg.com for more information.
PEOPLE Chris Ross, vice president, Sales, has announced the promotion of BILL ALHOFEN to National Sales manager of Charles Ross & Son Co. Alhofen joined the company in 1986. He previously served in the U.S. Air Force, where he specialized in photograph and imagery interpretation. While in the military, Alhofen pursued a bachelor’s degree in business administration He will handle general sales management duties and work with the company’s network of sales representatives, and will be based in the company’s Hauppauge, NY, corporate headquarters. Sartomer USA LLC has added BERNADETTE CORUJO to its business development team to focus on growth opportunities outside of the company’s traditional markets in the Americas. She will work to maximize market penetration with new and existing customers, as well as expanding product lines into adjacent markets. Celanese Corp. has named PETER HOLMES, PH.D., to the position of chief Marketing officer, effective December 13, 2010. Holmes has spent more than 24 years working in the fine chemicals and specialty materials industry. He most recently served as senior vice president for Cherokee Pharmaceuticals, where he was responsible for the company’s services business. He began his career as a senior scientist in Discovery Agricultural Chemicals at Rohm and Haas. H.B. Fuller Co. has announced that its board of directors has appointed JIM OWENS to succeed MICHELE VOLPI as president and CEO and director, effective immediately. Volpi will step down from the board of directors. Owens, H.B. Fuller senior vice president, Americas, joined the company in 2008. He has delivered two successive years of profit growth in Fuller’s North American business, has led the transformation of the company’s Latin American businesses and has been instrumental in driving the growth agenda for the company worldwide. He previously spent 22 years with National Starch’s adhesives business, a division of ICI, in a variety of management positions. In addition, he served on the board of directors for The Adhesive and Sealant Council, Inc. for the past seven years, most recently as chairman. January 2011
OBITUARY R. EMMETT CARROLL, JR. PASSES AWAY R. Emmett Carroll, Jr., CEO of R.E. Carroll Inc., passed away on November 15, 2010. He was 81. Carroll was with R.E. Carroll Inc. for over 50 years, including his tenure as president from 1987 to 2009; he most recently served as CEO. He was wellknown throughout the rubber, coating, and process oils industries, having served in varying capacities within the Rubber Division of the American Chemical Society, as well as the Philadelphia Society of Coatings Technology. Carroll was CARROLL a past president of the Philadelphia Rubber Group and a board member of the 25th Year Club of the Rubber Division. In lieu of flowers, the family is requesting that donations be made to the American Heart Association, 1 Union St., Suite 301, Robbinsville, NJ 08691; or the University of Virginia McIntire School of Commerce, P.O. Box 400173, Charlottesville, VA 22904.
H. E. “BUD” SCRUGGS h a s j o i n e d Huntsman Corp., filling multiple senior management roles in Huntsman’s various companies and foundations. Scruggs will serve as president and CEO of Huntsman Financial Corp., a privately held holding company with ownership interests in businesses around the world. In addition, he will hold a senior position within the legal department of Huntsman Corp. and assist with government affairs. Scruggs will also carry out key manage-
ment responsibilities in the Huntsman Cancer Foundation and other Huntsmanrelated charitable foundations. D o w C o r n i n g h a s n a m e d JAMES STEPHENSON global Marketing manager for its healthcare business. He will be responsible for setting the overall strategic direction and overseeing the development and commercialization of new silicon-based technologies. Stephenson joined Dow Corning in 1997 and has more than a decade of experi-
Interested in Green News? Visit www. adhesivesmag.com to subscribe to ASI’s new Green Opportunities e-newsletter, coming in January! ence in business development and commercial leadership. Bostik Inc.’s Consumer & Construction Division has added DAVID UMBARGER to its technical services team. As Technical Service manager, he oversees a team that specializes in answering questions about Bostik’s installation and maintenance products, including ceramic, hardwood, carpet/ vinyl/patch and rubber flooring solutions, as well as construction sealants.
How can you meet suppliers, network with peers and gain valuable education without leaving the office?
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An educational virtual event covering trends in manufacturing from design to delivery. No travel or registration fees so you can attend with your whole team No time spent out of the office Reach multiple suppliers with the click of a button (more than ten are already signed up!) Chat one-on-one with your manufacturing peers Download free whitepapers, case studies and new product information
Attend Keynote Presentation: Harry Moser - Founder and President of The Reshoring Initiative SPONSORED BY Chat with Harry LIVE during Ask the Expert session Listen to and download 15-minute educational How-to podcasts on hot manufacturing topics More to come! Save the date today!
SAVE THE DATE: Wednesday, May 4, 2011 | 8:30am – 3:30pm EDT www.TechManufactureXPO.com Presented By:
January 2011
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COMPANY NEWS CALENDAR JANUARY 17-19 The Coatings Summit; Washington, D.C.; www.coatings-summit.com
FEBRUARY 7-10 Medical Design & Manufacturing (MD&M) West; Anaheim, CA; www.canontradeshows.com 8-11 Green Manufacturing Expo; Anaheim, CA; www.canontradeshows.com/expo/gmx11/ ana_event.html
13-16 Adhesion Society Meeting & Expo 2011; Savannah, GA; www.adhesionsociety.org/Meeting/meeting.htm
14-17 Coverings; Sands Expo and Convention Center; Las Vegas, NV; www.coverings.com/coverings2011/public/enter.aspx
MARCH
16-17 Green Manufacturing Expo; Orlando, FL; www.canontradeshows.com/expo/gmx11/ ana_event.html
7-10 InformEx 2011; Charlotte Convention Center; Charlotte, NC; www.informex.com 8-9
RadTech uv.eb West; Santa Clara, CA; www.radtech.org
13-18 Pittcon 2011; Georgia World Congress Center; Atlanta, GA; www.pittcon.org
29-31 European Coatings Show; Nuremberg, Germany; www.european-coatings-show.com/en/default.ashx
APRIL 5-7
A word from our customers: "Merlin's flexibility is remarkable. They stock our material and can turn on a dime when our requirements change. They always ship quickly, and more than once have responded to emergencies with next-day delivery. Nice people that are easy to work with. Overall, Merlin is an excellent supplier." B. S. Specialty polymer supplier Merlin customer for 9 years
"Merlin is extremely qualityconscious, with fast delivery and excellent attention to detail. They've given us the opportunity to be competitive on smaller orders by downpacking drums into custom cartridges. Our sales have grown steadily, thanks in no small part to Merlin Packaging." Eric Watson Purchasing Supervisor Rudolph Brothers & Co. Merlin customer for 10 years Merlin provides accurate filling of dual cartridges, syringes, pouches, mixed frozen, and many other packaging options. For fast delivery of big or small orders of quality custom packaging, call Merlin Packaging Technologies today.
AeroDef Manufacturing 2011; Anaheim Convention Center; Anaheim, CA; http://aerodef.sme.org
17-19 ASC Spring Convention and Expo; Tampa, FL; www.ascouncil.org
MAY 3-5
Chemspec USA 2011; Pennsylvania Convention Center; Philadelphia; www.chemspecevents.com/usa/
9-13 PSTC Week of Learning; Hyatt Regency Grand Cypress; Orlando, FL; www.pstc.org 30-6/1 13th European PLACE Conference; Festpielhaus on Lake Constance; Bregenz, Austria; www.tappi.org
JUNE 7-9
Green Manufacturing Expo; New York City; www.canontradeshows.com/expo/gmx11/ ana_event.html
7-9
Green Manufacturing Expo; Toronto, Ont.; www.canontradeshows.com/expo/gmx11/ ana_event.html
19-21 Forest Products Society’s 65th International Convention; Portland, OR; www.forestprod.org/ ic65/overview.html
SEPTEMBER 15-16 FEICA Conference; Valencia, Spain; www.feica.eu 20-22 Green Manufacturing Expo; Rosemont (Chicago), IL; www.canontradeshows.com/expo/gmx11/ ana_event.html 20-22 Assembly and Automation Technology Expo; Rosemont (Chicago), IL; www.aatexpo.com 26-28 CPP Expo; Las Vegas Convention Center: Las Vegas; www.cppexpo.com/
OCTOBER 16-18 ASC 2011 Fall Convention; Indianapolis, IN; www.ascouncil.org
NOVEMBER 1-3
2011 CHEM SHOW; Jacob K. Javits Convention Center; www.chemshow.com
21-23 Abrafati 2011; Sao Paolo, Brazil; www.abrafati2011.com.br/index_engl.html
Gahanna, OH 43230 Toll-free: 888-648-7878
[email protected] www.merlinpackaging.com
MAY 2012 7-10 American Coatings SHOW 2012; Indianapolis, IN; www.american-coatings-show.com/en/default.ashx
For a more detailed listing, visit www.adhesivesmag.com.
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18 below in Chicago. Super De-icer. Dreams take flight. NuSil Technology.
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One Day of
A
Serendipity,
LIFETIME OF ACHIEVEMENT
Harry W. Coover has been awarded the National Medal for Technology and Innovation. By Dave Dunn, Ph.D., President, FLD Enterprises
N
ovember 17, 2010, was a momentous and historic day for the adhesives industry and, in particular, for Harry Coover, Ph.D., inventor of cyanoacrylates, better known as superglues. Coover was presented with the National Medal of Technology and Innovation by President Barack Obama in the East Room of the White House in Washington, D.C.
MAJOR DISCOVERY The invention and discovery of the adhesive properties of cyanaoacrycrylates was quite remarkable and, as Coover admits, somewhat fortuuitous. He actually invented them twice! In the 1940s at Eastman Kodak, Rochester, NY, he was told to develop an optically clear plastic for making precision gun sights for the war effort. “Cyanoacrylates worked great in reproducing the mold for the gunsights,” he says. “The problem was, everything I was working with stuck to everything else. It was just a big pain.” In the early 1950s at Eastman, Kingsport, TN, Coover was managing a group of chemists who were developing new acrylicc polymers for jet aircraft canopies. He suggested trying cyanoacrylates. es. A young chemist tried to measure the refractive index of the monomer nomer 14
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January 2011
and stuck the prisms of the refractometer together permanently. Coover had a sudden realization. “Serendipity had given me a second chance,” he says. “What we had was a new superglue. I went and got the material and started sticking everything in the laboratory together.” Cyanoacrylates were the world’s first single-component, high-strength adhesives. They have developed into a multibillion-dollar global industry that encompasses numerous industrial, consumer, and medical applications.
RECOGNITION The National Medal of Technology and Innovation is administered for the White House by the U.S. Department of Commerce’s U.S. Patent and Trademark Office. The award recognizes those who have made lasting contributions to America’s competitiveness and quality of life, and have helped strengthen the nation’s technological workforce. Nominees are selected by a distinguished independent committee representing both the private and public sectors. This medal represents the highest honor for achievement in science and technology that is bestowed by the U.S. president. Preceding the medal presentation was a Tuesday night gala at the RitzCarlton hotel in the Capital, where 13 members of Coover’s family joined the other laureates’ friends, families, and colleagues from the science, technology, and business communities to celebrate the honorees’ extraordinary achievements. The adhesives industry was represented by Ron Gravette and Marcia Littler of the Super Glue Corp. The gala celebration provided the opportunity for the audience to see and hear in the laureates’ own words what they do, why they do what they do, who inspired them and what they want to share with the next generation. There is no greater demonstration of our nation’s appreciation of these presidential medal honorees than the ceremony itself. The majesty of the ceremony is matched by the setting in the East Room of the White House. The laureates were announced and proceeded through the center doorway of the East Room, which was filled to capacity with their friends, family, colleagues, congressional representatives, cabinet members and the cameras of the White House press corps. January 2011
Harry Coover, front, with members of his family at the White House for the award ceremony.
