PRIMARY JOURNAL FOR THE COATINGS MARKET IN ASIA & THE PACIFIC RIM VOL 31 • NO 5 OCTOBER 2018
Inside: Asia Pacific Coatings Show Review Inside: Going Green Supplement
Bringing colour to coatings Pigments and dispersions ADHESIVES • LABORATORY & TEST EQUIPMENT • CHINA MARKET REPORT • ADDITIVES October cover 2.indd 1
VOL 31 No 05 October 2018
29 PIGMENTS BASED ON RENEWABLES Clariant explains how its quinacridone pigments contain raw materials based on renewable sources, producing brilliant colours in an environmentally friendly way
MARKET REPORTS 13 CHINA Mark Godfrey reports on how the country’s industry is becoming more environmentally conscious
ADHESIVES 18 INNOVATION AND SUSTAINABILITY IN CHINA APCJ speaks to Michael Olosky, Henkel, about how the adhesives company is progressing in China
WALLPAPER 22 CHANGING TIMES Sarah Gibbons reports on how innovations in wallpaper is driving a resurgence in the market
31 THE BASICS OF TIO2 DISPERSION Wai Ling Loong, Venator, outlines the basics of dispersing TiO2 particles in a coating
LABORATORY & TEST EQUIPMENT 35 SCALING-UP Richard Johnson, Xtrutech, explains how to accurately scale-up a powder coatings operation on extruder machines 37 DIGITALISING WET GRINDING Bühler is using digitalisation to improve its wet grinding process 39 UNIVERSAL CUTTING MILL Fritsch launched its latest version, with variable rotational speed
ASIA PACIFIC COATINGS SHOW REVIEW 24 SUCCESS FOR COATINGS IN KUALA LUMPUR
ADDITIVES 40 GRAPHENE-BASED, ANTI-CORROSION ADDITIVES Applied Graphene Materials discusses its Genable 3000 series
PIGMENTS & DISPERSIONS 26 HIGH PERFORMANCE PIGMENTS Julie Bostock, Smithers Rapra, gives an interesting insight into the world’s blossoming high performance pigment market
REGULARS 03 EDITOR’S PAGE Comment from the Editor
1 ELIMINATING LEAD FROM ASIA’S COATINGS Johnson Ongking, Pacific Paint (Boysen), details the ongoing efforts to rid Asia’s paint industry of lead 5 THE BASF BIOMASS BALANCE APPROACH How BASF is using sustainable renewables as raw materials 7 PLANT-BASED MONOMERS DSM discusses the use of plant-based binders as alternatives to fossil fuel-based binders in commercial wood coatings 11 AXALTA’S SUSTAINABILITY DRIVE How Axalta is helping its automotive customers decrease energy consumption and increase productivity 12 SYNTHOS’ GREEN DISPERSIONS Environmentally friendly dispersions
04 NEWS A digest of news from the global paint and coatings industries
08 REGULATIONS & EVENTS Regulatory round-up and coatings events for your diary
10 BUSINESS REPORT Terry Knowles looks at reports on minerals vital to coatings
14 INDUSTRY OUTLOOK Terry Knowles focusses on Japan this month, looking at the latest reports from Kansai Paint and Nippon
COVER IMAGE CREDIT: www.akzonobel.com 1 APCJ • October 2018 www.coatingsgroup.com
Contents October 18.indd 1
Global links for coatings professionals 26 – 28 February 2019 DWTC, Dubai UAE 14 – 15 May 2019 InterContinental Asiana Saigon Ho Chi Minh City, Vietnam
11 – 12 June 2019 Safari Park Hotel Nairobi, Kenya
Asia Pacific Coatings Sho Show 2019
4 – 6 September 2019 BITEC Bangkok, Thailand
23 – 24 September 2019 Egypt International Exhibition Center New Cairo, Egypt FOR UP-TO-DATE INFORMATION ON ANY OF THE ABOVE EVENTS, PLEASE CONTACT THE COATINGS GROUP
+44 (0)1737 855021 firstname.lastname@example.org www.coatingsgroup.com 'The CoatingsGroup' @CoatingsGroup
Opening, expanding, launching: it’s all happening in Vietnam
ne of the fastest growing economies in the region, Vietnam received an estimated US$11.25bn in foreign direct investment (FDI) in the January to August period, up 9.2% yr-on-yr, according to the Ministry of Planning and Investment. In 2017, Vietnam received a record US$17.5bn in FDI.
