paint and coatings industry may 2010

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May 2010May 2010VO LUM E 26, N UM B E R 5VO LUM E 26, N UM B E R 5

Paint Coatings IndustryGlobally Serving Liquid and Powder Manufacturers and Formulators

Paint Coatings IndustryGlobally Serving Liquid and Powder Manufacturers and Formulators

Color TechnologySustainable Coatings

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Properties Test Method Unit 101T 114T 118C 119N 150N 160N 124T4 131T1 132T1 132T2 141T2 141T3

Average particle size ASTM D4464 microns 6 - 9 4 - 8 4 - 6 4 - 8 4 - 6 5 - 8 16 - 30 4 - 6 4 - 6 10 - 13 10 - 13 14 - 22

Primary particle size

Scanning electron microscope (SEM) microns 0.2 0.2 0.2 0.2 0.15 0.15 N/A N/A N/A N/A N/A N/A

90% ASTM D4464 microns 13 12 10 12 9 13 40 10 10 20 20 35

Melting point ASTM D4591 C / F 323/614 321/610 320/608 320/608 321/610 321/610 325/617 328/622 328/622 327/621 328/622 327/621

Specific gravity ASTM D5675 g/cc 2.15 2.15 2.15-2.2 2.1-2.2 2.2 2.2 2.15-2.2 2.1 - 2.2 2.15-2.2 2.15-2.2 2.1-2.2 2.1-2.2

Bulk Density ASTM D4895 g/l 200 - 500 200-350 250 - 400 250-450 250-450 250-450 300-550 300 - 550 300-550 300 -500 250-400 300 - 500

Surface area ASTM D5675 m^2/g 6.0 - 8.0 6.0 - 8.0 6.0 - 8.0 7.0 - 9.0 11.0-13.0 11.0-13.0 1.0-3.0 3 3 1.0-3.0 1.0-3.0 1.0 -3.0

FDA Status 21CFR 177.1550 175.300 175.300 175.300 177.1550 177.1550 175.300 177.1550 175.300 175.300 177.1550 175.300

The Innovation Principle.Innovation is the most important formula for success. At BYK we know that innovation demands forward thinking about new products and processes, effective services and strong partnerships. It takes imaginative applications of state-of-the-art technologies. Ultimately, innovation requires knowledge, experience and the drive to discover new solutions. That’s BYK’s Innovation Principle – . Put it to work for you. Together, we can help you achieve a decisive competitive advantage.

Visit us at the Asia Pacific Coatings Show 2010, June, 23 – 24, Balai Sidang Jakarta Convention Center, Jakarta, Indonesia, Booth # E1.www.byk.com/innovation

6 Viewpoint

8 Industry News

11 Calendar of Events

12 Company News

16 Names in the News

48 Products

49 Classifieds

50 Advertiser Index

DEPARTMENTS

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.: $104.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $137.00 USD (includes GST & postage); all other countries: $154.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2010, 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 pub-lisher. 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 Bleuchip International, 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].

Audited byBPA Worldwide Associate Member Printed in the U.S.A.

May 2010V O L U M E 2 6 , N U M B E R 5

C O N T E N T S

O N T H E C O V E R : Cover photo courtesy of AkzoNobel.

FEATURES20 “Green” UV Coatings Technology Comes to Total Door,

Allied PhotoChemical Inc.

22 UV-Curable Systems for Sensitive Applications, BASF SE

28 Decorative Finishing Solutions for Automotive Interiors, AkzoNobel

30 The Missing Link: Real-Time UV Monitoring and Measurement, UV Robotics

34 Intelligent Concrete Coating Solutions for Sustainable Construction, Bayer MaterialScience

40 Ultramarine – the Eternal Pigment, Holliday Pigments, Ltd.

42 Bio-Based Materials for UV-Cured Coatings, Ecology Coatings

44 What Carbon Footprint? Anguil Environmental Systems

ONLINE FEATURES w w w . p c i m a g . c o m � New Waterborne Dispersion for Wood and Furniture

Coatings, Bayer MaterialScience

� Microbes in Compost: The Little Heroes Battle Climate Change, Bio Reaction Industries

� Furnishing the Home – Parquet Treated With Waterborne Coatings, ICA Group

� Specialty Silanes Protect the Roof of the Swiss Gotthard Tunnel, WACKER

BUSINESS TOOLS 18 RadTech Exhibitor Showcases

19 Supplier Showcases

28

22

20

MAY 2010 | W W W . P C I M A G . C O M6 � � �

V I E W P O I N TE W P O I N T

The 2010 American Coatings Show & Confer-ence wrapped up on April 15, and the general consensus of the organizers as well as all whom PCI staff spoke with was that the event was a success. Numbers were up from 2008, with 328 exhibitors and about 6,700 overall participants (2008: 331/5,600).

At the trade show, exhibitors from 17 countries (2008: 14) displayed a comprehensive range of prod-ucts on all aspects of coating formulation. Compa-nies from abroad accounted for 23 percent of the exhibitors, and, in addition to the United States, leading countries represented at the show included China, Germany, Canada and India.

Featuring almost 100 presentations as well as 958 par-ticipants from 40 countries (2008: 750/25), the Conference had significantly more visitors than the premiere two years ago. At the Conference, the best presentation was honored with the American Coating Award. Consisting of a $2,500 cash prize and a small sculpture, the award was given to Oihana Elizalde, Stephan Amthor and Collin G. Moore (BASF) for their presenta-tion on “Improving Waterborne Anticorrosion via New Binder Concepts.” In addition, the paper entitled “Role of Nanoparticle/Polymer Interface on Hybrid Coatings Performance,” by Xiao-hung Gu (NIST) and her co-workers received the Roon Award for “Best Technical Paper” at the Plenary Session on Monday.

The first keynote address of the Conference was titled “Sus-tainable Coatings Chemistry: New Product Development through Partnership and Technical Innovation.” The paper was presented by Dennis Ryer, Product Manager for Liq-uid and Powder Resins, Cook Composites & Polymers, and Robert Enouen, Associate Director for Customer Business Development, Procter & Gamble. The second keynote address, titled “Sustaining Innovation and the Environment in Difficult Times,” was presented by Kenneth Perry, Technical Director, North American Automotive Coatings, BASF Corp. He talked about sustainability and the improvement of environmental footprints, as well as innovation of products and processes.

The most important technologies for current and future coatings formulations were hot topics at both the Exhibi-tion and Conference. These included, but weren’t limited to, waterborne technology, low-VOC systems, smart coatings,

reducing the environmental footprint, manag-ing left-over paint, bio-based products, sustain-ability, nanotechnology, energy savings, inte-grated process and renewable resources. It is clear that “Green” technology has taken on even more of an emphasis in recent years.

An ACC survey revealed the top five most impor-tant future technologies according to delegates at the conference. In order from most important to least important, the results were: 1) waterborne,

2) functional/smart materials, 3) high solids, 4) nanomaterials and 5) UV/EB curing.

The Product Presentation booth on the Show floor featured back-to-back presentations hosted by nearly 60 companies throughout the three-day event. A wide variety of coatings topics were covered in-depth, with opportunities for questions following the speaker presentations. Attendees filled the seats in the booth, and there were often many more people stand-ing in the back. A schedule of presentations was posted at the booth, making it very easy to plan your day.

Perhaps the most encouraging news at the show was that all of the exhibitors we spoke to see clear signs of the economy improving. Companies are seeing an increase in sales and projects for 2010. Everyone seemed very optimistic with the direction the industry is moving.

Please visit PCI’s American Coatings Show website at www.pcimag.com/ac_show to read about many of the products and technologies that were exhibited at the show. Our Associate Editor, Karen Parker, blogged live from the show floor, and her reporting provides both informative and entertaining reading! We were truly impressed by both the creativity and the technology displayed at the booths. It was exciting to see the fruits of so much labor, both from the R&D perspective and the marketing side.

The American Coatings Show & Conference is organized by the American Coatings Association, Washington DC, and Vincentz Network, Hannover, Germany, and run by Nürn-bergMesse North America, based in Atlanta, GA. The next American Coatings Show & Conference will take place May 7-10, 2012 at the Indiana Convention Center in Indianapolis, IN. We’re already looking forward to it!

2010 American Coatings Show & Conference a Great Success!

By Kristin Johansson, Managing Editor | PCI

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.

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I N D U S T R Y N E W SN D U S T R Y N E W S

LONDON – IAL Consultants has released a new publication for the radiation-cur-ables sector, entitled Global Overview of the Radiation Curing Market. The study provides an overview of the 2009 market sizes for radiation-curable raw materials and formulations, together with trends that are driving these two segments.

The radiation-curable raw materi-als market reached 378,000 tonnes in 2009, led by the acrylated oligomers and diluents segment, which accounts for 43 percent of all the raw materials in use. Functional monomers comprise one-third of the market, and the near-quarter of the remaining market is occupied by non-acrylated compounds and photoinitiators. The use of most types of radiation-curable raw materials is growing at between three percent and five percent per year.

The global market for formulated radi-ation-curable products amounted to just over 464,000 tonnes in 2009, with sub-stantial variation in the importance of the different product segments between the main regions of the world. In the Europe, Middle East and Africa (EMEA) region, industrial coatings represent the largest segment at 85,740 tonnes, while in the Americas, the graphic arts segment is the largest at 55,900 tonnes. The Asia-Pacific market is led by opto-electronics applications (91,850 tonnes). The fourth key application segment, radiation-curable adhesives, is the smallest in every region, amounting to a global market of just over 16,900 tonnes. Little change is to be expected in any of these rankings over the next five years; the Asia-Pacific market is expected to outpace the other two regional

markets in terms of growth, coming in at between five and six percent per year.

Sustainability is increasingly impor-tant in the European market, and for that reason de-inking is becoming ever more important. In addition, suppliers are looking to include renewable raw materials in their product portfolio.

Good growth in UV-curable inks is expected from many emerging Eastern European markets such as Russia. Some of the smaller countries like Uzbekistan and Kazakhstan continue to demon-strate good growth that is also expected to continue in the future.

In North America, the fastest-growing technology is digital, where good growth opportunities exist in 100-percent-UV and low-viscosity, water-based UV chem-istries. Conductive inks are also receiving an increasing amount of attention.

Japanese companies have looked to China for investment opportunities, and

many have presence and manufacturing there. However, production costs have started to grow in China; therefore, the many Japanese suppliers are turning their interest to other Asian countries such as Thailand, Vietnam and India.

India is another key area of opportu-nity for ink manufacturers. UV-curing inks were introduced to the Indian market a few years ago but have not gained a significant market share. Not many printers are using UV inks for screen-graphics application; the majority of them are predominantly using solvent-based inks. Unless there is pressure from print buyers to adopt environment-friendly practices, the market will continue to be dominated by solvent-based inks.

There is a clear geographic split in the EMEA region when it comes to the use of UV-curable PUDs. It has been estimated that up to 75 percent of these products are consumed within the northern part of Europe, mainly Nordic countries and Germany. These countries have long tra-ditions with wood-based products and also have a much more strict approach to environmental, health and safety issues than the more conservative southern European countries, such as Italy and Spain. There is no reported demand for UV PUDs in the Middle East.

In the Russian wood coatings market, old-fashioned technologies are in plen-tiful supply and new technologies are implemented as a result of importation. As with most countries, the trend will be towards the greater use of water-based and UV-curable coatings.

Study Projects Growth in Radiation-Curing Market

Global UV/EB Technology Event Set for MayBETHESDA, MD – RadTech’s UV & EB Technology Expo & Confer-ence 2010 will be held May 24-26, 2010, in Baltimore, MD. The event features many new offerings including new short courses, new lunch-time-learning lectures and new hot-topic roundtables. The centerpiece of the event is RadTech’s technical conference, once again offering over 100 posters and presentations covering the spectrum of UV/EB technology. Topics will include equipment, renewable and traditional materials, photovoltaics, nanotechnol-ogies, and much more. Over 100 exhibitors will also be on hand to display the latest in UV/EB technologies. Visit www.radtech2010.com for details.

Demand for Carbon Black to Reach 11.6 Million TonsCLEVELAND – World demand for carbon black is forecast to rise 4.3 percent per year through 2013 to 11.6 million metric tons, bolstered by a healthy global rubber market. Gains will be exaggerated to some extent because growth will be rising off a relatively weak base in 2008, when a significant part of the world experienced the beginnings of recession. The vast majority of carbon black finds use as reinforcement material in vulcanized rubber goods, with over 60 percent devoted to motor-vehicle tires alone. Carbon black demand from the tire sector is projected to increase 3.7 percent per year through 2013. The non-tire rubber carbon-black market will expand 4.8 percent per year. These and other trends are presented in


I N D U S T R Y N E W SN D U S T R Y N E W S

World Carbon Black, a new study from The Freedonia Group Inc., a Cleveland-based industry research firm.

The market for special blacks will advance a strong 5.9 percent per year to 1.2 million metric tons. While spe-cial blacks comprise less than 10 percent of the overall global carbon-black mar-ket on a tonnage basis, they command considerably higher per-kilogram prices than commodity furnace blacks. Carbon-black manufacturers will continue to spend a disproportionate amount of their research and development budgets on the special-blacks sector.

The Asia-Pacific region will post the strongest gains in carbon-black demand through 2013. The large markets of China and India will post particular-ly impressive gains due to a continu-ing rapid expansion in their respective motor vehicle and tire industries. China and India saw the largest increases in new carbon-black capacity among all countries of the world over the 2003 to 2008 period, a trend that will continue through 2013. Demand for carbon black in the developed parts of the world will continue to post below-average gains through 2013. Carbon-black demand in the United States and Western Europe will recover from declines experienced in 2008, but growth in both markets will continue to significantly lag the global average through 2013. The Japanese mar-ket holds particularly weak prospects, although growth in the country will be coming off a relatively strong 2008.

Gerard E. Maratta Honored With Sammy AwardMEDIA, PA – Gerard E. Maratta was hon-ored by the Philadelphia Society for Coat-ings Technology as this year’s recipient of the Sammy Award. Maratta was recog-nized on March 11, 2010, in Media, PA.

Don McBride, General Manager of the Heucotech Fairless Hills plant, introduced Maratta to the Philadelphia Society mem-bers. Maratta is Heucotech’s Senior Vice-President. He is responsible for many areas within the company including research and development, tech service, and regulatory affairs. Recently, he led Heucotech’s design and construction of its Universal Colorant plant.

Maratta started his career with Inmont Corp., located in Bound Brook, NJ. He joined Heubach in 1986 as Technical Manager for Graphic Arts & Plastics, working at its

Newark, NJ, plant. Heucotech was formed in 1988, and Maratta was one of the found-ing fathers with Rainer Heubach in setting up the current plant in Fairless Hill, PA.

The Sammy Award is given every year to an individual who has shown expertise in management and technology and is dedicated to the advancement of science in the coatings field.

Task Group to Study Black GlassWASHINGTON, D.C. – ASTM is looking for participants to help study the proper-ties of black glass. ASTM Subcommittee D1.26 on Optical Properties of Coatings maintains a standard (D2805) that speci-fies black glass panels in the test method and refers to “black Carrara glass” in the footnote. Current practice is to use black glass, but not necessarily Carrara.