In his address, President Obama said that the honorees’ achievements “stand as a testament to the ingenuity, to their zeal for discovery and to the willingness to give of themselves and to sacrifice in order to expand the reach of human understanding. All of us have benefited from their work.” Following the presidential address, each laureate’s citation was read by a White House military staff member as he or she walked over to President Obama to receive their medal and receive a place in U.S. history. Coover’s citation reads: Harry W. Coover, Eastman Chemical Company, TN “For his invention of cyanoacrylates—novel adhesives known widely to consumers as ‘super glues’— which today play significant roles in medicine and industry.” President Obama concluded the event by saying, “Finally, let me just once again say to all the honorees who are here tonight, you have truly revolutionized the world in ways that are profoundly important to people in their day-to-day lives, but also help to create those steps in human progress that really make us who we are as human beings. And so we could not be prouder of you, could not be more grateful to you for your contributions.”
Research Institute Medal Achievement Award and Maurice Holland Award, the American Chemical Society’s Earl B. Barnes Award, and the AIC Chemical Pioneers Award. He was inducted into the National Inventors Hall of Fame in 2004 to join such figures as Thomas Edison, Alexander Graham Bell, Henry Ford, Samuel Morse, as well as George Eastman, the founder of Eastman Kodak.1 One of Dr. Harry’s favorite and apposite expressions is, “Innovation is the sum of invention and commercialization.” This philosophy ruled his commercial life and perfectly illustrates why this national award for technology and innovation is so appropriate for him. I know I speak for all of his former colleagues, friends and the entire adhesives industry when I say that we congratulate him for this award and his extraordinary lifetime achievements. A video of the presentation is available at www. whitehouse.gov/live.
ABOUT THE AUTHOR Dave Dunn, Ph.D., is president of FLD Enterprises, a technical and management consultancy specializing in the adhesives and sealants industry. A former vice president and director of Loctite Corp., he writes
LIFETIME ACHIEVEMENTS In addition to his work on cyanoacrylates, Coover is one of the world’s great inventors, with 460 patents and over 60 publications. He has received numerous other awards, including the Industrial
ASI’s monthly “Ask Dr. Dave” column. He can be reached at www.fldenterprises.com.
REFERENCE 1. Dunn, Dave, “SuperGlue–Superman,” Adhesives & Sealants Industry, July/August 2004, p. 24.
Adhesives & Sealants Industry
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FOCUS ON
CRAY VALLEY EXPANDS TEXAS POLYOLS PLANT
T
he Hydrocarbon Specialty Chemical division of Cray Valley recently announced it has obtained approval for a 40% capacity increase for its plant at Channelview, Texas. The company is expanding the plant to supply additional quantities of the company’s Poly bd ® hydroxyl terminated polybutadiene materials. Polybutadiene polyols typically react with isocyanates to produce high-performance urethanes that are used in adhesive and sealants, encapsulants, coatings, and other specialty applications. Polybutadiene polyols provide low-temperature flexibility, resistance to strong acids and bases, superior electrical properties, and a low moisture transmission rate. According to the company, demand has increased in all regions of the world from the depressed levels of 2009. Despite many competing technologies, the company expects continued growth for systems based on Poly bd due to the material’s unique performance capabilities. Poly bd is a core business for the Hydrocarbon Specialty Chemical Division of Cray Valley, which focuses on the adhesive and sealant market. In addition to making the Poly bd resins in Channelview, Texas, Cray Valley also makes these materials in a plant in Europe and has a joint venture
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producing these resins with Idemitsu in Japan. In addition, Cray Valley offers Wingtack® and Norsolene® hydrocarbon tackifying resins for hot-melt and label adhesives, pressure-sensitive tapes, and mastics. The Poly bd expansion is important to supply customers who frequently purchase multiple products from Cray Valley, according to the company. The additional capacity is expected to be online by September 2011. “The expansion of the Poly bd plant, which makes hydroxyl terminated polybutadiene, is proceeding on schedule so we expect to begin production by September 2011,” says Charles-Henri Robert, president, Cray Valley U.S. “Cray Valley ordered the major equipment and applied for the permits.“
ABOUT THE COMPANY Globally based in Exton, PA, Cray Valley USA LLC is part of Total’s Resins Division, one of the largest resin manufacturers in the world with sales of @1.9 billion (~ $2.6 billion) and 3,800 employees worldwide. The Hydrocarbon Specialty Chemical division of Cray Valley provides hydrocarbon resins, Norsolene and Wingtack tackifying resins, along with Poly bd, Ricon®, Krasol®, SMA® resins, and Saret® rubber coagents. For more information, visit www.crayvalley.com.
January 2011
February F b 2–4, 2011 | Ft. Lauderdale, Florida Explore the ASC Adhesive and Sealant Pavilion in Booths 1400-1407 featuring the following ASC member companies:
Other ASC member companies exhibiting at COMPOSITES 2011: Arkema Inc. – Booth 905 Ashland Inc. – Booth 525 Bayer MaterialScience, LLC – Booth 311 Graco, Inc. – Booth 636 ITW Companies – Booths 925, 935 and 1424 Kenrich Petrochemicals, Inc. – Booth 635 Momentive Specialty Chemicals – Booth 813 Sika Corporation – Booth 1229
DESIGN-ENGINEERS: Register to attend COMPOSITES 2011 at www.acmashow.org. COMPOSITES 2011 sponsored by
Promotional consideration by
Innovative solutions brought to you by
20-cc PGM with Direct-Mount Applicator
Technological developments offer additional control for metering and dispensing single-component materials. By Dave Behrens, Product Marketing Manager, and Nick DiDonato, Business Development Specialist, Graco Inc.
T
hree new technologies have been developed that provide significant improvements for precision dispensing control of single-component materials in the CASE (coatings, adhesives, sealants and elastomers) market.* Each product provides a unique solution to a range of single-component dispensing challenges.
PGM METERING SYSTEM The PGM Metering System was developed for automated applications where precise metering and bead control are critical for production. It includes a control center and a precision dispense positive displacement gear pump that is driven by a high-torque servo gear motor. Available gear pump sizes are 6 and 20 cc per revolution. 18
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The system provides precise metering control for singlecomponent bead, ribbon or extrusion applications. Using gear metering technology, programmable servo motor controls and an optional integrated heat package, the PGM offers accuracies of ± 1%, along with the ability to quickly change speed. Flow rates, which range from 8-1,600 cc/min with high-viscosity materials (100,000 to 3 million cps), can be programmed using a touchscreen interface. The system can be used for dispensing materials at ambient temperatures and for hot-melt materials up to 350°F (176°C), with pressures to 2,500 psi (172 bar). The servo control of the dispense speed ensures that the system can match almost any automated bonding, sealing or gasketing application. Metering accuracy is ± 1%. The modular system is configured with either Graco Supply Systems for ambient * Developed by and available from Graco Inc.
January 2011
materials or the Therm-O-Flow® System for hot-melt materials.
Figure 1. SmartWare Layout
PCF METERING SYSTEM The PCF Metering System provides a precise, continuous flow for sealant and adhesive dispensing. This closed-loop, continuous-flow metering and dispense system offers high accuracy with no shot reload times. With closed-loop, continuous-flow technology, material is constantly metered and controlled as it passes through the PCF fluid plate. This provides accurate control with no limitation on shot size. The primary components of the PCF are an advanced display module, fluid plate and field bus interface. With an accuracy capability of ± 1%, the PCF is ideal for a range of applications with lower material viscosities (1,000 to 1 million cps). The advanced display module provides easy setup, monitoring and system diagnostics, as well as a USB interface for data download. The fluid plate incorporates advanced sensors that provide feedback to the system controls, which enables real-time adjustments to be made for changes in material temperatures, viscosities, dispense rates or robot speeds. The fluid plate also supports a flowmeter and fluid regulator. The fluid control module located on the fluid plate receives a signal with requested flow rate information from the advanced display module. The module then checks the flow rate with the flowmeter and adjusts air pressure to the fluid regulator, as needed. The fluid control module constantly checks and adjusts while
20-l Supply System with SmartWare Shot Dispense Kit January 2011
material is dispensed. This configuration ensures consistency and offers realtime response to deliver a precise, continuous dispense. In addition, the Gateway fieldbus module allows the PCF to communicate with other automated systems within the manufacturing process (e.g., DeviceNet, Ethernet/IP, Profibus and Profinet options).
SMARTWARE TECHNOLOGY SmartWare™ offers a new meter and dispense method without a secondary metering system. The SmartWare Shot Dispense Kit allows end users to dose a preset amount of single-component material using a Graco pump. The kit comprises a local control module, sensors,
Advanced Display Module
cables and mounting hardware (see Figure 1). When the SmartWare Shot Dispense Kit is installed on a Graco Supply System, or Dura-Flo™ or Check-Mate ® pump, it turns the pump into an accurate, costeffective dosing system. (The Graco pump must be equipped with an NXT ® air motor.) General industrial applications include cartridge filling, kitting, converting, cavity filling/potting and batch formulating/blending. This new shot dispense system provides accurate dosing without flowmeters or gear meters in the fluid stream. Instead, a linear sensor tracks the pump position so the pump becomes the flowmeter. Using the primary pump as a metering system removes all secondary metering components from the fluid stream, which reduces cost and wear issues. This technology gives end users a lowcost solution when faced with urethane batching or dosing applications. It is an alternative to both manual methods (such
Fluid Plate Adhesives & Sealants Industry
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ADVANCEMENTS IN TECHNOLOGY POTENTIAL APPLICATIONS The PGM and PCF metering systems must be used in conjunction with ambient or heated bulk unloader feed systems, which can be configured for either 5- or 55-gal containers. Typical urethane applications for PGM and PCF include: • Solar panel rail bonding and frame sealing • Window assembly • Automotive applications including urethane windshield sealants, robotized window sealing, carpet bonding, headliner assembly bonding, bonding lead battery cells to polypropylene cases, head and tail lamp bonding, mirror bonding to casings, and dashboard insert bonding • Bonding ABS plastic housings • Speaker assembly bonding • Filter end cap bonding and seam sealing
PGM Controls with Touchscreen Interface
as mechanical counters or scales) and fully automated batch systems. The SmartWare system allows for shot sizes from 6 cc to 1,000 gal. Shot size accuracies range from 0.25 to 3%, depending on material, volume output, and system setup. The local control module offers a sequence mode, allowing the end user to dispense a series of up to
14 different shot sizes. The display shows the programmed shot size and the amount actually dispensed.
OTHER CONSIDERATIONS The PCF and SmartWare systems incorporate Graco Control Architecture™, the framework that provides end users with a quantum improvement in their
ability to monitor and control fluid management processes. Graco Control Architecture reduces point-to-point wiring and unique circuit boards to cut back on cost and points of failure. In addition, it also incorporates shared modular components that can be easily upgraded. These features lead to improved process monitoring and control capabilities, shorter lead times, and improved product quality. All three systems (PGM, PCF and SmartWare) are used in conjunction with hoses (ambient and/or heated) and Graco dispense valves, including the EnDure® auto dispense valve, the 1K Ultra-Lite™ precision dispense valve, and the Auto Plus™ valve.
