Paint & Coatings Industry February 2012

February 2012 VOLUME 28, NUMBER 2

INSIDE New Waterborne Technologies

Paint

Coatings Industry

Using DOE to Develop Coatings Advancing Pump Technologies

Globally Serving Liquid and Powder Formulators and Manufacturers

Architectural Coatings

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Markets:

Architectural Coatings

Industrial Coatings

Container Automotive

Civil Aerospace Engineering

Coatings Technologies:

SolventBorne Coatings

WaterBorne Coatings

Powder Coatings

Surface/Substrate:

Wood

Brick

Concrete

Marine & Maintenance

UV Coatings

Metal

Stucco

High Solids Coatings

Vinyl

Plastic

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

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

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performance loves low voc Concerned that moving to lower VOC 2K coatings will sacrifice excellent durability and resistance? Joncryl® OH 8313 in your 2K, water-based coating formulations is a low VOC alternative that delivers performance approaching that of standard solvent-based coatings. At BASF, we create chemistry. basf.us/dpsolutions

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CONTENTS PA I N T & C O AT I N G S I N D U S T RY, V O L U M E 2 8 , N U M B E R 2

February 2012

FEATURES 24 Advancing Pump Technologies in Coatings,

Wilden Pump & Engineering Co. 28 New Antimicrobial Meets Performance and

Low-VOC Requirements, Dow Microbial Control 35 Applying Statistical Design of Experiments

to VAE-Based Coatings Development, Forbo Bonding Systems 42 Defoamers and Wetting Agents for Waterborne

Alkyd Coatings, Air Products and Chemicals, Inc.

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ONLINE FEATURES www.pcimag.com Polyaspartic Gelcoat Technology Makes a Splash in Water Park Industry, Bayer MaterialScience LLC An Approach to Setting Standard Criteria for Green Additives, BYK-Chemie GmbH Intelligent Data Logging Operations, CAS DataLoggers, Inc. New High-Tech Microcorrosion-Inhibiting Coating, Cortec Corporation Simplifying Entangled Polymer Synthesis, Malvern Instruments Ltd.

DEPARTMENTS 6 Viewpoint 8 Industry News 14 Calendar of Events 16 Company News 22 Names in the News 52 Finishing Today News 56 Products 60 Classifieds 62 Advertiser Index

54 Chemically Bonded Phosphate Ceramics,

ON THE COVER:

EonCoat, LLC

Photo from photos.com.

BUSINESS TOOLS 58 Supplier Showcases

PCI - PAINT & COATINGS INDUSTRY (ISSN 0884-3848) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2012, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: PCI - PAINT & COATINGS INDUSTRY, P.O. Box 2145, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to PCI - PAINT & COATINGS INDUSTRY, P.O. Box 2145, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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Innovation and Technology Abound at International Auto Show in Detroit The world’s top automakers unveiled their latest models at the recent North American International Auto Show in Detroit. During the press preview days, Associate Editor Karen Parker and I had the opportunity to meet with Paul Czornij, Technical Manager, Color Excellence Group, and Stacey Russell, Marketing Communications Manager, BASF. BASF’s automotive coatings portfolio includes OEM and automotive refinish coatings. The company’s modern paint processes, combined with its special-effect pigments and technologies, result in a full-breadth of color solutions and development capabilities. Innovation and technology were clearly the focus at the company’s 4,500-squarefoot supplier exhibit. Czornij explained how BASF’s researchers have combined new technology with current trends to develop unique automotive colors, gloss levels and textures for the 2015 model year. Color trends point to a desire to go back to our roots, and are exhibited in BASF’s colors, which have a Native American feel with turquoise, earth tones and non metallics. Another trend is with pastels. Silver, grey, black and white are popular automotive colors around the world. The popularity of these elegant, sophisticated colors is linked to the surge in technology seen in so many other consumer areas. BASF has introduced a twist, however, by adding a hint of color to these, giving metallic colors with a splash of pastel tints. In addition to developing new colors, BASF researchers have focused on the company’s ColorFuse™ technology, an advanced coating technology that provides a highly efficient, integrated painting process via the integration, or “fusion,” of the traditional basecoat and clearcoat into a single coating layer. Using technical advancements, a coating system was developed with excellent appearance, physical properties and outdoor durability. Using this technology reduces material usage and lowers VOC emissions. We found the most interesting element of the BASF showcase to be a display showing the company’s Imager technology. With this technique, images can be embedded within the coating, using the effect of a magnetic field to generate shapes, words and the like. Coatings can then contain a fresh or personalized look, which arises from flaked effect pigments orienting to form the desired image. Depending on the strength of the orientation, the image comes from the difference in light reflection from certain viewing angles. The Auto Show is always an exciting event here in Detroit. It is great to be able to see all of the innovative ideas for the automotive coatings of the future!

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INDUSTRY NEWS PPG Shows the Power of Coatings at North American International Auto Show companies reduce vehicle weight. It also DETROIT – As the North American International reduces OEM energy consumption and CO2 Auto Show in Detroit shifted into full gear, the buzz in the industry continued around fuel effiand VOC emissions. The product is being ciency, CAFE standards and how car companies used in the United States and the Asiaare responding to demands for more sustainable Pacific region and is slated to be rolled out vehicles. At a press conference prior to the show’s in Europe and South America in 2012. opening, representatives from PPG showed how Another product showcased by Knavish was the company’s innovations help improve many the company’s new low-bake coating system parts of a car, from environmentally friendly elecfor plastic parts, such as bumpers and fascia. trocoat to more compact paint systems. The new one-component paint system allows Cindy Niekamp, Senior Vice President, Automanufacturers to eliminate a booth in the motive OEM Coatings, kicked off the press conpaint process, offering a less complex process, ference with a discussion of PPG’s commit- PPG’s Cindy Niekamp. lower energy costs and improved appearance. ment to innovation. Niekamp noted that the Rick Zoulek, General Manager, Industrial company has been awarded an R&D 100 Award nine times in Coatings USCA, discussed the company’s zinc-rich primer with the last 14 years and has received an Automotive News PACE Framecoat®. The primer facilitates OEM designs with reduced Award six times in the last 10 years. And while she presented vehicle weight. Its superior corrosion resistance allows for thincars at the Auto Show that feature PPG colors, including the ner gauge steel, which reduces vehicle weight, helping designChevrolet Spark’s Techno Pink and the Dodge Dart’s Redline, ers meet CAFE mpg requirements. she also pointed out that PPG provides more than color to the During his presentation, Knavish gave a glimpse into automotive industry, helping car companies achieve efficiency, what’s in the R&D pipeline for automotive coatings. New energy conservation and light-weighting. projects include OEM coatings for lightweight materials that Tim Knavish, Vice President, Automotive OEM Coat- provide improved appearance, cycle times and durability. ings, introduced Enviro-Prime ® 7000 Electrocoat, which Coatings are being designed for materials such as carbon fiber offers improved corrosion protection while reducing and fiberglass substrates, aluminum, and high-strength steel. excess. The new product offers 20-30 percent exterior The company is also working on adapting a lightweight 2K usage reduction with the same coverage for recessed/ adhesive, which was originally designed for wind turbine interior areas. This optimized material usage helps car blades, for automotive lightweight materials.

Study Indicates Slowdown in EU Alkyd Resins Market LONDON – According to a new BAC report recently published by MarketPublishers.com, demand for acrylic resins in the European Union (EU) is trending downward. In 2010, the demand amounted to 471,800 tons. Within the 2006-2010 period, alkyd resins consumption decreased by 30 percent. The decline is caused by the economic challenges of the last few years and the decline in demand for acrylic coatings in favor of more environmentally friendly materials. EU producers are working mainly to cover the domestic market, while export supplies share 7-10 percent in total output. Therefore, a decrease in demand domestically leads to a decline in domestic production. Germany covers 37 percent of EU production and consumption of alkyd resins. The other significant Western European manufacturing facilities are concentrated in Italy and France. For additional information about the report, Alkyd Resins: European Union Market Outlook 2011 and Forecast to 2016, visit http://marketpublishers.com.

EPA Releases Formerly Confidential Chemical Information WASHINGTON, DC – The Environmental Protection Agency (EPA) is making available to the public hundreds of studies on 8

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FEBRUARY 2012 | W W W . P C I M A G . C O M

chemicals that had been treated as confidential business information (CBI). The move is part of EPA’s plan to make public the chemicals that are not entitled to CBI status. In 2010, EPA issued new guidance outlining the agency’s plans to deny confidentiality claims for chemical identities in health and safety studies under the federal Toxic Substances Control Act (TSCA) that are determined to not be entitled to CBI status. EPA has been reviewing CBI claims in new and existing TSCA filings containing health and safety studies. Consistent with the guidance, the agency will request that the submitter voluntarily relinquish the CBI claims and make the studies available to the public. EPA also challenged the chemical industry to make available information that was previously classified as CBI. To date, more than 35 companies have agreed to review previously submitted filings containing health and safety studies and determine if any CBI claims may no longer be necessary. The newly available information can be found under a new “declassified tab” using EPA‘s Chemical Data Access Tool.

U.S. Coatings Consumption Worth $23 Billion in 2011 ELMWOOD PARK, NJ – According to a soon-to-be-released study by the consulting firm Kusumgar, Nerlfi & Growney, U.S. consumption of coatings in 2011 is projected to be 1.4 million

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INDUSTRY NEWS gallons, containing 7.8 billion pounds of solids, worth $23 billion. The industry saw its peak consumption in 2006 and has only partially recovered from the lows of the 2008-2009 recession. In 2011, coating solids remain down 18 percent from the 2006 peak. A 1.5 per-

cent annual rate of increase is forecast for coating solids through 2016. Coating consumption in dollars is only 3 percent lower compared to 2006, due to the sharp rise in prices during 20102011. Coating raw material price escalation has only partially been passed along

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by coating producers, and margins have come under pressure. Architectural coatings are the largest segment, with some 3.9 billion pounds of solids worth $9.1 billion expected to have been consumed in 2011. Coating demand from original equipment manufacturers (OEM) in 2011 is projected at 1.98 billion pounds of solids, valued at nearly $8 billion. OEM coatings have rebounded strongly since the recession, but many end uses are still down significantly from 2006. Special-purpose coating consumption in 2011 is expected to be 1.95 billion pounds of solids, with a sales value of $6 billion. For more information about the study, The U.S. Paint & Coatings Industry, 2011-2016, visit www.kusumgar-nerlfigrowney.com.

New Network Helps Manufacturers Go Green ROCKFORD, IL – The Fabricators & Manufacturers Association, Intl. (FMA) is inviting manufacturing executives to join its new Green Manufacturer Network, a professional organization of individual members working together to drive the transition toward environmentally friendly manufacturing. “The mission of the Green Manufacturer Network is to be the principal resource to advance sustainable manufacturing,” said Edward Youdell, President and CEO of the FMA. Members of the group receive discounts on conferences, workshops and webinars; helpful event announcements and topical discussions; and access to sustainability resources. For additional information, e-mail [email protected].

Wood Coatings Research Group Offers Training Program HIGH POINT, NC – The Wood Coatings Research Group has announced its 2012 Wood Coatings Technology Training Program. The Practical Wood Coatings Formulation and Application course is a threeday intensive training program combining both lecture instruction and laboratory demonstration. For more information, visit www.woodcoatingsresearchgroup.com/ training.html.

Unique Workshop Being Offered SAN DIEGO – Ray Fernando of Cal Poly and Don Sundberg, President of Emulsion Polymers Consulting and Education LLC,

INDUSTRY NEWS

are offering a new workshop that focuses on the rheology of synthetic latices and the formulated dispersions that are created from them. The workshop will take place March 21-23, 2012, at the San Diego Training and Conference Center in San Diego, CA. For additional information, e-mail [email protected].

ASTM News

New Standards Available From ASTM W. CONSHOHOCKEN, PA – A new ASTM International standard provides a test method for measuring volatiles from acrylate resins, which will allow suppliers to list emissions information on material safety data sheets. The new standard, ASTM D 7767, Test Method to Measure Volatiles from Radiation Curable Acrylate Monomers, Oligomer, and Blends and Thin Coatings Made from Them, is under the jurisdiction of Subcommittee D01.21 on Chemical Analysis of Paints and Paint Materials, part of ASTM International Committee D01 on Paint and Related Coatings, Materials and Applications. “Current methods for measuring volatiles from UV-curable coatings require that the material be coated on a substrate at the end-use thickness and cured per the manufacturer’s specification,” said Robin E. Wright, Staff Scientist, 3M Corporate Research Process Laboratory, and a member of D01.21. “The raw materials used in these coatings are not designed to be applied and cured alone, so there is no prescribed application thickness or cure condition. ASTM D 7767 provides the necessary specifications to repeatedly and reproducibly measure volatiles from these raw materials.” Increasing interest in the various uses of electrical contacts is the leading impetus for the development of a proposed new standard, ASTM WK 34423, Specification for Electrodeposited Coatings of Palladium-Cobalt Alloy for Engineering Use. The proposed standard is being developed by Subcommittee B08.08 on Metallic Coatings, part of ASTM International Committee B08 on Metallic and Inorganic Coatings. According to Sheikh H. Rahman, Lear Corp., and leader of the task group that is developing ASTM WK 34423, having a high temperature limit is an important advantage of palladium cobalt plating. “Currently, the highest temperature that can be achieved for an electrical contact is 165 to 170 °C through silver plating,” said Rahman. “The palladium cobalt plating will boost this temperature from 170 to 395 °C.”

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Updated Edition of ASTM Manual Available W. CONSHOHOCKEN, PA – Paint and Coating Testing Manual: 15th Edition of the Gardner-Sward Handbook is now available from ASTM International. A total of 79 comprehensive chapters, written by experts in their various fields, reflect the new and updated technologies within the coatings industry in the 16 years since the last edition was published. The heavily updated new manual describes briefly and critically most ASTM test methods that are significant in the world of paint technology. New and updated topics include measurement of gonioapparent colorants, surfactants, powder coatings, understanding osmotic activity in coatings, coalescing aids, radiation-curable powder coatings and more. For additional information, visit www.astm.org.

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INDUSTRY NEWS OBITUARIES Skip Klatt DEERFIELD, IL – Skip Klatt, long-time VP of Sales for American Chemet, passed away November 21, 2011. Klatt was an owner of American Chemet Corp., Deerfield, IL, and its subsidiary Royal Metal Powders, serving on boards and committees for more than 30 years. His vision and enthusiasm for the company led to its successful growth and diversification efforts during the past two decades.

Chuck Piske BELVIDERE, IL – Charles “Chuck” Alan Piske of Belvidere, IL, passed away Wednesday, November 23, 2011, in his home. Piske worked for Archway Sales for many years.

CICE to Take Place in June SHANGHAI, China – The dates for the 2012 China International Coatings Exposition (CICE) have been changed. The exposition will take place June 20-22, 2012, at the Shanghai New International Expo Centre in Shanghai, China. Visit www.coatshow. cn/yqh_en for additional information.

ICCE-20 Issues Call for Papers BEIJING – The 20th Annual International Conference on Composites, Nano or Metals Engineering, ICCE-20, has issued a call for papers. The event will take place in Beijing, China, July 22-28, 2012. Interested authors should submit tentative paper titles (changeable later) by e-mail to David Hui at [email protected]. For additional information, visit www.icce-nano.org.

Missouri S&T Offers Three Short Courses in 2012 ROLLA, MO – Missouri S&T (formerly UMR) will be offering three short courses in the spring and summer of 2012. “Basic Composition of Coatings” will be offered March 26-30, 2012. “Introduction to Paint Formulation” will be offered June 4-8, 2012. “Introduction to Coatings Composition and Specifications” will be offered July 18-20, 2012. For more information, visit http://coatings.mst.edu/index.html. 䡲

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CALENDAR Meetings, Shows and Educational Programs FEB. 13-17 Waterborne Symposium New Orleans www.psrc.usm.edu/waterborne 22-24 Smart Coatings Orlando, FL www.smartcoatings.org 28-29 RadTech Annual Winter Meeting Miami Beach, FL www.radtech.org

MARCH 7-9 Spray Finishing Technology Workshop Toledo www.owens.edu 11-14 SSCT 2012 Annual Technical Meeting St. Augustine, FL www.ssct.org 11-15 Pittcon 2012 Orlando, FL www.pittcon.org

12-14 The Middle East Coatings Show Dubai, United Arab Emirates www.coatings-group.com

22 Metropolitan New York Coatings Association Symposium East Rutherford, NJ www.mnypca.org

13-14 Professional Paint Formulation Hampton, UK www.pra-world.com

26-30 Basic Composition of Coatings Rolla, MO http://coatings.mst.edu/index.html

14-15 MN Paint & Powder Coating EXPO ’12 White Bear Lake, MN www.ccatc.com/expo.htm 20-22 FABTECH Canada Toronto, Canada www.fabtechcanada.ca 21-23 Rheology Fundamentals & Applications for Synthetic Latices and Associated Coating Formulations San Diego, CA [email protected]

27-29 WESTEC 2012 Los Angeles www.westeconline.com 27-29 UV/EB Technical Seminar Exton, PA www.sartomer.com/events.asp

APRIL 3 PSCT Technical Symposium Horsham, PA www.psct.org 10-12 ELECTROCOAT 2012 Orlando, FL www.electrocoat.org

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COMPANY NEWS DOE Commends OMNOVA Solutions FAIRLAWN, OH – OMNOVA Solutions received ved a letter of commendation from the U.S. Department ment of Energy (DOE) for the company’s achievementt of a 5.8 percent reduction in energy usage for 2010. As a partner in DOE’s Better Buildings, Better Plants program, OMNOVA has voluntarily developed internal targets to reduce its energy consumption by 25 percent over a 10-year period for all of its U.S.-based sed manufacturing locations. “OMNOVA Solutions’ most recent annual report eport showed a 5.8% reduction in energy intensity in n 2010, placing the company well on its way to meeting ting the pledge target,” wrote Dr. Leo Christodoulou, Program Manager for the U.S. Department of Energy. “Wee specifically acknowledge Mr. Doug Fox of OMNOVA’s LEAN AN SixSigma organization, who has worked closely with thee Department on this pubic/private partnership initiative.”