Subcommittee members want to remove the Carrara specification, but need to study the optical properties of glasses that are acceptable to use, because they know that some black glass panels work well and some are unsatisfactory for the test proce-dure. Therefore the subcommittee wants to form a task group to study the proper-ties of black glass. The subcommittee is looking for people who currently use black glass in their testing or have an interest in this topic to join the task group.

If you are interested in helping, contact D1.26 Chair Nick Barnes at [email protected].

Directory of Industrial Mineral Producers PublishedVICTORIA, Canada – Blendon Informa-tion Services, Victoria, Canada, has pub-lished the fourth edition of Industrial Mineral Producers of North America. The 200-page directory contains informa-tion on over 500 companies in Canada, Mexico and the United States.

Listings include contact names, address-es, telephone and fax numbers, Web sites, e-mail addresses, plant locations, plant

capacities, products supplied, corporate affiliations, annual sales, major markets served, and distributors.

The information is also cross-referenced by products manufactured and mine and plant locations. Visit www.blendon.com for additional information.

Pittcon 2010 Featured Innovations and EducationPITTSBURGH – Pittcon 2010 reported that 16,876 attendees from 87 countries participated in the annual conference and exposition, which was held in Orlando, FL, Feb. 28 to March 5, 2010. The event was marked by a two-percent increase in con-ferees over Pittcon 2006, which was the last time Pittcon was held in Orlando. A detailed summary of attendance is avail-able at www.pittcon.org.

Coating Process Fundamentals Short Course OfferedMINNEAPOLIS – The University of Min-nesota is offering a Coating Process Fun-damentals short course. The course will take place June 8-10, 2010, at the Uni-versity of Minnesota, Minneapolis, MN. The course provides coating engineers and their colleagues an understanding of the principles of the many process-es by which liquid coatings are applied and solidified. The course is designed for engineers who are engaged in coatings and who seek a deeper understanding of processes and processing problems. For more information, visit www.cce.umn.edu/coatingprocess.

Vincentz Network Hosts Fire-Retardant ConferenceHANNOVER, Germany – The European Coatings Conference, Fire Retardant Coat-ings IV, will be held June 3-4, 2010, in Berlin, Germany. Hosted by the Vincentz Network, the conference will focus on cur-rent developments in raw materials as well as mechanisms and standards. A number of high-level technical papers will be given by invited international experts. Topics include: halogen-free retardants for tex-tiles, intumescent coatings for protection of steel structures, clay-polymer thin films for imparting flame-retardant behavior to foam and textiles, and toxic and environ-mental hazards of fire-retardant coatings. The conference will host a pre-conference tutorial, Flame Retardant Fundamentals. Visit www.european-coatings.com for additional information. �

MAY 12-14NW Coatings Fest 2010www.pnwsct.whomedia.com/symposium-ncf

17-21Introduction to Paint Formulationhttp://coatings.mst.edu/index.html

18-19Sink or Swim 2010www.clevelandcoatingssociety.org

18-20Appalachian Underground Corrosion Short

Coursewww.aucsc.com

18-20Advanced Topics in Polymers and Coatingswww.emich.edu/cri

19-21Spray Finishing Technology Workshopwww.owens.edu/workforce_cs/spray2010.pdf

23-26RadTech UV& EB Technology Expo &

Conference 2010www.radtech2010.com

JUNE 2-4Principles and Practices of Coating

Formulationswww.emich.edu/cri

3-4Fire Retardant Coatings IVwww.european-coatings.com

8-10Improving Durability and

Performance of Coatingswww.emich.edu/cri

8-10Coating Process Fundamentalswww.cce.umn.edu/Coating-

Process-Fundamentals-Course

8-10NanoMaterials 2010 www.nanomaterials2010.com

22Ci4000/Ci5000 Weather-Ometer Workshopwww.atlas-mts.com

22-25A&WMA Annual Conference & Exhibitionwww.awma.org

23Fundamentals of Weathering Level Iwww.atlas-mts.com

23-24Asia Pacific Coatings Showwww.coatings-group.com

24Fundamentals of Weathering Level IIwww.atlas-mts.com

JULY 4-1018th International Conference on

Composites/Nano Engineering

http://myweb.polyu.edu.hk/~mmktlau/ICCE/ICCE_Main.htm

19-21Coatings for People in the General Industry,

Sales & Marketinghttp://coatings.mst.edu/index.html

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Evonik to Invest Millions in HTE TechnologyESSEN, Germany – Evonik’s Colorants Product Line is responding to customer demands for a shorter time to market with a million-euro investment in high-throughput experimentation (HTE) technol-ogy. This highly automated experimentation setup, located at the company’s Maastricht, The Netherlands, facility, will serve the com-pany’s global colorant business; it will increase the quality of results as well as reduce the development time for colorant design.

“HTE reduces our time to market to a minimum, enabling max-imum flexibility and rapid handling of lab work,” said Matthias Creutz, Head of Evonik’s Colorants business. “Research has shown that a critical success factor for colorants customers is the time interval between the screening of a new colorant and its market launch. By investing in HTE, we will set a new global standard in the colorant development process, thus providing our customers a clear advantage over their competitors.” Apart from greater flex-ibility and quicker results, HTE technology offers the additional advantage of further improvements in product quality.

Evonik’s Colorants Product Line uses the same standardized procedures throughout its R&D facilities, which are located in the United States, The Netherlands, Australia, China and Brazil. Managed by a team of technical experts, the Colorants Product Line is able to deliver high-quality, consistent results directly to customers at local levels.

Momentive Expands Distribution Agreement With Archway SalesST. LOUIS, MO – Momentive Performance Materials, Albany, NY, has announced the expansion of Archway Sales, St. Louis, MO, as an authorized distributor of its specialty silanes and coatings portfolio into Texas, Oklahoma and Louisiana.

Archway Sales is authorized to promote and distribute Momentive’s specialty silanes portfolio in Arkansas, Florida,

Georgia, Indiana, Kansas, Kentucky, Michigan, Missouri, Mis-sissippi, North Carolina, Ohio, South Carolina, Tennessee, Virginia, western New York, western Pennsylvania, West Vir-ginia, Texas, Oklahoma and Louisiana.

In addition, Archway Sales is an authorized distributor of Momentive’s specialty silicones for industrial, consumer care and select personal-care materials in Indiana, Kentucky, Michi-gan, Ohio, western New York, western Pennsylvania and West Virginia, and industrial materials in western New York, western Pennsylvania and West Virginia. Archway is also the exclusive distributor of SPUR*+ technology materials in the United States.

Dow Coating Materials Focuses on Sustainability at OCCA SeminarHORGEN, Switzerland – Dow Coating Materials’ scientists pre-sented “Coatings Industry Sustainability – Trends, Challenges and Opportunities” at the Ninth Annual Oil & Colour Chemists Association (OCCA) Seminar in Manchester, UK. The presentation, by Houshang Kheradmand, European Technology Awareness and Innovation Manager for DCM, and co-authored by Andrew Trapani, European Technical Director for DCM, focused on identifying sus-tainability trends and opportunities in the global coatings industry, as well as methodologies for integrating sustainable-development criteria across the lifecycle of a product.

The paper illustrated how a cross-disciplinary approach to sus-tainable development involves functions across an entire organi-zation. Kheradmand used examples from Dow Coating Materials to demonstrate how enabling technologies allow paint formula-tors to create innovative products that combine high performance with increasingly optimized eco-designs.

“Last year’s presentation was a more broad-based overview of how globalization, economics, population and ecological conditions affect all facets of the international coatings industry,” said Kheradmand.

SHANGHAI – AkzoNobel’s Internation-al Paint is the sole supplier of protec-tive coatings for the overhaul of the San Francisco-Oakland Bay Bridge. The work involves the complete replacement of the existing east span on the Oakland side, with coating of the new steelwork being carried out in China.

Following the 1989 Loma Prieta earthquake, which damaged a sec-tion of the east span, extensive stud-ies were undertaken to determine whether California’s largest bridges were seismically safe. As a result, it was determined that the entire Bay Bridge required major seismic safety

improvements. The west span has under-gone a major seismic retrofit, while the east span is being completely replaced at a cost of more than $5 billion.

The steel structures are being built by Shanghai Zhenhua Heavy Industry Co. Ltd.; the company chose to use protec-tive coatings from International Paint.

A total of 400,000 liters of Inter-zinc® 22 inorganic, zinc-rich silicate and Interfine® 979 acrylic polysilox-ane, supplied by AkzoNobel Inter-national Paint (Suzhou) Co. Ltd., will be used in this project. These products have the advantages of anti-corrosion, abrasion and impact resistance, gloss, and color reten-tion that meet the rigorous require-ments for the bridge. International Paint is offering a 20-year warranty for this project.

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C O M P A N YO M P A N Y N E W S N E W S

“This year, we will share practical examples of how we use key metrics to quantify the overall eco-impact, carbon footprint and volatile organic compound emissions of a product, as well as reductions in energy and raw-material consumption.”

3V Inc. Announces New Distribution AgreementsDAYTON, OH – 3V Inc., N.A., Dayton, OH, has announced new distribution agree-ments with Dunleary Inc., TCR Industries, EMCO Chemical, LV Lomas, D&F Distrib-uting and DB Becker.

The contact for Dunleary Inc. is John Behan, 800/828.1959. Jim Pasternak is the contact for TCR Industries. Paster-nak can be reached at 714/521.5222. The contact for EMCO Chemical is Michael Wolfe, 847/689.2200. George Robson will be the contact for LV Lomas. Robson can be reached at 800/575.3382. The contact for D&F Distributing is Julia Williams, 214/520.1334. The contact for DB Becker Co. is Dan Canavan III, 908/730.6010.

3V Inc., N.A. manufactures a wide range of additives for the plastics, coating, adhesive and ink industries.

Underwriters Labs and Atlas Form Alliance NORTHBROOK, IL – Underwriters Labo-ratories (UL), a third-party safety test-ing and certification provider, has entered into an alliance with Atlas Material Test-ing Technology, a leader in accelerated weathering instruments and weathering testing services. This alliance benefits both companies with increased global testing capacity and expertise in acceler-ated aging performance. It enables them to provide faster testing and certification turnaround time for manufacturers spe-cializing in solar energy products.

Perstorp Expands in India PERSTORP, Sweden – Perstorp has estab-lished a new application laboratory in India. The laboratory will meet the grow-ing demand for high-quality and tech-nologically advanced specialty chemical solutions in the country. The company is also expanding its sales team in India to support the expansion.

India continues to be a major growth market, with a GDP growth of seven to eight percent per year and rapidly rising stan-dards of living. As the automotive, construc-tion and textile industries continue to boom in the country, demand continues to grow.

Perstorp has also expanded its sales and marketing organization in India to better support its customers and has plans for continued recruitment.

BASF Plans Technical Center for Eco-Friendly Car CoatingsSEOUL, South Korea – BASF is establishing a technical center in Korea that will develop advanced, eco-friendly coatings technolo-gies for the automotive industry. BASF and the Gyeonggi Provincial Government of the Republic of Korea (GGPG) signed a memo-randum of understanding to confirm the collaboration in constructing this center.

The Coatings Technical Center will be located at the Gyeonggi Techno Park in Ansan City, Gyeonggi Province, South Korea. In the center, BASF plans to con-duct research and development of eco-friendly waterborne coatings for use by automotive OEMs as well as the technol-ogy for integrated coating process, which yields more cost-efficient results. The GGPG pledges to provide all the necessary support required to facilitate a seamless establishment and operation. The center will be in operation by mid-2010.

CCP Celebrates AnniversaryKANSAS CITY, MO – Cook Composites and Polymers (CCP) celebrated its 20-year anniversary as a company on Feb. 9, 2010. CCP was formed out of a joint-ven-ture partnership between Total Chimie of Paris, France, and the Cook Paint and Varnish Co. of North Kansas City, MO.

CCP is an industry leader in the coatings and composites markets. It has participated in the purchase or joint-venture partner-ships of approximately 12 manufacturing and distribution companies over its history.

Ferguson/ICC to Distribute for EPS-MaterialsMARENGO, IL/BRAMPTON, Ontario – EPS-Materials, a supplier of resins and colo-rants for the paint and coatings market, has appointed Ferguson/ICC as the exclusive distributor for northern Alberta and eastern Canada. Ferguson/ICC has a strong market presence in coatings, graphic arts, rubber, plastics, adhesives and specialty care.

TH Hilson to Distribute for SoltexWHEATON, IL – Soltex has announced that TH Hilson Co. will become its Mid-west distributor. Soltex product lines span a broad range of specialty chemical prod-ucts. Industries served by Soltex include coatings, adhesives, sealants, rubber, met-alworking, lubricants and consumer care. The new contact for Soltex products can be reached at [email protected].

JNS Smithchem to Distribute for ITPPATERSON, NJ – JNS Smithchem LLC has been appointed the distributor in New Eng-land for International Trading Partners’ (ITP) line of Orisil® and Konasil fumed silicas. JNS Smithchem currently distrib-utes these products in New York and New Jersey, and the territory will be expanded to include the New England states.

Sherwin-Williams Acquires SayerlackCLEVELAND – The Sherwin-Williams Co. has signed a definitive agreement to acquire the Industrial Wood Coatings busi-ness of Arch Chemicals Inc., Norwalk, CT.

Headquartered in Pianoro, Italy, Arch Industrial Wood Coatings trades under the Sayerlack brand name and is a leading coatings innovator in the joinery, furni-ture and cabinets markets. Net sales in 2009 were $147 million.

Founded in 1954, Sayerlack is one of the largest manufacturers of industrial wood coatings in Europe and a technology leader in polyurethane, water and UV coatings.

Sayerlack operates several manufactur-ing sites across Western Europe along with a comprehensive network of sales, techni-cal and distributor representatives serving clients in Asia and the United States. �

For more information, please contact your local Evonik Degussa Account Manager or the Colorants Customer Service department.

Evonik Degussa Corporation379 Interpace Parkway P. O. Box 677Parsippany, NJ 07054-0677

phone +1 800 367-4857 ext. 8958www.evonik.com/colortrend

In a world of infinite colors, we are realizing endless possibilities to design our own environment in safer and more creative ways. Evonik is proud to introduce COLORTREND® 808 High Performance colorants, the latest addition to our portfolio of No-VOC colorants.

Now you can experience broader color space potential for brighter colors, plus high performance solutions for better durability, superior fade resistance, and improved opacity.

With increased flexibility in customization, paint companies upgrading or investing in this latest No-VOC colorant technology can meet growing market demands, exceed environmental regulations and even reduce tinting costs.

As the largest independent colorant manufacturer and a global leader in specialty chemicals, Evonik continues to deliver eco-friendly, innovative, color system solutions. Just one more step to making our world safer, brighter, better – inside and out!

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N A M E S I N T H E N E W SA M E S I N T H E N E W S


� Matt Bestvina has joined Fitz Chem Corp.’s Customer Service Department as a Customer Service Representative. Additionally, Jason Gitt has been named Technical Industry Man-ager; he will help manage Fitz Chem’s expan-sion into the Texas, Oklahoma, Arkansas, Loui-siana and Mississippi markets.