SUMMARY P G M , P C F a n d S m a r t Wa r e o f f e r advancements in metering and flow control for ambient and heated singlecomponent urethanes. PGM and PCF offer additional control for both robotic bead placement and volumetric dispense, while SmartWare offers control of volumetric shots and batch dispense. All three technologies represent significant advancements in the ability to meter and dispense single-component materials. For more information, contact Graco at 8400 Port Jackson Ave. N.W., North Canton, OH 44720-0747; phone (800) 746-1334; fax (330) 966-3006; e-mail
[email protected]; or visit www.graco.com/sae. Editor’s note: This article is based on a paper given at the Center for the Polyurethanes Industry’s (CPI) Polyurethanes 2010 Technical Conference, September 2010.
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Nordson Wins 2010 German Packaging Award The MiniBlue® II adhesive applicator was recently honored at the FachPack International Trade Fair.
T
he MiniBlue II adhesive applicator from Nordson Corp. recently won the 33rd annual German Packaging Award during the FachPack Trade Fair in Nuremberg, Germany. Introduced globally in March 2010, the compact, high-speed, pneumatic, hot-melt adhesive applicator placed first in the Engineered Machinery category. A panel of 14 packaging industry and national trade association experts selected the MiniBlue II applicator based on criteria including economic impact on the manufacturing process, sustainability, engineering innovation, user-friendliness, safety and design aesthetics. According to a statement issued by the jury, “Nordson implemented unique innovations that advance hotmelt dispensing technology and further the advantages of packaging with hotmelt, over previous dispensers and alternate forms of bonding and sealing. In particular, they have significantly increased application precision as well as dispensing speed, enabling more efficient packaging at higher line speeds with less waste. Nordson’s patented and patent-pending seal technology delivers extended service life and permits longer maintenance intervals, making adhesive dispensing considerably more productive and user-friendly.”
MINIBLUE HOT-MELT DISPENSING GUNS MiniBlue II hot-melt adhesive applicators provide long life, less maintenance and reduced downtime in packaging 22
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operations. The ball-and-seat design features a patented hydraulic seal for longer life without leakage. Packaging-grade adhesives can be applied at cycle rates of 2 m/s using the MiniBlue II applicator and a Nordson Saturn® Platinum (SP) high-speed solenoid valve. MiniBlue II modules use standard Saturn nozzles and are backward-compatible with previousgeneration MiniBlue applicators. MiniBlue reduced-cavity hot-melt applicators virtually eliminate waste associated with adhesive stringing. Because these glue applicators provide clean adhesive cutoff and less stringing, packagers benefit from clean bonding and sealing and minimal maintenance and cleanup. MiniBlue II ball-and-seat and MiniBlue reduced-cavity applicators are ideal for applications with close compression sections and limited parent machinery space. Key features of the applicators include: • Fast (2 m/s) cycle times and superior high-speed performance • Integrated filters that capture contaminants and reduce nozzle clogs • Insulating covers that reduce energy use up to 50% and maintain temperature for better adhesive flow, cutoff, and bonding • Both reduced cavity and ball-andseat configurations
and industrial products during manufacturing operations. The company also manufactures equipment used in the testing and inspection of electronic components, as well as technology-based systems for curing and surface treatment processes. Headquartered in Westlake, OH, Nordson has direct operations and sales support offices in more than 30 countries. For additional details, visit www.nordson.com.
ABOUT THE GERMAN PACKAGING AWARD Employing the theme “Pack the Future,” the German Packaging Institute commended a total of 22 new developments in seven categories at the 2010 Nuremburg trade show. The German Packaging Awards competition, initiated in the 1960s, is open to international and domestic manufacturers, developers, designers, and users of innovative packaging solutions, and promotes creativity and innovation from new and established companies. To receive an award, product
ABOUT NORDSON
entries must demonstrate technological advancement
Nordson Corp. is a leading producer of precision
and functionality that positively impact and set new
dispensing equipment that applies adhesives, sealants,
standards for the future of the packaging industry. Visit
coatings, and other materials to a range of consumer
www.verpackung.org for more information.
January 2011
A new non-phthalate benzoate plasticizer product could satisfy the current needs of the adhesives industry. By Emily L. McBride, Applications Chemist; and William D. Arendt, Research Fellow, Emerald Kalama Chemical, LLC
H
ealth and environmental concerns have surrounded specific phthalate plasticizers since the 1970s, leading to these materials being regulated and controlled for years. Regulatory pressure has significantly increased in the 21st century; the search for non-phthalate plasticizers for use in many applications as phthalate replacements has intensified, particularly in the European Union. Benzoate plasticizers have been recognized as the plasticizers of choice for latex adhesive applications and have a proven track record that dates back to the 1950s. By nature, benzoates are non-phthalates and, as such, have gained attention as phthalate replacements. A value-added benzoate plasticizer product, K-Flex® 850S, has been developed to meet the global need for phthalate replacements and reflects the current plasticizer needs of the latex adhesive market. An evaluation was recently conducted to demonstrate the performance of the new K-Flex 850S product. The study consisted of testing the new benzoate blend in both polyvinyl January 2011
acetate homopolymers and polyvinyl acetate/ethylene copolymers at three levels vs. diisobutyl phthalate, di-2-ethylhexyl terephthalate, and current dibenzoate controls. Several key tests, including viscosity response and glass transition (Tg) suppression, indicated that K-Flex 850S is an excellent plasticizer for latex applications and compares very favorably with phthalates and other competitive benzoates. It also offers latex applications formulators wide latitude in compatibility with other polar adhesive polymers.
BACKGROUND Benzoate esters are established plasticizers for the adhesive market. As a family, benzoates have been available commercially since the 1930s.1 Diethylene glycol dibenzoate, dipropylene glycol dibenzoate and a 50/50 blend of these two plasticizers form the basis of the product line for use in adhesives.2-4 The principal reason why benzoates were established as general purpose plasticizers for latex applications was their polar Adhesives & Sealants Industry
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SEARCHING FOR A BETTER DIBENZOATE SOLUTION nature (compared to general purpose vinyl plasticizers, such as diisononyl phthalate), which allowed their compatibility with commonly used polymers in the adhesives or coatings industries. General purpose phthalates are not utilized as often in the adhesives industry as they are in the vinyl industry. Polar phthalates, such as butyl benzyl phthalate (BBP), di-n-butyl phthalate (DBP) and diisobutyl phthalate (DIBP) are more commonly associated with use in adhesives than the longer chain dialkyl phthalates. In terms of regulatory pressure, di2-ethylhexyl phthalate (DOP or DEHP) was initially suspect, but the lower phthalates also became increasingly regulated as time passed, leading producers of plasticized compounds to seek non-phthalate alternates.5 The pressure to move toward using non-phthalates—particularly in Europe—has increased in the 21st century. Benzoate esters have been effectively used as non-phthalate alternatives since before the need arose for such a technology and are the natural choice for adhesives.6 Generic grades of benzoates have been used for years for the diverse high solvator applications, but benzoate manufacturers are keeping pace with the needs of the industry with new technologies and products. 7-10 Although other plasticizers can and have been used in the adhesive industry, benzoates have proven to offer the best balance of performance and value.6
ADHESIVE EVALUATION K-Flex 850S is a proprietary blend of dibenzoates that keys off of the excellent performance of diethylene glycol dibenzoate, which is one of the blend’s components. As this product is based on existing dibenzoate technology, it: • Is listed on most of the chemical inventories in the world • Has 21CFR175.105, 21CFR176.170 and 21CFR176.180 U.S. Food and Drug Administration (FDA) approvals • Is free of both health and environmental hazard labels at the levels used in adhesives in Europe K-Flex 850S is specified to include 98% minimum as benzoate esters with a color of 150 maximum APHA. Typical properties are very similar to existing dibenzoates (e.g., K-Flex 500). The new material has a freeze point of about 7°C, so it is handled like existing grades of dibenzoates. Three basic performance characteristics are considered to be critical in the evaluation of 24
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any plasticizer or plasticizer blend for use in a latex adhesive. Undoubtedly, the first is compatibility of the plasticizer with the polymer used in the adhesive. Without at least partial compatibility, the plasticizer cannot provide good performance in an adhesive. The next parameter is viscosity response (normally a viscosity increase) of the base emulsion to the plasticizer. It is most desirable to have as good a viscosity response as
possible to allow the adhesive compounder to add water back to adjust the adhesive to the required viscosity for the application. The last characteristic is T g suppression of the polymer by the plasticizer. In the case of polyvinyl acetate homopolymer, Tg suppression is desired, as the Tg of the homopolymer is about 35-40°C. Tg suppression is considered to be an efficiency parameter, so a greater Tg suppresJanuary 2011
industry, a basic adhesive evaluation was conducted to illustrate the performance and advantages of using K-Flex 850S. The following protocol was designed to demonstrate the performance of K-Flex 850S in latex adhesives: Two emulsions selected for formulation • a polyvinyl acetate homopolymer, polyvinyl alcohol protected • a polyvinyl acetate/ethylene copolymer, polyvinyl alcohol protected 0°C Tg Plasticizers evaluated with K-Flex 850S • K-Flex 500: a classic blend of diethylene glycol dibenzoate and dipropylene glycol dibenzoate • A competitive blend of two dibenzoates • A competitive blend of three dibenzoates • Diisobutyl phthalate (DIBP): still used in adhesives and therefore used here as a primary phthalate control • Di-2-ethylhexyl terephthalate (DOTP): considered a non-phthalate by some and a general purpose plasticizer replacement in vinyl; GP vinyl plasticizers are generally not polar enough for many adhesive applications, so DOTP was added here as a negative control The plasticizers were added to the base emulsions at 5, 10 and 15% of the wet adhesive. Tests included neat plasticizer volatility, compatibility, viscosity response, Tg depression, and set and open time. The method of preparation and test details are listed in the Test Methods sidebar.
RESULTS AND DISCUSSION
sion is usually desired. However, in some instances, less depression is required to allow for solids addition, to optimize formulation cost, or to control other performance characteristics. In copolymers, the Tg is often low enough by itself, so a plasticizer is added to enhance other performance characteristics. The addition of a plasticizer affects other adhesive performance characterisJanuary 2011
tics as well. Neat plasticizer volatility will affect the volatile organic content of the adhesive. If a plasticizer is compatible, it can also affect the adhesive’s set and open times, adhesion, strength, and bond water resistance, among other characteristics.