Under requirements of the program, OMNOVA has established energy baselines, developed an energyestablish management plan and designated an energy leader/ managem manager. manage The company must also report its progress to DOE on an annual basis. “We “W are proud to be a participant in the Better Buildings, Better Plants program in our Performance Chemicals and Bette Decorative Products businesses,” said Kevin McMullen, Decor OMNOVA Solutions Chairman and CEO. “As a leader OMNO in our ou served markets and responsible neighbor in the communities in which we operate, it is great to see com the th progress we’ve made in pursuit of this energy reduction goal. This is an important element of our Vision 2014 sustainability effort to reduce our environmental footprint. The leadership efforts of Doug Fox and other associates across our company have enabled us to identify potential areas for change and to enact sustainable practices.”

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FEBRUARY 2012 | W W W . P C I M A G . C O M

C OMPANY NEWS

Rockwood to Build Iron Oxide Pigment Plant in Georgia BELTSVILLE, MD – Rockwood Holdings Inc. announced that its Color Pigments and Services business will build an advanced technology production facility in Augusta, GA, for the synthesis of iron oxide pigments. This $115 million investment will result in the first new iron oxide pigment production plant in the United States in nearly 35 years. Construction of the facility is expected to take place over the next 18 months, with commissioning targeted for the first half of 2013.

Maryland, West Virginia, Ohio, Kentucky, Michigan, Indiana, Illinois, Missouri, Wisconsin, Minnesota, Iowa, Nebraska, North Dakota and South Dakota. Additionally, Archway will handle the plastics market for all states previously listed and the additional states of

Virginia, North Carolina, South Carolina, Georgia, Florida, Alabama, Mississippi, Tennessee, Louisiana, Arkansas, Texas, Oklahoma and Kansas. Active Minerals International LLC has appointed Archway Sales as a distributor for its full line of Min-U-Gel and Acti-Gel

Fischer Technology Opens Sales and Service Office in California WINDSOR, CT – Fischer Technology, Inc., announced the opening of an additional sales and service office located in San Mateo, CA. The Fischer West office, run by Jim Bogert, supports Fischer’s complete line of coating thickness, material testing, material analysis and micro-hardness instrumentation. Services such as onsite re-certification of handheld coating thickness gauges and bench-top X-ray fluorescence instruments, including repairs and preventive maintenance, are available at the location.

WACKER Expands Technical Center in Mumbai MUNICH, Germany/MUMBAI, India – WACKER has expanded its technical center in India. This center of excellence, located in Goregaon, a suburb of Mumbai, now includes laboratories, applications technology and test equipment for polymer dispersions for coatings applications. The expansion focuses on dispersions based on vinyl acetate-ethylene copolymers used as binders for interior and exterior paints, marketed under the brand name VINNAPAS®.

Archway Sales Announces Two New Distribution Agreements ST. LOUIS, MO – Archway Sales Inc. has been named a regional distributor for Clariant Corp.’s Pigments Business Unit in North America. Under the agreement, Archway will distribute Clariant’s full line of organic pigments, pigment dispersions and dyes to the coatings, printing and plastics markets for the states of Maine, New Hampshire, Vermont, Massachusetts, Rhode Island, Connecticut, New York, New Jersey, Pennsylvania, Delaware,

Whether processing, dosing, blending, or transfer, Wilden air-operated doublediaphragm pumps have been providing solutions for the paint and coatings industry since 1955. s 3PECIlCALLY3UITEDFOR7ATER "ASEDAND /IL "ASED0AINTS#OATINGS s 3UPERIOR&LOW2ATESTO LPMGPM s %ASEOF-AINTENANCE s ,ONGEST-EAN4IME"ETWEEN2EPAIR -4"2 s 0RO &LO8™WITH%FlCIENCY-ANAGEMENT 3YSTEM%-3 s 7IDEST"READTHOF-ATERIALS!VAILABLEIN the Industry s #LAMPEDAND"OLTED-ODELS!VAILABLE

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COMPANY NEWS attapulgite mineral-based thickeners and suspension products. Archway will distribute these products in Illinois (northern half), Michigan, Indiana, Kentucky, Wisconsin, Minnesota, Iowa, North Dakota, South Dakota, Texas, Oklahoma, Arkansas and Louisiana.

Evonik Announces Additional Capacity Expansion ESSEN, Germany – Evonik Industries plans to expand capacities for the specialty polymer polyamide 12. The group is significantly expanding its existing plant in Marl, Germany, and the Executive Board has approved preliminary and basic planning for a new polyamide 12 production facility in Asia. The 5,000-metric-ton capacity expansion in Marl is expected to start operating in 2012. The Asian facility, which will provide a very significant expansion of 20,000 metric tons, is scheduled for completion within three years.

Elcometer Expands in Europe MANCHESTER, UK – Following the successful November opening of its offices in Japan, Elcometer announced the expansion of operations in Western Europe. The company has completed expansion of its sales and service facilities in Germany.

LANXESS Expands Distributor Network PITTSBURGH – LANXESS Corp. announced that two of its North American distributors for Bayferrox® inorganic pigments will expand their territories.

Dowd and Guild Inc., currently focused on the Southwest United States, will take over additional responsibility for pigment sales in the Pacific Northwest region, to include Oregon, Washington, Idaho, Montana and Wyoming. LV Lomas Limited, the company’s current distributor in eastern Canada, will also add western Canada, including Manitoba, Saskatchewan, Alberta and British Columbia, to its territory.

Perstorp and PTT Global Chemical Sign JV Agreement GRENOBLE, France – At a ceremony in Grenoble, France, specialty chemicals company Perstorp and PTT Global Chemical (PTTGC) signed an agreement forming a joint venture dedicated to the manufacture and sales of aromatic (TDI) and aliphatic (IPDI, HDI and derivates) isocyanates. The agreement includes the former Perstorp Business Group Coating Additives with its manufacturing sites at Pont-de-Claix, France, and Freeport, TX. PTTGC will hold 51 percent of the joint venture, and Perstorp will hold 49 percent. Plans for the joint venture include expanded capacity at the manufacturing plant in Pont-de-Claix, France, and new capacity in Asia, including the investment in a new joint plant for HDI derivatives in Asia.

Cappelle Pigments Names Distributor for Canada ALPHARETTA, GA – Cappelle Pigments, Alpharetta, GA, has entered into an agreement with Ferguson Chemical Innovation to

C OMPANY NEWS

represent its pigment products in the Canadian market. Ferguson is a well-recognized entity in Canada, committed to serving the coatings, plastics, rubber and printing ink markets.

Evonik Industries Continues as Distributor of Shell GTL Sarawax ESSEN, Germany – Shell MDS and Evonik Industries signed a six-year contract for Evonik Industries to continue as Shell MDS’s distributor of Shell GTL Sarawax waxes (FT waxes) in Europe. Evonik will produce and sell modified GTL waxes globally with the brand name VESTOWAX®.

Lintech Partners With Clariant Corp. MACON, GA – Lintech International, LLC, is now the strategic distribution partner for the Clariant Additives and Clariant Pigments business units. Lintech will cover the entire southeast, southwest and western United States for both Clariant product lines. The Clariant Additives business unit offering will include polymer additives, waxes and flame retardants. The Clariant Pigments business unit offers an extensive line of products that includes organic pigments, dyes and pigment dispersions.

Heucotech Appoints Superior Materials, Inc. GARDEN CITY, NY – Heucotech Ltd., a Heubach company, announced the appointment of Superior Materials, Inc., Garden

City, NY, as sales representative and distributor in the Northeast for all graphic art, specialty ink, coating and adhesive industries. Superior will handle the territory that includes Maine, Vermont, New Hampshire, Massachusetts, Rhode Island, Connecticut, New York, New Jersey and eastern Pennsylvania.

Troy Receives BPD PT8 Authorization for Wood Preservatives FLORHAM PARK, NJ – Troy Corp. announced that the Danish Competent Authority (Danish Environmental Protection Agency) has granted BPD (Biocide Product Directive) PT8 master authorization for four Troy wood preservative products: TWP085, TWP077, TWP555 and TWP21. These products are fully formulated, ready-to-use preservatives offered licensefree to customers. Troy is now in the process of applying for mutual recognition and assisting customers in gaining local authorization for their brand-name products based on these master authorizations.

Partnership for Nano-Enhanced Products AKRON, OH/COLUMBUS, OH – Molecular nanotechnology company Zyvex Technologies, Columbus, OH, and NanoFusing LLC, a subsidiary of APV Engineered Coatings, Akron, OH, have announced a partnership to provide nano-enhanced concentrates and products to infrastructure markets and OEM industries.

The EnVia™ certification program from Arkema Emulsion Systems simplifies your sustainability efforts by providing a choice of coatings raw materials to meet your specific performance and regulatory benchmarks. Our range of EnVia™ certified products includes a variety of product chemistries – 100% acrylic, styrene acrylic, vinyl acrylic and vinyl acetate ethylene binders, and our new SNAP™ 720 Structured Nano-Acrylic Polymer – so you don’t have to compromise performance or value in your final product. And, with Arkema Emulsion Systems’ commitment to EnVia™ certification of all new products, there’s no time like the present to turn over a new leaf in your sustainability program.

sustain yourself.

Visit www.arkemaemulsionsystems.com/EnVia to learn more about the EnVia™ certification program. At Arkema Emulsion Systems, we’re focused on your future.

EnVia™ and SNAP™ are trademarks of Arkema Inc. ©2011 Arkema Inc.

arkemaemulsionsystems.com

COMPANY NEWS Leveraging the nanotechnology scientific resources of Zyvex and the manufacturing and nanotube dispersing expertise of NanoFusing LLC, the companies will produce custom carbon nanotube-enhanced concentrates. NanoFusing™, NanoFusing LLC’s proprietary CNT dispersing process, homogenously disperses carbon nanotubes into liquid resins and materials (host matrix) safely. The unique Kentera technology from Zyvex creates chemical bonds on carbon nanotubes, which allow them to connect to the host matrix, creating a sustained and stable bond between the molecules and materials.

Clariant Named Pigment Supplier of the Year MUTTENZ, Switzerland/SÃU PAULO, Brazil – Sitivesp, the Union of Paints & Coatings Producers of the State of São Paulo, Brazil, has named Clariant Supplier of the Year in the Pigment category of its annual award. This is the 17th time, in the 20-year history of the award, Clariant has been chosen as the best pigment supplier. The Sitivesp Supplier of the Year Award highlights the work done by companies that promote continuous improvements in the products and services offered to the coatings market.

Deacom Receives Best of Inventory Software 2011 Award WAYNE, PA – Deacom, Inc., was awarded the Best of Inventory Software 2011 award by product-review site FindTheBest.com for

its Integrated Manufacturing ERP Inventory Software. Deacom topped FindTheBest’s Smart Rated Inventory Software list by reaching a 100-percent score, one of four inventory software packages to achieve this rating out of the 48 systems reviewed on FindTheBest’s Web site.

Wilden Receives Top Chamber Business Award GRAND TERRACE, CA – Wilden® Pump & Engineering Co. has been selected as one of 55 businesses in California’s 63rd Assembly District, and one of five nominated by the Grand Terrace Chamber of Commerce, to receive an inaugural Top Chamber Business Award. Wilden Pump & Engineering is a leader and innovator of air-operated double-diaphragm pumps.

H.B. Fuller to Buy Industrial Adhesives Business ST. PAUL, MN – H.B. Fuller Co. has signed an agreement to purchase the global industrial adhesives business of Forbo Group, Baar, Switzerland. The business to be acquired represents about 80 percent (by revenue) of the Forbo Bonding Systems division of Forbo Group.

Honeywell Purchases Wax Technology From Evonik MORRIS TOWNSHIP, NJ – Honeywell has purchased Evonik Industries’ portfolio of manufacturing technology, including patents, for the production of polyethylene waxes used in a variety of applications, from coatings to adhesives and inks. 䡲

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Celebr r ates s

40 Ye ears

NAMES IN THE NEWS 䡲 Dow Coating Materials has named Jose Maria Bermudez as the new General Manager for North America. Bermudez will lead all aspects of Dow Coating Materials’ business in North America. 䡲 Brookfield Engineering Laboratories has appointed Eric Chiang Product Manager, Texture Analyzers. Chiang will replace Len Thibodeau, who recently announced his retirement.

as Senior Technical Engineer. Her work will focus on glass bubbles, ceramic microspheres and fluorochemicals.

Chiang

Collette

䡲 Plasticolors Inc. has named Lisa Collette Technical Service Applications Representative. Collette will provide direct technical support to customers in the polyurethane RIM, slabstock foam and elastomer marketplace. Sara Wischhusen has been appointed Colormatch Technician. Gittleman Wischhusen will formulate custom color matches for SMC/BMC, pultrusion, epoxy and urethane customers.

䡲 Micro Powders, Inc. has promoted David Gittleman to Director of Business Development. In addition to identifying the needs of the current product line and finding appropriate solutions, Gittleman will be responsible for expanding the business by identifying new markets, products and uses for the existing product line. Gittleman will also continue in his current role as Global Sales Director of the Personal Care Division of MPI.

䡲 Elcometer has appointed Philippe Marzin West European Regional Sales Manager. Marzin will be responsible for Elcometer European sales offices in the U.K., France, Germany, Belgium and the Netherlands, as well as the company’s Western European distribution network.

Wischhusen

䡲 Christine A. Gehres has joined Sudarshan’s Pigment Division as the new Vice President Global Marketing and Strategy. Gehres will lead the Pigment Division’s global marketing initiative. 䡲 3M announced that Lesbia Giron has joined the Energy and Advanced Materials Division U.S. Paints & Coatings team

䡲 VersaFlex Inc. has appointed Dudley J. Primeaux II to the newly created position of Director of Education and Development. Primeaux will lead the training program offered by VersaFlex, continue his role in new product development, and continue providing field and project consulting services. 䡲

AMAZING FINISHES DON’T JUST HAPPEN But we’ve had years of practice to perfect ours. Few specialty chemical manufacturers can offer the same level of performance or experience in the coatings industry. That has given us plenty of practice at perfecting an extensive line of additives to achieve that perfect finish. So don’t settle for anything less than a proven performer. When you need a high performance finish – toughness & durability, with excellent chip, chemical and corrosion resistance – turn to CVC Thermoset Specialties, the leader in thermoset materials for coatings:






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800.296.0040 t 856.533.3000 © 2009 Emerald Performance Materials, LLC

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FEBRUARY 2012 | W W W . P C I M A G . C O M

® Registered trademarks of Emerald Performance Materials, LLC. ™ Trademarks of Emerald Performance Materials, LLC.

Advancing Pump Technologies in Coatings Wilden® Advanced™ Series Metal PX1500 air-operated double-diaphragm (AODD) pump.

W

AODD enhancements help operators improve performance, product containment and energy efficiency

hile the first “paints” came from natural substances like charcoal, blood and berry juice, coatings are now comprised of a wide variety of highly stylized components using high-tech manufacturing processes. Most major enhancements in coatings manufacturing have taken place over the past 25 years. Spurred by these technological advancements, the market has evolved into one of the most diverse and important industries in the world. Coatings are now vital components in applications as varied as traffic marking, architectural, automotive and aluminum cans. Though the global recession, which hit the new-housing market exceptionally hard, saw the coatings market stagnate in 2007 and 2008, the first signs of an economic rebound saw coatings revenues grow by 2.1% in 2009 to reach a worldwide value of $110.5 billion. With future growth, the industry’s worldwide value is expected to be $128.6 billion by 2014. Opportunities abound for coatings manufacturers both at home and abroad. While this anticipated growth creates opportunities for manufacturers to increase production, the current realities of the manufacturing climate dictate that their production processes be as efficient and environmentally friendly as possible. With pumps playing a key role in all aspects of coatings manufacture, increasing operational efficiency through the utilization of pumps featuring advanced technology should be front-of-mind for the manufacturing facility operator. This article examines current challenges that must be overcome in maximizing production manufacturing processes and recent technological advancements in air-operated double-diaphragm (AODD) pump technology that can help manufacturers control costs, reduce

product loss, save energy, optimize uptime performance and meet environmental regulations.