nnINCREASING DEMAND FOR DECORATIVE PAINTS
Chris Malthouse Editor
According to the latest report, the paint & coatings market is expected to reach US$585M by the end of 2022 on account of rising demand for paints & coatings from the country’s construction and manufacturing sectors. The boost in the real estate sector in Vietnam, which is driving demand for decorative paints, is said to be mainly due to the implementation of new laws, which came into effect in July 2015, relaxing real estate ownership rules for foreign entities and individuals. Additionally, a rising trend towards renovation and repairing homes is expected to augment demand for decorative paints over the next five years. In August, Huntsman Corporation opened a multi-purpose facility at the Amata Vietnam Industrial Park, near Ho Chi Minh City to house its Polyurethanes and Advanced Materials businesses and last month, DKSH’s Business Unit Performance Materials, a leading ingredients and speciality chemicals distributor, expanded its operations in Vietnam by opening a new
EDITORIAL Editor: CHRISTINE MALTHOUSE Tel: +44 (0)1737 855106 Email: email@example.com
FAN LANDERS Asia Pacific & India Tel: +44 (0)1737 855078 Email: firstname.lastname@example.org
Deputy Editor: SALLY ROBERTS Tel: +44 (0)1737 855161 Email: email@example.com
PRODUCTION Production Manager: MELANIE CHILES Tel: +44 (0)1737 855044 Email: firstname.lastname@example.org
ADVERTISEMENT SALES RANJEET SANDHU UK, Germany & Switzerland Tel: +44 (0)1737 855105 Email: email@example.com CHRIS REYNOLDS Europe (excluding UK, Germany & Switzerland), Saudi Arabia, Turkey, Jordan & Iran Tel: +44 (0)1737 855109 Email: firstname.lastname@example.org JESSICA SZUTS-NARANJO Middle East (excluding Saudi Arabia, Turkey, Jordan & Iran), Africa & America Tel: +44 (0)1737 855162 Email: email@example.com firstname.lastname@example.org
MARKETING Marketing Manager: KIERAN PROVERBS Tel: +44 (0)1737 855067 Email: email@example.com CORPORATE Vice President: IAN FAUX Tel: +44 (0)1737 855070 Email: firstname.lastname@example.org
state-of-the-art 3600m2 distribution centre in Dong Nai Province.
nnDRIVING BUSINESS Meanwhile, VinFast, a unit of Vietnam’s largest conglomerate Vingroup is set to become the country’s first fully-fledged domestic car manufacturer when its first production models built under its own badge hit the streets next August. From a standing start, VinFast will have the capacity to produce 250,000 cars/yr in the next five years or so, equivalent to 92% of all the cars sold in Vietnam last year, according to data collated by the Vietnam Automobile Manufacturers’ Association. Perfect timing then, for next year’s Asia Coatings Congress, which will take place, once again, at the InterContinental Asiana Saigon, in Ho Chi Minh City from May 1415. For more information about attending or presenting a paper, please visit the website: www.coatings-group.com/acc
nnSUSTAINABILITY CATCH-UP This issue contains our annual Going Green supplement. Including an update on eliminating lead in the Asian coating industry written by Johnson Ongking, Vice President of Pacific Paint (Boysen), BASF’s Biomass Balance Approach and DSM Coating Resins’ plant-based binders that can be used as alternatives to standard fossil fuel-based binders in commercial industrial wood coatings; it’s a must read for all in the industry.