EVALUATION PROTOCOL As dibenzoates and dibenzoate blends are well known to the latex adhesive
The evaluation presented here is abstracted from the data presented at the 2010 Fall Convention of The Adhesive and Sealant Council, Inc. meeting (October 3-5, 2010) in Covington, KY.11 As mentioned earlier, the plasticizer’s volatile organic compound (VOC) content will have an effect on the total VOC of the adhesive. The lower the VOC of the plasticizer, the better. In general, benzoates are quite low in VOC. A modified ASTM D 2369 VOC test (0.5 g sample with 1 ml toluene) was used to determine VOC. Figure 1 illustrates how K-Flex 850S is similar in neat VOC to the control benzoates and significantly lower than DIBP. DOTP is very low in VOC, as would be expected for a higher molecular weight dialkyl phthalate. Adhesives & Sealants Industry
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SEARCHING FOR A BETTER DIBENZOATE SOLUTION Compatibility is the key parameter in any plasticized formulation. As expected, it was experimentally proven that all of the benzoates and DIBP were compatible at the level of test. However, DOTP was completely incompatible with polyvinyl acetate and only partially compatible with the polyvinyl acetate/ ethylene copolymer. Figure 2 shows photos of some of the dried adhesive films used to judge compatibility in the polyvinyl acetate homopolymer. Note that, in the case of DIBP and K-Flex 850S, the films are clearer than the film without plasticizer and free of any exudation. This indicates excellent film formation and compatibility of these plasticizers with the polymer. In the case of the DOTP film, the photo does not show significant exudation but does show a very hazy film, which is indicative of incompatibility. The unplasticized emulsion will form a film at room temperature, as water is a fair plasticizer in a homopolymer emulsion stabilized with polyvinyl alcohol. Figure 3 illustrates the data on the effect of select plasticizers on the Tg of the polymers tested. In the case of the polyvinyl acetate homopolymer, the benzoates are similar in Tg suppression while DIBP is slightly better in suppression. DOTP does not affect T g at any level of incorporation in the homopolymer, further indicating its complete lack of compatibility with the homopolymer. In the copolymer, DOTP displays partial compatibility. At 5% loading, DOTP does depress Tg well, but the response levels off at the 10% and 15% loading. This is not the case for the benzoates, which are all similar in their ability to increasingly suppress Tg as the plasticizer concentration increases. Figures 4 and 5 show the viscosity response data. While there are some slight variations in the viscosity response of the compatible plasticizers of this evaluation, they all provide excellent response and are all similar in this aspect of performance. As expected, DOTP does not provide adequate viscosity response. In polyvinyl alcohol-protected emulsion adhesives, the polyvinyl alcohol provides reasonable wet tack and set times before any contribution provided by a plasticizer. Figure 6 illustrates the set times of the 5% copolymer and the 10% homopolymer adhesives (these concentrations were selected as representa26
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tive of average plasticizer loadings in these types of adhesives). In each case, the benzoates shortened set times in the adhesives as compared to the unplasticized base polyvinyl alcohol-protected emulsion. Compatible plasticizers can lengthen the open time of an adhesive; long open times are also indicative of good wet tack. Figure 7 illustrates the effect of
the evaluated plasticizers on open times. Both the benzoates and DIBP provided excellent open times.
CONCLUSION While it is certainly important today for our industry to identify ways to become greener and more committed to using safe materials, the overriding fact remains that the materials we use January 2011
must function as required while providing value. The results of this evaluation indicate that K-Flex 850S, which has been tailored to provide the value demanded as a non-phthalate alternative, provides both the value and the performance characteristics required for the adhesive market. In addition, it is in line with today’s stricter environmental and health standards. For more information, contact the authors by e-mail at
[email protected] or william.
[email protected]. Editor’s note: K-Flex® is a registered trademark of Emerald Kalama Chemical, LLC.
REFERENCES 1. Farben, I.G., “Improvements Relating to the Production of Artificial Materials from Highly Polymeric Materials,” GB 496, 574, 12/1/1938. 2. Reeves, Howard, et. al., “Polyalkylene Glycol Dibenzoate, Process of Making Same and Resinous Compositions Plasticized Therewith,” U.S. 2,956,978, October 18, 1960.
TEST METHODS Preparation The adhesive emulsions were prepared by mixing the plasticizer into the polymer for 10 minutes at 750 RPMs using a Caframo outfitted with a Jiffy blade. The plasticizer was added within the first minute of mixing. Volatility, Oven Plasticizer samples of about 0.5 g in 1 ml of toluene were held at 110°C for one hour in a type 2A oven. Compatibility Emulsions were drawn down 10 mils wet on glass and allowed to dry overnight. Samples were evaluated for clarity and exudation. Viscosity The viscosity response of the emulsions to the plasticizers was determined at low shear by a 30-second reading at 20 RPMs on a Brookfield DVII, RV viscometer (22°C, ± 2°C). Set Time Set time was determined by laminating two strips of 50-lb unbleached Kraft paper and measuring the time it took before 80% fiber tear occurred when peeling the strips apart. The top and bottom strips of paper were 1 x 14 in. and 1.5 x 14 in., respectively. Approximately 1 g of emulsion was metered onto the bottom strip using a #20 wire wound rod while the top strip was laminated to the bottom strip with a second rod. Open Time Open time was determined using a method akin to the set time method. The top and bottom strips of 50-lb unbleached Kraft paper were 1 x 14 in. and 1.5 x 14 in., respectively. Approximately 1 g of emulsion was metered onto the bottom strip using a #20 wire wound rod; the top strip was laminated to the bottom strip with a second rod after the determined time interval (a multiple of 5 seconds) had elapsed. Strips were peeled apart immediately following lamination and were considered set once greater than 50% fiber tear occurred. Glass Transition The glass transition data was gathered on 10 mg samples of 10 mil wet film that had dried at least overnight. Samples were run by jumping from room temperature to -90°C and then ramped at 10°C per minute on a TA Instruments Q2000 DSC. January 2011
3. Arendt, W.D., “Utilization of Glycol Benzoates in Polyvinyl Acetate Emulsion adhesives and Acrylic latex Caulks,” Proc. Adhesive & Sealant Council Seminar, Cambridge, MA, 186-210. 4. Arendt, William D., “Plasticization of Polyvinyl Acetate Adhesive Emulsions,” Tech Pap Soc Manuf Eng., 1985, AD85-782, p. 23. 5. Gravel, Shamsi P., McBride, Emily L., “Dibenzoate Plasticizers Offer a Safer, Viable Solution to Phthalates,” Adhesives & Sealants Industry, February 2010, pp. 15-18. 6. Skeist, Irving, Edit., Handbook of Adhesives, Third Edition, Chapter 21, Harold Jaffe and Franklin Rosenblum, Van Norstrand, Reinhold NY, NY, 1990, p. 395. 7. Arendt, William D., “Increasing Plasticizer to Eliminate Solvent from Latex Adhesives,” Adhesives Age, vol. 36, August 1993, pp. 17-19. 8. Arendt, W.D., Streeter, B.C., Holt, M.S., “New Benzoate Plasticizers for Latex Caulks and Adhesives,” J. Adhes. Sealant Counc., October 1997, pp. 85-103. 9. Arendt, W.D., Streeter, B.C., Holt, M.S., “New Benzoate Plasticizers for Latex Adhesives,” Adhesives Age, vol. 41, March 1998, pp. 36-39. 10. Arendt, William D., Strepka, Arron M., Stanhope, Bruce, “New Cost-Effective Benzoate Plasticizer Blend Enhances Latex Adhesive Systems,” Adhesives Age, vol. 45, June 2002. 11. McBride, Emily L., and Arendt, William D., “Introduction of a New Benzoate Plasticizer Product for Latex Applications,” presentation at the The Adhesive and Sealant Council, Inc. Fall 2010 Convention, Cincinnati, OH, October 5, 2010.
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Chemical industry executives must be extremely attentive to compliance-related changes. By James Kosch, Shareholder, LeClairRyan
F
or executives in the U.S. chemical industry whose responsibilities include regulatory compliance, life can seem like a bowl of acronyms. After all, much of their time is spent absorbed in meditations on the likes of TSCA (Toxic Substances Control Act), EPCRA (Emergency Planning and Community Right-to-Know Act), CERCLA (Comprehensive Environmental Response, Compensation and Liability Act), FIFRA (Federal Insecticide, Fungicide and Rodenticide Act) and RCRA (Resource Conservation and Recovery Act). This is only the beginning, of course, as there are myriad federal, state, and local regulations and agencies (another set of acronyms entirely) to consider.
COMPLY WITH THE LAW When it comes to the top five corporate-compliance challenges facing chemical companies, number one is simply staying on top of the many layers of formal requirements that are put forth in this thicket of regulations. Naturally, smart companies pay extremely close attention to both the broad, overarching goals of such regulations (what we might call their “spirit”), as well as to the specific ways in which this acronym soup might affect company operations (the letter). Ironically, however, companies that actually do go above and beyond on worker protection or toxic emissions reduction often pay a steep price for making what might seem like relatively insignificant compliance mistakes. They might be sticklers for getting the right emissions permits, for example, but then fail to read the fine print on the permit obligations. Even simple errors, like failing to fill out the required forms for waste disposal, can land an otherwise-compliant company in regulatory hot water. 28
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Plant explosions and chemical spills tend to dominate the headlines, but the fines and penalties for failing to comply with the regulatory compliance paperwork can often be just as expensive and ensnaring as major violations of the primary operative points of a particular federal act. For example, one company with an exemplary environmental record was nonetheless targeted by the U.S. Environmental Protection Agency’s (EPA) Multimedia Enforcement Program, which focuses on comprehensive audits of potential pollution of the air, water or land. Essentially, this environmentally responsible company failed to dot a few i’s and cross a few t’s in its regulatory paperwork. As a result, it faced a penalty demand of about $1 million. In another example, a company might dutifully record its emissions levels in parts per billion when the pertinent regulatory act stipulates that those emissions be logged in parts per million. Though not a violation of the spirit of the regulation, this technical flub could easily translate into penalties of approximately $1,000 a day, retroactively enforced for the three years in which the documentation errors occurred. These were minor infractions, in a certain sense, because they resulted in neither pollution nor an employee injury. Nonetheless, the penalties associated with such documentation errors can stack up quickly. The basic message here is simple enough, though it might be somewhat counterintuitive: For chemical companies, maintaining accurate and compliant documentation deserves just as much attention as big-picture compliance goals like cutting emissions or running a safer workplace.
FOLLOW YOUR OWN RULES Formal compliance with state, local and federal regulations always translates into stated company policy. However, drafting clear polJanuary 2011
icies is just the first step. For chemical companies, making sure employees at all levels actually follow those stated policies can be a big challenge. The regulations themselves, after all, tend to be technically complex and highly specific, affording little or no leeway for deviation. Moreover, the high stakes involved in a failure to comply with chemical regulations—fouled waterways, sickened or burned employees and the like—creates an unforgiving regulatory atmosphere in which employee behavior is more likely to come under close scrutiny. Thus, the second-biggest compliance challenge facing chemical companies is to make sure they actually follow their own rules and procedures. From a liability standpoint, this is huge; the favorite smoking gun of any plaintiff’s attorney is one that dramatically demonstrates a company’s failure to abide by its own stated policies. Communication is central to this effort. At many chemical companies, a seniorlevel risk-management executive will be wisely focused on the complexities related to insurance coverage. A good risk manager will know the company’s insurance policies inside and out, and he or she will make sure those policies are always the right ones
for the company’s particular footprint of exposure. Sometimes, this risk manager also doubles as the company’s environmental, health and safety (EHS) officer. This is fine—as long as the risk manager/EHS officer is equally well-versed in the insurance landscape and the considerable technical complexities associated with running a safe and compliant chemical company. At companies that have a risk manager on one hand and an EHS officer on the other, communication between these two executives must be clear and strong. Make sure they talk to one another frequently and are in the plant on a regular basis. They need to know what is going on in those facilities and be up to date on the requirements of both company policy and applicable regulations. Compliance with right-to-know laws is a matter of communication, pure and simple. Nearly every chemical company has a clearly written policy designed to make sure employees are informed about the risks of, and proper techniques for, handling and working around certain chemicals. However, making sure these policies are followed can be particularly challenging, and companies should be clear-eyed about certain
realities, like the veteran floor manager who takes a wink-and-a-nod approach to, say, uncomfortable safety equipment or timeconsuming safety procedures. Ultimately, employees at all levels must get a strong sense that the company places a top priority on compliance with all of its internal policies. Forgetting to fill out those safety data sheets, in other words, will not result in a slap on the wrist; it can get an employee fired.