The Challenge Today, a wide variety of pigments, additives and polymers (binders) are used to mass-produce uniform batches of paint. New, environmentally friendly, low-solvent and solventless formulations reduce VOC emissions, making the production and application of coatings safer. While pigments for paints were ground in stone mills 100 years ago, today sand mills and high-speed dispersion mixers are used to grind easily dispersible pigments. Because of these significant changes to the raw materials used in coatings production, the manufacturing processes have become a more refined science. To ensure the highest quality standards, coatings manufacturers must utilize robust equipment that offers the highest degree of flexibility and performance in terms of reliability, productloss prevention, environmental protection and energy efficiency, while retaining the versatility necessary to handle a wide variety of coatings components, all of which have their own unique handling characteristics. Coatings manufacturers generally fall into one of two camps: waterborne or solventborne producers. Both of these producers may use the same binders, pigments and additives in their products, but there is a major difference in the way they are constructed and perform: waterborne paints are typically water-based emulsions, while solventborne paints are most often oil and/or alkyd-based formulations. Whether waterborne or solventborne, the paints contain four basic components: pigments; binders (combine the paint’s constituents into a solution that cures into a film after application); liquids/solvents (a medium that allows the pigment and binder to be applied to the painted surface); and

By Edison Brito, Chemical Market Development Director, Americas | Wilden Pump & Engineering and Pump Solutions Group, Grand Terrace, CA 24

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FEBRUARY 2012 | W W W . P C I M A G . C O M

additives (provide specific paint properties, such as thickening, mildew/bacteria resistance, defoaming, etc.). This mélange of styles and components that are found in current-day coatings means that the producer must utilize manufacturing technology that is versatile enough to handle an array of raw materials in a way that maximizes production schedules, energy efficiency and product containment, all while meeting strict environmental regulations that govern the release of VOCs and hazardous air pollutants (HAPs) to the atmosphere during paint production and application.

The Solution Invented in 1955 by Jim Wilden as the solution for demanding utilitarian pumping applications that require a robust design, positive displacement AODD pump technology has grown to become the top choice for liquidhandling and transfer in a wide variety of industries, including coatings manufacture. AODD pumps are able to satisfy the demands of the industry because their design allows the product flow to stay constant with the speed of the pump, which is a major consideration in coatings production. Other benefits of AODD technology include its ability to be used in a wide range of pressure and flow specifications; self-priming and low-wear operation; ability to handle corrosive and abrasive solutions; improved energy efficiency; and overall low maintenance costs. In some large coatings manufacturing facilities, upwards of 200 to 300 air-powered pumps may be in operation at any one time. Thanks to recent technological advancements that Wilden Pump & Engineering LLC has made to its Advanced™ Series Metal AODD Pumps, these pumps are now designed to offer the best performance in coatings manufacture, optimizing production, energy savings and product containment. Operators of coatings manufacturing facilities are all about speed. They incorporate batch-type operations where the product being manufactured is mixed, then sent to a fill tank and fill line. They also have raw ingredients that are moved off of truck tankers or railcars, transferred to a storage tank, diverted to a mix tank based on the recipe required, moved to a day tank or fill tank, then finally transferred to a filling line. Because of this style of fluid-handling, AODD pump technology is used in every step of this process. They are ideal for these coatings manufacturing applications because: • • • • •

Most applications require less than 125 psi; Shear-sensitive fluids that can’t be agitated are always in use; Thick, viscous fluids are also constantly in motion; Leak-free operation is paramount; and Dead-heading occurs during filling operations, a task that motor-driven pumps are not able to handle effectively.

With these considerations in mind, Wilden offers a complete size range of Advanced Series Bolted AODD pumps. In addition, Wilden now offers bolted “drop-in” configurations in the following sizes: • 1-inch (25 mm) stainless steel and aluminum; • 1.5-inch (38 mm) stainless steel; • 2-inch (51 mm) stainless steel; • 3-inch (76 mm) stainless steel.

Rating AODD Performance When highlighting the performance capabilities of their products, manufacturers of AODD pumps often focus most specifically on what is called the pump’s “performance ratio.” This ratio is the number of gallons of product that are pumped per standard cubic foot per minute (scfm) of compressed air that is consumed. Since using compressed air is expensive, facility operators and engineers want this ratio to be as high as possible, which signifies that the pump is working at its efficient best. To optimize the performance ratio of its pumps, Wilden Pump & Engineering LLC has developed the Pro-Flo X™ Air Distribution System (ADS). The Pro-Flo X ADS features a patented Efficiency Management System (EMS) that allows the user, through the use of a control dial, to set the pump’s optimal flow rate for any application. For instance, turning the control to setting “4” on the Pro-Flo X ADS might achieve a pump output of 103 gallons per minute (gpm), but might take 77 scfm to achieve. That’s a performance ratio of 1.34 gallons pumped per 1 scfm consumed. However, if the user sets the Pro-Flo X ADS control dial to “2,” the pump’s output might be 64 Operators can use Wilden’s free PX gpm, but it will need only Simulator (www.wildenpump.com/see37 scfm to achieve it, which moregreen) to see how adjusting the is a performance ratio of dial on their Pro-Flo X ADS can improve 1.73 gallons pumped per the efficiency of their AODD pumps. 1 scfm consumed. This is a 22% increase in efficiency that not only reduces the amount of air that is consumed, but is also a reduction in wear on the pump components, which can double part life and reduce by 50% downtime, maintenance, labor and part costs. Or, consider this: A test was conducted involving a 2-inch AODD pump that did not have an EMS incorporated into its ADS versus one that did. The test was conducted using water as the media. The nonEMS pump was run at a 100 psig air inlet against a discharge pressure of 20 psig. At these conditions, the non-EMS pump used 130 scfm of compressed air to achieve a flow rate of 116 gpm. When the same test was conducted using an AODD pump with an EMS ADS, the same flow rate of 116 gpm was achieved while “dialing back” the air usage so that the pump was not running at maximum capacity. In this test, the AODD pump with an EMS ADS reduced the air consumption by 42% (or 54 scfm) at the desired flow rate of 116 gpm. So, while AODD pumps will always play a key role in the manufacture of coatings, only those that feature an ADS with an EMS option will allow the facility operator to reduce the consumption of costly compressed air while still achieving the flow and transfer rates that allow the plant to meet its production quotas. For more information on optimizing AODD pump performance, visit www.wildenpump.com/seemoregreen.

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

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Advancing Pump Technologies in Coatings

Drop-in Pump Configuration – Allows a pump to be installed in an existing footprint without the need to disturb the piping. These drop-in pumps have a larger flow path, resulting in increased flow rates and decreased energy consumption when compared with competing AODD pump technology.

Full-Stroke PTFE.

Pro-Flo X

Bolted Config

Wilden 1.5-inch bolted stainless steel pumps offer various advantages over standard AODD pumps, such their Pro-Flo X™ air-distribution system, bolted configuration and full-stroke PFTE diaphragms.

In addition, these pumps now come outfitted with new technologies that make them even more perfectly suited for coatings manufacture. These new features include: Pro-Flo X™ Air-Distribution System (ADS) – Provides operational flexibility through its patented Efficiency Management System (EMS™) that allows the user to optimize the ADS for any application demands regardless of pump size by using a control dial to select the flow rate that best suits the application. Bolted Configuration – Gives the pump better leak-containment and sealing properties at higher pressures when compared to traditional clamped configurations.

Easy Install Wil-Flex™ Diaphragms – Made of Santoprene®, these diaphragms are easy to install and are an excellent low-cost alternative to PTFE diaphragms when used in coatings applications that involve the handling of abrasives. Wilden has recently upgraded its Wil-Flex Diaphragms, introducing a flat-profile design that eliminates the need to invert the diaphragm when rebuilding a pump, which allows for easy, cost-effective installation. Additionally, this design enhancement increases the diaphragm’s flex life. The performance-enhancing operation of the upgraded Wilden Advanced Series pumps also equates into energy savings for the facility operator, as lower amounts of compressed air are needed to maintain desired flow rates and pressures (see Sidebar). All of these features combine to make Wilden’s Advanced Series Metal AODD Pumps the ultimate answer for all liquid-handling applications in coatings manufacturing operations.

Conclusion Manufacturers in every industry can no longer be solely concerned with meeting production quotas. As utility costs continue to rise, they must also take measures to guarantee that their operations run in the most efficient manner possible. Then, when all those operational parameters are met, they must also ensure that their production processes meet the tenets of increasingly strict environmental regulations. These unique, and growing, challenges are why many manufacturers, especially those in the coatings industry, are turning to pumping technologies that not only ensure production quotas are met, but that they are done so in the most cost-effective and environmentally sensitive manner possible. Wilden has recognized these challenges and has taken innovative steps to meet these demands through the technological enhancements it has developed for its AODD pumps, specifically the Advanced Series Metal AODD lines. These pumps are now designed to offer the best performance in coatings manufacture, performance that will optimize production, energy savings, product containment and environmental consciousness in one of the most Wil-Flex important industries on the globe. 䡲

Full-Stroke PTFE Diaphragms – The full-stroke design of these diaphragms results in increased product displacement per stroke, which translates into greater Drop-In Pump flow rates and higher efficiencies when compared with AODD pump Wilden 1.5-inch “drop-in” bolted stainless steel brands that rely on reduced-stroke pumps allow operators to drop-in replacement PTFE diaphragms. pumps without disturbing the piping. 26

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For more information on Wilden, visit www. wildenpump.com.

Troy Corporation provides paint and coatings manufacturers with the 'Key to Green Coatings' by offering ecological friendly products that are designed to meet or exceed the toughest performance standards without compromising sustainability, environmental sensitivity, or regulatory compliance. Troy is the leader in VOC and formaldehyde-free preservation and provides solutions for complex technical formulations. Troy develops and promotes sustainable technologies that satisfy wet-state and dry film material protection needs. Contact your local Troy representative to obtain your "Key to Green Coatings' and unlock your specific formulation solution.

Troy Corporation • 8 Vreeland Road • Florham Park, NJ 07932 USA • tel +1.973.443.4200 • fax +1.973.443.0843 Green Key Preservatives.indd 1

2/1/2010 1:42:09 PM

Green Key Preservatives.indd 1

2/1/2010 1:42:09 PM

New Antimicrobial Meets Performance and

Low-VOC Requirements

F

ungal spoilage and algal defacement of industrial and private structures has been an ongoing challenge to the coatings industry for decades.1 In recent years, dry film preservation, such as in-can preservation, has evolved such that today it requires formulation expertise paired with regulatory excellence and strict quality control. Due to increased awareness of the environmental impact of microbicides, stringent requirements have been set, which has resulted in fewer available options for dry film preservation. In addition, important attributes for dry film preservatives, such as low leachability, limit choices further. Additionally, paint manufacturers need support in their efforts to produce low- or zero-VOC coatings.2 Dow Microbial Control spearheaded new technology for dry film preservation by developing the active ingredient 4,5-dichloro-2-n-octyl-4-isothiazoline-3-one (DCOIT), which received the Presidential “Designing Greener Chemicals Award” in 1996 from the U.S. Environmental Protection Agency (EPA).3 More recently, DCOIT was recognized by the European authorities as the first active substance used in Product Type 21 (antifouling products) for which a positive recommendation for Annex I inclusion has been issued.4 This is further proof of the excellent

environmental profile of the active ingredient even in view of the most stringent regulations to date. The active ingredient and its metabolites are non-persistent in the environment, and the low solubility in water (3.5 mg/L)5 renders it an ideal film preservative, effective over years in low concentrations. The EPA-registered DCOIT is also a well-proven mildewcide, providing algaecidal properties. In certain cases, it has been demonstrated that it can contribute to bactericidal efficacy of in-can preservatives, especially against Pseudomonas sp. Its antifungal efficacy is excellent, particularly against Aureobasidium pullulans, which is recognized as the primary fungus responsible for mildew development.6 Longstanding successful products that benefit from the inherent properties of DCOIT are the 20% active formulations, ROZONE™ 2000 Antimicrobial and ROCIMA™ 200 Antimicrobial. BIOBAN™ 200, Dow Microbial Control’s new product incorporating DCOIT, takes dispersion development one step further, supporting manufacturers’ and consumers’ growing demand for lower VOC content. BIOBAN 200 also incorporates the proprietary stabilization technique used in ROCIMA 200. Due to technology enhancements, the product has been formulated with negligible VOCs

TABLE 1 | VOC determination in two latex flat interior paints, 5500 ppm BIOBAN 200 concentration. Samples Blank wb Paint 1 Paint 1 5500 ppm BIOBAN 200 Blank wb Paint 2 Paint 2 5500 ppm BIOBAN 200

Δ-Total Blk

ASTM 6886 % VOC BIOBAN200

0%

0

0%

0%

0.11%

0.11

0.11%

0

0.48%

0.48%

0

0%

0.43

0.48%

0.57%

0.09

0.09%

ASTM 6886 ASTM 6886 Total Texanol

Method 24

Water % (KF)

Δ (Meth 24-KF)

Δ – Blk

51.25%

50.24%

1.01%

0

0%

51.6%

50.43%

1.17%

0.16

57.16%

55.65%

1.51%

57.24%

55.3%

1.94%

By, Thomas Köhler, Dow Microbial Control, Buchs, Switzerland; Kenneth M. Donnelly, Dow Microbial Control, Spring House, PA; Claudinei A. Fava, Dow Microbial Control, Buffalo Grove, IL; and Gerhard Tiedtke, Dow Microbial Control, Buchs, Switzerland

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compared to ROCIMA 200, yet keeps its excellent performance characteristics in both exterior and interior coatings applications. It is formaldehyde-release free, does not contain heavy metal-based active ingredients and does not require ZnO for mildewcidal stability. BIOBAN 200 is an aqueous dispersion that is easily incorporated into coatings formulations and it is U.S. EPA registered for use in coatings.

Experiment Determination of VOCs in Two Water-Based Paints Formulated with BIOBAN 200 • VOC by U.S. EPA method 24.7 This involves heating the coating sample for 1 h at 110 °C and measuring weight loss not accounted for by the water content. • Water concentration was measured by Karl Fischer titration. • VOC by ASTM D 6886 test method8 involves dispersion/ extraction of a known weight of coating in tetrahydrofuran (THF) or acetone, use of an internal standard, and analysis by gas chromatography (GC) to quantify VOCs and exempt organic compounds, if any, present in the coating. Summation of the individual volatile organic compound weight fractions gives the total VOC content of the coating measured in weight percent. Table 1 shows the low contribution of BIOBAN 200 to the VOC content of two latex flat interior architectural paints.

Dry Film Efficacy of BIOBAN 200 Against Fungi by ASTM Method 55909 Experimental Preparation • Fungal spores were harvested from mature microorganisms grown on potato dextrose agar. • Organisms used in this study include: Aspergillus niger ATCC# 6275, Penicillium funiculosum ATCC# 11797 and Aureobasidium pullulans ATCC# 9348. • Each spore sample was adjusted to a concentration of ~2 x 106 spores/mL. Equal volumes of each spore suspension were pooled prior to sample inoculation (A. niger ATCC# 6275 and P. funiculosum ATCC# 11797 were tested as a pooled inoculum, whereas A. pullulans ATCC# 9348 was tested separately). Test Method • The samples were prepared by casting 3-mil wet films of the paint samples on Leneta™ drawdown paper and air dried for 24 h. • Two 1-inch strips were cut from each dry film. One set of strips was leached for 24 h with distilled water in 1-gal containers at a flow rate of six changes per day and dried again, while the other set remained unleached. • The coated strips samples were placed on potato dextrose agar. • 0.5 mL of the fungal inoculum was deposited directly onto the coated samples and evenly spread over the entire substrate/agar surface. • Agar plates were incubated at 30 °C, with high humidity, for the course of the experiment. Fungal Growth Measurement • Plates were scored at seven-day intervals over a 28-day period.

TABLE 2 | Dry film efficacy of BIOBAN 200 in three paint systems against fungal species (green colored data point = pass, red colored data point = fail). Unleached/Leached Samples accd. to ASTM D 5590

Sample A.niger/P. funiculosum Flat exterior paint - 5500 ppm BIOBAN 200 (as supplied) Flat exterior paint - 4000 ppm BIOBAN 200 (as supplied) Flat exterior paint unpreserved control Flat interior paint - 5500 ppm BIOBAN 200 (as supplied) Flat interior paint - 4000 ppm BIOBAN 200 (as supplied) Flat interior paint unpreserved control Semi-gl. ext. paint - 5500 ppm BIOBAN 200 (as supplied) Semi-gl. ext. paint - 4000 ppm BIOBAN 200 (as supplied) Semi-gl. ext. paint unpreserved control

Aureobasidium pullulans Flat exterior paint - 5500 ppm BIOBAN 200 (as supplied) Flat exterior paint - 4000 ppm BIOBAN 200 (as supplied) Flat exterior paint unpreserved control Flat interior paint - 5500 ppm BIOBAN 200 (as supplied) Flat interior paint - 4000 ppm BIOBAN 200 (as supplied) Flat interior paint unpreserved control Semi-gl. ext. paint - 5500 ppm BIOBAN 200 (as supplied) Semi-gl. ext. paint - 4000 ppm BIOBAN 200 (as supplied) Semi-gl. ext. paint unpreserved control

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• The readings at week four were used to determine sample pass/fail (see Table 2). Samples with scores of 0 or 1 were considered to have passed the test and are shown in green. Samples with scores 2 and above are considered a fail and are shown in red. • Scoring scale: No growth = 0; T Trace (<10% coverage) = 1; Light (10 - 30% coverage) =2; Moderate (30 - 60% coverage) = 3; and Heavy (60 - 100% coverage) = 4. The unleached as well as leached samples show the efficacy of BIOBAN 200 at 800 and 1100 ppm DCOIT active ingredient concentration against a mixture of A. niger/P. funiculosum and A. pullulans in two architectural paints. The unleached samples exhibit a maximum <10 PA I N T & C O A T I N G S I N D U S T R Y

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New Antimicrobial Meets Performance and Low-VOC Requirements

FIGURE 1 | Defacement evaluation in acrylic semigloss coating. 100 % Clean of Defacement

90 80 70 60

Blank

50

Bioban 200 (0.58%) (1100 ppm)

40

Competitive Fungicide (1520 ppm)

30 20 10 0 0

5

10

15

20

25

30

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Age (Months)

FIGURE 2 | Evaluation of overall defacement in acrylic semigloss coating after 30 months. Defacement 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%

Summary

Bioban 200 (0.58%, 1100 ppm DCOIT)

Clean of defacement after 30 months

Clean

Clean

Clean

Defacement

Defacement

Defacement

Blank

Competitive Fungicide (1520 ppm)

% rating, most specimens are clean of fungal growth. The untreated paints readily support fungal growth. The leached samples show the potency and low leachability of the active ingredient DCOIT. There are no significant differences between the leached and unleached series.