� Dallam (Ted) Blandy has been named Cray Valley’s new Director of Sales. He is responsible for management of sales and customer service for the Americas.

� Gaco Western has hired Kynny Carlson and Greg Stewart. Carlson has been appointed Area Sales Manager for the Arizona territory. Stewart will serve as the new Southeast Regional Sales Manager for the company’s residential WallFoam division.

� Lintech International LLC has promoted Charles Churn III to Product Manager – Additives. Kathy Briggs has recently joined the Lintech team as Product Manager – Resins.

� Infratrol Manufacturing Corp. has appointed Mike Grande as Engineering Manager. Grande is responsible for overseeing Infratrol’s Engineering Department and will be the liaison between engineering and manufacturing.

� Shamrock Technologies Inc. has named Steven M. Parker as its President and Chief Operating Officer. William B. Neuberg will remain Chairman and Chief Executive Officer. Parker served in an advisory role to the Sham-rock leadership team during much of 2009. Additionally, Craig Baudendistel has been named Director of Sales for Shamrock.

� BYK-Gardner has promoted Richard Scott to Director of Key Accounts for North America. The company has also hired Carol Traister as Regional Sales Manager for the Ohio Valley area and Blake Burich as Regional Sales Manager for the Eastern Great Lakes area.

� Frank J. Sutman, of Ashland Hercules Water Technolo-gies, has been designated one of nine TAPPI Fellows for 2010. Fellow is an honorary title given to individuals who have made extraordinary technical or service contributions to the industry and the association.

� Draiswerke Inc. has appointed Leon Von Fintel to the posi-tion of Service Manager. Von Fintel has more than 30 years of industry experience and expertise in mixing, dispersing and milling applications. �

Email: [email protected] l Worldwide Contact information: www.cytec.com l US Toll Free: 800-652-6013 l Tel: 973-357-3193

© 2010 Cytec Industries Inc. All Rights Reserved.

Cytec Coating Resins delivers innovative products beyond our customer’s imagination. We are pioneers in the development and production of high performance coating solutions.Our line of low-VOC coatings, radiation curing and powder coating resins and additives allow our customers to create sustainable change for the industries they serve. For more information, visit us at the American Coatings Show in booth #2625.

Pioneering Sustainable Change


Carlson Stewart

George Lu,General Manager, China Operations

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MANUFACTURED BY H&S AUTOSHOTFOR SITE-APPLIED COATINGS

UV CURING EQUIPMENT

Georgetown, ON • Niagara Falls, NY1-888-677-3798 • www.hsautoshot.com

VISIT US AT RAD TECH • BOOTH NO.908In-house design& engineering!

FUNCTIONAL FILLERS AND EXTENDERS

Superior in Clear Coats

For more information and our complete product portfolio visit:

www.BrilliantAdditions.com

RadTech Booth #1014


Going green? Go here first. www.BYK.com/greenability

RadTech Booth #427

RadTech Booth #725RadTech Booth #725

Cycloaliphatic Epoxy ResinsSynasia is a manufacturer of cycloaliphatic epoxy resins used with UV cationic or conventional curing techniques. Our products are a direct replacement for certain resins.

� UVR-6110/ERL-4221/Syna-Epoxy 21, production capacity: ~2000 ton scale.

� UVR-6105/ERL-4221D /Syna-Epoxy 06� UVR-6128/ERL-4299 /Syna-Epoxy 28� UVR-6107-Syna-Epoxy 07� Synasia supplies Photoinitiators and resin curatives.

Synasia also specializes in custom synthesis and contract and toll manufacturing from our three well-equipped fully integrated manufacturing production sites in China. 631-859-3988www.synasia.com RadTech Booth #906

R A D T E C H U V & E B 2 0 1 0 E X H I B I T O R S

Visit these companies at RadTech UV&EB 2010May 23-26, 2010

Baltimore, MD

Spot light sources for UV curingSpot light sources for UV curingHamamatsu offers spot light sources for UV curing, includ-ing LED- and lamp-based systems. These products offer high output intensity, low heat emission, high stability, and long lifetimes. Our UV-LED light sources (LC-L1, LC-L2, and LC-L3 series) provide monochromatic UV light at 365 or 385 nm. We also offer UV spot light sources equipped with xenon or mercury-xenon lamps (LC8 series).

http://sales.hamamatsu.com [email protected] Booth #918


SU

PP

LIE

R S

HO

WC

AS

ES

Email: [email protected] l Worldwide Contact information: www.cytec.com l US Toll Free: 800-652-6013 l Tel: 973-357-3193© 2010 Cytec Industries Inc. All Rights Reserved.

Cytec Coating Resins is a pioneer in the development of low-VOC coatings, radiation curing and powder coating resins and additives that allow our customers to create sustainable change for the industries they serve. For

more information, visit us at the RadTech UV&EB 2010 show in booth #707.

Pioneering Sustainable Change

watch the video at www.hunterlab.com/Industry/PaintCoatingwatch the video at www.hunterlab.com/Industry/PaintCoating

The MiniScan EZ is a portable color measurement instrument that can be used on the plant floor, the production line, or outdoors to measure the reflected color of your product. Its ergonomic design features a rubberized handle that provides sure-handed carrying and virtually eliminates user fatigue when measuring a large number of samples. The measurements can be stored in memory for later printout or download to a PC.

703-471-6870 or [email protected]

RadTech Booth #929RadTech Booth #929

Flexibility and AffordabilityNow You Get Both In A SinglePulsed UV/VIS Curing SystemX-LITE™ offers low surface heat, rapid curing solutions for a number of demanding UV-curable materials. Features include a high-intensity light source with instant on/off operation for batch processing applications, spot or flood illumination settings and high peak-power UV/Visible pulses. And for OEMs, there’s a flexible X-LITE unit perfectly matched to demanding, low-energy requirements.

XENON CORPORATIONWilmington, MA+1-978-661-9033www.xenoncorp.com

EMD Chemicals Inc.480 South Democrat RoadGibbstown, NJ 08027www.emdchemicals.com

For more information call: [email protected]

Innovative Effect Pigments Designed for Caotings

Iriodin®Colorstream®Biflair®Minatec®

Miraval®Pyrisma®Xirallic®

RadTech Booth # 507RadTech Booth # 507

M AY 2010 | W W W . P C I M A G . C O M20 � � �

“In a time of unprecedented economic uncer-tainty, we have been able to strategically position ourselves to meet the current and future needs of our customers.” Those were the words stated by Patricia Yulkowski,

Total Door® Chief Executive Officer, marking the grand opening of Total Door’s new environmentally con-scious, Feng Shui-inspired, innovative manufacturing and training facility.

What may not have been touted as loudly as the signifi-cant historical event of the grand opening are the impres-sive “green” innovative processes, materials and tools that Total Door has designed into its manufacturing system. Patricia Yulkowski notes that “80% of our material is recycled, and we have significantly reduced the use of volatile organic compounds. Our door systems are also made in the United States, whereas 80% of builder’s hard-ware product is manufactured overseas.”

An exceptional example of one of Total Door’s innova-tive process changes was moving from solvent-based coat-ing to UV coating technology. The move was a major part of the company’s green strategy, and teaming with Allied PhotoChemical, Inc., a Michigan-based UV technology company, delivered the right solution – streamlining the manufacturing process, for Total Door’s needs.

Total Door’s decision to move from solvent-based coating to UV coating technology was based on “sus-tainability” of the technology. UV coating provides a platform for Total Door’s manufacturing based on the following key attributes:

• faster production speed;• reduced work in process;• reduced manufacturing footprint;• reduced energy costs;• reduced quality costs;• cleaner – no VOCs or HAPs; and• cleaner and safer work environment.Sustainable UV coating technology offers a process that

has many benefits that deliver to the bottom line for Total Door. This technology enables the company to run its door manufacturing process at a higher line speed, which offers them more production capacity and flexibility. In addi-tion, the UV coating process offers a cure time of less than two seconds, which offers many benefits, from immediate handling to reduction in quality costs. Also, UV coatings are typically 100% solids, meaning no solvent or water content to deal with – a much greener process.

From a production standpoint, UV coating technology offers Total Door the ability to implement a process that consumes a great deal less floor space, mainly by reducing or eliminating conventional ovens and conveyors. “Work in Process” is virtually eliminated due to the instant cure properties of the UV coating process. With these reduc-

By Michael Kelly and Dan Sweetwood | Allied PhotoChemical Inc., Kimball, MI; and Kevin Joesel, Fusion UV, Gaithersburg, MD

“Green” “Green” UV Coatings Technology UV Coatings Technology Comes to Total DoorComes to Total Door

FIGURE 1 | Overview of Total Door UV manufacturing systems.

Fusion UV Lights on Reciprocators

Fusion UV Lights

Bell System – Spraying

Bell System – Static

PA I N T & C O A T I N G S I N D U S T R Y � � � 21

tions, energy costs are also reduced. One main area of focus for Total Door is overall quality and the costs associated with quality. The ability to immediately inspect UV-coated cured parts is criti-cal to Total Door’s goal to continually reduce quality defects. The UV paint process delivers this capability.

The sustainability of UV coating technology offers Total Door a means to greatly reduce its VOC emissions, as most UV coatings contain no VOCs or HAPs (Hazardous Air Pollutants). Typically, UV coatings offer the manufacturer reduced reporting as well as cleaner and safer work environments.

Total Door Manufacturing FlowFigure 1 outlines the details of the UV coating process at Total Door. The system has two bell atomizers that are reciprocated. The coating is applied electrostatically, ensuring excellent coating coverage.

After the coating is applied, two Fusion microwave UV lights are reciprocated on each side of the product. This ensures that adequate curing of the coating takes place. Figure 1 is a pictorial representation of the UV coating and cure of the UV coating pro-cess at Total Door.

Total Door Color Match CapabilitiesAnother important feature of the Total Door UV system design and implementation is that the UV coating technology provides on-site color matching capabilities.

ConclusionFrom the company’s modest beginning, Total Door’s mission has been, as Leon Yulkowski so humbly put it, “to fill a hole in a wall”. However, on closer examination it is much more than a simple statement. What it stands for is the focus on its customers’ ulti-mate success by providing a highly differentiated custom product to meet specifically determined, valued customer needs, as well as excellent service that makes the installed product look superior and exceed performance expectations. Implementing UV coatings technology to replace a solvent-based system serves as an example of Total Door’s commitment to quality, higher production capa-bilities and a safer work environment for employees. �

Color UV matching system.


New Total Door manufacturing facility, located in Waterford, MI.

Company web shot.


UV curing consists of a polymerization reaction that transforms a liquid resin into a solid film within a fraction of a sec-ond under the action of light. This tech-nology is an effective alternative to con-

ventional printing processes, which commonly involve the use of solvents, and it simultaneously addresses economic and environmental concerns. However, some well-known UV-curing issues still remain to be tackled, e.g., migration of unreacted materials, a potential health hazard, particu-larly in indirect food contact applications, where compo-nents could migrate from the packaging into food. It is of primary importance to find solutions to prevent migration, especially since there is a clear trend today toward reducing multi-layer packaging – for environmental reasons – and, therefore, care must be taken to ensure suitable material selection, curing conditions and printing processes. This paper reports on the influence of curing conditions and photoinitiator migration, with a special focus on photoini-tiator structure, UV dose and curing atmosphere.

IntroductionUV curing has become a well-accepted technology, mainly due to unique environmental and economic benefits compared to conventional drying processes. Solvent-free systems, low-energy consumption and high production rates explain the fast growth of this technology in various industrial sectors such as printing inks, protective coat-ings, adhesives and composites.

In a UV-curing process, a liquid resin is transformed within a fraction of a second into a solid polymer with outstanding mechanical properties. The cure reaction is initiated by means of a photoinitiator that decomposes when absorbing light (Figure 1).1,2

UV Curing in the Packaging IndustryHigh productivity and the superior quality of UV-printed over conventionally printed materials have made this technology especially successful in the graphic arts indus-try. However, to gain full acceptance by the packaging industry, a well-known UV-curing issue still has to be tackled: the migration of additives, e.g., photoinitiators, from the packaging into food. Indeed, after exposure to UV light, the photoinitiator has not been completely photolyzed. Significant amounts remain trapped in the printed ink and can be further extracted from the layer and transferred to the contents of the package.

Type I photoinitiators, shown in Figure 2, directly initiate the UV-curing process by α-cleavage.3,4 Here, concomitantly with the photolysis of the photoinitiator, photodecomposition products are generated, as shown for α-hydroxyketone HK-1.5 Volatile molecules release the film during or just after exposure to UV light and in some cases give off a strong odor, while components with a

By Katia Studer, Sébastien Villeneuve, Emmanuelle Brendlé and Emanuela Chiappini | BASF SE, Ludwigshafen, Germany

UV-Curable Systems forUV-Curable Systems for

SensitiveSensitive ApplicationsApplications

R CH2C

CH2O

OROC O

CH CH2

C OCH2 CH

C OCH2 CH

CCH2 CH

C O

CHC O

CH2 CHC OORO

O

CH

CH CH CO

O R O CO

CH CH2

.

Acrylate oligomer Polyacrylate

Radical photoinitiator

2

O O

UV-light

Radicals R .

FIGURE 1 | Free radical UV-curing with acrylates.


higher molecular weight remain trapped in the cured ink and, like the photoinitiator, can be extracted when enter-ing into contact with an organic or aqueous phase.

A second type of initiating process, shown in Figure 3, involves Type II photoinitiators, which do not undergo α-cleavage when exposed to light but go through a bi-molecular initiating reaction in the presence of hydrogen donors. Type II photoinitiators are essentially based on aromatic ketones (e.g., benzophenone, thioxanthones or camphorquinones). Polymerization is initiated by the amino alkyl radical, whereas the ketyl radical does not initiate polymerization of acrylate double bonds.6,7

Since they do not generate secondary breakdown prod-ucts, they were, until recently, regarded as low-emission photoinitiators but were unfortunately found to migrate significantly. This can be explained by the fact that they are not grafted or attached in the final network.

UV-printed packages are essentially used in indirect food contact applications. Some migrating species are occasion-ally supposed to diffuse from the printed exterior of the packaging to the inside, but the most probable explanation for migration lies in the production process and storage method of packages. Once printed and rolled, the inside of the packaging comes into direct contact with the printed outer surface. This is probably the crucial stage at which small molecules are transferred to the inside, where they will later come into direct contact with the foodstuffs.8

The objective of the following discussion is to dem-onstrate that a combination of the right initiator pack-age and the right processing conditions can actually address this issue and provide a safe solution to the UV-curing industry, which is seeking low-emission and low-migration systems.

ExperimentalProductsThe structures of photoinitiators mentioned in this paper are shown in Figure 4.

FormulationTable 1 shows an overprint varnish (OPV-1) formulation used for reactivity assessments. This formulation was further modified to provide a special overprint varnish (OPV-2) with reduced odor. The UV-curable formulation was applied using a 6 μm-thick wire-wound bar coater.

For migration tests, radical photoinitiators were incor-porated in a radically curable blue flexo UV ink at con-centrations ranging from 2 wt% to 6 wt%. The flexo UV-curable ink was applied on aluminum foil using a Prüfbau printing machine.