ANTICIPATE COMPLIANCE-RELATED TRENDS When it became clear in 2008 that the federal administration would change—including a new EPA administrator—there was a lot of talk in the chemical industry about the arrival of a new sheriff in town, so to speak, and a newly aggressive enforcement climate. In many ways, these predictions were true enough. However, the much-discussed aggressiveness on the regulatory front has not taken shape in quite the way many observers expected. Rather than a massive increase in environmental audits or a rash of new regulations, the new administration seems most focused on reinterpreting regulations in ways that expand its regulatory authority. In
G
orman-Rupp positive displacement rotary gear pumps are versatile enough to handle virtually any liquid or pumping application. They are manufactured with unique features and flexible seal designs that enable them to perform better and last longer than other gear pumps.
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CORPORATE COMPLIANCE CHALLENGES December 2009, for example, the EPA issued two distinct findings regarding greenhouse gases under section 202(a) of the Clean Air Act. In the so-called endangerment finding, the EPA declared that current and projected concentrations of six greenhouse gases “threaten the public health and welfare of current and future generations.” In the second finding, it pointed the finger for this health threat at the combined emissions of these gases from motor vehicles. These findings imposed no specific requirements on industry, but their implications, particularly for emissions standards, are broad indeed. Anticipating changes in the regulatory environment is always a guessing game. From a strategic standpoint, however, playing that guessing game is important. If a particular chemical is in the headlines—perhaps as a result of toxicology studies pointing to its harmful effects—a company that produces that chemical might well face a greater risk of being audited by regulators. Are there easy solutions to this challenge? No. But there are efficient, and inefficient, approaches to reading the tea leaves. Smart companies rely on multiple sources—including news “clipping services,”
consultants, industry associations, and their own lobbyists and attorneys—to gather the best possible information with which to make these guesses. Today, for example, proactive firms are already sketching out how they will adjust their business models based on which provisions of the proposed Safe Chemicals Act of 2010 might eventually become law.
KNOW YOUR COMPANY’S HISTORY— AND ITS ASSOCIATED RISKS One of the more interesting compliance challenges facing chemical companies is the trend for governments to make wide-reaching cleanup claims for urban rivers and other bodies of water polluted during the industrial age. At the federal level, the EPA’s well-publicized Urban River Restoration Initiative is a good example of the high priority now being placed on these efforts. Suddenly, companies that thought they were no longer located along a body of water, or believed that all their waterfront assets had been sold, are being hauled to account for pollution caused by their predecessor entities decades ago. In the most extreme examples, these cases date back to the Civil War. Given the scope and scale of the pollution that occurred
CONSULTING BY “DR. DAVE” Adhesives and Sealants-Technology, Applications and Markets
Dr. Dave Dunn writes the monthly “Questions and Answers” column in Adhesives & Sealants Industry magazine, and is a unique source of both technical and management consulting for the adhesives and sealants industry. Technical Consulting • Formulation advice • Sourcing information • New developments • Application development • Application troubleshooting • Problem solving Market Research • Opportunity analysis • Customer surveys • Mergers and acquisitions • New developments • Market analysis • Industry structure • Competitive intelligence • Key trends
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Technology Focus • Anaerobics • Cyanoacrylates • Reactive acrylics • Epoxies • Hot melts • Gasketing Market Focus • Industrial • Automotive OEM • Automotive aftermarket • Medical • Construction Management Consulting Innovation can be planned and managed to meet the strategic goals of a company. We have concentrated on integrating the R&D functions of companies into their strategic plans and putting systems in place to continuously measure the effectiveness of investments in R&D.
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About the principal… Dr. Dave Dunn is President of F.L.D. Enterprises, which is located near Akron, Ohio, USA. He is a former Vice President and Director of Loctite Corporation and has consulted for many adhesives and sealants manufacturers and users in both North America and Europe. He is the author of several books and many articles, including the recent book Adhesives and Sealants-Technology, Applications and Markets, published by Rapra Technology Ltd. (www.polymer-books.com). F.L.D. Enterprises Inc. 242 Trails End Aurora OH 44202 Tel. 330-562-2930 FAX 330-247-1690 e-mail
[email protected] web site www.fldenterprises.com
during America’s many unregulated decades of industrial development, these cleanups are always staggeringly expensive. As a result, implicated companies now face huge liabilities for natural resource damage claims. This is a “compliance” challenge in the sense that companies with significant longevity must look far back into their histories and try to figure out when, where and how they might have violated regulations that came into existence long after the deed was done. Even if a company does not currently produce a particular banned chemical or chemical byproduct, one of its predecessor entities might have done so in the past. Thus, compliance officers, risk-management experts and maybe even a hired-gun historian should work together in planning for historical legacy claims.
AVOID COMPLIANCE MYOPIA Given the aforementioned “acronym soup” involved in regulatory compliance, chemical companies can hardly be blamed for being narrowly focused on the specific challenges faced by this particular industry (and its various sub-sectors). However, compliancerelated changes are afoot in a host of other areas, and, in some cases, these changes hold the potential to be every bit as significant for chemical companies as revisions to a particular federal act. The pace of change for modern corporations—touching on everything from electronic discovery to green building, from immigration to the privacy and liability implications of employee use of social networking sites like Twitter and Facebook—has never been more frenetic. The seismic shifts now occurring in our society and business culture have far-reaching consequences for compliance, and a myopic “old school” approach simply will not do. With a view toward staying ahead of the curve on compliance trends, chemical industry executives must look not just outside the confines of their own particular companies and industries, but also past their own national borders. Fortunately, the same technologies that are driving many of these trends make staying informed about them easier than ever. And in any case (with apologies to the authors of TSCA, CERCLA, FIFRA, RCRA and the like), almost anything is more fun to read than federal regulations. For more information, visit www.leclairryan.com. Editor’s note: This article originally appeared in the September 13, 2010, edition of Corporate Compliance Insights and has been reprinted with permission.
January 2011
Weather Durability Testing Testing long-term weather durability can be more accurate when done on a larger scale. By Allen F. Zielnik, Weathering Science Senior Consultant, Atlas Material Testing Technology LLC
A
dhesives and sealants are used by the solar energy industry in applications such as bonding photovoltaic solar panels, preventing moisture ingress into modules or electrical junction boxes, and adhering mirrors to tracking mounts in concentrating solar power applications. The building and construction industry also uses adhesives and sealants for attaching and waterproofing curtain-wall systems and fenestration. These diverse applications share two key commonalities: the expectation of a long life performance (e.g., 20 years or more), and direct exposure to a variety of harsh environmental and end-use stresses.
PREDICTIVE TESTING To understand (and hopefully predict) the long-term weather durability of certain materials, a number of smallscale, materials-level accelerated stress tests have been devised, including UV and moisture condensation, water immersion, and thermal cycling and laboratory-accelerated (xenon arc) weathering, among others. These tests are in addition to the requisite real-time-testing (RTT) that helps to validate the accelerated tests. January 2011
Available time, money and resources comprise the necessary tradeoffs in any test. Designing appropriate tests typically requires detailed knowledge about specific failure modes and causes, as well as RTT data for validation of the accelerated tests (both of which are often missing or incomplete). Tests that involve the use of known factors apply stresses that are as similar to the real-world environment as possible. Cured-in-place waterproofing sealants for curtain-wall cladding are exposed to frequent cyclic movements during their cure, which can result in permanent and detrimental changes in sealant bead geometry and performance characteristics. During their service life, these sealants are exposed to environmental degradation stresses and cyclic joint movement, which can lead to sealed joint failure. RILEM has developed a durability test method1 that alternates between laboratory-accelerated weathering, thermomechanical cycling and optional fatigue cycling. According to the Handbook of Sealant Technology, “Durability studies of construction sealants specified for outdoor applications should be based on 5,000 to 20,000 hours of artificial weathering and ideally include joint movement during cure as well as during the artificial weathering of the specimen.”2 Adhesives & Sealants Industry
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WEATHER DURABILITY TESTING A MATTER OF SIZE Another key aspect of testing is sampling. It is important to know whether a small test sample of a material or product truly represents that product in use and whether the stresses it will encounter are accurately represented in the test. Sealants typically need to be tested under tensile, compressive or shear stress for the results to be valid. But do small test jigs adequately represent the mechanical load of a large curtain-wall panel or the edge seal of a solar panel subjected to solar and ambient thermal cycling, wind load, and other stresses? The need and willingness is increasing to test larger or full-scale products or mock-ups to better reproduce real-world conditions in accelerated testing. Solar panels in use experience temperature changes from ambient conditions as well as unidirectional solar load (as do building panels). These temperature changes can produce mechanical stresses very different from either steadystate conditions or climate chamber tests without solar load. Moisture stress (as relative humidity) changes daily with ambient and product temperature, and condensation, saltwater, wind-blown rain sprays, or even acid rain may be present and can affect a full-size product differently than a small test sample. Other industries, such as the automotive industry, have learned these lessons from experience. Today, the suitability of an item such as basecoat-clearcoat car paint or the skin of an instrument panel is first validated by small-scale accelerated tests and RTT weather-durability tests. Next, mid-level testing of intermediate assemblies is often performed. This step adds processing and manufacturing stresses to the mix, as well as different materials in combination or proximity, such as everything that goes into an auto’s instrument panel. Then intermediate-scale tests (e.g., DIN 75-220 3) are conducted at elevated temperatures and full-scale solar simulation or in special solar tracking test boxes under natural sunlight in the Arizona desert. Unfortunately, these trials do not eliminate the need for larger or full-scale product testing, as a complete product may behave differently in the field or a laboratory test than a smaller specimen. The automotive industry routinely exposes cars outdoors in known harsh climates such as Arizona, the Kalahari, and subtropical 32
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The need and willingness is increasing to test larger or full-scale products or mock-ups to better reproduce real-world conditions in accelerated testing.
south Florida. In addition, some manufacturers perform larger scale weathering chamber tests in drive-in solar/climate chambers or solar/wind tunnels. Until recently, adhesives and sealants manufacturers or users had few options for accelerated weather durability testing on 3-D or full-size products or test fixtures. However, advances in largescale full-spectrum solar simulation (in combination with climatic tests) are now available as commercial testing services or equipment. For example, several large solar simulation climate chambers can be used for accelerated weather testing of photovoltaic solar panels. The chambers permit rapid cycling of fullspectrum solar load, temperature, and humidity in both daily and seasonal (including freeze/thaw) cycles according to a number of benchmark climates, or a hypothetical worst-case global ”composite” climate, to better understand product durability issues.