Outdoor Exposure Results A 100% acrylic latex semigloss paint was prepared. The formulation contained a TiO2 slurry as the sole pigment and used HEUR rheology modifiers to control viscosity. The final formulation had a pigment volume concentration of 22% with 34% volume solids. Various biocides were post-added to the finished paint with adequate agitation provide by an overhead laboratory mixer. Panel preparation was completed under controlled conditions. The primer used in these experiments was a biocide-free acrylic stain-blocking primer. One coat was applied to the white pine substrate followed by two coats of test paint. The cedar subs trate received two coats of primer. All paints were brush applied using a spread rate of 400 sq ft/gal, with 24 h between coats. All panels were exposed in Glen St. Mary, FL, in a north vertical (NV) orientation. 30

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Figure 1 shows the graphical evaluation of the overall defacement over time in an acrylic semigloss coating exposed in Glen St. Mary, FL, on primed white pine. After seven months, the blank sample deteriorated quickly to total defacement by 16 months. BIOBAN 200 showed just 10% defacement after 14 months and stabilized at 30% defacement after 30 months, whereas a competitive microbicidal active deteriorated quickly after 18 months (initially 5% defacement) to 60% defacement. Figure 2 exhibits a similar picture. Here, the substrate was changed to primed cedar, exposure conditions identical to Figure 1. After 30 months, BIOBAN 200 at 1100 ppm outperformed the competitive fungicide in higher concentration by far. Eighty five percent of the panels were free of defacement, whereas the competitive mildewcide deteriorated to a value similar to the untreated panel (25- 30% free of defacement). Again, the DCOIT-based BIOBAN 200 showed remarkable performance because of its inherent low leaching characteristics and excellent microbicidal efficacy.

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The proprietary stabilization of the active ingredient DCOIT paired with proven microbicidal efficacy and low leaching characteristics provides the remarkable performance characteristics of BIOBAN 200. Further, BIOBAN 200 supports the growing demand of architectural paint manufacturers and consumers for lower-VOC-content products. 䡲

References 1

2 3

4

5 6

7

8

9

Warscheid, T. Impacts of microbial biofilms in the deterioration of inorganic building materials and their relevance for the conservation practice, Internationale Zeitschrift für Bauinstandsetzen 2 (6), (1996) 493-504. Köhler, T.; Carlsen A.; Tiedtke, G. Breakthrough innovation for in-can preservation, PPCJ (201), 4563, 28-29, (2011). United States Environmental Protection Agency, The Presidential Green Chemistry Challenge Awards Program, Summary of 1996 Award Entries and Recipients, http://www. epa.gov/greenchemistry/pubs/docs/award_entries_and_ recipients1996.pdf, p.4 (EPA744-K-96-001). Dow Microbial Control Press Release: DCOIT, an Active Substance of Dow Microbial Control, recommended by the EU Competent Authority for approval and inclusion in BPD Annex I listing under PT 21: Antifouling Products. http://www.dow.com/microbial/news/2011/20110329a.htm Dow Microbial Control, Material Safety Data Sheet (2011), KATHON™ 287T biocide, sect. 9. Sadasivan, L; Gandhi, U. A “two-for-one” biocide for latex coatings: provides effective in-can and dry film preservation. PCI Magazine, July, (2003). EPA Test Method 24: Determination of volatile matter content, water content, density, volume solids, and weight solids of surface coatings, p.1180-1194. http://www.epa.gov/ttn/emc/promgate/m-24.pdf ASTM D 6886 (2003) Standard Test Method for Speciation of the Volatile Organic Compounds (VOCs) in Low VOC Content Waterborne Air-Dry Coatings by Gas Chromatography. ASTM D 5590-00 (2005) Standard Test Method for Determining the Resistance of Paint Films and Related Coatings to Fungal Defacement by Accelerated Four-Week Agar Plate Assay.

Tego – Adding Advantages

Applying Statistical Design of Experiments to

VAE-Based Coatings Development A Formulator’s Perspective

W

hen developing and introducing new technology, customers expect supporting data on how to best use new products. The question is always, “How can the product be formulated to best take advantage of its features?” Since time and resources are always limiting factors, statistical design of experiments (DOE) is a useful tool in this characterization work as it provides a focused approach to generating significant studies in a timely fashion. In this article, the use of DOE from a coatings formulator’s perspective is presented, and advantages and myths surrounding the approach, along with real-world examples, are discussed. Forbo manufactures vinyl acetate ethylene latex, acrylic latex and vinyl acrylic latex. Markets for these latexes include architectural coatings, construction and adhesives. A new product is ELVACE® 750, a high solids, non-APEO, ultralow-VOC-capable, no-formaldehyde-added vinyl acetate ethylene latex for flat and semigloss coatings. Statistical design of experiments was used extensively to develop formulation guidelines for this product.

comb from StatEase provided the following definition in their publication, DOE Simplified: Practical Tools for Effective Experimentation, Productivity, Inc., 2000. “Design of experiments (DOE) is a planned approach for determining cause and effect relationships. It can be applied to any process with measurable inputs and outputs.”This simple explanation doesn’t say anything about coatings, but one can apply the various parts of the definition. First, there’s the “planned approach.” Coatings formulators always have a plan when starting a new project, whether it’s a quick, competitive study or an extensive reformulation project. Next, there’s “cause and effect.” When doing a project, the formulator is always looking at cause and effect: if this ingredient is changed, how does that effect the performance of the paint system? Finally, there’s measurable inputs and outputs. A paint formulation certainly has measurable inputs – raw materials and amounts are an obvious example. The measurable outputs are performance parameters, be it scrub resistance, gloss, salt spray resistance, dry time, oven stability and so forth. Thus, by definition, DOE should be a viable formulating tool for the coatings chemist.

Statistical DOE

Ladders and Scaffolds

To most coatings formulators, statistical design of experiments is an interesting approach to testing, but the feeling is that it’s not applicable to their jobs. It’s something that is more likely to be used in high technology areas, like polymer synthesis. But what is the real definition and use of design of experiments? Mark Anderson and Pat Whit-

DOE has been dismissed by some as a “glorified ladder study.” This is basically a way to hold onto the traditional, one-factor-at-a-time (OFAT) approach to testing that was often taught to the paint chemist from the first day in the lab. DOE can be compared to a ladder in the same way a scaffold can be compared to that same ladder.

By Richard A. Caldwell, Project Leader, Coatings | Forbo Bonding Systems, Synthetic Polymers Group PA I N T & C O A T I N G S I N D U S T R Y

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35

Applying Statistical Design of Experiments to VAE-Based Coatings Development

Imagine painting a large run of wall with a ladder (OFAT) versus a scaffold (DOE). With the ladder, the painter has limited reach – basically an arm’s length in either direction. With a scaffold, that same painter has a broader, more stable reach. For the paint chemist, results from an OFAT study can be a reach, just like getting that extra inch of wall from a ladder. Every chemist can remember at least one study where an experimental result was achieved, never to be repeated. DOE, like the scaffold, gives a firmer base. DOE studies look at several factors at once. Additionally, mix designs and even factorial designs require replicates to establish error and fit. Interactions of factors are seen in DOE; viewing those interactions is not possible with the OFAT/ladder study. And in DOE, erroneous results are either discounted as not being statistically significant, or are readily visible as outliers in the resulting analysis. Thus the base for conclusions and further work is much broader and more stable. On the cautionary side, like a scaffold, considerably more care is required to set up a DOE than an OFAT study. The various pertinent factors and ranges need to be considered carefully, calling on the chemist’s experience with the technology. A poorly designed DOE can lead to meaningless, or worse, erroneous, results, just like a poorly assembled scaffold can lead to disaster.

DOE Myths There are many myths surrounding the use of DOE in coatings applications. A few of the more common are investigated below. Myth #1: Extensive statistical knowledge is required to use DOE. This may have been true in the pre-computer age, but modern software is very user friendly, even for those with little or no knowledge of statistics. Basically, the programs will crunch the numbers, determine significance and present results. Myth #2: DOE requires too many samples. Typically, a DOE study will require more samples initially. But if the formulator is looking at a complex formulation issue, the number of samples in a DOE is typically less than that required in a one-factor-at-a-time approach. Plus, DOE offers the capability, especially in factorial designs, to run

FIGURE 1 | Cleansability interaction: amine and coalescent level. Interaction 25.00

X1=B: Amine X2=C: Coalescent Level

20.00

Actual Factor A: Coalescent=Average

C1 2% C2 4%

Cleansability

Design-Expert® Software Factor Coding: Actual Cleansability

C: Coalescent Level

15.00 10.00 5.00 Amine 1

Amine 2 B: Amine

36

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fewer samples than statistically specified and still provide meaningful results. Myth #3: Testing needs to be precise to the fourth decimal place. Precision and accuracy in testing based on sound lab methodology and execution is always good. However, DOE works as well on visual ratings (scale of 1 to 10) as it does on a 4-decimal place property. The software will calculate the significance of a given property, and provide input if a data point is an outlier. Myth #4: One DOE will solve all my problems. Large DOEs can be all-encompassing, but they are also more difficult to manage. Logistically, timing of tests and the sheer volume of samples can be daunting and a source of error. It’s best to address a large, complex technical issue with smaller, more manageable DOE studies. Like OFAT, another DOE may be required to address the results seen in the first DOE. Going back to the ladder-scaffold scenario, a scaffold covers more ground, but to paint a large wall, it still has to be moved. Myth #5: DOE works better for the “any area but mine” part of the business. Synthesis people will often say that application work is more DOE friendly. Applications people say that DOE is way too technical, best left to the synthesis folks. Or they’ll say it is more adaptable to the process side of the business. In Forbo’s development process, DOE has been used with success in both the synthesis side of the business to optimize new latex formulas and the applications side for formulation optimization and to troubleshoot performance issues. Going back to the definition of DOE, paraphrased from Anderson and Whitcomb, it can be used in any area where you have a planned approach to study cause and effect relationships with measurable inputs and outputs.

DOEs: When and What Kind? A perplexing issue for many chemists that are new to statistical design of experiments is when to use DOE, and what type to use. A statistician will tell you the only type of DOE that’s worthwhile for a coatings system is a mix design. While mix designs are very useful in coatings formulation, there are also some excellent applications for factorial designs as well. For the beginner, there are three basic DOE formats to consider: 1) factorial designs; 2) mix designs and 3) response surface methods (RSM) designs. Factorial designs are the most basic of designs and are primarily for screening. The simplest factorial design is a 2-level factorial. This is for screening many different items. A general factorial is also a screening tool. However, it is used after you’ve determined the most significant factors. Full factorial designs allow the user to zero in on an area, or factors, of interest. These designs are very useful to the coatings formulator for screening things like new coalescents, new surfactants, ingredient levels and so forth. The next type of design commonly used in paint formulating is the mix design to optimize the system. Mix designs look at key ingredients and their percentage in the formulation. The total of the mix always equals 100%, but can be expressed in terms of percentages, weights or volumes. Mix designs include replicates and typically look for curvature and a fit in the data. Frequently the results are expressed as a quadratic or even cubic model.

General Factorial Design Factorial designs are excellent for screening new raw materials in coatings formulations. An example is a coalescent study that was run in a semigloss paint based on ELVACE 750. The purpose was to evaluate some of the new ultralow zero-VOC coalescents versus the industrystandard coalescent, Texanol. AMP 95 and AEPD VOX 1000 from Dow/Angus were also evaluated in the study. Finally, different coalescent levels were investigated. The factorial design was set up as follows: Factor 1: Coalescent Type Texanol (TMB) Eastman Velate 375 (Coal-1) Eastman (formerly Genovique) Loxanol EFC-200 (Bio-1) BASF (formerly Cognis) Chimista LC-200 (Bio-2) Chimista Oxicure 1000 (Bio-3) Cargill Note that each of these coalescents represents a “level” under Factor 1. Factor 2: Coalescent Level (% on latex solids) 2% 4% Factor 3: Amine Type AMP 95 Dow/Angus AEPD VOX 1000 (Bio-3) Dow/Angus

greater, while the 2% coalescent level is constant with both amines at 2% coalescent. If the chemist were going to use Amine 2, cleansability would be optimum at 2%. The data shows that Amine 1 is more tolerant of different coalescent levels, with cleansability being essentially equivalent at either level. Figures 2 and 3 show the actual bar graphs of this data. The cleansability results with Amine 1 (Figure 2) are practically equivalent at both levels. It is evident from Figure 3 that the 4% level cleansability results are consistently higher (worse) than the 2% level.

FIGURE 2 | Cleansability, Amine 1. 25.00 Cleansability

Finally, there are RSM designs. These are used mostly for optimizing processes. In terms of setting up an RSM, they are a basically a factorial design on “steroids.” They include replicates and more center points. The purpose of the RSM designs over a straight factorial is that it shows curvature of the data.

20.00 15.00 10.00 5.00 2% 4%

C: Coalescent Level

TMB

BIO-1 COAL-1

BIO-3

BIO-2

A: Coalescent

FIGURE 3 | Cleansability, Amine 2. 25.00 20.00 Cleansability

The number of samples was basically 5 levels for Factor 1 times 2 levels for Factor 2 times 2 levels for Factor 3: 5 x 2 x 2 = 20 total paint samples. Several properties were checked: viscosity, gloss, burnishing, block resistance, cleansability and low-temperature touchup were all highlighted in the original project presentation. An advantage to design of experiments for the paint chemist is that once the paints are made, you can run and analyze as many tests as you need or have an interest in. Results are analyzed by the design program. In factorial designs, interactions are the “gold standard” – where the best information about your systems is obtained. An interaction is where the results behave differently than expectations, or the lines of the results graph either diverge or cross. Interactions would be difficult, if not impossible, to spot with the one-factor-at-a-time methodology.

15.00 10.00 5.00 2%

C: Coalescent Level

4%

TMB

BIO-1 COAL-1

BIO-3

BIO-2

A: Coalescent

FIGURE 4 | Optimization graph: desirability. 0.900 0.771 Desirability

Interactions An interaction was seen in the semigloss coalescent study in the cleansability property. Cleansability is run per the Master Painters Institute (MPI) method, where aggregate color change from the removal of five stains (ketchup, mustard, hot coffee, red wine and powdered graphite) is measured. The interaction graph is shown in Figure 1. As seen, the cleansability is lower with Amine 1 (AMP 95) at a 4% coalescent level, although it is fairly close to the 2% level (red square). Interestingly, with Amine 2 (AEPD), the cleansability color change is considerably

0.643 0.514 0.386 0.257 0.129 0.000 4% BIO-1 COAL-1

C: Coalescent Level

2%

TMB

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

BIO-3

BIO-2

A: Coalescent

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37

Applying Statistical Design of Experiments to VAE-Based Coatings Development

TABLE 1 | Optimum composition compared to no-coalescent version. Latex

ELVACE 750

Coalescent Level Buffer Desirability Stormer Gloss @ 60° Low Temp, 36 °F, 6 gloss Block resistance, total Cleansability, total VOC, g/L, calculated VOC, g/L, ASTM D6883

None None Amine 2 --80 29.2 -6.4 104 15.35 49 44

BIO-1 2% Amine 2 62.40% 90 37.6 -3.3 108 11.34 49 40

TABLE 2 | List of samples, pigment mix design. Run

Comp 1 A:Clay gal/100 gal

Comp 2 B: NephSy gal/100 gal

Comp 3 C: CaCO3 gal/100 gal

Factor 4 D:NephSy Grade

0.00 4.98 2.49 4.98 0.00 1.66 0.00 0.00 2.49 0.83 0.83 0.00 0.00 0.00 1.66 0.00 0.00 0.83 2.49 2.49 3.50 3.50 0.75 0.83

0.00 0.00 0.00 0.00 2.49 1.66 4.98 4.98 0.00 3.32 0.83 4.98 2.49 2.49 1.66 4.98 0.00 0.83 2.49 2.49 0.75 0.75 3.50 3.32

4.98 0.00 2.49 0.00 2.49 1.66 0.00 0.00 2.49 0.83 3.32 0.00 2.49 2.49 1.66 0.00 4.98 3.32 0.00 0.00 0.73 0.73 0.73 0.83

NephSy-4 NephSy-2 NephSy-4 NephSy-4 NephSy-4 NephSy-2 NephSy-2 NephSy-4 NephSy-2 NephSy-2 NephSy-4 NephSy-4 NephSy-4 NephSy-2 NephSy-4 NephSy-2 NephSy-2 NephSy-2 NephSy-2 NephSy-4 NephSy-4 NephSy-2 NephSy-4 NephSy-2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

FIGURE 5 | Mix design, ingredients.

FIGURE 6 | Total block resistance.