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ASIA PACIFIC COATINGS JOURNAL (ISSN 1468-1412) is published bi-monthly by dmg events (MEA) Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK Tel: +44 (0)1737 855000 Fax: +44 (0)1737 855034 Website: www.coatingsgroup.com
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3 APCJ • October 2018 www.coatingsgroup.com
OCTOBER APCJ.indd 1
NEWS IN BRIEF Chemours renews Teflon contract with Yung Chi The Chemours Company, a global chemistry company, has signed a three-year extension of a trademark license agreement for the Teflon™ brand with Yung Chi Paint & Varnish Manufacturing Company, the largest producer of decorative paints in Taiwan. The collaboration between Chemours and Yung Chi began 30 years ago when the two companies worked together to develop innovative coatings technologies for the Taiwanese market.
Evonik and Wynca form JV Evonik Industries and Chinese company Wynca have agreed to form a joint venture (JV). The company, in which Evonik will hold 60%, will produce fumed silica marketed under the name AEROSIL®. The product is used in transparent silicones, coatings and paints, modern adhesives, as well as non-combustible high-performance insulation materials. The JV, Evonik Wynca (Zhenjiang) Silicon Material Co Ltd, plans to build a fumed silica production facility in the Zhenjiang New Material Industry Park (Jiangsu Province, China).
Huntsman opens formulations manufacturing facility in Vietnam
Huntsman Corporation has opened a multipurpose facility at the Amata Vietnam Industrial Park, near Ho Chi Minh City, Vietnam. The site is a greenfield investment and will house Huntsman’s Polyurethanes and Advanced Materials businesses. It comprises manufacturing, R&D capabilities, a technical service centre, warehouse and distribution space and a commercial office. Commenting on the new facility, Huntsman’s CEO Asia Pacific and President of the Polyurethanes business, Tony Hankins, said: “Vietnam is one of the largest and fastest growing countries in Asia Pacific. For Polyurethanes, we’ve seen double digit growth rates for
a sustained period and fully expect this to continue. At the new site, we’ll manufacture formulated systems for the footwear and automotive markets; rigid insulation foam used in construction and cold chain applications; and simulated wood for the furniture market. “These products will be consumed primarily in Vietnam, with the balance being exported to Cambodia. The facility will enable Huntsman to collaborate more effectively with Vietnamese customers and will also strengthen our strategy of globalising downstream bolton acquisitions.” Scott Wright, President of Huntsman’s Advanced Materials business added: “This is the first manufacturing expansion investment outside China for our business in Asia Pacific and we see many opportunities in Vietnam to support large-scale infrastructure and construction projects in one of the fastest growing economies in the region.” In addition to this facility, Huntsman has a distribution warehouse located in the inland container depot at Long Binh, Dong Nai Province and a site in Hanoi that offers technical service and comprises warehouse and distribution space and a commercial office.
PPG to build new R&D centre in Tianjin, China PPG has acquired land in Tianjin, China where it plans to build a new, state-of-the-art paint and coatings research and development (R&D) centre. Plans for the facility, which will be located in the Tianjin Economical and Technological Development Area (TEDA) and is scheduled to be completed in 2021, are
currently being finalised. The new facility will be part of the company’s efforts to continue to strengthen its R&D footprint to better serve customers in China, the Asia Pacific region and globally, and will service all of PPG’s strategic business units. “PPG continues to enhance its research and development
ACC 2019 call for papers
Kansai and Jotun to collaborate
The Asia Coatings Congress 2019 will take place at the InterContinental hotel, Ho Chi Minh City, Vietnam, on May 14-15, 2019. Those interested in presenting a paper at the two day conference and exhibition can email sallyroberts@dmgevents. com for further information. The event focusses on trends affecting the region’s environmental, manufacturing and industrial needs.