TESTING REALITIES In testing, only two opportunities really exist for acceleration. The first is overstress acceleration, whereby stress levels greater than those that will be encountered in service are used. However, this practice may result in failures that would not naturally occur, and, in some instances, the overstress (such as low-
wavelength UV) has skewed the degradation mechanisms and did not produce the failures seen in the field. The other acceleration opportunity is time compression, which may involve a more rapid thermal cycling than is normally seen in a 24-hour period. This approach is best used for single-stress cause-and-effect failure modes that are primarily physical in nature, since chemical degradation mechanisms may not be as easily accelerated. An additional caveat to accelerated testing is that failure mechanisms that result from simultaneous or time-dependent sequential degradation processes may not be uncovered in tests that use only a limited number of the stresses that the product will encounter. In solar panels, for example, a “hot spot” can develop in one of the cells, and this can lead to electrical arcing and even a fire. A hot spot may result from the corrosion of the transparent conducting oxide (TCO) electrode layer, which causes high electrical series resistance. In turn, the corrosion may be the result of sodium-ion electrochemical migration out of the cover glass under conditions of current flow in the presence of moisture in the panel. Moisture ingress may be the result of UV degradation of the polymeric edge seal in the module; hence, that would be the root cause. January 2011
Tests that do not combine solar radiation (for the UV degradation and electrical current production), moisture (for the ingress) and thermal cycling (for the moisture pumping action) would most likely not be able to reproduce this sequential failure mechanism.
ing façade panels. However, as these products become more common and the expectations for long-term durability are increased, more comprehensive and realistic testing needs to be performed.
REFERENCES
For more information, contact Atlas Material Testing
2. Wolf, Andreas T., Handbook of Sealant Technology, Chapter 13: Construction Sealants, CRC Press, 2009.
Technology LLC at 4114 N. Ravenswood Ave., Chicago, IL 60613; phone (773) 327-4520; fax (773) 327-5787; e-mail
[email protected]; or visit www.atlas-mts.com.
1. RILEM TC 139-DBS, “Durability Test Method— Determination of changes in adhesion, cohesion and appearance of elastic weatherproofing sealants for high movement façade joints after exposure to artificial weathering,” www.rilem.net.
3. DIN 75 220, Aging automobile components in solar simulations units.
As expectations for longterm durability increase, more comprehensive and
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realistic testing needs to be performed.
DUAL NATURE OF BIPV A marriage of solar products and building materials in building integrated photovolatics (BIPV) presents new challenges for testing adhesives and sealants when solar panels are incorporated into building products (such as curtain-wall louvers and canopies or solar windows). The large size and integrated functionality of these products demands large-scale testing, including laboratory-accelerated weather testing, to accurately determine long-term durability and performance. These issues are beginning to be addressed now that large-scale, laboratory-accelerated weathering chambers, once the exclusive domain of the automotive industry, are becoming more common in the solar energy industry. In addition, commercial testing laboratories and building product manufacturers are also showing more interest in largescale testing.
CONCLUSION While traditional small-scale materialslevel accelerated tests have been convenient, they do not subject adhesives and sealants to either the simultaneous and cyclic stresses of the service environment or the in-use stresses of large complex products such as solar modules or buildJanuary 2011
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PACKAGING
SUCCESS
Changes in packaging can help adhesive and sealant manufacturers increase their products’ performance and reduce environmental impact.
P
ackaging designers, engineers and material scientists at Sonoco Recycling are using the company’s proprietary sustainable packaging design software to help manufacturers reduce their packaging environmental footprint by substituting or eliminating materials, down-gauging structures, and simplifying packages to improve recyclability. Sonoco is also working with customers to reduce and ultimately eliminate landfill waste at their manufacturing facilities. “We are working to balance the growing demand from our customers, consumers and retailers for ‘greener’ packaging with requirements for convenience, performance, and price,” said Jeff Schuetz, staff vice president, Global Technology, Consumer Packaging. “Retailers and consumer product companies are increasingly integrating sustainability into their business strategies.” Sonoco’s True Blue ™ line of sustainable packaging solutions and recycling services provides packages that offer multiple environmental advantages, including the use of more sustainable materials; reductions in the amount of energy, water and/or raw materials required; and/or the production of fewer carbon emissions. At PJ’s Coffee of New Orleans, for example, Sonoco developed and is producing 34
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vibrant, three-ply, foil-based flexible coffee bags that require 10% less material and 15% less energy to produce and result in 10% fewer carbon emissions than traditional four-ply flexible coffee bags. Sonoco also helped Kraft Foods convert its Maxwell House, Nabob and Yuban® brands of coffee from metal cans to more environmentally friendly rigid paperboard containers without sacrificing abuse resistance or shelf life. Less costly and more environmentally responsible than metal, the new cans are made from paperboard that contains more than 50% recycled materials and has received chain-of-custody certification from the Rainforest Alliance’s SmartWood program. The move to Sonoco’s high-performance composite can bodies also reduced both brands’ environmental footprint through material, energy and greenhouse gas emissions reductions. “Our True Blue brand gives consumer product manufacturers a one-stop shop for sustainable packaging solutions,” said Schuetz. “By combining our True Blue line of products with our total packaging solutions capabilities, we’re creating sustainable value for our customers.” Unilever USA strengthened its Suave ® brand image, cut packaging costs and reduced its environmental footprint by January 2011
working with Sonoco Global Plastics to redesign Suave’s rigid plastic shampoo and conditioner bottles. The attractive new curve in the bottles’ walls improved the overall strength of the bottles and reduced the resin required to produce the bottles by 16%. True Blue eco-friendly point-of-purchase displays like the one Sonoco’s Global Services division designed and produced for Unilever’s Vaseline® Sheer Infusion ™ body lotion are helping customers and their retail partners meet their sustainability and sales goals. By redesigning an existing floorstand wing unit, Sonoco cut the paperboard required to produce the display in half—from 65.2 to 32.65 ft2—without sacrificing its ability to attract customer attention.
our customers’ performance, cost, and sustainability requirements.” Sonoco is also helping manufacturers reduce and ultimately eliminate landfill waste through its fast-growing Sonoco Sustainability Solutions (S3) wastereduction consulting service. By identifying recycling alternatives for materials being sent to landfills and developing a more comprehensive recycling program at Unilever’s Lipton Tea plant in Suffolk, VA, for example, Sonoco helped the
largest tea processing plant in the U.S. become a zero landfill facility in 2009.
ABOUT SONOCO RECYCLING Sonoco Recycling’s team begins with a thorough waste and reclamation audit to better understand specific waste processing practices. The company then helps set productive and realistic goals for waste reduction, and will provide monthly reports to monitor progress, productivity, and profitability. Sonoco also offers a leasing program for customized recycling equipment designed to meet specific needs. For more information, visit www.sonoco.com.
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One of Sonoco’s new protective packaging designs for Hewlett-Packard (HP) LaserJet printers reduced the volume of foam required by more than half, cut the pack’s corrugated weight by 69% and decreased overall packaging volume by 52%. Most of the pack’s components are made from recycled paperboard, so it’s easier to recycle than the previous protective packaging. And although it’s lighter, less expensive and more sustainable than the previous package, it provides the same level of product protection. “Because we’re not limited to just one sustainable packaging platform, technology or format, our customers can choose from a variety of innovative options that meet their unique needs,” added Schuetz. “Our True Blue brand leverages Sonoco’s skill and experience in developing superior design concepts that meet January 2011
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Packaging technologies have evolved to enable manufacturers to enhance their brand’s standing in the marketplace.
A
ccording to statistics shared by PackSmart at the recent Emballage Packaging Exhibition, 90% of industry respondents believe that designers provide a significant impact in reinforcing the integrity of all packaging functions.1 Those are strong numbers, but consider this: more than 50% of industry respondents support the premise that great design makes a difference in product differentiation and contributes to the product’s unique selling proposition (USP). Packaging’s primary function is to protect, store and transport, but the evolution of production, graphics, and printing technologies during recent decades has presented tremendous opportunities for differentiation.
STRUCTURE It used to be that form followed function. However, evolutions in plastics, extrusion and molding have sculpted shapes that create a new world of interaction between packaging and its intended end users. Structure is no longer a rigid frame, but an ergonomic paradigm of possibilities. Hot trends include high-end nestability, where spout and cap shapes are molded at the bottom of containers. Some caulk cartridges no longer feature a 4-in. spout, which adds height to the product. Instead, a side-ring spout attachment provides more efficient transportation, stackability and retail shelving. Some plastic gallon cans are fully nestable and provide prominent logistics gains in the supply and warehousing of packaging components. The migration toward a thinner sidewall in polypropylene (PP) containers is an eye-opener when it comes to 2-, 3- and 5-gal containers. Sustainability and key logistics savings are appropriately becoming determining driving forces. Cultural differences often dictate packaging preferences. North America is still entrenched in high-priced metal gallon containers, for example, while simultaneously using 36
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High-impact in-mold labeling and metallic effects from Superfos.
sustainable fiber cartridges as the norm for caulk and sealants. Meanwhile, Europe’s shelves have been filled for years with plastic cartridges and in-mold labeled gallons. Hermetic fiber drums for liquids are also used successfully in Europe, even for outdoor storage.
GRAPHICS A variety of printing and decorating technologies have been developed in order to embrace these new structural trends. These innovations primarily come in the form of shrinksleeves and more efficient and high-definition printing techniques. However, the adhesives and sealants industry has not fully embraced these printing and imaging advances to their fullest potential. Most retail brands in adhesives and sealants still rely on bold, solid colors and pictograms to generate interest. The use of photography—in addition to illustrations and pictogramlike symbols—has a definite place in the communication of information and hierarchy in a brand’s message. Photography offers the potential to help facilitate the end user’s comprehension of our industry’s complex regulations and safety concerns. As we develop the next generations of packaging, new opportunities arise in the areas of sustainability, longevity and usability. Structural designers, brand managers and graphic artists can use innovative technologies to provide new and improved methods of communication with end users. It is now possible to create an experience and enhance the brand’s bond with weekend DIYers and contractors alike. The Emballage Packaging Exhibition website is located at http://en.emballageweb.com.
REFERENCE 1. Design Packaging Study, Salon Emballage, June 2010, http://en.emballageweb.com.
January 2011
Growth in emerging economies will be robust, while modest increases in the mature economies of Europe and North America are forecast. By Minesh Kusumgar, Director, Kusumgar, Nerlfi & Growney Inc.
A
fter years of uninterrupted growth, adhesive demand fell 5% in 2009 as the global recession took its toll. Global GDP declined by about 1% in 2009 and industrial production was off by nearly 3%. Formulated adhesive consumption in 2009 was 16.6 billion lbs (worth $20.6 billion). Volume is forecast to expand at a 4.5% annual rate through 2014 as the global economy rebounds. Growth in emerging economies will be robust, while modest increases in the mature economies of Europe and North America are forecast. Formulated adhesive consumption varies from over $12 per capita in the European Union and North America to less than $3 per inhabitant in China, India, and Brazil.