0.000

0.000

Block, Total

A: Clay 4.980 120 100 80 60 40 20 C (0.000) B (4.980) 2

4.980 B: NephSy

2

0.000

A (0.000)

4.980 C: CaCO3

Std Error of Design 38

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A (4.980) B (0.000) C (4.980)

Significant Factors In addition to the interaction, the data also showed that coalescent type (Factor A) was significant in the cleansability property. TMB is generally the best, regardless of amine or coalescent level. The Coal-1 (Velate 375) and Bio-1 (Loxanol EFC-200) are very close to the TMB in cleansability performance. Note that in this particular property, lower values are preferred. The analysis of factors shown in Figures 2 and 3 for cleansability was also run for other key properties, like viscosity, gloss, block resistance and low-temperature touchup. Optimization The design program has an optimization section that allows the user to input parameters, like maximize gloss, minimize 6E for cleansability, maximize block resistance, minimize VOC, and so forth. The program will then provide a list of options with a desirability factor. A desirability factor of 1.0 indicates that all of the user-specified parameters have been met. The program will generate a table of factors, as well as illustrate those factors graphically. An optimization graph with one of the more desirable compositions is shown in Figure 4. The useful information for the paint chemist in this work is that the two bio-coalescents, Bio-1 (EFC-200) and Bio-2 (LC-200), look very good overall with the ELVACE 750 latex in a semigloss formulation. Finally, a chemist can compare the optimum sample(s) to a control sample outside of the DOE. This could be a commercial paint, a competitive product, or simply the existing formulation. In the case of this semigloss coalescent DOE, we used a coalescent-free, zero-VOC paint to see how the optimum coalescent package faired. The results are shown in Table 1. It is clear that, while a decent paint can be made with ELVACE 750 using no coalescent, there are advantages to using an ultralow-VOC bio-coalescent like EFC-200. As the data shows, DOE can be a powerful tool for screening a variety of coatings ingredients; in this case coalescents.

Mix Designs Mix designs are more complicated and require a little more planning in their setup. The following example is from a pigment study that was run with ELVACE 750 in semigloss systems. The purpose of the study was to look at various extenders to see which gave the best overall properties. This could be termed a trouble-shooting study, in that a specific goal was to minimize gloss burnishing and color float in the formulation. The fine-particle-size clay extender, Polygloss 90, gave excellent block resistance, cleansability and color float, but tended to burnish. The question was whether a finer-particle-size calcium carbonate (Hubercarb G-3) or finer-particle-size grades of nepheline syenite (Minex 7 and 10) could improve the burnishing as either a substitute or in combination with the fine-particle-size clay. The approach for this study was a combination design – optimal mixture with factorial. The factorial was Minex selection – 7 versus 10. A 30% PVC paint formulation was used; the total amount of extender in that paint formula-

Applying Statistical Design of Experiments to VAE-Based Coatings Development

tion was 4.98 gal/100 gal of finished paint. It was decided that each pigment would be checked from a level of 0 gal/100 gal to 4.98 gal /100 gal. Inputting these requirements into the DOE software provided the list of samples seen in Table 2. Examine the list of samples carefully and you will note several repeats, samples with 100% (4.98 gal) of each pigment, and several different combinations or blends of pigments. Once the concept of the study is

FIGURE 7 | Pigment study optimization plot. A: Clay 4.98

Design-Expert® Software Component Coding: Actual Factor Coding: Actual Overlay Plot Burnish Block, Total Color Float, 72 hr RT CleansabilityTotal

Cleansability Total: 14.000 Burnish: 0.400

• • Design Points

Block, Total: 90.000

0.000

X1=A: Clay X2=B: NephSy X3=C: CaCo3

0.000

Burnish: 0.020

2

Actual Factor D: NephSy Type=NephSy-2 2

4.98 B: NephSy

4.98 C: CaCO3

0.000

Overlay Plot FIGURE 8 | Pigment study optimization, with flag. A: Clay 4.98

Design-Expert® Software Component Coding: Actual Factor Coding: Actual Overlay Plot

Burnish 0.216 Block, Total 110.398 Color Float 13.266 X1 2.814 X2 2.155 Cleansibility Total: 14.000 X3 0.011

Burnish Block, Total Color Float, 72 hr RT Cleansibility Total

Burnish: 0.400

X1=A: Clay X2=B: NephSy X3=C: CaCo3

0.000

Actual Factor D: NephSy Type=NephSy-2

Block, Total: 90.000

0.000

Burnish: 0.020

4.98 B: NephSy

4.98 C: CaCO3

0.000

Overlay Plot TABLE 3 | Optimization – desired properties. Range of Tested Values Minimum Maximum

Property Burnish resistance Color float Block resistance Cleansability total

40

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0.02 3 39 9.51

1.30 9 119 28.37

Desired Values Minimum Maximum 0.02 6.5 100 9.51

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0.40 9 119 14.00

conceived, the software generates a list of samples, such as the one in Table 2, in seconds. The study and samples can be illustrated graphically with a triangle plot, as seen in Figure 5. The arrows show the progression from 4.98 gal (100% of one pigment) to 0 gal. Where the arrows intersect in the middle of the triangle is 1.33/1.33/1.33 gal of each pigment. In Figure 5, this point is circled. This would correspond to Runs #6 (Minex 10) and #15 (Minex 7).

Responses Four responses are featured for this article – cleansability, block resistance, burnishing and color float. Several more tests were run, but these gave the best example of using mix designs to optimize and troubleshoot paint formulations. All four of these properties were significant in their results. An example of the output on each property is shown in the block resistance results in Figure 6. The results are a sum of 16 different block resistance readings, under various conditions, dry times, dwell times and block temperatures. A is Polygloss 90 clay, B is nepheline syenite (either Minex 7 or 10, both performed the same) and C is Hubercarb G-3 (calcium carbonate). The orange section shows the best block resistance on the line between A (clay) and B (nepheline syenite). The dark blue section is the worst block resistance, between calcium carbonate and nepheline syenite, as well as between clay and calcium carbonate. Similar outputs were seen with the other properties in the study. Overall, the data showed that the clay/Minex blends had the best block resistance. Increasing clay in the system provided significant improvements in color float. Conversely, by decreasing clay and increasing either calcium carbonate or Minex, or both, burnish resistance was greatly improved. Finally, straight clay gave the best cleansability, but the clay/Minex blends were also respectable. Calcium carbonate and blends with high levels of calcium carbonate had the worst cleansability. Optimization Even with four properties, this could be a lot of data to interpret – although the design software, as seen in Figure 6, makes interpretation easy. But the software, through the optimization segment, allows the paint chemist to see an optimum composition that would conform to specified parameters. Table 3 shows the range of parameters, along with the desired properties or values, from this pigment mix design. The results are illustrated graphically in Figure 7. The yellow highlighted area is the area that meets the desired values – the “sweet spot.” Figure 8 shows how the chemist can point to a certain area of the highlighted, optimum region and “plant” a flag. The flag will give the actual composition, as well as the desired properties. A quick look at the properties in Figure 8 shows that they are within the desired requirements in Table 3. The results showed an optimum mix for the semigloss formulations. There was no significant difference in performance between Minex 7 and Minex 10 (fine and finerparticle-size nepheline syenites). Clay, perhaps due to its oil absorption, was excellent for color float. Conversely, the Minex and calcium carbonate, theoretically due to their

round as opposed to platy morphology, were much better for burnish resistance. The optimum formulation from above was re-made and tested, to confirm successfully the results of the mix DOE.

Conclusions These two projects show some typical paint studies that can be run very effectively and efficiently using statistical design of experiments. Extensive results are obtained using a relatively small number of samples. As presented, factorial designs can be used to screen a significant number of coalescents, and a mix design can be used to troubleshoot and optimize certain paint performance parameters. Modern software – StatEase’s DesignExpert 8.0 was used in this work – makes setting up, analyzing and optimizing data very easy. While using the software does not require extensive statistical knowledge, the coatings chemist may find that the more they use it, the more they will want to learn more about the statistical side of DOE.

Acknowledgements The author would like to acknowledge the management of Forbo Bonding Systems, Synthetic Polymers for allowing this work to be presented. Special thanks to my colleagues at Forbo who supported this project: Rich Vetterl, Shawn Daniel, Tim Tegen, Janice Mayer, Mike Brown and Ashley Hebert.

Emulsion Paints, Paint & Coatings Industry Magazine, September 2003. 5 Asbeck, W.K. Critical Pigment Volume Concentration Measurement – A Very Fast Method, pp. 64-66, JCT Coatings Tech, Vol. 2, No. 14, March 2005. 6 Broome, T.T. Approaches to Formulating Interior Latex Paints for the Southeastern

U.S., Paint & Coatings Industry Magazine, February 2008. 7 Hare, C. and Beck, R. “Extenders,” http:// www.nycominerals.com 8 Kaolin Clay for Industrial Specialties, Kamin LLC, 2008. 9 Paint and Coatings Dictionary, Federation of Societies for Coatings Technology, 1978.

The New MCR Series: Modular Rheometers Ready for Everything Whatever your rheological requirements are and will be in the future – MCR rheometers are always efficiently and comfortably adapted to meet your needs.

Forbo Presentations Forbo’s coatings group uses statistical design of experiments extensively for coatings development and commercialization efforts. Several papers and presentations, including more in-depth versions of the two cited in this paper, have been presented. These are available to readers: please contact Rick Caldwell at rick. [email protected] for copies. 䡲

References 1 Anderson, M.J. and Whitcomb, P.J. DOE Simplified. Practical Tools for Effective Experimentation, Productivity Press, 2000. 2 Werner, R. Effect of Extenders with Narrow and Broad Particle Size Distributions on the Properties of Coatings, pp. 71-76, Journal of Coatings Technology, Vol. 72, No. 903, April 2000. 3 Hare, C.H. and Kurnas, J.S. Reduced PVC and the Design of Metal Primers, Journal of Coatings Technology, Vol. 72, No. 910, November 2000. 4 Dietz, P.F. The Effect of Fine-Particle-Size Extenders and Entrapped Air on TiO2 in

Find out more about the MCR rheometer series at www.anton-paar.com.

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Defoamers and for Waterborne

T

here continues to be renewed focus on waterborne alkyd resins due to advancements in their chemistry, as well as increased interest in green chemistry. This has led to new waterborne alkyd resins and coatings that offer many of the attractive performance features of older alkyd resins while also providing some additional benefits. Of course these newer resins pose different formulation, application and performance challenges, some of which are due to different surface chemistry properties. This can lead to different surface wetting, flow and leveling characteristics, as well as a tendency to foam. These traits, if not addressed adequately, lead to coating application and performance deficiencies. This article describes the selection of optimal defoamer and wetting agent additives for use with newer waterborne alkyd resin technology and related coating formulations. Recommendations for specific additives are provided, along with associated performance benefits.

Introduction Alkyd resins are prepared from the polycondensation reaction of a polyhydric alcohol with a polybasic acid, and modified with an oil or fatty acid (i.e., natural oils). They can be further modified with a variety of other polymer chemistries such as polyurethane, acrylic, silicone and epoxy esters to tailor and obtain specialized properties. Recently, water-based alkyd resin technology has expanded with a variety of different chemistries and morphologies. (1-5) One example is the development of waterborne resins containing particles with an alkyd core surrounded by an acrylic shell to provide attractive features of both polymers, such as the long shelf life, quick drying, good weathering of acrylics, and the crosslinking and high gloss of alkyds. Oxidizing alkyd resins cure by the oxidation of the unsaturated fatty acid ester chains in the alkyd. These reactions are accelerated with metal-based catalysts, also known as driers. This drying reaction occurs after application and yields a crosslinked applied coating. The wide variety of available chemistries to produce and modify alkyds, along with their oxidative crosslinking cure, results in a broad range of attractive properties,

from soft and flexible to hard and brittle. They also are characterized by good adhesion, high gloss and chemical resistance. References 6 and 7 provide further description of alkyd resins and their use in coatings. Alkyd resins can be designed for use in solventbased or waterborne coatings. Waterborne versions can be water reducible or dispersions. Waterreducible alkyds are solubilized in water and cosolvent by neutralizing the acid groups on the alkyd with amine(s). They are typically formulated at 25-35% solids with VOCs of > 200 g/L. Waterborne alkyd dispersions are newer technology, where alkyd resins are dispersed as particles in water. They can be formulated at 40-60% solids, with VOCs of < 120 g/L, with some formulations well under 50 g/L. This offering of extremely low VOCs, along with the use of “green” raw materials (i.e., natural oils), also makes waterborne alkyds attractive from an environmental, health and safety standpoint. Alkyd resin properties make them suitable for interior and exterior architectural coatings, especially wood paints and stains, as well as industrial metal primers and topcoats. Waterborne alkyd coating formulations have ingredients similar to most other waterborne coatings. The alkyd resin serves as film former and binder. Specific alkyd chemistry and type are selected based on the end-use application and desired properties. Other typical formulation ingredients include metal driers (noted above), pigments and fillers (for color coats), co-solvent, wetting agents, defoamers, rheology modifiers and other additives. Although ingredient types in waterborne alkyd coatings generally are similar to those with other waterborne resins (e.g., acrylic latex, polyurethane dispersions, waterborne epoxy, etc.), the specific types and combinations of ingredients, mixing styles and procedures, applications and cures are somewhat different. This poses unique application and film characteristics, especially those related to surface

By Charles R. Hegedus, Jonathan E. Sefko, Christine Louis, and Wilco Chaigneau | Air Products and Chemicals, Inc., Allentown, PA 42

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Wetting Agents Alkyd Coatings chemistry, such as flow, leveling and foam. For example, waterborne alkyd resins and coatings can generate substantial foam when agitated during manufacturing, mixing and application processes. This foam can lead to a variety of difficulties that can be avoided with the proper selection and incorporation of suitable antifoam and defoamer additives. The work described below was undertaken to study the flow, leveling and foam characteristics of waterborne alkyd resins and coatings, and to identify optimal defoamers and wetting agents for waterborne alkyd formulations.

Basics of Wetting and Defoaming Due to the high surface tension of water, waterborne coatings typically require surfactants to reduce surface tension and improve wetting and leveling of the applied coating, especially on low-energy surfaces such as wood, plastic, contaminated metal and previously coated surfaces. Surfactants reduce surface tension by diffusing to, concentrating, and aligning at an interface such as the coating/substrate and coating/air interfaces. References 8-10 discuss surface tension, substrate wetting and the use of surfactants in greater detail. An additional consideration is that many coating-related processes, such as paint manufacture (e.g., pigment dispersion), mixing and application, are high-speed agitation processes. These processes disrupt the surfactant concentration and alignment at the surface, thereby causing higher surface tension during and after agitation, which is also known as dynamic surface tension (DST). Surfactants that quickly diffuse back to the interface, align and lower surface tension have low DST, i.e., they provide low surface tension during and shortly after these dynamic agitating processes. They are effective and efficient at providing good wetting and leveling, and avoiding problems such as craters, fisheyes and other defects. Gemini (twin) surfactants have proven their efficiency and effectiveness at reducing surface tension in waterborne coating formulations and applications to obtain superior film

formation and performance. They obtain this low DST due to their unique chemical structure, which contains two hydrophobic and hydrophilic groups in a single molecule, thus being more efficient than typical surfactants that contain a single hydrophobe/hydrophile structure.11,12 Waterborne coatings also have a tendency to foam when agitated, which occurs during every manufacturing, mixing and application process. Foam can be very tenacious and last for hours or even days, and it can cause numerous problems in coating production, application, film formation, and throughout the coating’s service life. Foam can reduce pigment grinding efficiency and increase production time and energy demand; it can also lower product density leading to incomplete filling of production vessels and final product packaging. Foam also can create problems during application by reducing the efficiency of transferring the product to the substrate and by creating defects in the dry film that reduce the protective and aesthetic qualities of the finished product. To avoid these problems, defoamers are commonly used in waterborne coatings; they can be very effective but they need to be carefully selected. In general, defoamers work by disrupting the surfactant “bi-layer” around the air bubble, destabilizing the bubble wall so that the bubble can break and release the trapped air. Conventional defoamers such as silicones and mineral and other organic oil-based defoamers are insoluble, low-surface-tension materials that are capable of entering and spreading across bubble surfaces. They displace the stabilizing surfactants and form an unstable film at the bubble surface that easily ruptures, breaking the bubble and collapsing the foam. Molecular defoamers have a different defoaming mechanism than conventional defoamers. They work by replacing foam-stabilizing surfactants at the bubble surface on a molecular level.13 Molecular defoamers are

TABLE 1 | Waterborne alkyd resin properties. Appearance Solids (wt %) pH Viscosity (cPs) Density (lb/gal; g/mL) Oil length

WBA-A

WBA-B

WBA-C

Milky white 55 7.6 700 9.18; 1.1 Medium

Milky white 53 7.0-9.0 1580 9.0; 1.1 Short

Milky white 45 7.4 180-530 8.9; 1.1 Short

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Defoamers and Wetting Agents for Waterborne Alkyd Coatings

particularly effective at controlling microfoam (small bubbles <70 μm, trapped within the liquid) because they are partially soluble in water and are available to move to bubbles below the liquid surface to help de-aeration. They can also provide additional dynamic wetting properties to the formulation.11, 14 Selection and performance of wetting agents and defoamers are complicated further by their possible competition within a formula. As mentioned above, conventional defoamers work by an incompatibility

TABLE 2 | Resin WBA-A high-gloss white architectural enamel formulation*. Material

Pounds

GRIND Water Natrosol® 250 MBR (rheology) AMP® 95 Defoamer Dispersant Ti-Pure® R706 (TiO2) LETDOWN Resin WBA-A Defoamer Dryer mixture Propylene glycol Water Acrysol™ RM8W (rheology) TOTAL * Formulation parameters Total solids by weight Total solids by volume Pigment volume concentration Pigment to binder ratio Volatile organic content

Gallons

135.76 2.11 0.73 0.63 12.54 278.67

16.30 0.18 0.09 0.06 1.41 8.36

533.33 0.48 8.55 7.41 86.96 5.01 1072.19

60.61 0.05 1.08 0.86 10.43 0.57 100.00

55% 42% 20.6% 0.95:1 48 g/L

TABLE 3 | Resin WBA-B low-VOC interior/exterior high-gloss white topcoat formulation (*). Material GRIND Water Acrysol RM12-W (Rheology) Defoamer Dispersant Ti-Pure (TiO2) LETDOWN Water Resin WBA-B Defoamer Acrysol RM-2020 Additol® VXW 4940 TOTAL (*) Approximate formulation parameters Total solids by weight Total solids by volume Pigment volume concentration Pigment to binder ratio Volatile organic content

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Pounds

Gallons

118.90 4.54 1.08 13.94 267.86

14.28 0.52 0.12 1.58 8.04

69.18 537.56 0.54 62.75 5.08 1081.43

8.25 59.75 0.06 6.85 0.55 100.00

53% 40% 21.4% 0.94:1 39 g/L

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mechanism. Therefore, conventional silicone and mineral oil defoamers, if not selected and incorporated properly, can cause surface defects such as craters by forming localized areas of very low surface tension, which do not wet, thus forming craters. Formulators who experience this often utilize higher concentrations of wetting agent to induce better, more complete surface wetting. But many surfactants generate and stabilize foam, which then requires more defoamer. This potential competition between defoamer and wetting agent can cause this difficult cycle. There are a large variety of wetting agents and defoamers that can be used in coating formulations. The combination of these two additive types leads to an extreme number of formulation possibilities. The performance of these additives is highly influenced by the specific coating chemistry and how the coating is prepared and applied. Therefore, selection of proper defoamers and wetting agents for optimal coating performance is critical yet complex, so selection can be difficult.15 This applies to alkyd resins and coatings as well. The following studies were performed to assess and select defoamers and wetting agents that will provide optimal performance in waterborne alkyd resin systems and coatings.