UV IrradiationUV exposure was performed on an IST UV belt line equipped with a medium-pressure mercury lamp (from 80 to 200 W/cm) at different belt speeds and under different atmospheres (air or nitrogen with 500 ppm residual oxygen).

MigrationTest samples were immersed in ethanol 95%, placed in a pre-heated oven and left there for 2 hours at 70 °C.

These conditions correspond to the extraction of the photoinitiator from the printed ink placed in direct contact with the food simulant, which does not give the real levels of migration but provides a worst-case scenario, allowing differentiation between several pho-toinitiators. Extracted photoinitiators were quantified by using reversed phase HPLC methods with UV detec-tion. All experiments were performed in triplicate.

O

HO

OOH

O

HO

OOH

O

HO

OOH O

HO

O

H O

OH O

O

HO

O

O

O OHHO

OH

+

Cage reactionSeparation

Recombination

+DH

Polymerization

Combinations, rearrangements, DH

+

+ + +

+

++

HK-1

FIGURE 2 | Photolysis reaction scheme of a substituted hydroxyalkyl phenylketone.

TABLE 1 | Overprint varnish formulation.

Binder Weight [%]

Bisphenol A epoxyacrylate 30.0

Amine-modified acrylate 10.0

Reactive diluent – tetrafunctional 5.0

Reactive diluent – trifunctional 30.0

Reactive diluent – difunctional 25.0

O

N

H

N

H

N

C

+

+

H

+

+

Curing

OH

+

+

Exciplex

+

+

O

FIGURE 3 | Initiation of UV-curing process by a Type II photoinitiator.

UV-Curable Systems for Sensitive Applications


Curing EfficiencyCure speeds were measured by determining dry rub resis-tance (DRR), by transfer testing and by performing the KMnO4 test (optical density measured after 1 min contact). Chemical modifications resulting from acrylate crosslink-ing were monitored by IR spectroscopy with an ATR unit for surface measurements (Digital FTIR Excalibur Spec-trometer FTS 3000 MX). The reaction of the acrylate double bonds was determined quantitatively by monitoring the disappearance of the IR band at 1410 cm-1 and 810 cm-1 – bands characteristic of the acrylate double bond.9

Results and DiscussionCurrent OfferThe ability of a photoinitiator to migrate depends on its type, as reported in Table 2. The results of extraction tests performed on fully cured printed ink containing dif-ferent photoinitiators show that, at a comparable molec-ular weight, the amount of extracted photoinitiator can vary by a factor of more than five, depending on type.

A second factor controlling migration levels is clearly molecular weight. With their enhanced mobility, it is mainly small molecules that are involved in contami-nated beverages. Thus, increasing the molecular weight of the photoinitiator is one alternative way of reducing its mobility and consequently its ability to migrate. However, this is achieved at the expense of reactivity (Figure 6), as shown with high-molecular- weight ben-zophenone photoinitiators whose structure is shown in Figure 5. Those results associated with the molecular weights reported in Table 3 show that there is a direct link between cure speed and molecular weight (HMW-1 and HMW-3), and that one way to address the loss of reactivity is to incorporate lower-molecular-weight spe-cies (HMW-1 and HMW-2). However, this alternative carries with it the risk of losing the benefit of using high-molecular-weight components, as again these small spe-cies are able to migrate even at low concentrations.

In all cases, however, reactivity is significantly lower than that of HK-3 and HK-4, which themselves are ranked as low-emission photoinitiators. Reducing their concentration could allow migration levels to be reduced while achieving a similar cure speed to that of HMW photoinitiators.

These results clearly show that thus far no suitable product, i.e., a photoinitiator with good reactivity and low/no emission, is available on the market.

Development WorkThe structure of HK-3 was modified as shown in Figure 7 to give a high-molecular-weight photoinitiator called MacroPICS so that, once exposed to light, it generates heavy and/or crosslinkable breakdown products with very low migration potential and highly volatile break-down products that simultaneously minimize the migra-tion potential of the photoinitiator and of its by-products and ensure that there is no persistent odor. The molecular weight of MacroPICS lies between 900 and 1200 g/mol.

In the first step, reactivity of MicroPICS was assessed and compared to that of HK-2 (worst case in terms of emission but used as a reference for reactivity), HK-3 and a combination of benzophenone and HK-4. The reactivity of

TABLE 2 | Amount of photoinitiator extracted from a UV-printed film by ethanol 95% at 70 °C (2 hours); 2% PI in blue flexo ink; 500 ppm; lamp output=200 W/cm; belt speed=20 m/min under nitrogen – direct extraction.

Photoinitiator Type Molecular Weight (g/mol)

Extracted Photoinitiator

(μg/dm2)AAK-1 α-amino-ketone ~ 370 9.8

BAPO-1 acyl-phosphine oxide ~ 420 37HK-3 α-hydroxyketone ~ 340 59.1

O O O OO

O

O

O

O

O

O

O

O

O

On

mo

p

OO O+

HMW-1

O

O

OO

OO

HMW-1O

O On O

* *

O

n

HMW-3HMW-2

O OO

O

HMW-2

[OCH2CH2]a-[OCH(CH3)CH2]b-[OCH2CH2]c

FIGURE 5 | Generic chemical structures of HMW photoinitiators.

0

0.1

0.2

Optical DensityKMnO4

Cure Speed(m/min)Cure Speed

>>200 >>200Optical Density

0

40

80

120

160

200

HMW-3HMW-1 HMW-2 HK-3 HK-4

FIGURE 6 | Cure speed and efficiency in OPV-1 containing 10 wt% PI + 2% ethyl-4-dimethylamino benzoate; Hg lamp at 200 W/cm, under air, 6 μm thickness.

PO OO O

N

NO

O

OHO

OH

CHn

BAPO AAK

HK-2

HK-4

OO

OH OH

HK-3

CH2 Rn

FIGURE 4 | Chemical structures of photoinitiators used in this study.

UV-Curable Systems for Sensitive Applications


MacroPICS under these conditions is basically very similar to that of standard photoinitiators (Table 4), confirming that it is practically possible to combine high molecular weight, low polydispersity index and adequate reactivity. Such a product could allow a reasonable photoinitiator concentration, whereas concentrations of up to 15% of the HMW photoinitiators mentioned above are usual.

Extraction experiments were conducted in parallel on UV-printed samples containing MacroPICS and compared to HK-3: the results reported in Table 5 confirm that the increase in molecular weight significantly reduces the ability of the photoinitiator to be extracted from the film under drastic extraction conditions.

Odor developing from films containing MacroPICS and other photoinitiators was also assessed. Two curing condi-tions were defined: in one case, all films were thoroughly cured; in the other, films were cured at the maximum speed that still gave tack-free surfaces (borderline conditions). Again MacroPICS shows by far the best behavior (Table 6).

Oxygen InhibitionDeveloping highly reactive HMW photoinitiators is the key to minimizing migration, but it is also essential to select the right curing conditions. We examined the influ-ence of the curing atmosphere, which directly affects the efficiency of the curing process. Indeed, atmospheric oxygen interferes with free-radical UV-curing processes: the free radicals formed by the photolysis of the initiator are rapidly scavenged by O2 molecules to yield peroxyl radicals,10,11 which do not polymerize the acrylate double bonds and can therefore not initiate or participate in any polymerization reaction. To surmount this issue, which directly impacts cure speed, additional amounts of photoinitiator are traditionally introduced into the formulation, allowing the photoinitiator to compete more efficiently against oxygen scavenging.

Another well-known practice to overcome this prob-lem, which is unfortunately not sufficiently used on an industrial scale, is the utilization of an inert atmosphere, usually nitrogen or carbon dioxide.12 Working under inert atmosphere has many advantages:• it allows a significant reduction in the amount of photoini-

tiator required, while maintaining stable cure speed;• free radicals are more likely to participate in the curing

process and to be grafted to the network;• a limited number of by-products is generated; and• last but not least, crosslinking density is much higher.

All these elements help to reduce photoinitiator migration levels.

The behavior of MacroPICS was thus investigated under inert conditions. In particular, the concentration required under nitrogen to match the cure speed reached when exposed under air was determined.

Figure 8 shows that working under nitrogen allows the photoinitiator concentration to be reduced by a factor of more than 10, as acrylate conversion is close to 90% for the same UV dose, with both 5% MacroPICS cured under air and 0.2% MacroPICS exposed under oxygen-reduced conditions. This very low concentration combined with a low-emission photoinitiator leads to extremely low amounts of extractables.

ConclusionUntil now, the only solutions suggested were not satisfying in terms of emission or reactivity, and the poor purity of commercial high-molecular-weight photoinitiators entailed risks that converters were not aware of. Along with a high molecular weight, which makes it unlikely to migrate exten-sively, the newly developed MacroPICS photoinitiator allows a significant reduction in concentration while still maintain-ing good reactivity, especially under inert conditions.

These results provide a real understanding of the value that can be extracted from UV-curing technology by the printing industry when combining the right photoinitia-

TABLE 4 | Cure speed and efficiency of MacroPICS compared to other photoinitiators in OPV-2; Hg lamp at 200 W/cm, under air, 6 μm thickness.

Photoinitiator 5% MacroPICS 5% HK-2 5% HK-3 2% BP + 3%

HK-4Cure speed (m/min) and

efficiency

Speed OD Speed OD Speed OD Speed OD50 m/min

0.1560 m/min

0.1570 m/min

0.1570 m/min

0.14

TABLE 3 | Molecular weight of the different photoinitiators.

Photoinitiator Molecular Weight (g/mol)HMW-1 ~ 1000HMW-2 From 500 to 3200HMW-3 From 500 to 800

HK-3 ~ 340

TABLE 6 | Odor of UV-printed films containing different photoinitiators and cured under different conditions; 5% PI in OPV-2; lamp output = 200 W/cm under air. Odor ranking: from 0 (no odor) to 5 (very strong odor).

Samples Odor After 24 Hours

MacroPICSBorderline (50 m/min) 2Well cured (30 m/min) 0-1

HK-2Borderline (60 m/min) 5Well cured (30 m/min) 4-5

HK-4Borderline (70 m/min) 3Well cured (30 m/min) 3

TABLE 5 | Migration of different types of photoinitiator in ethanol 95% at 70 °C;2% PI in blue flexo ink; 500 ppm; lamp output=200 W/cm; belt speed = 20 m/min under nitrogen – direct extraction.

Photoinitiator Extracted Photoinitiator (μg/dm2)HK-3 59.1

MacroPICS 34.6

A

O O

OHOH

G

Anchoring Group

Highly volatileleaving products OH

A

OH

FIGURE 7 | Structure of MacroPICS.

tor with the right processing conditions. The packaging indus-try gains a new vision, as it becomes possible to achieve very low emission levels using this technology. This thorough work should open up new application fields to UV-curing and allow

significant growth for food applications in the flexible packag-ing, folding carton and label markets. �

AcknowledgmentsThe authors would like to thank Dr. G. Weidenbrück and A. Metzger for checking the article, as well as B. Spony and G. Haller for the experimental work.

References1 Decker, C. Pigment & Resin Technology 2001, 30 278.2 Decker, C. Macromol. Rapid. Commun. 2002, 23 1067/3 Decker, C. Materials Science and Technology, Processing of Polymers, ed. by

H.E.H. Meijer, VCH Verlagsgesellschaft mbH, Weinheim, 18 (13), 1997.4 Crivello, J.V.; Dietliker, K. Chemistry and Technology of UV&EB Formulation for

Coatings, Inks & Paints, G. Bradley Ed., John Wiley and Sons, New York, Sita Technology Ltd, London, Vol. 3, 1998

5 Masson, F.; Decker, C.; Andre, S.; Andrieu, X. Progress in Organic Coatings 2004, 49 1.

6 Cook, W.D. Polymer 1992, 33, 600.7 Segurola, J.; Allen, N.; Edge, M.; Parrondo, A.; Roberts, I. J . Photochem. Photo-

biol. 1999, A, 122, 115.8 Simian, H.; Veyrand, J.; Klump, S.; Spack, L.; de la Cruz García, C.; Papilloud, S.

4th International Symposium on Food Packaging, November 2008, Prague.9 Decker, C.; Moussa, K. Makromol. Chem. 1988, 189, 2381.10 Claveyrolles, L.; Villeneuve, S. Radtech News 2000, 3, 4.11 Decker, C. Handbook of Polymer Science and Technology, 3 (1989), 541.12 Studer, K.; Decker, C.; Beck, E.; Schwalm, R. Progress in Organic Coatings 2003,

48, 92.

This article is based on the presentation “UV-Curing Systems for Sensitive Applica-tions” given at the European Coatings Congress, 2009, in Nuremberg, Germany, by Katia Studer, BASF SE.

For more information, contact [email protected], or call +41 61 63 64083.


50

60

70

80

90

100

5%Air

0.2%

Acrylate Conversion (%)IR band at 1410 cm-1

IR band at 810 cm-1

500 ppm remaining oxygen[MacroPICS]Atmosphere

FIGURE 8 | Acrylate conversion of OPV-2 containing different concentra-tions of MacroPICS exposed under air and nitrogen atmospheres; Hg lamp at 200 W/cm; 50 m/min; 6 μm thickness.

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Once upon a time in a land far, far away, gas stations were called service stations and they had a team of atten-dants to pump your gas, clean your windshield and lift the hood to check

your oil every time you filled up…and gas cost less than 30 cents per gallon. To many of today’s kids, this is as much of a fairy tale as Cinderella or Snow White.

Is it any wonder why automobile designers install both oil dip-sticks and dashboard oil warning lights? Wouldn’t just one of these suffice?

Obviously, while these measurement devices are related, they measure different oil properties and have markedly different functions. The risk of driving your car without enough oil is important enough to merit constant vigil – and you obviously can’t check the dip stick while driving. On the other hand, the need for absolute oil level measure-ments during maintenance (like oil changes and tune ups) or to provide mechanics with a quantitative measure when diagnosing engine problems requires the dip-stick.

Despite the risks, most UV systems operate without a warning light or a dip-stick. (“Dip-stick” in this case refers to a test or measurement device and not a person running the line.) Even the best-managed lines too often rely only on periodic checks with a belt radiometer as the means of measuring UV cure. But, like driving without a warning light, the potential damage that can occur by operating a

UV line without a warning light should stop operators in their track and cause them to consider the value of adding real-time UV measurement.

Having worked on literally hundreds of production lines, it’s ironic that while almost no system designer would sup-ply a thermal convection oven without a process thermo-couple, we rarely see a system with a real-time UV sensor installed. This is ironic considering that UV curing is often associated with high-speed production for things like print-ing, optical fiber, packaging, CD/DVD manufacturing, or high-speed wood finishing lines. These are applications where an undetected problem could mean hundreds, even thousands of bad parts in just hours. By the time these guys break out their belt radiometer it’s far too late. It is locking the barn door after the horse has gone.

The Big Three automakers tackled this problem during the 1990s when they drafted the QS-9000 standard that required process monitoring rather than allowing suppli-ers to rely on finished parts inspection alone. They real-ized that preventing defects and not just fixing them was the key to cutting costs.