REGIONAL OVERVIEWS The Asia-Pacific region is the largest consumer of formulated adhesives; it achieved 40% of the 2009 volume and 34% of the dollars. Regional volume was up slightly in 2009 compared to the January 2011
prior year, while the sales value was slightly lower. China is the largest consumer in Asia-Pacific with 53% of the volume and 49% of the value. Chinese adhesive consumption was up 6% in 2009 as the domestic economy expanded, despite weak export demand for its manufactured products. A robust 9% annual rate of growth is forecast for adhesives in China. Japan, the second-largest market for adhesives in the region, took 16% of the 2009 volume and one-fifth of the dollars. Volume in Japan declined significantly compared to 2008, and lackluster growth is forecast. India is a smaller user of adhesives, with 6% of the regional volume and 5% of the value. Like China, it is one of the few countries in the world to have experienced modest adhesive growth in 2009. Adhesives in India are projected to expand 11% per year through 2014. Europe is the second-largest regional consumer of formulated adhesives, with 30% of the world’s volume and 32% of the value Adhesives & Sealants Industry
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THE GLOBAL FORMULATED ADHESIVES MARKET in 2009. Europe had been the leader in adhesive dollars prior to 2009. The sharp decline in European consumption allowed the Asia-Pacific region to capture the lead, which is projected to widen in future years. A 3% annual growth rate is forecast for European adhesives, with Eastern European countries expanding somewhat faster than Western Europe. European Union members consumed about 93% of the adhesive dollars. North America took 24% of the global adhesive volume in 2009 and 27% of the dollars. As was the case in Europe, the market declined significantly from 2008. The U.S. consumed nearly 90% of the regional total, with the rest about equally split between Canada and Mexico. A modest 3% annual rate of growth is forecast for North American adhesive volume. South and Central American countries consumed 5% of the global adhesive volume and dollars in 2009. Brazil is the leading regional consumer with 57% of the value. Brazil weathered the global recession better than most, with adhesive volume only down 2% in 2009. South and Central American adhesives are projected to advance 5% annually through 2014. Figure 1 shows adhesive dollar consumption by region in 2008 and 2009, as well as the 2014 forecast.
END USE REVIEW Pressure-sensitive products are the largest adhesive end use, representing 28% of the global volume in 2009 and 25% of the value. Applications include tapes, labels, decals and a host of other specialty products. Over 45 billion m2 of product is adhesive-coated, with tapes comprising over 60% of the total. Two-thirds of the adhesive value is produced in-house by pressure-sensitive product manufacturers. Pressure-sensitive adhesives are forecast to grow 5% annually through 2014, with emerging economies (China, India, Brazil, etc.) expanding faster. Packaging is the second-largest end use, with 22% of the volume and 18% of the dollars in 2009. Global volume was down only slightly from the prior year and a 4% annual rate of increase is forecast. Flexible packaging is a higher value segment that represents one-quarter of the packaging adhesive dollars in 2009. Construction was the third-largest adhesive outlet in 2009, with 16% of the volume and 10% of the dollars. Construction adhesive applications include ceramic tile and flooring installation, pipe cements, roofing, wall coverings, etc. Volume was down more than 10% compared to 2008, as activity declined significantly in the mature economies. 38
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Figure 1. Adhesive Consumption by Region ($ Billion)
Woodworking is the fourth-largest end use, taking 11% of the 2009 volume and 8% of the dollars. Wood furniture is a leading application, and global production suffered the effects of the recession. The automotive industry is the fifth-largest end use in dollars, with a 6% share despite representing only 2% of the dollars. Adhesives consumed by car and truck manufacturers are included, as well as those used in the aftermarket. Global vehicle production was 61 million units in 2009, which was down 13% compared to 2008. Steep declines occurred in Europe and North America. In contrast, production in Asia-Pacific remained about the same as output surged in China. Some 810 million vehicles are on the world’s roads, with adhesives used by both the professional and consumer. Excluded from automotive adhesives are windshield sealants, a nearly $600 million market in 2009, as well as several other sealant types. The five largest adhesive applications took 80% of the adhesive volume in 2009 and twothirds of the value. Figure 2 shows adhesive consumption by end use in dollars for 2009. Electronics, bookbinding, and aerospace are larger end uses in the “other” category.
ADHESIVE TECHNOLOGIES Figure 3 summarizes the four major adhesive technologies in value for 2009. Water-based adhesives are the leading type, with $6.7 billion consumed (33% of the global adhesive sales dollars). Water-based adhesives are generally lower in cost and they represented over one-half of the 2009 pounds. Solvent-based technology is second in dollars, with its $5.7 billion (28%) of the value. Hot-melts were third, representing one-fifth of the dollars, with packaging and
disposable products leading outlets. The 100% reactive category was slightly behind hot-melts in dollars, with a 19% share. These products are generally the highest priced adhesives, and they captured only 4% of the volume. Epoxy, polyurethane, cyanoacrylate, anaerobic, structural acrylic, etc. products are included.
ADHESIVE TYPES Adhesives employ a host of polymer types in their formulation. Sales of the leading adhesives by polymer type in 2009 are shown in Figure 4. Acrylics are topmost, with their $3.6 billion in sales representing a 17% share. Acrylic emulsion-based formulations were 72% of the dollars and solvent-based acrylics accounted for 23%. Smaller amounts of structural acrylics and radiation-cured hot-melts are used. Water-based polyvinyl acetate (PVAC) and vinyl acetate-ethylene (VAE) adhesives comprised 14% of the adhesive dollars. Woodworking and packaging are the larger outlets. Polyurethane adhesives were 12% of the sales and are formulated using each of the four major technologies. Solventbased formulations were one-half of the polyurethane dollars, with flexible packaging and footwear the largest applications. The 100% reactive polyurethanes were about onethird of the dollars, with flexible packaging and automotive its major outlets. Hot-melt polyurethanes were 10% of the sales and water-based formulations another 7%. Ethylene-vinyl acetate (EVA) and polyethylene hot-melts were 9% of the adhesive dollars in 2009, as were styrenic block copolymer hot-melts. Packaging is the major user of EVA and polyethylene hot-melts. Some 95% of the styrenic block January 2011
Figure 2. Adhesive Consumption by End Use, 2009 ($20.6 Billion Total)
copolymer adhesives are used in pressure-sensitive products and disposable products (diapers and other). Epoxy adhesives are used in several higher dollar value end uses, which include the electronic, aerospace and automotive industries. Polychloroprene adhesives are largely solvent-based, although water-based versions have gained share in recent years. Footwear, woodworking and construction are the larger outlets. Larger dollar value adhesives included in “other” are cyanoacrylate, anaerobic, rubber, starch and dextrin, polyester, and polyamide.
COMPETITIVE OUTLOOK
Figure 3. Adhesive Consumption by Technology, 2009 ($20.6 Billion Total)
Acquisitions continue to alter the adhesive supplier structure. In 2009, the top 20 formulated adhesive suppliers captured 47% of the sales value. These companies sold about 55% of the adhesives in North America, Europe, and South and Central America. Their share in the Asia-Pacific region was only about one-third of the total, but it is expected to rise. Many adhesive suppliers augment their sales with related products, which can include sealants, binders, construction products, electronic potting and encapsulating compounds, coatings, etc. Although the supplier base in large-volume end uses is concentrated, the wide range of end users, applications and technologies yields thousands of suppliers and an environment where novel technologies thrive. The above information is based on The Global Adhesives Industry, a new study by Steven Nerlfi, Minesh Kusumgar, and Michael Growney. For more information, phone (201) 7730785, e-mail
[email protected] or visit www.kusumgar-nerlfi-growney.com.
Figure 4. Adhesives Consumption by Type, 2009 ($20.6 Billion Total)
January 2011
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12/15/09 3:08:47 PM
By Marjorie Miller, Principal Partner, The Miller Group Resource Information Xchange, LLC
Maximizing
the R&D Tax Credit
I
n order to keep investment from going offshore, U.S. policymakers created incentives for domestic companies to keep jobs and capital in America. One of these incentives is the research tax credit, better known as the R&D tax credit. Every successful company is potentially eligible for R&D tax credits in some amount. This is especially true for companies with increasing revenues and expanding markets. The perception exists among many businesspeople that only high-tech activities qualify for the R&D tax credit. Companies in many industries are surprised to discover that much of what they do to keep their businesses profitable and growing also qualifies them for significant tax credit benefits. Opportunity is especially broad for manufacturing operations. Creating new and improved products, developing new processes (or improving existing processes), implementing new manufacturing systems, and writing software for internal use are
Much of what manufacturers do to keep their businesses profitable and growing also qualifies them for significant tax credit benefits. just some of the expenses that qualify for the credit. Under current U.S. Internal Revenue Service (IRS) rules, these activities—and many others—can result in substantial R&D credit dollars if they are properly identified and documented.
WHAT IS THE R&D TAX CREDIT? The R&D tax credit was created by Congress as part of the Economic Recovery Tax Act of 1981 to encourage American industry to invest in research and development activities. The purpose of the credit was to stimulate R&D activities among businesses through tax incentives. To understand the complexity of the R&D tax credit, consider the fact that it was enacted in 1981 as a temporary credit. Since that time, it has expired 14 times and been
extended 13 times, often retroactively, over its almost 30-year history. It took the Treasury over 23 years to issue final regulations defining qualified research activities. In addition, multiple methods are used to compute the credit based on a company’s fact pattern and elections made as long ago as 1984. Recently, President Obama unveiled an economic plan that includes improvement and expansion on the R&D tax credit. He also proposes to make the credit permanent. Though nothing is certain, experts say it is likely that the credit will be extended at least temporarily, given its bipartisan popularity and job creation appeal. As such, now is a good time for companies (especially those that may not have taken advantage of the credit before) to
*On September 27, 2010, President Obama signed into law H.R. 5297, which includes significant modification in the law for both corporations and business owners with respect to their utilization of general business credits. Prior to this new law, the maximum amount of general business credits that a company or individual business owner could utilize in a given year could be no greater than the amount that their regular tax exceeded their alternative minimum tax (AMT). Also, if their AMT exceeded their regular tax, they could not utilize any general business credits. With the enactment of H.R. 5297, these limitations no longer exist. General business credits can be utilized up to the full amount of the corporation or individual’s tax liability. In addition, the new law allows for a carryback of 2010 general business credits to any of the previous five years, whereas the previous law only allowed for a carry-back of one year. It is important to point out that H.R. 5297 only applies to general business credits in the 2010 tax year and that you cannot offset AMT if you are carrying back credit from the 2010 tax year to one of the previous five years.