Experimental Resins, Formulations and Wet Coating Properties To assess a variety of waterborne alkyd resin types and chemistries, seven commercial samples were obtained from four separate manufacturers. Suggested starting coating formulations for these resins also were obtained from their suppliers. Although all the resins were evaluated with defoamer and wetting agent additives, the work described here focuses on three resins and associated formulations from three separate suppliers. While these resins are used in somewhat different applications, their results are representative of what was observed with the entire set of seven resins studied. The three resins discussed here are designated WBA-A, WBA-B and WBA-C, respectively. Table 1 lists their typical properties. WBA-A and WBA-B initially were evaluated as received (i.e., adding only defoamer and/or wetting agent). For these resin/additive mixtures, the additives were incorporated slowly into the resin while being gently mixed for 10 min with a propeller blade, creating a small vortex. Additive concentration in this phase was 53.3 g of resin to 0.11 g of additive (0.2%). These samples were equilibrated overnight and then density (foam assessment) was measured after vigorously shaking the resin/defoamer mixtures by hand for 1 min. Following the above resin screening phase, all three resins were evaluated in the control formulations provided by their respective suppliers as listed in Tables 2-4. The formulations were prepared per the ingredients and procedures provided in the resin manufacturers’ starting formulations, including the listed defoamers and wetting agents (these formulations are designated as “control”). A series of additional formulations were prepared similarly by substituting other silicone, mineral oil and molecular defoamers, as well as candidate wetting agents. Wet coating properties were characterized after the coatings were prepared and equilibrated. They included pH,

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Defoamers and Wetting Agents for Waterborne Alkyd Coatings

Stormer viscosity (Krebs Units, KU), viscosity after aging for 7 days at 50 oC (aging/storage stability), density and agitated (foam) density. As with the resin/additive mixtures, the agitated density for the WBA-A and WBA-B formulated coatings was obtained by measuring the paint density after vigorously shaking by hand for 1 min. The foam density for the WBA-C coating was measured using a Dispermat® foam test for an 80 g sample, stirred for 2 min at 4000 rpm. Density of the mixed sample was measured 30 sec after mixing (anti-foaming assessment) and 4 min after mixing (defoaming assessment).

TABLE 4 | Resin WBA-C anti-corrosion primer formulation. Material

Pounds

GRIND Water AMP-90 Dispersant Pastorit Micro Kronos® 2059 Blanc Fix F Micro Talc AT Extra Zinc Phosphate ZP10 Aerosil® R972 LETDOWN Resin WBA-C Durham cobalt (10% Co) TruCure calcium (5% Ca) Wetting agent Rheolate® FX1010 solution Water Surfynol® DF-58 (at 0.5%) or DF-75 (at 1.0%) TOTAL

100.0 0.8 7.5 72.0 142.0 108.0 58.0 48.0 1.3 429.0 3.5 3.5 4.5 0.44 FX1010; 1.32 Water; 0.44 glycol 5 or 10 1005 or 1010

TABLE 5 | Resin WBA-A foam density and film appearance. (Appearance ratings 0 – 10; worst – best) Resin

Foam Density (g/mL)

Stirred/ Draw Down

Stirred/ Brush

Shaken/ Draw Down

Shaken/ Brush

Total

0.63 1.05 1.00 1.05

10 5 10 8

7 5 8 7

2 3 7 4

2 4 8 6

21 17 33 25

WBA-A W/ R643 W/ DF-58 W/ DF-66

TABLE 6 | Resin WBA-A high-gloss white architectural enamel properties. Property Viscosity (KU) Viscosity after 7 day at 50 °C Density (lb/gal; g/mL) pH Foam density (g/mL) 20, 60° gloss Contrast ratio Sag resistance (mils) Scrub resistance(cycles) Adhesion to wood

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With Control Defoamer

With DF-66

With DF-66 and D607

98 >141 10.6; 1.28 7.2 1.21 64, 90 0.994 24 850 5A (no removal)

99 >141 10.6; 1.28 7.3 1.35 72, 94 0.993 24 850 5A (no removal)

92 104 10.7; 1.28 7.3 1.18 66, 94 0.994 18 900 5A (no removal)

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Resin and Coating Application, Cure and Tests Initially resins WBA-A and WBA-B were evaluated neat (i.e., not fully formulated), with only defoamer and wetting agent additives. These mixtures were applied to Leneta 5C charts with a 3 mil drawdown bar and with a 2-inch Purdy Sprig brush, respectively. The initial applications were performed after gentle stirring of the resin/additive mixtures to ensure homogeneity, and these are noted as “Stirred”. After these applications, the mixtures were shaken vigorously by hand for 1 min, then a second set of applications were made and these are noted as “Shaken”. After setting for several days, the applied coatings were evaluated for film quality and coating defects, i.e., flow, leveling, foam, craters, fisheyes, etc. A rating system of 0 (worst) – 10 (no defects) was used to characterize the coatings. In this manner, we assessed application and applied coating characteristics of un-agitated and agitated resin/additive mixtures. In the next phase, formulated coatings with resins WBAA, B and C were prepared, applied and evaluated. Coatings were prepared as described above and in Tables 2-4, and then applied to various substrates using drawdown bar and/or brush depending on the specific test to be performed. The WBA-A and WBA-B coatings were applied to Leneta 5C charts and yellow pine wood with drawdown bar and brush as described for the resin/additive mixtures above. After curing for 7 days at 70 oF, properties of the applied WBA-A and B coating were evaluated per the following procedures: gloss using a Hunter ProGloss glossmeter (ASTM D 523), contrast ratio using a Spectro-Glide 45/0 (ASTM D 2805), sag resistance (ASTM D 4400), scrub resistance using a Gardco D10 washability and wear tester (ASTM D 2186, method B), and cross cut tape adhesion to yellow pine (ASTM D 3359, method A). The WBA-C coatings were applied to Leneta BK black charts and Q panel S36 I steel panels (SAE 1008/1010 ground; ASTM A1008, D 609 Type 2) using a 6 mil (150 micron) drawdown bar. The coatings on Leneta charts were evaluated for coating appearance and craters using a rating of 1 (worst) to 5 (best). After curing, the steel panels of the control coating and those with selected defoamers (those which were most promising after defoamer and appearance evaluations) were placed in an ASTM B117 5% salt spray and evaluated after 150 and 300 hours exposure durations.

Results and Discussion Approximately 22 defoamer and wetting agent additives were evaluated in the waterborne alkyd resins and coatings throughout this study. The defoamers represented a variety of silicone, organic (mineral) oil and molecular defoamer types from several suppliers. The wetting agents evaluated generally were Gemini surfactants based on acetylenic chemistry. As the evaluations progressed, silicone defoamers, and particularly two silicone defoamers, Surfynol® DF-58 and Surfynol DF-66, clearly provided the best results related to foam density, wet and applied coating properties in all of the resins. Surfynol DF-75 defoamer, an organic oil-based defoamer, also performed well in the WBA-C primer formulation. In addition, two particular additives, Surfynol 420 and

TABLE 7 | Resin WBA-B low-VOC interior/exterior white high-gloss topcoat properties.

Dynol™ 607 surfactants provided benefits in some of the applications when used in combination with these defoamers. The results presented below focus on the performance provided by these additives, which are representative of the best results obtained and compared with the “control” formulations that contain the additives in the formulations provided by the resin suppliers. Table 5 lists the results for the two best defoamers (DF-58 and DF-66), as well as the control defoamer and no defoamer in WBA-A. The first dramatic difference is the foam density of the agitated neat resin (0.63 g/mL) versus that for the resin/ defoamer mixtures of ~1.00 g/mL. This clearly indicates the inherent tendency of this resin to foam. Furthermore, the foam for this neat resin was tenacious and lasted for hours. In fact, all of the waterborne alkyd resins evaluated had similar substantial foaming tendencies, which is common for waterborne alkyd resins. This tendency to foam is attributable to surfactants used in the resin synthesis, which stabilize foam as described previously. Most, but not all, of the defoamers evaluated improved foam density to ~1.0 g/mL (density of the neat unagitated resins was about 1.1 g/mL). The two best performers from a foam density perspective are those listed in Table 5, DF-58 and DF-66, both of which are silicone-based. Table 5 also illustrates the application ratings for the drawdown and brush-applied coatings after gentle stirring and after vigorous shaking. These ratings

Property Viscosity (KU) Viscosity after 7 day at 50 °C Density (lb/gal; g/mL) pH Foam density (g/mL) 20, 60° gloss Contrast ratio Adhesion to wood

With Control Defoamer

With DF-58

With DF-58 and S420

82 81 10.7; 1.28 7.0 1.25 85, 96 0.98 5A (no removal)

82 79 10.7; 1.28 7.1 1.18 95, 100 0.98 5A (no removal)

86 84 10.7; 1.28 7.1 1.19 94, 100 0.98 5A (no removal)

illustrate tendencies of the applied coatings to display defects such as foam, craters, fisheyes, etc. Although the neat WBA-A resin looked nearly perfect with drawdown application after gentle stirring (rating = 10), the ratings for the brush-applied and shaken samples are much lower (i.e., 7 and 2 respectively) mainly due to foam trapped in the applied coating, which again illustrates the need for a defoamer for this resin system. The application ratings for WBA-A with the control defoamer also are poor, with ratings of < 5, and these low ratings are due to numerous large craters caused by the control defoamer. In this case, the control defoamer is

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Defoamers and Wetting Agents for Waterborne Alkyd Coatings

extremely incompatible in the formulation and, when the coating is applied, creates numerous localized areas of very low surface tension, causing the coating to retract and form craters in these regions. The two best defoamers, and especially DF-58, have considerably higher ratings in all of the scenarios, including the most demanding

of being applied immediately after vigorous shaking. Subsequent to these evaluations, the resin supplier evaluated this defoamer in a wood varnish clearcoat and confirmed excellent foam control, clarity, gloss and distinctness of image. A variety of defoamers and wetting agents were then evaluated in formulated

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coatings containing WBA-A and WBAB, as described in Tables 2 and 3. The WBA-A formulation is a high-gloss white interior wood trim coating. The WBA-B formulation is a high-gloss interior/exterior topcoat. Results for these coatings with the control defoamer and the best performing additives from those tested are listed in Tables 6 and 7, respectively. It should be noted that one of the major differentiating features of waterborne alkyd resins over other waterborne resins, including latex, is the ability to obtain high gloss with pigmented coatings, which strives to reach that of solventborne systems. Therefore, approaches to increase these gloss levels even further and improve wetting and appearance become an even greater benefit. Tables 6 and 7 illustrate that the DF-66 in WBA-A and the DF-58 in WBA-B provide exceptional gloss, with substantial increases over the control formulations. For the WBA-A formulation, 20o and 60o gloss values increase from 64 and 90 in the control to 72 and 94 with DF-66. The DF-66 also improves foam density versus the control from 1.21 g/mL to 1.35 g/mL. The addition of D607, an alkoxylated acetylenic diol surfactant, along with DF-66 also increases gloss over the control. Although the gloss values do not reach the values obtained with just DF-66, appearance related to flow, leveling and distinctness of image were noticeably improved. D607 also improves heat age stability, which is reflective of aging and shelf life, by maintaining an applicable viscosity after 7 days at 50 oC. Other properties of the WBA-A coating, such as pH, contrast ratio, sag resistance, scrub resistance and adhesion, are comparable between the control defoamer and the DF-66 and DF-66 / D607 additives. Table 7 provides results for the WBA-B interior/exterior high-gloss topcoat. In this formulation, use of DF-58 increased both 20o and 60o gloss values. The 20o gloss values increase from 85 to 95 with use of DF-58 defoamer. Considering that 20o gloss is a demanding value for high-gloss coatings, an increase of this magnitude and to this level (i.e., 95) is very significant. This is a notable differentiating feature for formulators trying to reach ultrahigh-gloss with lowVOC waterborne technology. It also should be noted that this formulation has a VOC of 39 g/L. As with the D607 wetting agent in the WBA-A coating, addition of S420,

an ethoxylated acetylenic diol wetting agent, improves gloss, as well as visual appearance from flow, leveling and distinctness of image. Other coating properties are comparable with the control defoamer, DF-58 and DF-58 / S420. WBA-C is designed for metal applications, and most specifically corrosion preventive primers as illustrated by the control formulation listed in Table 4. A variety of alternate defoamers were evaluated in this formulation to assess defoaming, appearance (e.g., foam, crater formation), and corrosion protection. Foam density of the agitated samples with various defoamers and wetting agents ranged from 0.80 g/mL to 1.43 g/mL, with the un-agitated sample being approximately 1.49. Of these, the best additives were DF-58, DF-66 (silicone-based) and DF-75 (an organic oil). Figure 1 illustrates anti-foaming (30 s after mixing) and defoaming (4 min after mixing) density results with these additives, as well as the no “blank” defoamer formulation, and the control defoamer formulation. DF-58, DF-66 and DF-75 all provide both good anti-foaming and defoaming with densities close to or exceeding 1.4 g/mL, while the blank (no defoamer) is considerably lower (approximately 0.9 g/mL), and the control defoamer gives <1.2 g/mL. The entire series of WBA-C coatings were applied to black Leneta charts to assess tendency to form craters. The blank, control, DF-58 and DF-75 all performed well by displaying continuous high- quality films with no crater indication. These coatings were then evaluated on steel panels in B117 5% salt spray. Figures 2 and 3 illustrate the 150 h and 300 h exposure results for these panels. At both exposure durations, the results clearly show considerable rust with the blank (no defoamer) and the control defoamer, compared to no rust with DF-58 and DF-75. The rust is caused by foam trapped within the applied coating, which creates pinholes and thin areas that are susceptible to corrosive contaminants attacking the steel substrate. In contrast, the DF-58 and DF-75 specimens show no signs of corrosion due to exceptional elimination of foam, thus preventing defects and resulting in a high-quality, continuous film from both an aesthetic and protective standpoint. As mentioned above, seven waterborne alkyd resins were evaluated throughout this effort, with detailed results from only three discussed in detail in this article. Results with the other four resins were very similar in nature to those experienced with WBA-A, B and C resins and coatings formulations. Silicone defoamers DF-58 and/or DF-66 provided the best defoamer results in both the bulk wet coating and during application and cure of the applied coating. Additionally, wetting agents S420 and D607 also provided benefits, mainly better flow and leveling as expected. All of these coatings resulted in coatings with less defects, higher gloss and better appearance than their control counterparts (i.e., with the initially specified additives). These waterborne alkyd resins are recommended for a variety of architectural and industrial coating applications, including interior and exterior architectural primers and topcoat, wood interior and exterior (e.g., siding and decking) clearcoats and stains.

Summary New waterborne alkyd resins offer a wide spectrum of compositions and properties, including very low VOCs (< 50 g/mL) and use of “green” raw materials, making them attractive from both a performance and environmental standpoint. These resins are suitable for a variety of applications, including interior and exterior architectural and industrial coatings. However, they also display somewhat different surface chemistry characteristics than other waterborne coatings. For example, many of these resins have a tendency to foam and, if unaddressed, this

FIGURE 1 | Anti-foam (30 s) and defoam (4 min) density for WBA-C primer (Table 4) with various defoamers. Surfynol DF-75 Surfynol DF-58 Defoam (4 min)

Control defoamer

Antifoam (30 s)

Blank (no defomer) 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 Density (g/mL)

FIGURE 2 | WBA-C primers with various defoamers (Table 4) exposure in 5% salt spray for 150 h.

Blank (no defoamer) Foam density: 0.92

Control defoamer Foam density: 1.21

Surfynol DF-58 defoamer Foam density: 1.46

Surfynol DF-75 defoamer Foam density: 1.43

FIGURE 3 | WBA-C primer formulations with various defoamers (Table 4) exposure in 5% salt spray for 300 h.