Fortunately, the technology to continuously monitor UV curing not only exists, but is easy to implement, and cost-effective. This paper describes what you need to mea-sure to safeguard your line and how to do it.

Changes to UV Output in the Real WorldIn day-to-day operation, UV lamps, particularly arc lamp systems, show a pronounced drop in irradiance over time. Like a spark plug, continuous and repeated use cuts the lamp’s life from the first time it’s fired. It’s not unusual to see a 50% change in output after less than 1,000 hours of use.

Cleanliness of the reflector, changes in cooling, and power supply problems can all impact irradiance. So can any changes in distance of the lamp to the part or angle of the bulb that might occur from handling during maintenance.

What to Measure?There are two parameters of UV curing that most users should measure regularly: peak irradiance and energy density. Let’s take a quick look at what each of these terms means.

By Paul Mills | UV Robotics, Cleveland, OH; and Jim Raymont | EIT Instrument Markets, Sterling, VA

The Missing Link: The Missing Link: Real-Time UV Real-Time UV Monitoring and Monitoring and MeasurementMeasurement


Irradiance: In lay terms, this measures how “bright” the UV lamp is. Irradiance can be affected in a number of ways: by “increasing the wattage” just as you might by switching from a 25W to a 60W light bulb, or, by “turning up or down” the intensity through a variable power sup-ply. The common measure of irradiance is Watts/cm2.

Energy Density: Time is the second factor critical to proper curing, and this is referred to as energy density. You may also hear it called “dose” even though this term does not accurately fit. As sun-tanners can attest, it’s not just the intensity of the UV source that produces their glow, but exposure time. A few seconds in even the bright-est sunlight won’t produce a bronzed body.

To produce properly cured products, both irradiance and time must be within the prescribed material specifica-tion. Like most cooking recipes that require a certain time and temperature, UV recipes usually require minimum irradiance and exposure time (energy density). The com-mon measure of energy density is Joules/cm2. (This is a simplification and assumes that you have the right type of UV source for your formulation and that other process parameters are controlled and maintained.)

Belt Radiometers versus On-Line SensorsThe conventional approach to checking UV system performance (in those refreshing instances where it’s being done) usually relies on running a logging radiom-eter through the system. The belt radiometer is the ideal tool for this purpose.

The latest generation of belt radiometers records peak irradiance and energy density over a number of important UV bands simultaneously. Since the belt radiometer mim-ics a production part, it provides very useful information about the UV exposure of production parts.

The belt radiometer, like the car dip-stick, provides an absolute, quantitative evaluation of cure. Its values can be compared to the material specification as an indicator of how the process is running, and provides enormous insight when troubleshooting is needed.

But since it is a data logging device, it cannot pro-vide the continuous, real-time monitoring needed to detect problems that might occur between data col-lection runs. For these continuous measurements, a simple sensor integrated either into the process cham-ber, or installed into the UV source itself, provides a simple but effective solution.

These sensors provide continuous irradiance data, which when combined with line speed monitoring and control, provide an added layer of process security. So the prudent operator will utilize both tools: a logging belt radiometer for quantitative, absolute data required for establishing, optimizing, maintaining and trouble-shooting the process; and a compact, on-line sensor to

continuously watch for changes in UV output. Again, these devices aren’t any more redundant than a dip-stick is to a warning light.

Selecting and Installing Real-Time UV MonitoringHaving determined that a warning light on your UV line can save you time, money and perhaps some gray hair – how should this device best be designed and inte-grated into the system?

The best solution embodies a few topics: sensor selec-tion, sensor placement and data handling.

Sensor Design and SelectionThe ideal UV sensor must embody a number of features. First it must be compact enough to be located in the sys-tem, often in close quarters, without interfering with the production process. Today’s sensors measure as small as 0.57” x 0.60” x 0.75” (1.45 x 1.52 x 1.91 cm), making them a truly compact device. These sensors are even avail-able with a purge design which allows a whisper of low-pressure air or nitrogen to keep the sensor window clean even in dirty environments where airborne contaminants might interfere with measurements.

The sensors are available in a variety of fixed spectral bandwidth responses (UVA, UVB, UVC, UVV) that cover short, mid and long wave UV. Each sensor incorporates a single bandwidth in the optics of the sensor. The actual bandwidth that you decide to use for the sensor is based upon a combination of things including formulation, lamp system, bulb type (mercury or mercury-additive), process window and application. An application with a relatively steady UV source can go ‘out of spec’ because reflectors and/or quartz plates/tubes get dirty and less UV is transmitted to the cure surface. In other cases, it is more important to monitor changing output conditions from the actual source. Some customers may decide to moni-

“When you can measure what you are speaking about, and express it in numbers, you know something about it; but when you cannot

measure it, when you cannot express it in numbers, your knowledge is of a meager and unsatisfactory kind.” -Lord Kelvin

The Missing Link: Real-Time UV Monitoring and Measurement


tor the source with a long wave sensor (UVA or UVV) and reflectors with a short wave (UVC) sensor.

One of the daunting challenges to sensor design is mak-ing a unit tough and stable enough for the extreme expo-sure in high-intensity UV applications where extreme UV irradiance and heat are common. The compact sen-sor has been designed to withstand thousands of hours of direct exposure to UV without noticeable degradation. For example, solarization, which is the deterioration of optical components common with exposure to intense UV light has been virtually eliminated in the latest generation of sensors. These sensors supply an analog output signal, proportional to the UV light exposure to an electronic interface.

Sensor LocationWhile the compact and rugged design of the sensor provides a great deal of flexibil-ity in where the sensor can be mounted, some locations make more sense than others. Locating the sensor near or in the lamp itself has several advantages, since it provides the most direct measurement of the light source. The sensors have a narrow field of view and on multi-lamp systems, individual sensors can supply data for each lamp without the confusing effects of exposure to several lamps at a time. But great care should be taken with mounting a sensor in the lamp housing, and the lamp manufacturer needs to be consulted. The sensor should not inter-fere with the proper or safe operation of the lamp.

Fortunately, a few lamp manufac-turers are now warming to the idea of installing these sensors in the lamp during construction. The relatively small incremental cost of this valuable feature makes sense and we expect to see more lamps with built-in monitor-ing in the future.

Sensors can be installed viewing the lamp in many locations provided that the temperature is below 100 °C. Typically a sensor just a few inches from the lamp will provide suitable conditions. Adjusting the sen-sor so that it “looks at” the reflected light and not directly at the bulb provides useful data, since the condition and efficiency of the reflector can account for a significant proportion of the UV available for curing, (and is directly proportional to the direct output of the bulb anyway).

Alternatively, the compact sensor can be installed in the process chamber where it observes the lamp or reflected light. Recall that with online monitoring we are more concerned with relative, minute-to-minute changes in measured UV rather than in the value of the absolute reading itself. This premise allows greater latitude in locating sensors.

Data Handling and IntegrationAssuming you have chosen the right sensor and properly positioned it to monitor your lamps, the only remaining question is what to do with the sensor output. The sensor provides an analog signal, which varies proportionally with the incident UV light. Sensors can be connected directly to a self-contained, pre-engineered interface which provides a real-time read out, alarms and other features, or connected to a standard DIN rail signal pro-cessing module that converts the signals into a standard

0-10 volt signal that can be utilized by industrial PC or PLC control systems.

The simplest UV intensity display mod-ule provides a straightforward display of a single lamp’s status. The module pro-vides the capability of setting a reference point, typically the 100% output level of a new lamp. The digital readout shown on the panel mounted unit can then pro-vide a continuous “percent-of-power” reading that compares the current con-ditions to the UV conditions when the bulb was new and reflectors clean. A user-settable low-threshold limit can also be programmed into the module, which will provide both a visual warn-ing light (your dashboard oil light!) and activate a relay closure so that additional actions can be triggered when the lamp is not operating within the process win-dow. These simple pre-assembled panel mount modules are easily integrated into any existing system and engineered to be easily installed in the system elec-trical enclosure.

A more sophisticated, 4-lamp ver-sion of the panel mount display, dubbed Multibrite®, allows simultaneous moni-toring of four sensors. A user select-able dial on the interface allows the percentage of full power of any of the four sensors to be displayed as well as quick visual monitoring of the status of all four lamps with audible and LED

alarms and relay closures. The Multibrite is fully assem-bled and self contained, and is supplied in a standard 19’ rack mount enclosure for easy installation.

For those plants that desire a more customized solu-tion, the compact sensor and DIN rail transceiver are the building blocks for a completely flexible architecture. The module processes the compact sensor signal and provides a corresponding 0-10 volt analog signal that can be fed to an appropriate PLC or PC control system. Customized screens including password protection, alarm thresholds, data graphing, data export for statistical process control and other features can be designed. �

For more information see www.eit.com or www.uvrobotics.com.

“In God we trust, all others bring data.” -Dr. W. Edwards Deming

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As sustainable requirements become more prevalent in most construction projects, coatings technologies have been forced to evolve or go extinct. Because of their widely adjustable attributes, polyure-

thane coatings can be formulated to provide the durabil-ity, renewable content, and VOC requirements now speci-fied by many of the Green Building guidelines. Regarding durability, few coating solutions exist for protecting con-crete in the built environment that have the long-term, proven performance of those based on polyurethane tech-nology. In addition, as VOC and indoor air pollutant limits have shrunk, polyurethane coatings have continued to excel by meeting new regulations through increased durability and faster return-to-service times.

IntroductionMany solutions have been discussed regarding macro components of the built environment such as concrete, metal, wood and lighting. However, there are many intel-ligent ways that minor components such as coatings can greatly impact the overall sustainability of a structure

by improving the indoor air quality, lighting efficiency, renewable content, graffiti resistance or long-term dura-bility of major design components.

Waterborne coatings products and plant-derived reac-tive polymer resins have gained in popularity due to increased environmental awareness and the polymer industry’s efforts to quantify the carbon footprint of many ubiquitous industrial, building and construction products. Early waterborne-based polyurethane coatings required the end user to compromise on physical proper-ties as compared to solventborne technologies. In the past, many natural oil-based resins or additives often referred to as Natural Oil Polyols, (NOPs), were used to supplant their petroleum counterparts but often compromised at least some of the desirable traits needed for the final end-use application. With a focus on Sustainability and Green Building practices, many U.S.-based coatings formulators, end users and building owners are requesting products with low VOC or 100% solids, as well as a significant renewable content.

Natural Oil Polyol CoatingsCurrently, NOPs are commercially available in the United States from several sources and in several different forms. These polyols have been formulated into products requir-ing minimal structural or tensile properties but can help the bulk finished polymer satisfy other require-ments such as rigidity, flexibility or insulative needs. For example, soy-based polyols can be used for polyurethane foam production and have suitable properties for foamed applications.1-3 However, their properties haven’t proven to provide the necessary physical properties needed for high-performance coatings. Castor oil has been looked at both in its unmodified state and as a chemically modified derivative in the coatings and adhesives markets. Many of these products are derived from castor beans grown in the top producing countries such as India, China and Brazil due to the current limited United States demand for locally grown and sourced resins (Table 1).4 With consistent and

By Steven Reinstadtler, Market Development and Green Building Manager | Bayer MaterialScience LLC, Pittsburgh, PA

Intelligent Concrete Coating Solutions for Intelligent Concrete Coating Solutions for

Sustainable Sustainable ConstructionConstruction

TABLE 1 | Top 10 castor oil seed producers – June 2008.

Country Production (in Tons) FootnoteIndia 830,000 *China 210,000 *Brazil 91,510

Ethiopia 15,000 FParaguay 12,000 FThailand 11,052Vietnam 5000 *

South Africa 4900 FPhilippines 4500 F

Angola 3500 FWorld 1,209,756 A

No symbol = official figure, F = FAO estimate, * = Unofficial/Semi-official/mirror data, A = Aggregate (may include official, semi-official, or estimates)

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repeatable supply, modified castor oil-based coatings have been successfully developed into formulas that address both on-site and end-use challenges while providing the market with highly-renewable content products.

Two-Component Waterborne Polyurethane CoatingsFor decades, solventborne polyurethane coatings have been considered the mainstay for high-performance coat-ings used in architectural, industrial maintenance, corro-sion and construction applications due to their excellent mechanical and weathering properties. But increased governmental, regulatory and sustainability pressures have created a need for coatings technology that would reduce or eliminate VOC, HAPS, heavy metals and/or other environmentally detrimental compounds. In the past decade, the first generation of waterborne polyure-thane coatings was formulated and introduced to the market. While offering the chance to replace some of the VOC and solvents with water, many of these coatings still had in excess of 250 g/L of co-solvent. In addition, these coatings often fell significantly short of the solventborne polyurethane standard in chemical, abrasion and UV resistance. This limited their use in many applications. As with most emerging technologies, the learning curve was steep and the second generation of waterborne poly-urethane coatings was developed with the goal of meeting or exceeding the desired traits of the solventborne poly-urethane coatings but with significant reductions in VOC and solvent levels. These second-generation waterborne polyurethane coatings have achieved the property goals and are “truly waterborne” – having 0-20 g/L VOC levels.

Natural Oil Polyol CoatingsExperimentalTo obtain desirable coatings properties, several castor oil-based resins were formulated. All three of these NOP prod-ucts are created by hydroxyl modification of castor oil. Castor oil has linolic, oleic and linoleic functional groups that can be further modified to form functionally active reactive sites. Functionality is adjusted to a desired point above 2.0 for optimized polymerization with minimal chain termination when reacted with a polyisocyanate. The long (16+) carbon chains of the modified castor oil give the polymer its unique strong hydrophobic nature. This hydrophobic trait helps the product to resist atmo-spheric moisture during the on-site application process as well as after the polymer has fully cured into the final end-use protective coating.

A range of NOP polyol resins were created to aid in the formulation of several different types of coatings used in the built environment. One was created to maximize renewable content while several others gave the formula-tor the ability to obtain a range of durometers and vis-cosities. Table 2 summarizes the bulk properties of three modified castor oil resins that can be used to formulate high-performance coatings described later in this paper.

These resins were then formulated into guide formulas for flooring and architectural coatings technology with the target of acquiring the following attributes:• 100% solids formulas with near zero VOC, HAPS or

exempt solvents;

• no added phthalates, heavy metals or formaldehyde; • finished coating to contain >35% by weight of renew-

able content as formulated; and • durability comparable to competitive petroleum-based

resin systems.

To formulate the coatings, additional components such as flow aids, deaerators, fillers and pigments are typically employed to maximize the desired traits for application and end use. Therefore, guide formulas are typically developed that include both the resins as well as these other needed components (Table 3). The end-use application considered within the scope of this research was self-leveling floor coatings so guide formulas were developed to target those properties. The resin or polyol blends were prepared in step-wise fashion to effectively disperse the needed additives and

TABLE 2 | Natural oil polyol attributes.

Properties Units Desmophen 1145

Desmophen 1150

Desmophen 1155

Type

Branched polyalcohol with ether and ester

groups

Polyalcohol with ether and ester

groups

Branched polyalcohol with ether and ester

groupsRenewable

content% 55 70 55

Equivalent weight 239 340 340Hydroxyl number mg KOH/g 165Viscosity at 23 °C cps 2950 ±250 3500 ±500 425 ±75Density at 20 °C g/ml 1.01 1.01 0.99Water content % ≤0.2 ≤0.2 ≤0.2

Use and attributes

Harder resin,

slightly hydrophilic,

used as modifier

Workhorse, general purpose

resin, hydrophobic

nature

Softer resin, slightly

hydrophilic, used as

modifier

TABLE 3 | NOP guide formulas.