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January 2011
determine whether they could qualify. In fact, no matter what happens politically on the federal level, companies should keep in mind that many states offer similar R&D tax credits. Federal and state tax credits provide permanent benefits to reduce tax rates and generate cash flow. The R&D tax credit is a dollar-for-dollar credit against taxes owed or taxes paid. A company can take advantage of the tax credit for all its open tax years (the three past tax years, plus the current year). A business may go beyond this time period if it has former net operating loss (NOL) or tax years open by agreement. As part of the general business credit, the R&D tax credit can now be carried back to offset past year’s taxes and carried forward for 20 years.*
HOW DO YOU GET YOUR FAIR SHARE? The first step is to determine if your business qualifies for the R&D tax credit, which can be a challenge for businesses because the R&D tax credit regulations are complex and illogical. The reality is that tax laws are not written by businesspeople. Once written and passed by Congress, tax laws are transformed into elaborate tax regulations by the IRS. Accountants or tax preparers who do not specialize in the R&D tax credit often find it difficult to interpret the regulations and assist their clients in claiming their R&D tax credits. Frequently, these tax preparers mistakenly conclude that their clients do not qualify for the R&D tax credit when they actually do. Consequently, companies often lack the resources to provide the requisite mechanism for documenting and keeping their credits. In order to qualify for the credit, a product or project must satisfy the four-part test specified in Internal Revenue Code (IRC) §41.** Congress has enacted a very broad definition of qualified research activity. It is much more expansive than the academic definition of research and development. Examples of initiatives that may be eligible for the R&D tax credit include those which: • Increase overall knowledge or capabilities, where the information on how to do this is not in the public domain. • Create or appreciably improve a process, material, device, product or service; or duplicate an existing process, material, etc., but in a new or appreciably improved way. • Attempt to achieve desired geometry at the limit of the material’s formability. • Result in the development of a formed material, part of which would meet the required form while achieving deformation requirements under impact and conforming to manufacturing constraints. A significant number of prototypes and eligible consumable materials were also associated with these development areas.
The second step in claiming the R&D tax credit is to identify and gather qualified research expenditures (QREs), which fall into three specifically defined categories: • Wages: Taxable wages incurred for employees involved in qualified activities are eligible. This includes direct involvement, direct supervision and direct support of the R&D activity. • Supplies: Qualified supply expenses include tangible supplies that are used up in the R&D activity. Depreciable assets are not qualified supply expense. • Contract research: Amounts paid to third parties for direct involvement, direct supervision or direct support of R&D activities are eligible. Qualified contract research costs are included at 65%. The next step is to calculate your R&D tax credit. In recent years, companies basically have two tax credit options: the regular research credit (RRC) or the alternative simplified credit (ASC). The RRC is complicated, and it involves looking at expenses over a historical period (1984-1988), taken as a percentage of revenue, and comparing that to your revenues and how much you are spending now. The RRC is allowed for spending in excess of a specified base amount—a ratio of R&D to sales expenses. Firms that existed from 1984 to 1988, the base period, receive a 20% credit on R&D. For newer firms, the credit is calculated on a sliding scale. The simpler ASC became available in 2007. It replaces the alternative incremental research credit (AIRC), which was available for QREs paid or incurred on or before December 31, 2008. The ASC is a 14% credit for expenses in excess of 50% of R&D expenditures
**There is a four-part test for the R&D tax credit: 1. Eliminate uncertainty: eliminate uncertainty concerning capability, methodology or appropriateness of design [IRC 41(d)(1)(A)]; 2. Technological in Nature: Discover information that fundamentally relies on the principles of physical science, biological science, computer science or engineering [IRC 41(d)(1)(B)(i)]; 3. Permitted Purpose: Develop a new, or improve an existing function, performance, reliability, quality or significant cost reduction [IRC 41(d)(1)(B)(ii)]; 4. Process of Experimentation: Substantially all the activity constitutes elements of a process of experimentation [IRC 41(d)(1)(C)].
January 2011
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MAXIMIZING THE R&D TAX CREDIT
Automated Metering and Dispensing Technology
averaged over the firm’s three preceding tax years. This allows a firm to continue receiving the credit even if its research costs remain static or decrease. Companies should carefully evaluate which of the two credit calculation methods, the RRC or the ASC, yield the best results for their particular situation. For example, if a company has a high base amount under the RRC, has incomplete records to determine the base period, has significant growth of gross receipts in recent years, or a complex history of organizational activity (e.g., acquisitions, mergers, dispositions), it may benefit from using the ASC method.
is one litmus test, but another test investigates how secure the documentation is after it is reported. If supporting documents are created and then edited and modified after the fact, the data’s integrity is lowered. Finally, accuracy and completeness are paramount. A documentation system is only as good as the information fed into it. If data is incomplete, not supported by other activities or occasionally incorrect, an examiner will assume that most (if not all) of the documentation is of the same quality. Retaining your research tax credits under review is straightforward if you prepare from the beginning for these challenges.
BE PREPARED HOW DO YOU KEEP YOUR FAIR SHARE?
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Properly documenting your R&D tax credit is critical. Section 41 allows project accounting or cost-center-based accounting. Companies that use project-based accounting may have an easier time matching a qualified activity to its QREs, but this approach may not include all the qualifying costs. It is great news to receive the credit, but losing the credit under review by taxing authorities is intolerable. If a company wishes to sustain its R&D tax credit treasure trove under review, it is crucial to demonstrate the highest level of quality in the collection, substantiation, and calculation of the research tax credit from the very beginning. The research tax credit is now a tier 1 issue for the IRS. As a result, IRS examiners are severely adjusting research tax credit claims, even for companies in highly technical industries. Federal and state reviews have become much more onerous and contentious. The IRS has a bias against research credit projects that use a “look back” methodology. The IRS wants to see research credit claims that utilize contemporaneous documentation. By this, they mean documentation that is collected from several sources in real-time to the QRE being performed. Examiners also look at the integrity (i.e., reliability) of the documentation. Being created and collected contemporaneously
Manufacturers need to look at the way they record expenses and develop a methodology for quantifying associated costs with creditable projects. It is becoming more challenging to retain research tax credits under IRS §41 audits, but the best defense is a great offense. Prepare from day one by collecting data “contemporaneously” from a wide range of sources; guarantee the “integrity” of your documentation by demonstrating that every document is untouched from the day it was created; and ensure “accuracy and completeness” by collecting a variety of supporting data from an unlimited number of sources and linking that data so an auditor can quickly and easily drill down electronically into any QRE to verify the most finite level of documentation. One option may be to consider a technological solution that addresses and responds to the problematic characteristics of the research tax credit indicated by taxing authorities. For more information, contact The Miller Group Resource Information Xchange, LLC at 3250 Pt. White Dr. NE, Bainbridge Island, WA 98110; call (206) 619-9500; e-mail
[email protected]; or visit www.rixtechnology.com.
Disclaimer: As provided in Treasury Department Circular 230, this article is not intended or written by The Miller Group Resource Information Xchange, LLC, to be used, and cannot be used, by a client or any other person or entity for the purpose of avoiding tax penalties that may be imposed on any taxpayer.
January 2011
WHAT’S NEW RAW MATERIALS
SPRAYMATION STAINLESS STEEL PUMPS
CVC THERMOSET SPECIALTIES
This company has improved its stainless steel pumps with several new features that can be added to most existing pumps during normal maintenance at Spraymation. The equipment offers equal fluid pressure on the up and down stroke. All wetted parts are constructed of stainless steel, and various configurations and ratios are available to suit the application. Clear inspection windows allow users to easily observe seals or packings during operation, and an exhaust muffler can reduce sound levels. Web: www.spraymation.com
GLYCIDYL ESTERS
This company, an Emerald Performance Materials company, has introduced a new glycidyl ester product line. The patent-pending technology addresses a need in the marketplace for impact modifiers that deliver both high peel strength and high impact strength while maintaining a high Tg in the epoxy matrix. The new products can provide effective alternatives to traditional core-shell and high-molecular-weight non-epoxy type polyols used as impact modifiers, which may offer either high impact or high peel adhesion but typically are not delivered optimally. Web: www.cvc.emeraldmaterials.com
EQUIPMENT BROOKFIELD ENGINEERING TEST FIXTURES
A number of new test fixtures are now available for use with the CT3 texture analyzer, including the TA-STJ syringe test fixture. From vaccines to
January 2011
dental adhesives, many injectable products are now distributed in pre-filled syringes, which must allow for good flow control during discharge. The TA-STJ allows manufacturers to precisely measure the force required to push or pull the syringe plunger. The syringe test fixture features both compression and tension modes that allow manufacturers to complete a range of tests. Phone: (800) 628-8139 Web: www.brookfieldengineering.com/products/texture-analysis/ ct3.asp
Have Product News to Share with the Industry? E-mail news releases to Teresa McPherson at
[email protected].
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SERVICES MARKETPLACE L A B O R AT O R Y & T E S T I N G S E R V I C E S C O N S U LT I N G S E R V I C E S Haas Technical Consulting ........................................................................... 44
D I S T R I B U T I O N S E RV I C E S Heigl Technologies ...................................................................................... 44
L A B O R AT O R Y & T E S T I N G S E R V I C E S Chemsultants International Network ............................................................ 44
M A N U FA C T U R I N G & P R O C E S S I N G S E R V I C E S Polymeric Systems, Inc. ............................................................................... 45
P R I VAT E L A B E L I N G S E R V I C E S The Ruscoe Company .................................................................................. 44
C O N S U LT I N G S E R V I C E S
This index is a feature maintained for the convenience of the advertiser. It is not part of the advertiser’s contract, and ASI assumes no responsibility for its accuracy.
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Adhesives & Sealants Industry 5/21/09 9:38:43 AM
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12/1/10 9:25 AM
ASK
AD INDEX
DR.DAVE
QUESTION: We are a manufacturer of measurement (e.g., pressure) sensors and use a range of adhesives and potting agents during the assembly of our products. We would like advice on how best to use these adhesive materials, which include single- and two-component epoxies, as well as silicones (both addition and condensation/alkoxy types), cyanoacrylate adhesives, and anaerobic threadsealing compounds. Various combinations of these materials are used in close proximity during manufacturing, and we sometimes notice that the curing products of one adhesive affect the cure of another. However, these effects are rather ill-defined and difficult to prove, and many other factors may or may not be involved (e.g., correct mixing ratio and application, cleanliness, etc.). Is this cross-interference between different kinds of adhesives a known problem in the industry? If so, are there guidelines on best practices in the use of multiple kinds of adhesives and potting compounds? For example, is it recommended to handle different adhesives physically apart from one another, possibly using a fume extractor hood? ANSWER: I have seen quite a few problems over the years caused by similar situations to yours. First, I would recommend Silicones can that you keep silicones away from all of your other adhesives. While useful adhesives and sealcondense on ants in their own right, most silicones contain small amounts of volatile components and tend surfaces and cause to “creep” all over the production environment. The silimany problems. cones can condense on surfaces and cause many problems with adhesion of the other adhesive technologies. Second, be careful of things like amine hardeners that are used with the epoxies. These can cause the premature curing of cyanoacrylates, in particular, and can also speed up the cure of anaerobic adhesives. You should bear in mind that the maximum properties of a particular adhesive can be strongly influenced by how quickly or slowly they cure; external influences on the cure rate should be eliminated wherever possible. The real solution to the problem is to use the different technologies in separate rooms or in separately ventilated environments. Your idea of using fume hoods is a very good one.
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[email protected]
4
Dr. Dave Dunn is a former vice president and director of Loctite Corp. and has spent many years troubleshooting adhesive and sealant problems in the adhesives, sealants, specialty rubbers, and plastics fields. Questions for publication should be directed to him at 242 Trails End, Aurora, OH 44202; (330) 562-2930; FAX (330) 247-1690; e-mail
[email protected]; or visit www.fldenterprises.com. Any views or opinions expressed in this column are those of the author and do not represent
This index is a feature maintained for the convenience of the advertiser. It is not part of the advertiser’s contract, and ASI assumes no responsibility for its accuracy.
those of Adhesives & Sealants Industry, its staff, Editorial Advisory Board or BNP Media.
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January 2011
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