Blank (no defoamer) Foam density: 0.92

Control defoamer Foam density: 1.21

Surfynol DF-58 defoamer Foam density: 1.46

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

Surfynol DF-75 defoamer Foam density: 1.43

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Defoamers and Wetting Agents for Waterborne Alkyd Coatings

will lead to poor aesthetics (e.g., reduced gloss, haze, etc.) and protection (e.g., pinholes, corrosion protection). Therefore, defoamers are required for these resins and coatings to meet their optimum performance. However, not all defoamers provide the same level of defoaming and coating quality. Therefore, tangible benefits can be obtained by utilization of optimum defoamers. These coatings also can benefit from use of wetting agents to improve substrate wetting, flow and leveling to avoid surface defects and improve overall appearance, especially on difficult surfaces such as wood, poorly prepared metal and previously painted surfaces. Seven waterborne alkyd resins with a variety of specific chemistries and properties were evaluated with 22 different defoamers and wetting agents in the neat resins, as well as in suggested starting formulations published by the resin manufacturers. Results of the various additives were compared for defoaming capability as well as applied coating appearance, optical

and physical properties. Two particular silicone defoamers, Surfynol DF-58 and DF-66 surfactants, consistently provided significant improvements in the formulations. In particular, these defoamers increased gloss and appearance of a high-gloss architectural trim paint, as well as a high-gloss interior/exterior topcoat. Gloss values (20o) were increased 8 to 10 units, in one case up to 95, and 60o gloss up 4-6 units, up to 100. These gloss values rival those displayed by traditional high-gloss solventborne coatings. Gemini surfactant wetting agents Dynol 607 and Surfynol 420 surfactants also increased gloss and overall appearance by improving flow and leveling of the applied coating. In a waterborne alkyd corrosionpreventive metal primer formulation, Surfynol DF-58 and DF-75 defoamers provided significantly better defoaming while leading to better coatings (i.e., no craters or other defects). They provided more dramatic improvements to corrosion protection as displayed in salt spray exposure. This was accomplished by

eliminating or minimizing coating defects such as craters and foam, thereby improving coating quality and protecting the steel substrate from corrosive contaminants. This work demonstrates the differentiating properties provided by optimum defoamer and wetting agent additives and the resulting improvement in aesthetic and protective properties provided by coatings. This is especially true for new resin technologies such as new waterborne alkyd resins and coatings. 䡲

References 1

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Akintayo, C.O,; and Abedowale, K.O. Synthesis and Characterization of Albizia Benth Medium Oil Alkyds, Prog. Org. Coat. 2004, 50 (4), 207-212. Akbarinezhad, E.; Ebrahimi; Kassiriha, S.M.; Khorasani, M. Synthesis and Evaluation of Water-Reducible Acrylic-Alkyd Resins with High Hydrolytic Stability, Prog. Org. Coat. 2009, 65, 217-221. Uschanov, P.; Heiskanen, N.; Mononen, P.; Maunu, S.L.; Koskimies, S. Synthesis and Characterization of Tall Oil Fatty Acids-Based Alkyd Resins and Alkyd-Acrylate Copolymers, Prog. Org. Coat. 2008, 63, 92-99. Dziczkowski, J.; and Soucek, M.D. A New Class of Acrylated Alkyds, J. Coat. Technol. Res. 2010, 7 (5), 587-602. Clark, M.D. Acrylic Modified Waterborne Alkyd Dispersions, US Patent 6,242,528, June 5, 2001. Hare, C. Protective Coatings Fundamentals of Chemistry and Composition, SSPC The Society for Protective Coatings, Pittsburg, 1994, 137-148. Wicks, Z.W.; Jones, F.N.; and Pappas, S.P. Organic Coatings Science and Technology, WileyInterscience, New York, 1999, 268-285. Patton, T.C. Paint Flow and Pigment Dispersion, Wiley-Interscience, New York, 1979, 205-238. Rosen, M.J. Surfactants and Interfacial Phenomenon, John Wiley and Sons, New York, 1989, 278-282. Adamson, A.W. Physical Chemistry of Surfaces, Wiley and Sons, New York, 1990. Schwartz, J. The Importance of Low Dynamic Surface Tension in Waterborne Coatings, J. Coating Technol. 1992, 64 (812), 65. Medina, S.W. Ethoxylated Acetylenic Glycols Having Low Dynamic Surface Tension, US Patent 5,650,543, July 22, 1997. Louis, C.; and Chan, S. New Additives for Waterbased Coatings: A New Class of Defoamers is Born, Eurocoat 2004. Schwartz, J.; and Bogar, S. An Additives Approach to Defect Elimination in Thermoplastic Water-based Industrial Maintenance Coatings, J. Coating Technol. 1995, 67, 840. Reader, J.; Hegedus, C.R.; Lai, T.K.; Snow, R.A.; Tian, X.; Sun, Y.; Chaigneau, W.; Louis, C.,; Peck, M.; Sefko, J.E.; and Bennett, R. Defoamer Theory and Application in Paints and Coatings, Proceedings of the International Waterborne, High-Solids, and Powder Coatings Symposium, New Orleans, February 10-12, 2010, Storey, R.F., Ed. University of Southern Mississippi, Department of Polymer Science.

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NEWS OAS Unveils Solvent-Resistant Hydrophobic/ Oleophobic Coating Technology OXFORD, England – Oxford Advanced Surfaces Group Plc (OAS) has produced a solvent-resistant oleophobic and hydrophobic coating system using its proprietary technology, Onto™ XL highly reactive chemistry. The technology has been used to modify the wetting and surface energy characteristics of both glass and plastic substrates, but could also be utilized on other materials. A common approach for simultaneously imparting both hydrophobic and oleophobic functionality to a surface is to coat it directly with a fluoropolymer, but there are often associated problems with the stability of the film towards solvents, especially on plastic substrates. Using Onto XL technology in conjunction with a fluoropolymer prevents delamination,

Coatings Event Takes Place in Indonesia JAKARTA, Indonesia – The Indonesian Paint Manufacturers Association, the Indonesian Synthetic Resin Association, the Federation of the Indonesian Chemical Industry and the China National Chemical Information Center are jointly organizing INACOAT, Indonesia’s coatings, paint, ink, adhesive and surface finishing expo and conference. The event will take place in Jakarta, Indonesia, July 11-13, 2012. The three-day industry event is held alongside the second edition of INACHEM, Indonesia’s largest chemical, petrochemical, fine and specialty chemical expo and conference. For additional information, visit www.ina-coatingpaint.com.

resulting in an oleophobic/hydrophobic surface that is stable to solvent exposure. The coating is applied in two layers from non-fluorinated solvents by common wet chemical processing techniques, giving it scope to be printed and therefore patterned. “This technology has the potential to be used in several applications, but we believe that one of the most important markets will be organic electronics,” claims Dr. Sarah Vickers, Product Marketing Scientist at OAS. The use of Onto XL to anchor a coating to a substrate is not confined to fluoropolymers and has the potential to be used in conjunction with other types of coatings. For more information, visit www.oxfordsurfaces.com.

operate 14 coating lines. We saw significant growth in 2011 and expect another major leap forward in 2012 by virtue of this expanded capability.” For more information, visit www.3sigma.cc.

Victor Champagne Receives 2011 Cold Spray Innovation Leadership Award

TOLEDO – DeVilbiss, Binks and Owens Community College have teamed up to present a Spray Finishing Technology workshop. The training program is scheduled for March 7-9, 2012, in Toledo. Classes meet from 8:30 a.m. to 4:00 p.m. daily and include both classroom and hands-on sessions. Two continuing education units are awarded. For additional information, visit www.owens. edu/workforce_cs/spray2012-brochure.pdf.

WINDSOR, Canada – CenterLine Limited’s Supersonic Spray Technologies Div. has announced that Victor Champagne, U.S. Army Research Laboratory at Aberdeen Proving Ground, MD, is the 2011 recipient of its Cold Spray Innovation Leadership Award in recognition of outstanding contributions made to the industrial development and application of cold spray technology. The award was presented during the recent North American Cold Spray Conference in recognition of Champagne’s leadership and contributions to advancing cold spray technology through the establishment of the Cold Spray Action Team Workshop in May of this year. Champagne established the ARL Cold Spray Center located in Aberdeen, MD, whose focus is aimed toward the development of cold spray applications for military and industrial applications.

New 3 Sigma Coating Line Nears Completion

CCAI Releases New Training Manual

TROY, OH – 3 Sigma is installing a wide-format specialty coater, with production trials beginning in the first quarter of 2012. The new coater, designed and built to 3 Sigma specifications, will accommodate 76-inch web materials and can apply multiple coatings and/or adhesives on both the front and back of the web. A laminating station produces pressure-sensitive constructions with liner or multi-layered product designs. Announcing the new capability, Mike Sotzing, 3 Sigma Vice President of Operations, said, “This new 3 Sigma specialty coater will be our most versatile piece of equipment. With it, 3 Sigma will be able to produce more complex applications and constructions for specialty and niche markets, as well as those we now serve. When installation is complete, 3 Sigma will

TAYLOR MILL, KY – The Chemical Coaters Association International has released a new edition of the training manual, Pretreatment for Industrial Finishing Applications, a guide to surface cleaning and conversion coating methods used in effective industrial finishing operations. It includes the latest information on pretreatment through the efforts of CCAI’s corporate members under the guidance of Editor Duane Fudge of Chemetall. The new edition of the CCAI pretreatment manual was reviewed and completely re-written to include information about current technology and methods for paint pretreatment. There is also a new chapter discussing the latest advances in pretreatment technology, Advanced Pretreatments. To order the manual, visit www.ccaiweb.com. 䡲

Spray Finishing Workshop Takes Place in March

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FEBRUARY 2012 | W W W . P C I M A G . C O M

Save the Date

Indianapolis, Indiana May 8-10, 2012 American Coatings CONFERENCE May 7-9, 2012 www.american-coatings-show.com

Chemically Bonded Phosphate Ceramics More Than a Temporary Corrosion Covering

C

orrosion of steel, aluminum and other structural metals erodes the safety and financial stability of industries and countries alike. Fighting corrosion in ships, tanks, planes and equipment costs the Pentagon $22.9 billion a year. Corrosion costs advanced industrialized nations about 3.5% of GDP to replace damaged material and components, plus a similar amount due to lost production, environmental impact, disrupted transportation, injuries and fatalities. While traditional corrosion protection has relied mostly on short-lived, physically bonded coverings of substrate surfaces, a new category of chemically bonded phosphate ceramics (CBPCs) can create a long-lived passivation layer that stops corrosion. This is further protected by a tough ceramic outer layer.

The Limits of Traditional Corrosion Protection For generations, polymer paints have acted as a physical barrier to keep corrosion promoters such as salt water and oxygen away from steel and aluminum substrates. This works until the paint is scratched, chipped or breached, and corrosion promoters enter the gap between the substrate and polymer coating. Then the coating can act like a greenhouse − trapping water, oxygen and other corrosion promoters − allowing corrosion to spread. Placing sacrificial, reactive elements next to steel that will corrode first, such as zinc and galvanized coatings, is another strategy. This works until the sacrificial elements are consumed and recoating must be done, usually after a few years. By Del Williams, Technical Writer | Torrance, CA 54

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FEBRUARY 2012 | W W W . P C I M A G . C O M

Cathodic protection, where a negative voltage is imposed on steel, can limit corrosion on pipelines or other stationary, continuous metal structures where voltage can be attached. But this can fail if it’s not properly insulated and voltage goes to ground. For assets that demand long-term corrosion protection, stainless steel alloys work. But with stainless steel costing up to six times more than mild steel, this option is often cost prohibitive.

A New Approach to Corrosion Protection Ideally, engineers, facility managers and industrial paint contractors would want the long-term corrosion resistance of a stainless steel part with the lower cost of coating application. A new category of CBPCs, such as EonCoat, is now basically making this possible. “Unlike polymer paints that simply cover a substrate, CBPCs essentially ‘alloy’ the surface,” says Tony Collins, CEO of EonCoat. Dr. Arun Wagh, a former materials engineer at Argonne National Lab, and lead developer of the technologies underlying EonCoat ceramics, explains it like this: “When a dual-component spray gun mixes an acid phosphate with base minerals and metal oxides in a water slurry, a chemical reaction occurs on the surface of the steel substrate.” “A hand-held thermometer indicates a 10-12 °F temperature rise, as iron becomes a corrosionresistant passivation layer of iron oxyhydroxide. Because the passivation layer is electrochemically stable, like gold and platinum, it does not react with corrosion promoters such as water and oxygen.” Scanning electron microscopy indicates this passivation layer is about 20 microns thick. X-ray diffraction indicates

this passivation layer is about 60% iron with components of phosphate, magnesium, silicon, hydrogen and oxygen. “History suggests that EonCoat’s passivation layer may resist corrosion indefinitely, as demonstrated by the Iron Pillar of Delhi,” says Wagh. “The Iron Pillar, a 7-meter high, 6-ton Indian artifact that has resisted corrosion for 1600 years with its original inscriptions still legible, has a virtually identical passivation layer to that of EonCoat.” In contrast to typical polymer coatings, which sit on top of the substrate, EonCoat bonds through a chemical reaction with the substrate, so slight surface oxidation actually improves the reaction. This makes it virtually impossible for corrosion promoters like oxygen and humidity to get behind the coating the way they can with ordinary paints. The corrosion-resistant passivation layer is further protected by a true ceramic outer shell. This dense ceramic outer shell is impermeable to water, and resists impact, abrasion, chemicals and fire. The ceramic outer shell forms simultaneously with the passivation layer and chemically bonds with it, after acid and base materials mix in the spray gun nozzle then react with the substrate surface. The dual-layer ceramic coating can be used both as a primer and a topcoat, and can be applied in a single pass that’s dry to the touch in 1 min, hard dry in 15 min, and can be returned to service in an hour. Though CBPCs such as EonCoat have proven themselves in the laboratory and in examples such as the Iron Pillar, Tony Collins knew that the effectiveness of the new material had to be compared to that of traditional anticorrosion coatings. Duplicating a NASA corrosion test, Collins immediately put EonCoat to the test against 19 leading anti-corrosion coatings in a live corrosion test, viewable to the public by webcam. Coated samples were scribed, then exposed to 12 h of sea spray, followed by 12 h of sunlight (or the UV light equivalent). After 45 days, every other highperformance coating tested failed. Except for the rust on its scribe (gouge) line, the EonCoat sample looked the same as day one. To monitor another ongoing corrosion test modeled on NASA’s sea spray test, the public can view, zoom and control a live webcam at www.eoncoat.com. In the latest test, which has passed 120 days and includes brand names matched to numbers, 20 Q panels coated with a popular primer, topcoat, or EonCoat are sprayed daily with corrosive seawater. “There’s nothing like seeing results with your own eyes,” says Collins of the ongoing corrosion tests displayed by webcam. “The product has gone more than 10,000 h with no corrosion in a salt spray ASTM B117 test, but we believe that engineers, facility managers and industrial contractors will see value in comparing its effectiveness with leading brands. CBPCs like EonCoat are a new approach to corrosion protection that should be looked into as aging plants, equipment and infrastructure need to be safely maintained as long as possible.” 䡲

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PRODUCTS 䡲 Double Conveyor Oven

PRECISION QUINCY CORP. This Class “A” double conveyor oven features a gas-fired, top-mount heat chamber. At the oven’s core, there are two powered side-by-side chain-driven roller conveyors whose drive direction is also reversible,

along with pneumatically operated vertical lift doors on both ends of the oven chamber. The unit was designed to accommodate the processing of up to 4,000 lb of product at a time, and is capable of reaching and maintaining a maximum temperature of 500 °F. Visit www.pqovens.com.

䡲 Resin

CYTEC INDUSTRIES INC. RESYDROL™ AY 6705 waterborne acrylicmodified alkyd resin extends durability with outstanding penetration for timber substrates. Its quick drying time and affinity for timber with varying degrees of tannin content promote fast and easy recoating. A hybrid system, it captures properties of both alkyds and acrylics. Visit www.cytec.com/Liquids/resydrol.php.

䡲 Wireless Drum Racking

MORSE The wireless control for drum racking with wireless drum-tilt function allows for maximum control, precision and efficiency. Tilting control is easily alternated between the wireless option and the direct wire pendant option. Racker response is brisk and without interference from other RF sources due to a strong 300-foot range and 900MHz frequency hopping. E-mail [email protected].

䡲 Filling Machine

IDEAL MANUFACTURING & SALES An economical line of liquid filling machines for half-pint to five-gallon containers features rigid steel frame construction, electronic net weight filling,

pneumatic controls, Rice Lake touch pad weight control (for high-accuracy filling), and single or double filling positions. The machine is compact, portable and ideal for any manufacturing facility. Call 608/241.1118.

䡲 Wetting/Adhesion Promoter

TROY CORP. A next-generation wetting and adhesion promoter intended for dry-mix products, Troysol™ PWA improves adhesion to substrates and enhances pull-off strength. It is ideal for cement-based adhesives, EIFS adhesives, mortar, gypsum board, tile adhesive and other dry-mix products. Visit www.troycorp.com. Visit ads.pcimag.com 56

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䡲 Ultrahigh-Shear Mixer

CHARLES ROSS & SON CO. The Ross PreMax is an ultrahigh-shear mixer featuring the patented Delta rotor/stator assembly, which produces a double vortex that draws batch material from both the top and bottom of the mix chamber, accelerating dispersion and producing rapid turnover rates. Running at a maximum tip speed of 5,000 fpm, the PreMax handles viscosities up to 50,000 cP. It delivers superior particle size reduction and can finish viscous emulsions up to six-times faster than ordinary highshear mixers. Call 800/243.7677.