Component 1 Percent by WeightBayer NOP Formula 1

Bayer NOP Formula 2

Bayer NOP Formula 3

Desmophen 1150 38.1 26.4 26.4Desmophen 1145 - 8.9 8.9Molecular sieves 7.6 7.2 7.2

Barytes 32.0 - -TiO2 3.7 1.7 1.7

Pigment composition 1.2 - -Deaeration agent 0.4 0.45 0.45Dispersing agent - 0.45 0.45Defoaming agent - 0.45 0.45

Quartz filler - 31.8 31.8Talc - 4.0 4.0

Fumed silica - 0.30 0.30

Component 2

Desmodur VL 17.0 18.01 -Desmodur VL 50 - - 18.01

Intelligent Concrete Coating Solutions for Sustainable Construction


pigments into the blend. Vacuum dissolvers have proved ideal as they prevent the incorporation of air.

Sample coating draw downs were prepared using com-binations of the Desmophen® NOP polyols, additional additives and a hardener. In this case, the hardeners chosen were Desmodur® VL or VL 50 reactivity-modified MDI isocyanates. The crosslinking NCO/OH ratio was set at 1.10 for all films and the mixing ratio of the resin blend with the isocyanate was approximately 10:2.1 (resin blend:hardener). The working time or potlife for all of the blends was approximately 30 minutes at 23 ºC.

The films were made at a thickness of 1.5 mm and allowed to cure for a minimum of 7 days before test-ing. It was noted that the films did not exhibit the customary reaction with ambient humidity often seen when curing MDI isocyanate-based coatings in humid environments that can cause defects such as bubbles, blisters or fish eyes. The isocyanate groups can react with dissolved or absorbed water to form urea. This pro-cess liberates CO2 gas bubbles, which can be caught in the film and cause diminished physical properties and aesthetics. After ambient curing, the test samples were subjected to physical property testing.

DiscussionThe testing results on several guide coating formulas yielded acceptable results for a self leveling floor coat-ing type product (Table 4). These results suggest the applicability of these coatings in a wide variety of floor refurbishment uses including the reuse of badly spalled or worn concrete. Current Green Building practices prefer the reuse of former industrial and heavy use built environments into new commercial or retail uses. By eliminating the need to remove and replace damaged concrete due to the aesthetically unappealing surface, energy and materials can be saved. A self-leveling floor coating, especially one based on a high renewable con-tent, offers designers and specifiers an alternative to concrete replacement when evaluating a building for floor remediation and eventual renovation.

An additional trait noted when working with these types of NOP resins is the reduced effects of atmospheric moisture in the form of humidity on the application, speed and cure characteristics of the technology in the field. Contractors and coatings applicators often apply f loor coatings when relative humidity levels are fairly high, resulting in bubbles or blisters in the film. These defects are caused in part by the reaction of the water in the air with components of the liquid coating. Since the NOP resins are very hydrophobic, they limit the effects of atmospheric moisture on the quality of the final coat-ing. This makes the products easier to use in a variety of field application conditions.

All three formulas that were tested satisfied the tar-get requirements: near zero VOC, a renewable content over 35% and the lack of added heavy metal catalysts or phthalates.

Two-Component Waterborne Polyurethane CoatingsExperimentalSeveral waterborne resins were considered within the scope of this paper for use in the construction environ-ment due to their desirable physical traits (Table 5). These traits include:• near zero VOC formulas with excellent abrasion, chemi-

cal, and weathering resistance;• no odor when applied in the field with other trades or

building occupants present;• adjustable gloss levels from high gloss to matte; and• ability to be used as an acceptable topcoat for self-

leveling high renewable content floor coatings.Similar to the development and testing for the self-lev-

eling NOP-based coating, these criteria will be the targets for the research.

Guide formulas were prepared using two Bayer water-borne resins along with the necessary additives (Table 6). The gloss levels were varied via the resins employed in the formula rather than the use of flattening aids. Bayhy-dur® XP 2547, a hydrophilic HDI trimer, was used as the hardener with a NCO:OH ratio of 3:1. This over-indexing can be accomplished with aliphatic isocyanates without detrimental bubble formation.5 The guide formula coat-ings were applied at approximately 4-6 wet mils with a dry mil thickness of approximately 2-3 mils per coat. Dry

TABLE 5 | Waterborne resin attributes.

Properties Units Bayhydrol® A 2542 Bayhydrol A 2546Hydroxy functional

polyacrylic dispersionHydroxy functional

polyacrylic dispersionSolids content % 50 41

Equivalent weight 630 1000pH 7.5 7.5

Viscosity at 23 °C cps 2000 120Weight/gal @ 25 °C lbs 9.5 9.2Use and attributes High gloss resin Matte resin

TABLE 4 | NOP guide formula physical properties.

Test Units Bayer NOP Formula 1

Bayer NOP Formula 2

Bayer NOP Formula 3

Tensile StrengthDIN EN ISO 527

MPa 13 15 11

Elongation at BreakDIN EN ISO 527

% 70 40 83

Tear Propagation ResistanceDIN EN ISO 34-1

N/mm 50 41 63

Shore Hardness D D 65 70 51

TABLE 6 | 2K waterborne guide formulas.

Component 1 Percent by WeightBayer Gloss Formula Bayer Matte Formula

Bayhydrol A 2542 45.75 15.26Bayhydrol A 2546 - 35.60

Deaerating additive 0.31 0.32Defoaming agent 0.12 0.14

Flow and leveling additive 0.49 -Rheology additive - 2.28

Water 14.2 9.61Component 2

Bayhydur XP 2547 39.1 36.79

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times for the coatings ranged from 2 hours for the matte formulas to approximately 6 hours for the gloss formula. The trend was noted that as the formulas were made to be less glossy, i.e., as more Bayhydrol A 2546 was used in the formula, the dry time was reduced. The Bayhydrol A 2546 resin is a faster curing resin when compared to the Bayhydrol A 2542 resin.

DiscussionBased on the excellent abrasion, chemical and weather-ing resistance data that was observed, several areas of coatings use in the built environment were targeted for further testing. These include aliphatic light and weather stable topcoats for industrial, commercial and decorative flooring as well as graffiti-resistant wall coatings.

Over the past few years, an increasing trend has been to promote greener technologies in the interior construc-tion of buildings. The primary focus has been on the release of toxic substances that may build up in the air due to the enclosed space. Indoor environmental air qual-ity guidelines have been written into many third-party certifications such as Green Seal, GreenGuard and others. For example, Green Seal GS-11 cites limits and exclusions of certain compounds such as formaldehyde and VOCs for use on the interior surfaces of building being considered for LEED certification.6 Proof of these trends comes in three major areas – stricter Federal VOC regulations via

the National AIM Rule, increased communication and awareness of environmental issues impacting consum-ers, and increased sensitivity to solvent odor by building occupants and tradesmen. Changes made by California to its VOC regulations are expected to be adopted by other states. Parts of California instituted a 50 g/L limit for residential flooring applications and 100 g/L limit for commercial applications in 2006. These limitations severely restrict the coating systems that can be used in the flooring market.

For floor coatings used as a topcoat, there are several desirable physical properties that are required in order to have an aesthetically pleasing and durable finish. Abra-sion resistance is a key parameter when considering the durability. Chemical resistance also plays into the durabil-ity equation since many industrial flooring applications can be exposed to common chemicals such as gasoline, brake fluid, solvents, acids and bases, and staining agents. Another desired property for topcoats is the ability to apply the flooring system without offensive odors that can disrupt production or other activities in the adjacent areas. The testing results demonstrated that the 2K water-borne coating guide formulas fulfilled the desired physical properties and traits while greatly reducing the VOC, HAPS and solvent levels (Table 7). In particular, both the gloss and matte guide formulas had very low abrasion and odor while exhibiting excellent resistance to many ubiqui-tous industrial and commercial chemicals.

Another application area for these types of 2K water-borne coatings is graffiti-resistant coatings. This class of coatings is under the same scrutiny and tight regula-tions for VOC as floor coatings. In addition to the drivers outlined previously for flooring topcoats, there is often an additional requirement for graffiti-resistant coatings – the ability to adjust the gloss level while retaining the excel-lent chemical resistance that is needed for the coating. The external concrete and steel on a building is looked at as an integral design element by the architect. The architect envisions a certain look to the building and does not want to change that look by the addition of a protective coating. Therefore, there has been resistance to the use of other graffiti resistant coatings on the exterior of buildings that change the look or gloss level of the coated area. Typically, the undesirable trait is the noticeably higher gloss on the exposed architectural concrete. In the case of the Bayer Matte Formula defined in Table 6, a very low-gloss, matte finish was achieved by utilizing a Bayhydrol A 2546 resin instead of solvents and flattening additives.7 This allows the coating to retain the excellent graffiti resistance with minimal to no effect on the aesthetics of the concrete. This is achieved while working with a coating with less than 15 g/L of VOC.

The ability to dial in the gloss level was further investi-gated and it was found that by varying the ratio of the two Bayhydrol waterborne resins, many gloss levels could be achieved (Figure 1). The trend line shows that 60º gloss levels from approximately 90 down to nearly 5 are achiev-able and predictable at all levels in between. This ability to vary gloss levels has utility in the flooring industry as well, since a slightly lower gloss topcoat can favorably hide imperfections in the underlying flooring substrate.

TABLE 7 | 2K waterborne guide formula physical properties.

Test Units Bayer Gloss Formula

Bayer Matte Formula

60º Gloss 90 < 10VOC g/L 8 15

Taber Abrasion CS-17 wheel1000 cycles

mg loss 33 35

Odor level Very low Very lowChemical resistance* Very good Very goodHardness, Pendulum sec. 184 162

*Chemicals tested by a spot test included 10% acetic acid, 10% sulfuric acid, 10% hydrochloric acid, 14% ammonium hydroxide, 50% sodium hydroxide, isopropanol, methyl ethyl ketone, DI water, Betadine, 10% bleach and gasoline. Skydrol and brake fluid were tested by immersion.

0102030405060708090

100

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Percent Bayhydrol XP 2546 Replacing Bahydrol XP 2542 in Guide Formulation

Glo

ss

Gloss 60°

FIGURE 1 | Effect of Bayhydrol A 2546 on gloss level.

ConclusionsPolyurethane coating solutions have demonstrated long-term performance in a variety of building needs. The uses for these types of products have grown as sus-tainable guidelines tighten and exclude technologies that cannot adapt. As VOC and durability becomes a larger part of the Green Building initiative, high-perfor-mance coating solutions are being speci-fied as an integral intelligent component of overall sustainable building designs. �

AcknowledgementsThe author extends his appreciation to various indi-viduals who were involved in the testing, data cre-ation, and general consultation during the research and summary of these unique technologies: Terry Wayt, Kathy Allen, Pete Schmitt, Karl Heinz-Wuehrer.

References1 Hager, S.; Reese, J.; McVey, S.; Moore, M.;

Skorpenske, R. “Production and Evalua-tion of New Natural Oil Derived Polyols for Flexible Slabstock Foam”, presented at CPI Polyurethanes 2008.

2 Schilling, S.; Wardius, D.; Lorenz, K. “Novel Natural-Oil Polyols and Their Use in Rigid Polyurethane Foams”, presented at the CPI Polyurethanes 2007.

3 Sounik, D. “Novel Natural-Oil Based Rigid Foams For Demanding Applications: A Class I Polyisocyanurate Foam For Insu-lated Metal Building Panels”, presented at CPI Polyurethanes 2008.

4 “Top Ten Castor Oil Seed Producers” June 11, 2008, Food and Agricultural Organi-zation of United Nations: Economic and Social Department: Statistical Division.

5 Wuehrer, K. H.; Allen, K. Chemical Resis-tant Waterborne Polyurethane Topcoats for Flooring. Journal of Protective Coatings & Linings 2007 24(2), 58-66.

6 Green Seal GS-11 Environmental Standard for Paints and Coatings.

7 Allen, K.; Schmitt, P. Greener Gambits in the Antigraffiti Game. Journal of Architec-tural Coatings 2009, 5, 38-47.

This paper was presented at Polyurethanes 2009 Tech-nical Conference in Fort Washington, MD, on behalf of the Center for the Polyurethanes Industry (CPI).


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When the ancient Egyptians came to decorate the works of art that they buried with their Pharaohs, they used a blue pigment of such brilliance that it would enhance

the quality and value of any object. The pigment was derived from the semi-precious mineral, Lapis Lazuli, and it continued to be used for many centuries.

The quality of the blue produced by this method was never in question. But the scarce availability and difficulty of extracting the pigment meant that the cost was high and that the pigment could only be used in the most pres-tigious applications. It was clear that a rich prize awaited anyone who could devise a synthetic route to manufacture this pigment, which is now known as Ultramarine Blue.

Discovery of the Synthetic ProcessThe process for the synthetic manufacture of Ultramarine was discovered in 1828 by a French scientist, Guimet. Soon there were factories springing up all over Europe, as the more affordable synthetic pigment stimulated the use of Ultramarine in many applications. Of particular note was the discovery that a small amount of Ultramarine would, if added to the rinse water during the laundering process, absorb the unwanted yellow undertone, which became apparent as white clothing aged. This unwanted yellow caste was replaced by a blue undertone that sug-gested extra brightness and cleanliness. In fact it was for this purpose in 1884 that James Reckitt built an Ultra-marine factory in Hull to extend his range of existing laundry products. This factory was still producing Ultra-marine under the name of Holliday Pigments Limited up

until 2007, and today – from its Comines factory in North France – remains one of the world’s leading manufactur-ers and distributors of Ultramarine Blue.

Modern ApplicationsWhile Ultramarine continued to be used both in artists’ colours and laundry products, it was the birth of the plas-tics industry, which stimulated the development of the Ultramarine pigment that we know today. Ultramarine had been perfect for use in artists’ colours due to its unique shade with unrivalled brightness and its excellent light-fastness. It was non-toxic and non-irritant, perfect for an application like laundry with its inevitable skin contact. But add to these virtues its excellent heat stability, an obvious advantage in a high-temperature applica-tion such as plastics, and it is no wonder that Ultramarine soon became regarded as an indispensable plastics colourant.

But how does Ultramarine come to pos-sess such a combi nat ion of admirable properties? The answer is in its produc-tion process – which is itself a fascinating story.

The chromophore responsible for the blue colour in Ultramarine is based on sulphur and has the formula S3

-. It is strange to think of a yellow element like sulphur giving a blue colour, but in this particular form it does. However the discovery of the chromophore was only one step in the development of a synthetic process to manufacture Ultra-marine. The problem is that the chromophore is unstable and is readily oxidized to non-pigmentary sulphate. It needs to be protected from these chemical reactions, and this is achieved by stabilizing the chromophore within the protective cage structure of a clay (kaolin) lattice.

The production process involves heating a mixture of sulphur, clay and sodium carbonate to a temperature of almost 800 oC in a kiln, excluding air to prevent premature oxidation of the sulphur before the reac-tion temperature is reached. After sufficient residence time at this peak temperature to form the initial chro-mophore, the mixture is allowed to cool before air is slowly allowed into the kiln to complete the reaction with an oxidation stage. This high-temperature process takes more than two weeks to complete.

By Dave Masterman, Technical Support Manager | Holliday Pigments, SA France

Ultramarine – the

0

50

100

150

200

0 2 4 6

Particle Size (Microns)

Stronger

Brighter

Greener

Technical Applications

Non-technical Applications

FIGURE 1 | Ultramarine pigment typical particle sizes.


With this knowledge of the production process we can already see the reason for some of the desirable qualities of Ultramarine. The chromophore is very unusual, leading to a unique shade that cannot be matched by other pig-ments. Being transparent, Ultramarine adds an attractive blue undertone to transparent polymers as well as neu-tralizing unwanted yellowness in opaque white plastics. The high-temperature manufacturing process provides the Ultramarine pigment with an inbuilt stability to heat. In fact, Ultramarine blue pigments are stable to more than 350 oC, high enough for use in all common plastics. Finally the raw materials are all quite benign – no heavy metals are used in the production of Ultramarine and organic

compounds would not survive the high manufactur-ing temperature. Ultramarine is one of the

safest known pigments by virtue of its raw materials and pro-

duction process.

This high-temperature process produces the ‘raw’ Ultramarine, but the process is far from complete. After this ‘dry’ process it is necessary to refine the raw Ultra-marine, a process that starts by slurrying the raw Ultramarine with water. This second stage is commonly called the ‘wet’ process. In this stage the impurities present within the raw Ultramarine are removed. The most important of these is unreacted sulphur, which would otherwise give rise to an odour when used in high temperature applications like plastics. Soluble material, primarily sodium sulphate, is also removed.

Finally the pure Ultramarine pigment is ground to its final particle size then separated from the water. The grinding process leaves a broad spread of particle sizes with a range from less than 1 up to 3 microns. By a pro-cess known as classification, these particles are sepa-rated into a number of discrete fractions. Each fraction is dried to produce a fine powder. Why is a fine particle size so important? The properties of an Ultramarine pigment depend primarily on its particle size. Finer par-ticles are stronger in tinting power, they are brighter

and also greener in undertone than the coarser par-ticles produced at the same time. Ultramarines intended for technical applications range from less than 1 to 3 microns, Ultramarines coarser than this are normally confined to low-quality applications such as laundry powders (Figure 1). The correct product can be selected from the particle size range available based on tint strength, undertone and brightness.

Once again knowledge of the Ultramarine manufac-turing process provides another indication of the final property of the Ultramarine. Pigment particles of 1 to 3 microns are relatively large and as one might expect, Ultramarine disperses very easily.

Benefits of UltramarineUltramarine has the following advantages:• a unique shade of unrivalled brilliance;• excellent lightfastness and heat stability;• is safe in use and is approved worldwide for use in food-

contact plastics and toys; and• improves the undertone of off-white articles.

In addition, Ultramarine has no adverse effect on the dimensional stability of polyolefins, which is important in large or complex polyolefin mouldings. This is because Ultramarine is an inorganic pigment. Organic pigments often have an adverse affect on the dimensional stability of polyolefin mouldings.

Ultramarine has many positive attributes that make it ideal for most plastics applications, but there are some potential problems to be aware of. In its standard form, Ultramarine is sensitive to acids. Even mild acids will attack the chromophore and destroy the colour. How-ever, Holliday Pigments has developed acid-resisting grades for such applications. In these grades the pigment particles are protected by a coating. By selection of the correct grade, Ultramarine can still be used in polymers that may have acidic degradation products, such as PVC, or in containers for acidic products like fruit juice. Acid-resisting grades are also recommended for outdoor appli-cations that may be exposed to the effects of acid rain.

Ultramarine has been the blue pigment of choice for thousands of years. Despite more choice in the blue area of the spectrum the properties that made Ultramarine popu-lar so long ago are still valued just as much today. And probably thousands of years in the future our descendants will still be marvelling at the brilliant colour of Ultrama-rine, the eternal pigment. �

For more information, visit www.holliday-pigments.com.

Eternal Pigment


Most of us grab the sunscreen before heading out to the pool or work-ing in the yard. We’ve all heard of it. UV radiation creates free radi-cals, which cause damage in living

systems. If you are a living system, this is generally not regarded as a good thing. In the world of UV-curable coatings, however, the generation of free radicals and the subsequent breaking and remaking of bonds is not only desirable, but necessary. Historically that task has been accomplished by the use of synthetic materials, most of them originating from fossil fuels. The most commonly used materials are acrylates and methacrylates.

Some acrylates and methacrylates may be derived in some part from bio-based materials. Such materials derived from soy have been around for over 20 years. Ecol-ogy incorporates such materials wherever possible. These materials, however, have not been the major thrust of our bio-based research.

In the 1990s, a great deal of attention was paid to the possible irradiation of foodstuffs for safety. As a result, a flurry of papers was released describing the effects of radiation, mostly gamma, on various foodstuffs. We began to wonder if some foodstuffs, especially those show-ing polymerization w i t h i o n i z i n g radiation or even thermal energy, might be coaxed to polymerize with the application of UV radiation as well. It is indeed the case that such p o l y m e r i z a t i o n takes place.

DiscoveryWe have identified mixtures of pro-teins, (which have been designated

EQ-6000), available as foodstuffs, that may be incorpo-rated into coatings in several ways. One use for EQ-6000 is as a self-photoinitiating film former. Natural proteins tend to be tightly curled. In order to make them more active groups available for crosslinking, it is necessary to relax or denature the protein structure. This can be done with the use of a mild acid. Such acids can also be derived from foodstuffs. The denatured EQ-6000 may be dispersed in a water carrier. A bio-derived emulsifier may be added as well. Such a coating has been demonstrated to cure at 400 feet per minute with 600-Watt UV lamps. The coating has shown barrier properties to air and solvents.

Other ApplicationsSimilar coatings may be further modified with other foodstuff-type materials to resist water or grease. These coatings are potentially edible. Flavorings have been added as well and cured into the resulting coating. These “GRAS” coatings may be and have been made of compo-nents considered as food rather than additives and thus have potential for food contact without the monitoring of extractables. This could be a great boon for label and package converters who don’t have the resources to determine extractables.

A second use for EQ-6000 is as a photoinitiator with conventional UV-curable mate-rials. This is par-ticularly notable for materials cov-ered under FCN 772, which can be used for food c o n t a c t u n d e r prescribed condi-tions. Two mono-m e r s c o v e r e d under FCN 772 are TMPTA and TMPEOTA. Both

By Sally Ramsey, Vice President, New Product Development | Ecology Coatings, Akron, OH

Bio-Based Materials

Matted and unmatted coating on wood.s


of these monomers may be cured by using EQ-6000 as a photoinitiator or co-initiator. In this case, curing proceeds better without a denaturing agent. An amino acid found to be an active element in this mix may be used to boost curing as well.

A third use for EQ-6000 is the extension of cover-age by conventional pigments. Pigmentation of UV-curable coatings presents difficulties. Some pigments absorb the very frequencies of light, which are needed to cure the coating. There are established ways of han-dling this problem. One is by the use of doped lamps, which deliver frequencies that are not absorbed by the pigments. Another is to use photoinitiators that absorb in different frequency ranges. These methods may also be combined. EQ-6000 adds another weapon to this arsenal. Suspended in powder form it can increase coverage. Since it also is self-curing and acts as a photoinitiator, rather than interfering with the curing process it actually promotes it.

The final use highlighted in this discussion is that of EQ-6000 as a matting agent. When used in powdered form, there are multiple advantages to be seen. The first is that, as in the use with pigments, it enhances rather than interferes with UV cure. Since it does actually cure into the finished film, it does not migrate. In many sys-tems, it does not appear to substantially raise viscosity. It may also be combined with other bio-based additives to provide a rough surface that produces a release sur-face. This is unusual, as most release surfaces, such as silicones or f luorinated hydrocarbons, are smooth. By the manipulation of the additives the roughened sur-face may also resist water or grease.

ValueThe big question in the case of a new technology such as this always is: “What is the value proposition?” The material in EQ-6000 is available as a commodity in bulk quantities from both China and South America. Raw materials for analogs are available in bulk as commodities as well. Since none of these materials are petroleum based, the prices do not f luctuate with oil. In addition, since acrylates are not involved, the current supply problem and price squeeze for acrylic acid has no impact. As a film former, coatings are substantially less

expensive than those from conventional UV-curable materials; EQ-6000 is less expensive than many pig-ments and some matting agents. The familiar cry of, “I’d love to go green but I just can’t afford it,” could not be justified for EQ-6000.

Ecology Coatings does not consider EQ-6000 the end-point of our research in this area. Rather it is an encour-aging start to a whole new family of safer and more sus-tainable products. We look forward to both the products and new applications in a greener world. �

For more information, visit www.ecologycoatings.com.

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Bio-based film with marker.

Bio-based film with marker backside.


By Kevin Summ | Anguil Environmental Systems, Milwaukee, WI; and Steve Newell | Spooner Industries Ltd., West Yorkshire, UK

“What Carbon One of Europe’s Largest Steel

In case you haven’t heard, our planet is getting warmer. At what rate it is occurring or how much human activity has to do with the increas-ing temperatures is a heated debate, pardon the pun. One thing we do know for sure…carbon

dioxide (CO2) is a contributing factor in global warming, and humans are responsible for a large portion of these emissions. If you had asked someone five years ago what their carbon footprint was, most people would have likely responded by looking towards their feet, thinking they stepped in something. That same person would probably laugh uncontrollably if you had told them that Al Gore, former Vice President of the United States and once Presi-dential hopeful, would star in a 2006 movie that brought climate change to the forefront by drawing millions of viewers from all over the world.

Carbon FootprintsIndeed, things are much different today than they were five years ago; individuals and businesses alike are trying to reduce their environmental impact and GHG (Green House Gas) emissions. What the average person does not realize is that they have two types of footprints, a primary and secondary. The primary footprint is a measure of our direct CO2 emissions from the burning of fossil fuels includ-ing domestic energy consumption and transportation, e.g., car and plane. The secondary footprint is a measure of indirect CO2 emissions from the whole lifecycle of products we use, those associated with their manufacturing and

eventual breakdown. To put it simply – the more we buy, the more emissions will be caused on our behalf.

Reducing the Secondary FootprintThankfully companies like Corus, a subsidiary of Tata Steel, are doing their part to reduce the world’s secondary footprint by improving the energy efficiency of their man-ufacturing processes. Corus is Europe’s second largest steel producer and comprises three operating divisions: Strip Products, Long Products, and Distribution & Build-ing Systems. Corus Colors, as part of the Strip Products Division, is an international business manufacturing pre-finished steel for the building envelope, domestic appli-ances and manufactured goods markets.

Corus Colors – Shotton Works, located at Deeside, North Wales, produces organic paint-coated prefinished steel principally for cladding, composite walling and roofing applications within the building and construction sector both in the UK and overseas.

There are two manufacturing processes at Shotton Works for coating steel strip with paint. They use a series of driven roller coaters and industrial curing ovens, controlled within a continuous process line, that are capable of applying protective and decorative high-quality finishes to the galvanized flat steel strip substrate. The number-one Colorcoat Line process is capable of coating strip widths up to 1400 mm with a thickness up to 1.6 mm, giving a weekly throughput capability of up to 4000 tonnes subject to product type and dimensions.

Manufacturing ProcessThis manufacturing process requires large amounts of natural gas to ensure proper application and fast curing time in the ovens, which, in turn generates a substantial amount of CO2 and NOX (Nitrous Oxides). In addition to these emissions, the solvent-based coatings release HAPs and VOCs during the drying process that need to be treated by an air pollution control device such as an oxi-dizer. New oxidizer systems are capable of destroying over 99% of the HAPs and VOCs through the process of high temperature destruction with very little fuel consump-tion. However older technologies can be a source of CO2 and NOX as well as the requirement for high maintenance and large operating expenditures.

Pollution ControlPollution control initiatives are nothing new to Corus. The company has been monitoring and controlling its oven emissions at the Shotton Works, North Wales facility, since the 1970s. Their first oxidizer/incinerator was installed on the paint coating processes for abating


exhaust gases and solvents. Even then, the company was thinking green by utilizing waste heat from these older oxidizers/incinerators to pre-heat the ovens and to supply their manufacturing facility with additional process steam. However, as environmental regulations tightened, energy prices increased and new technolo-gies emerged, the company decided to re-evaluate their entire system as part of their manufacturing efficiency improvements as well as the wider Corporate Responsi-bility Program for energy usage reduction. The objective was to reduce the gas consumption by at least 45% and increase processing speeds on certain products. They quickly realized another benefit to their sustainable energy plans…a much smaller carbon footprint.

Sustainable Energy SolutionLooking for a sustainable energy solution, they turned to Spooner Industries in the United Kingdom, who has worked closely with Corus on a number of projects over the past 30 years. Oven technology and safety regula-tions had changed dramatically since the line was first installed, but Spooner was able to successfully complete several upgrades that brought the system up to current standards and increase its’ flexibility.

• Each zone was retrofitted with a special low-NOX burner to reduce emissions.

• Variable-frequency drives or inverters on every oven fan were incorporated into the control system to make each section more efficient and reduce electrical con-sumption.

• The ductwork was changed to bring hot air into the system quickly, reducing maintenance issues.

• New thermocouples (temperature measurement), pres-sure transmitters, pressure switches and flow measure-ment systems were installed in the ovens to bring the equipment up to today’s technology standards, allow-ing for remote monitoring and fine-tuning.

• A new computer-controlled system was integrated with the SCADA (System Control and Data Acquisition) pro-gram. The proper PLC (Programmable Logic Controller) allows the central Corus system to communicate with the ovens so they can be setup for different production runs, eliminating errors and decreasing setup time.The oven alterations brought this production line from

the least efficient in the Corus group to the most, meeting one of the two objectives for the company. While some of these improvements reduced the company’s environ-mental footprint and gas consumption, the increased throughput would further complicate their environmen-tal responsibilities.

Two existing, inefficient oxidizers for the prime and fin-ish ovens were being used to control VOC and HAP emis-

sions at the North Wales facility. To achieve proper destruc-tion the systems required large amounts of natural gas, which affected operating expenses and contributed to CO2 and NOX emissions. Furthermore, breakdowns and mainte-nance problems were not only costing the company money to repair but also revenue in lost production. Because the oven and oxidizer are so vital to each other, Corus wanted a solution provider with experience and knowledge on both. In addition, they were looking for a system with low operat-ing costs and heat recovery capabilities that could achieve 99.5% DRE (Destruction Removal Efficiency), which was well above their permit requirements.