䡲 Pigment

THE SHEPHERD COLOR CO. Blue 10C595 has significantly lower surface area and resin demand, which means more gloss. Meeting numerous regulations governing packaging, recycling and toys, it also has a high solar reflectivity (30 percent). It can be used in coatings applications where low heat build-up and/ or exceptional durability are required. E-mail [email protected].

䡲 Dispersant

CRODA COATINGS & POLYMERS Zephrym PD 4974 is a low-VOC, highperformance polymeric dispersant specially designed for iron oxide pigments. Providing excellent formulation stability in systems containing iron oxide pigments, it also enhances color development and reduces, or even eliminates, the level of thickeners in the formulation. Visit www.crodacoatingsandpolymers.com.

䡲 Mixing Packages

ADHESIVE PACKAGING SPECIALTIES, INC. A-PAK offers the advantages of a syringe applicator, offering pinpoint accuracy. Initially designed for high-end optical/

conductive materials, it is offered in sizes from 2-9 grams. The A-PAK syringe uses an advanced packaging technique with “burst” seal for instant mixing/ dispensing of two-part resin systems. E-mail [email protected]. 䡲

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䡲 Surface Profile Gage

DEFELSKO PosiTector SPG Surface Profile Gage measures and records peak-to-valley surface profile height in accordance with ASTM D 4417-B and others. Available with standard or advanced features, it has a fast measurement rate of over 50 readings per minute, ideal for quickly and accurately measuring surface profile over large surface areas. Call 800/448.3835.

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SUPPLIER SHOWCASES

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AllUthane 30522 is a solvent-free, water-based aliphatic polyurethane dispersion. It has excellent adhesion to a variety of substrates making it suitable for formulating low-VOC coatings for metal, wood and plastic substrates. The polymer exhibits exceptional toughness and has superb abrasion and chemical resistance making it ideal for challenging interior or exterior applications.

NATURAL RESINS COPAL – DAMAR – EAST INDIA – ELEMI – MASTIC – SANDARAC PLT is a leading supplier of natural resins (exudates) including Copal, Damar, Mastic and more. Natural resins have been used for centuries in printing inks, coated materials and protective purposes. PLT has more than 50 years experience sourcing quality natural products globally. For fast delivery resins are stocked locally in our NJ warehouse.

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Proxel® Preservatives = Sustainable, Formaldehyde Formaldehyde-Free Products We have the right polymer for your needs! • More than 250 polymers for the paint and coatings industry

We understand the importance of being a good corporate citizen and minimizing our environmental impact. For over two decades, our Building Products portfolio has contained an ever-increasing number of formaldehyde-free products, including Proxel® BZ Plus Preservative Preservative. We offer cost-effective solutions for bringing your products up to today’s sustainability standards and the protection you’ve come to rely on against microbial spoilage. Our product features include: ‡&RORUVWDEOHIRUPXODWLRQV ‡'XDODFWLRQSURWHFWLRQ ‡=HUR92&V ‡&0,70,7DQGIRUPDOGHK\GHIUHH ‡/RQJWHUPSUHVHUYDWLRQ ‡%URDGVSHFWUXPDFWLYLW\ &RQWDFWXVWROHDUQPRUHDERXWKRZ/RQ]D0LFURELDO&RQWUROLVIXUWKHUSURJUHVVLQJ to become a responsible part of your environmentally-preferred solution.

Tel: 800.523.7391 Email: [email protected] Use biocides safely. Always read the label and product information before use. Some biocides may not be registered or registered for only certain uses in your country

www.specpoly.com www.archbiocides.com www.lonza.com

COMPLETE SPECTRUM OF QUALITY RESINS For more than six decades OPC Polymers™ has provided customers in the coatings industry with a complete spectrum of quality resins, flexible manufacturing and innovative solutions.

Talk to us today about: 䡲 Alkyd Emulsions and Dispersions 䡲 New Advances in Compliant pliantt SSolvents olvent ents 䡲 100% Renewable Resins. s.. 800-848-1898 [email protected] m 58

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• A 40-year track record of product innovation

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1-800-770-7523

INNOVATIVE • RESPONSIVE • FLEXIBLE Vicinity Manufacturing The premier software solution for the formula manufacturing industry. Vicinity extends the Microsoft Dynamics™ financial and distribution offerings to deliver a complete ERP solution specific to formula manufacturers. Key Features

• MSDS • Scheduling by Formula • Formula Management • Shop Floor Control • Batch Yield Analysis

• Certificate of Analysis • Formula Project Tracking • Materials Requirements Planning • Integration to Control Systems • Real-Time Inventory

global links for coatings professionals

The Coatings Group Events www.coatingsgroup.com Asia Pacific Coatings Show 2012 Balai Sidang Jakarta Convention Centre, Indonesia 19 - 20 September 2012

NACC NORTH AFRICAN COATINGS CONGRESS

North African Coatings Congress 2012 Hyatt Regency Hotel, Casablanca, Morocco 17 – 18 October 2012 Middle East Coatings Show 2013 Cairo International Convention and Exhibition Centre, Egypt 26 – 28 February 2013

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Asia Coatings Congress 2013 Windsor Plaza Hotel, Ho Chi Minh City, Vietnam 14 – 15 May 2013 Latin America Coatings Show 2013 World Trade Centre, Mexico 17 – 18 July 2013 3

Asia Pacific Coatings Show 2013 BITEC, Bangkok, Thailand 12 – 13 September 2013 3

Middle East Coatings Show 2014 Dubai International Convention & Exhibition Centre, UAE 8 – 10 April 2014 For up-to-date information on any of the above events, please contact the Coatings Group Tel: +44 (0)1737 855021 Email: [email protected] or visit our Website: www.coatingsgroup.com

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CLASSIFIEDS PRODUCTS & SERVICES Focus Pigment (Taiwan)

Manufacturer of Organic Pigments Aluminum Paste

Resin-Coated Aluminum Paste Waterborne Aluminum Paste Aluminium Powder Metallic Aluminum Paste Leafing Aluminum Paste Email: [email protected] Website:www.focuspigment.com We are seeking distributors

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Custom Pigment Dispersions Reitech Corporation

.. It’s time.to go green!

Let us solve your Color Match Puzzle with our Aqueous products. 37+ years of technical expertise. www.reitechcorporation.com (610) 929-9451

CUSTOM MANUFACTURING

‡6SHFLDOO\'HVLJQHG%ODGHDOORZVIRUKLJK HIILFLHQF\JULQGLQJRUGLVSHUVLRQZKLFK VDYHV\RXWLPHDQGHQHUJ\ ‡ 8VLQJ4XLFN%ODGHVGHFUHDVHVWKH QHHGWRXVHDPLOO ‡ :HRIIHU/DERUDWRU\ 3URGXFWLRQEODGHVZLWK VHYHUDOGHVLJQVWRFKRRVHIURP ‡ 6DPHGD\VKLSSLQJPRVWFDVHV BLADES

TOLL BLENDING ISO-9001 certified manufacturer with nationwide network of plants seeks toll blending inquiries: sand/cement blends, latex or epoxy liquid packing, FFS form fill & seal packaging, private label products. Contact Dominic Di Cenzo 203.915.0279 or [email protected]

Find out more at www.quickblades.net new & used 877.618.8304

High Speed Dispersion Blades

SPECIALTY COATING CHEMICALS Our New Jersey-based synthesis company can ensure your project’s success with high quality, competitively priced specialty chemicals. We toll manufacture under NDA, and can recommend a solution to your chemistry problems.

TYGER SCIENTIFIC, Inc.

Stainless IT

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CONN Blade®s

The Most Efficient & Aggressive Available

UHMW Poly

(888) 329-8990 www.TygerSci.com • [email protected] YUXING PIGMENT The largest manufacturer of iron oxide pigments in China

Iron oxide red/yellow/black /brown/orange/green/blue www.asiapigment.com

www.connblade.com

RECRUITMENT SERVICES

www.yuxingpigment.com

Email: [email protected] Tel: 86-510-87226777

Contact [email protected] to place your PCI Classified.

Spencer M. Hermann 28052 Camino Capistrano, Suite 209 Laguna Niguel, CA 92677 (949)429-8813 • [email protected]

NEED REPRINTS? Have you or your company been featured in a recent issue of PCI? Reprints can be a single sheet or multiple pages. They are available in color or black and white in quantities of 500 or more. Remember, you can use these reprints to distribute at trade shows, display in showrooms or corporate offices, or as part of an advertising piece – just to name a few!

Jill DeVries • 248-244-1726 BNP Media 2401 W. Big Beaver Road, Suite 700, Troy, MI 48084 Email: [email protected] 60

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(814) 723-7980

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

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www.grindingmediadepot.biz

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P R O D U C E D BY:

www.coatingsconference.com

CALL FOR PAPERS

Benefits of Speaking: • Educate your customers • Engage potential customers in future projects • Share ideas • Connect with key decision makers

Coatings Trends & Technologies is now accepting papers covering the following topics.

Septem be r 11-12, 2012 Oak Brook, IL

• Renewable Technology

• Resins and Polymers

• Architectural Coatings

• Mixing/Milling

• UV-curing Technology

• Industrial Coatings

• Calibration Standards

• Waterborne Systems

• Marine Coatings

• Improvements in Adhesion

• Nanotechnology

• Automotive Coatings

• Pigments/Extenders/Colorants

• Solventborne Systems

• Legislation and Regulatory Issues

• Solvents

• Accelerated Weathering

• Additives

• Powder Coatings

• Test Methods, Materials Characterization and Performance Evaluation

“Sessions were relevant and informative.” “Great knowledge base for individuals attending.” “Good cross-section representation of suppliers to the industry.” “Excellent opportunity to network with key suppliers during and after the sessions.”

How to Submit your Paper:

–2011 Attendees

Visit www.coatingsconference.com and click on “Speakers”

• Include the title and abstract of your proposed paper (100 words) and speaker contact information. • Identify three take-away points for attendees; what can attendees learn from your talk? how can they apply your information to their job? For consideration, submit your abstract online at www.coatingsconference.com

Deadline: March 16, 2012 Questions? Email Kristin Johansson, Editor, PCI Magazine, at [email protected]

CLASSIFIEDS EQUIPMENT

EQUIPMENT

HOCKMEYER

HIGH SPEED DISPERSERS

EQUIPMENT CORPORATION A leader in the grinding and dispersion industries New & Used Equipment Dispersers • Mills • Mixers • Tank & Tote Washers • Particle Size Analysis • Vessels

Scan to see units in stock for fast delivery.

Visit us at www.hockmeyer.com or call us at 252-338-4705

Free Tag Reader: http://gettag.mobi

1-800-243-ROSS

Wanted to purchase: Used Dispersers & Mixers

www.dispersers.com

AD INDEX AllCoat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

EYE Lighting International . . . . . . . . . . . 16

www.allcoattech.com

www.eyesolarlux.com

American Coatings Conference . . . . . . . 53

Paul N. Gardner Company, Inc. . . . . . . . 55

www.american-coatings-show.com

www.gardco.com

Anton Paar . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Glen Mills Inc. . . . . . . . . . . . . . . . . . . . . . . . . 6

www.anton-paar.com

www.glenmills.com

Arkema Emulsion Systems . . . . . . . . . 18-19

Heubach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

www.arkemacoatingresins.com

www.heubachcolor.com

BASF Corporation . . . . . . . . . . . . . . . . . .3, 45

Konica Minolta Sensing Americas . . . . . 58

www.basf.us/dpsolutions

www.sensing.konicaminolta.us

Bayer Material Science. . . . . . . . . . . . . . . . 50

Lonza Microbial Control . . . . . . . . . . . . . . 58

www.bayermaterialsciencenafta.com

Brenntag North America . . . . . . . . . . . . . . 2 www.brenntagnorthamerica.com

Buhler Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . 10 www.buhlergroup.com

Burgess Pigment . . . . . . . . . . . . . . . . . . . . . 39 www.burgesspigment.com

BYK USA Inc. . . . . . . . . . . . . . . . . . . . . . . . . 15 www.byk.com

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

www.archbiocides.com www.lonza.com

Micro Powders, Inc. . . . . . . . . . . . . . . . . . . 21 www.micropowders.com

Mitsubishi Gas Chemical America, Inc. 13 www.aromaticchemicals.com

MYERS Engineering, Inc. . . . . . . . . . . . . . 56 www.myersmixer.com

Nanophase . . . . . . . . . . . . . . . . . . . . . . . . . . 57 www.nanophase.com

Nexeo Solutions, LLC . . . . . . . . . . . . . . . . . . 4 www.nexeosolutions.com

The Coatings Group 2012 Events . . . . . . 59 www.coatingsgroup.com

OM Group . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Coatings Trends & Technologies . . . . . . 61

www.omgi.com www.borchers.com

www.coatingsconference.com

OPC Polymers . . . . . . . . . . . . . . . . . . . . . . . 58

Conn and Co. . . . . . . . . . . . . . . . . . . . . . . . . 48

www.opcpolymers.com

www.connblade.com

P.L. Thomas. . . . . . . . . . . . . . . . . . . . . . . . . . 58

DeFelsko Corp. . . . . . . . . . . . . . . . . . . . . . . . 14

www.plthomas.com

www.defelsko.com

Reichhold. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Dow Corning . . . . . . . . . . . . . . . . . . . . . . . . . 7

www.Reichhold.com

http://webinars.pcimag.com

Ross, Charles and Son . . . . . . . . . . . . . . . . . 9

EAG Coatings Solutions (Formerly CAS-MI Laboratories) . . . . . . . 55

www.mixers.com

www.cas-mi.com www.eaglabs.com

www.sartomer.com

Elcometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

www.sasoltechdata.com

www.elcometer.com

Siltech Corporation. . . . . . . . . . . . . . . . . . . 41

Elementis . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

www.siltechcorp.com

www.elementis.com

Specialty Polymers . . . . . . . . . . . . . . . . . . . 58

Emerald Performance Materials . . . . . . . 22

www.specpoly.com

www.emeraldmaterials.com

Troy Corporation. . . . . . . . . . . . . . . . . . . . . 27

Ethox Chemicals, LLC. . . . . . . . . . . . . . . . .64

www.troycorp.com

www.ethox.com

Vicinity Manufacturing . . . . . . . . . . . . . . 58

Evonik Goldschmidt Corporation . . . 31-34

www.vicinitymanufacturing.com

www.evonik.com www.tego.us

Wilden Pump Solutions . . . . . . . . . . . . . . . 17

Sartomer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Sasol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

www.wildenpump.com

Visit ads.pcimag.com 62

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FEBRUARY 2012 | W W W . P C I M A G . C O M

For subscription information or service, please contact Customer Service at: Tel: 847/763.9534 or Fax: 847/763.9538 or e-mail [email protected]

P U B L I S H I N G / S A L E S S TA F F Publisher/ Donna M. Campbell East Coast Sales Tel: 610/650.4050 • Fax: 248/502.1091 E-mail: [email protected] Midwest/ Lisa Guldan West Coast Sales Tel: 630/882.8491 E-mail: [email protected] China Media Rep. Arlen Luo Tel: 0086-10-88579899 E-mail: [email protected] Europe Regional Uwe Riemeyer Manager Tel: 49 (0)202-271690 E-mail: [email protected] Inside Sales Manager Andrea Kropp Tel: 810/688.4847 E-mail: [email protected] Production Manager Brian Biddle Tel: 847/405.4104 • Fax: 248/244.3915 E-mail: [email protected]

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

O P E R AT I O N S S TA F F Single Copy Sales Ann Kalb E-mail: [email protected] Reprint Manager Jill L. DeVries 248/244.1726 E-mail: [email protected]

Have you given up on a formula that doesn’t balance sag resistance and leveling? Have we got a solution for you.

Our new zero-VOC associative thickeners offer great paint properties while minimizing viscosity loss. If frustration over a lack of sag and leveling balance in your formulation is making you see red, RHEOLATE CVS® Associative Rheology Modifiers will help you solve your rheology challenges. Because of their unique polymer design, RHEOLATE CVS®-10 and RHEOLATE CVS®-11 associative thickeners provide an excellent balance of efficient thickening, color viscosity stability, superior color properties, and application rheology. They’re useful in defining the rheology for modern zero-VOC, APEO-free binder systems. This new advanced technology also offers excellent shelf stability and syneresis control. Sometimes thin is in but not when it comes to paints. www.elementis.com 609.443.2000 800.866.6800

Come to Elementis—an innovator in chemistry.

Get to know us better.

[email protected]

Elementis: a leading world producer of rheology, colorants, and surface active chemistry

Ethox Chemical partners with PPS to open a PTFE reprocessing plant at their industrial complex in Greenville, SC.

Our proprietary process designed by Ethox engineers is a quantum step forward in improving the recycling of PTFE vs. older technology utilized by most PTFE reprocessing companies for decades. Due to the effectiveness, processing safety, and environmental stewardship, Ethox has entered into multi-year supply agreements wherein Ethox is assured a continuous, consistent feed of high quality recyclable PTFE. Paralleling our backward integration in PTFE, Ethox has worked closely with the SEM Dept. of Clemson University and a major producer of prime material to design PTFE optimized for ink, paint, and coatings industries. Our process improvement in re-engineering PTFE was validated when a major ink manufacturer reported that Ethox PTFE provided the highest quality results. Combining our improvements in PTFE with our chemical processing expertise, we have developed the first bulkable PTFE Dispersion. We are now positioned to be the global leader in both oil and aqueous PTFE dispersions, as well as powders.

Ethox Chemicals, LLC

For additional information, contact Paul Sullivan 860/277.1620 or [email protected] www.ethox.com