Spooner-Anguil Partnership Offers SolutionsSpooner, having recently partnered with Anguil Envi-ronmental Systems in the United States to fabricate and install its oxidizer designs on applications throughout Europe, was confident that it could be done. After consult-ing with the engineers at both Spooner Industries and Anguil Environmental Systems, Corus made the decision to replace their multiple air pollution control systems with one, RTO (Regenerative Thermal Oxidizer) from Spooner Anguil. It would give them the desired efficiency and single-source solution they were looking for. The system has the following features and benefits.• The oxidizer is a three-chamber design that processes

83,000 NM3/hr (55,000 SCFM) of air, achieving 99%+ DRE without visible emissions and 85%+ heat recovery for energy-efficient operation.

• The RTO self-sustains at low solvent-loading condi-tions, meaning that once the oxidizer is at operating temperature and receiving process airflow it requires no additional fuel for emission destruction, releasing very little CO2 and NOX.

Footprint?” Producers Asks…

“What Carbon Footprint?” One of Europe’s Largest Steel Producers Asks…


• A secondary heat exchanger sends waste heat directly back to the ovens, reducing the amount of natural gas required for product curing.

• Stainless-steel components throughout the system prevent corrosion and allow for high-temperature process streams.

• A hot-gas bypass on the RTO is used during high loading situations to avoid over heating the oxidizer.

• An intelligent bake-out feature cleans the RTO of condensable organics with-out internal fires or safety concerns.

• The control panel has a large opera-tor screen with a built-in maintenance manual and trouble-shooting guide, which makes for ease of use.Corus has made a significant invest-

ment for the new equipment, upgrades and implementation of this energy reduction project. It has dropped their cost, per ton of steel produced, consider-ably and they estimate the payback will be less than one year.

The reduction in carbon emissions and energy consumption from this facil-ity is dramatic. Gas usage has dropped by more than 60%, an average reduc-tion of 522 m³/hr (or 5742 kW) per hour – saving over £1million a year. At 181 grams of CO2 produced per KWH used, Corus is preventing 1 tonne of car-bon from reaching our atmosphere each hour, nearly 8,000 tonnes per year.

With innovation and continuous improvement at the heart of its business, the company is already planning for simi-lar modifications at other Corus plants.

A spokesperson from Corus com-mented, “We are committed to minimiz-ing the environmental impact of our operations and our products through the adoption of sustainable practices and continuous improvement in environ-mental performance.” �

For more information, contact Steve Newell of Spooner Industries Ltd. at www.spooner.co.uk, +44 (0) 1943 609505; or Kevin Summ of Anguil Environmental Sys-tems, Inc. and www.anguil.com, 800/488.0230.

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� ResinCOGNIS: Versamid® 116 is the first in a series of TETA-free polyamide curatives introduced into the market. It is based on a novel amine feedstock, which will reduce the potential for interrupted supply due to shortages in key amine building blocks. This product will yield performance prop-erties consistent with existing backbones, minimizing reformulation requirements. Visit www.cognis.com.

� Weathering DeviceATLAS MATERIAL TESTING TECHNOL-OGY: The LS-200 full-spectrum monitoring device has been specifically designed for use in Ci Series Weather-Ometers® to pre-cisely measure the SPD output of the xenon lamp. This device has excellent correlation to the spectro-radiometers used in the Atlas Calibration Laboratory. The device is easily mounted on the specimen rack, and the output is measured over a short amount of time (30 minutes is sufficient). The data can be downloaded and exported into a common spreadsheet program and ana-lyzed to determine compliance to perfor-mance-based standards. The LS-200 works with any generation of Weather-Ometer. E-mail [email protected].

� Matting AgentEVONIK INDUSTRIES: EXP 3600 is a sil-ica-based matting agent perfectly suited for use in UV-cured coatings. It has high

transparency, low residual gloss, excel-lent surface quality and scratch resistance. It is easy to incorporate and does not negatively impact the coating system’s other application properties in any way. E-mail [email protected].

� AdditivesRHODIA: Rhodoline® OTE, APE-free and zero-VOC additives extend waterborne coating open time two- to four-fold and enable the formulation of high-per-forming low- to zero-VOC coatings. This low-odor, eco-friendly solution has been developed for sustainable coatings, being compliant with Green Seal (GS-11) or EU eco-label requirements. It also enhances gloss, boosts stain and scrub resistance, and delivers freeze-thaw stability. An easy-to-use solution for formulators, it is suit-able for a wide range of polymer binders. Visit www.rhodia.com.

� SoftwareELCOMETER INC.: Elcometer 320 is a powerful system that can simultaneously monitor climate parameters in up to 254 distinct locations. It is launched along with the ElcoMonitor™ software, allowing for fail-safe, real-time climate observation. Audible and visual indicators provided by a signal tower give an instant warning that climatic conditions have surpassed parameters. The system provides an accurate indication of relative humidity, air and surface tempera-ture, specific humidity, and the difference between relative humidity and dewpoint. E-mail [email protected].

� Adhesives and Curing EquipmentDYMAX CORP.: The Selector Guide for Industrial Assembly Adhesives is a refer-ence tool that provides detailed guidance for selecting the best DYMAX adhesives and curing equipment. Selector tables list glass, metal and plastic bonding adhesives, their properties and the unique applica-tions for each prod-uct. Tables detail typical substrates and the bonding capabilities of products. Also described are the types of light-curable products available and their chemistries, as well as compat-ible light-curing and dispensing systems. Visit www.dymax.com. �



C L A S S I F I E D SL A S S I F I E D S

EQUIPMENT EQUIPMENTPOSITIONS AVAILABLE

Stainless IT Stainless ITT

The CONN Blade®sMost Efficient & Aggressive Available

UHMW Poly

w w w . c o n n b l a d e . c o m (814) 723-7980

856-467-3399 www.heinkelusa.com

Horizontal Peeler Centrifuges

Vertical Basket Centrifuges

Inverting Filter Centrifuges

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

[email protected] Industrial Blvd., McKinney, TX 75069972-864-0865 x 25 / 972-542-0072

HOCKMEYEREQUIPMENT CORPORATION

A leader in the grinding anddispersion industries

New & Used EquipmentDispersers • Mills • Mixers •

Tank & Tote Washers •Particle Size Analysis • Vessels

Visit us atwww.hockmeyer.com

or call us at 252-338-4705

Wanted to purchase:Used Dispersers& Mixers

LOWER COST MILLING SOLUTIONSHolding off on capital purchases? Union Process still has several low cost options for you to get the job done economically and efficiently using the finest size reduction equipment on the market.

TOLL MILLINGSave on capital equipment, personnel and space. Let Union Process toll grind your product in our Pilot Plant.

REBUILDING Got a used Attritor in need of an update? Talk to Union Process about our 8-step refurbishing process using all OEM parts.

SPARE PARTS Make sure your Attritor is performing at peak efficiency. Order critical OEM spare parts today. Union Process stocks many parts ready for immediate shipping.

Expanding the Possibilities for Size Reduction

Partner with Union Process.

TECHNICAL SALESPERSON Waterbased pigment dispersion mfr. seeking salesperson located in eastern PA, with 50% US travel. Must have technical sales or lab experience in color applications. Reitech CorporationSend resume to: [email protected]

EQUIPMENT

CUSTOM MANUFACTURING

COATINGS R&D CHEMISTWe are seeking a coatings research and development chemist with experience in formulation of liquid coatings for indus-trial product finishing.

Northern Coatings and Chemical Company is a manufacturer and supplier of innovative product finishes, including waterborne and high solids air dry and baking enamels, urethane and NISO sys-tems, acrylics, epoxies, coil coatings, and UV-cure systems for wood, plastic and metal, as well as many specialized custom formulated coatings. Our customer base includes many international Fortune 500 corporations, as well as regional manu-facturers. We are located in the Upper Peninsula of Michigan, 50 miles north of Green Bay, Wisconsin.

The primary responsibility of this position will be hands-on product research and development, including interaction with customers and materials suppliers. This position could lead to outside sales. This is an excellent opportunity for the detail-oriented and self-motivated chemist who is seeking to have a significant impact on cus-tomer satisfaction and company success.

Candidates meeting the requirements for this position should have a bachelor’s degree and at least three years bench-top experience with formulating liquid coatings for industri-al product finishing.

Send resumé/inquiries to Mark LaValley

[email protected] inquiries will be held in strict confidence.



AD INDEX

C L A S S I F I E D SL A S S I F I E D S

CUSTOM MANUFACTURING REPS WANTEDCUSTOM MANUFACTURING

RECRUITMENT SERVICESRECRUITMENT SERVICES

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

Spencer M. Hermann

SEARCHLIGHT PARTNERS30092 Ivy Glenn Dr., Suite 210

Laguna Niguel, CA 92677 (949)429-8813 • [email protected]

Executive Search & Organizational Design for the Coatings IndustryTHOMAS BROOKE INTERNATIONALContact Nicola James888-896-3330 ext. 22www.thomasbrooke.com

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/Europe/ Tel: 610/650.4050 • Fax: 248/502.1091 Far East Sales E-mail: [email protected] Midwest/ Lisa Guldan West Coast Sales Tel: 630/882.8491 E-mail: [email protected] Inside Sales Manager Andrea Kropp Tel: 810/688.4847 E-mail: [email protected] Production Manager Monica Hackney Tel: 248/244.6434 • Fax: 248/244.3915 E-mail: [email protected]

E D I T O R I A L S TA F F Editor Darlene R. Brezinski, Ph.D. Tel: 906/779.9498 E-mail: [email protected] Managing Editor Kristin Johansson Tel: 248/641.0592 • Fax: 248/502.2094 E-mail: [email protected] Associate Editor Karen Parker Tel: 248/229.2681 E-mail: [email protected] Art Director Clare L. Johnson

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

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

Toll Manufacturing, Converting, Packaging, Fill Off and Private Labeling� Urethanes, Solvent & Water-Based Systems,

Acrylics, Epoxy, Ink, etc.� Packaging from quarts to totes� High speed dispersion, blending, milling� Best color matching in the industry� QC and testing equipment� Enviro, UV, abrasion, adhesion testing� California permitted to meet enviro regs� Sony Green Partner

Jeff Laird (866) 894-5252 ext. 220Jeff Laird (866) 894-5252 ext. 220Huntington Beach, CAHuntington Beach, CA

www.paintmfg.comwww.paintmfg.com

Custom/Contract ManufacturingPolymers-Coatings-Adhesives

Polymerization: Acrylic Emulsion, Solution Acrylic, Waterbased & Solventbased Urethanes Pigment Dispersion & Pigmentation Resin Cuts, Blending R&D, Q.C., Custom Color Matching Drums, Totes, Bulk ISO 9001: 2001 Registered

Contact Mike LombardPh: 978-988-0880, ext. 304

FAX: [email protected] www.allcoattech.comwww.pcimag.com/classifieds

Novafl ow Systems, Inc., a leader in computer automated

“gravimetric” dispensing systems, is currently seeking sale agents

outside of North America.Interested parties should apply by email to

sales@novafl ow.com

13th Annual CoatingsTrends & Technologies . . . . . . . . . . . 47www.coatingsconference.comBASF Corporation . . . . . . . . . . . .19, 33www.basf.com/naftaresinsBrenntag North America. . . . . . . . . . 7www.brenntagnorthamerica.comBuhler Inc. (PARTEC). . . . . . . . . . . . 21www.buhlergroup.comBYK USA Inc. . . . . . . . . . . . . . . . . . 3, 18www.byk.com/innovationCINIC . . . . . . . . . . . . . . . . . . . . . . . . . . . 9www.cinic.comConn and Co. . . . . . . . . . . . . . . . . . . . 11www.connblade.comCytec Industries Inc. . . . . . . . . . .16, 19www.cytec.comDeFelsko Corp. . . . . . . . . . . . . . . . . . . 46www.defelsko.comDow Microbial Control . . . . . . . . . . . 13www.dowmicrobialcontrol.comElcometer . . . . . . . . . . . . . . . . . . . . . . 27www.elcometer.comEvonik Industries. . . . . . . . . . . . . . . . 15www.evonik.com/colortrendEvonik Industries. . . . . . . . . . . . . . . . 37www.evonik.com/chroma-chemEvonik Industries. . . . . . . . . . . . . 15, 37www.evonik.com/chroma-chemH&S Autoshot. . . . . . . . . . . . . . . . . . . 18www.hasutoshot.comHamamatsu . . . . . . . . . . . . . . . . . . . . 18sales.hamamatsu.com

Heubach. . . . . . . . . . . . . . . . . . . . . . . . 25www.heubachcolor.comHoover Color Corporation . . . . . . . . 52www.hoovercolor.comHunterLab . . . . . . . . . . . . . . . . . . . . . . 19www.hunterlab.comHuntsman Advanced Materials . . . 48www.huntsman.com/advanced_materialsJyoti Ceramic Industries. . . . . . . . . . . 4www.jyoticeramic.comMason Color Works, Inc. . . . . . . . . . 51www.masoncolorpigments.comMitsubishi Gas Chemical America, Inc. . . . . . . . . . . . . . . . . . . . 29www.aromaticchemicals.comRoss, Charles & Son. . . . . . . . . . . . . . 17www.mixers.comRussell Finex Inc.. . . . . . . . . . . . . . . . 46www.russellfinex.comSartomer . . . . . . . . . . . . . . . . . . . .19, 39www.sartomer.comShamrock Technologies, Inc. . . . 2, 19www.shamrocktechnologies.comSpectra Group. . . . . . . . . . . . . . . . . . . 18www.sglinc.comSynasia. . . . . . . . . . . . . . . . . . . . . . . . . 18www.synasia.comTRICOR Systems Inc. . . . . . . . . . . . . 19www.tricor-systems.comUnimin Corp. . . . . . . . . . . . . . . . . . . . 18www.BrilliantAdditions.comXenon Corporation . . . . . . . . . . . . . . 19www.xenoncorp.com

Mason Color’s high performance pigment technology for coatings provides the ultimate in heat resistance, UVdurability, and chemical resistance. Our mixed metal oxide pigments meet the most exacting color and durabilityrequirements of the defense, architectural, stove and heating products, and roofing industries. These pigments addvibrant color to building facades, stove equipment, exhaust parts and outdoor furnishings and equipment. Theseadvanced technology pigments can be incorporated into any coating platform including powder coatings, electrocoat,high solids and waterborne paints.

Mason Color Works, Inc. A History of Pigment Technology ExcellenceMason Color Works has been manufacturing high temperature, inorganic pigments since 1842.

For more than 40 years Mason Color has been a global supplier of high performance pigments to all sectorsof the ceramic industry including pottery, artware, bricks, sanitaryware and roofing materials.

In the last 45 years, Mason Color has expanded into the high technology Investment Casting Industry. OurISO Compliant Cobalt Aluminate products are integral in the manufacturing jet turbine blades and medicaldevices.

In the 1990s heralded the emergence of the fireplace gas log industry and Mason Color's participation as asupplier of high quality, high temperature pigments for this use.

Soon thereafter, the Swimming Pool and Spa colorant industryembraced Mason's pigment technology. Our high quality pigment

exceed the demands for resistance to punishing UV energy and theaggressive chemicals used in swimming pools.

Our fully outfitted Powder Coating Laboratory and skilledtechnicians will help you choose the perfect color for your mostdemanding requirements.

See you at the American Coatings Show,April 2010 in Charlotte, NC.

paint and coatings industry may 2010

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