Kansai Paint Co Ltd has signed a general agreement with Jotun A/S to collaborate in the protective coatings business, globally. Kansai Paint has had an alliance (“Sea Star Alliance”) with Jotun in the Marine business since 2002 and has built an intimate relationship. Subsequently, the alliance has been such a great success that both Kansai and Jotun attained the number one position of the global market share. Recently, both companies have agreed
to seek synergy in protective coatings business by extending this long-term relationship. Morten Fon, President and CEO of Jotun, said: “I believe that based on our long relationship and good cooperation we have made a good basis to develop this together.” Hiroshi Ishino, President and CEO of Kansai Paint, said: “I expect that we can go beyond with Jotun more quickly for infrastructure demand of the protective segment, which is expected to grow even more.”
capabilities to ensure consistent, ongoing innovation and service to customers,” said David Bem, PPG Vice President, Science and Technology and Chief Technology Officer. “The new Tianjin R&D centre will best position the company to leverage scale, promote collaboration and continue enhancing our capabilities.”
Kansai Paint will aim to expand global PC business through this agreement.
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China’s coating industry completes consultation on ‘low-VOC’ standard An industry consultation in China on a standard for coatings with reduced volatile organic compound (VOC) content has closed. The consultation was for suppliers and end users of the coating industry on a draft standard for technical requirements for low volatile organic compound content coating products. It was jointly prepared by the Chinese government and the coatings industry. The draft standard, which was published on July 18, specifies: • The terms and definitions of “low” VOC content coating products; • Product classifications; • Requirements; • Test methods; and • Packaging label identification. The aim of the standard is to provide a unified basis for government law enforcement
of VOCs and to help the industry develop along environmentally sound lines. The standard lists a number of product types to which it applies. These include: • Architectural coatings; • Water-based industrial coatings; and • Powder coatings. Each of the product types also has associated VOC content requirements including the maximum VOC level for which this coating type is considered low VOC. The industry partner consultation ended on August 24. Adoption of the final standard is expected in 2019. The proposed standard follows a 2016 action plan by China’s Ministry of Industry, Information and Technology to reduce industrial VOCs emissions by 3.3Mt by the end of 2018.
Sauradip Chemical Industries inaugurates paint application laboratory Sauradip Chemical Industries has recently inaugurated its paint application laboratory in Mumbai, India, to cater to the coatings industry. Dr Swarnendu B Kar, Managing Director of Behr Process Paints India, opened the laboratory on July 6, 2018, in the presence of Dr Kishore Shah, Chairman; Shri Rajive K Shah, Managing Director;
Shri Jaideep K Shah, Director; and the team from Sauradip Chemical Industries Pvt Ltd. Speaking about the facilities available, Rajive Shah noted that the laboratory is equipped with the latest technology, such as a Brookfield viscometer, film applicators, sag index applicator, wet scrub testing, glossmeter and incubators, etc.
The laboratory will be able to manufacture water-based paint as per customers’ requirement. The laboratory is designed to check the micron size, gloss, wet scrub abrasion and stability of any paint sample. Dr Kar added that he was impressed with the facilities and that the lab will help to offer solutions for paint manufacturers.
Asia Pacific Coatings Show 2018 success The Asia Pacific Coatings Show 2018 (APCS) was held at the Kuala Lumpur Convention Centre, Malaysia, on September 13 and 14. Welcoming more than 2100 attendees from across the coatings industry, the event was a busy two days of networking and business for visitors and exhibitors alike. Visitors came from across the globe, with more than 40
countries represented. The show was complemented by the free to attend Business Presentations and the conference, ‘Coatings for the Future’. For more information, turn to the official APCS Show Review in this issue of APCJ. Next year, the Asia Pacific Coatings Show and Conference will be held in September in Bangkok, Thailand.
NEWS IN BRIEF Evonik and Sanju sign MoU Evonik and Beijing Sanju Environmental Protection & New Materials Co Ltd (“Sanju”) have signed a Memorandum of Understanding (MoU) for strategic co-operation in Beijing. According to the MoU, Evonik and Sanju will deepen co-operation in innovation, process and application technology. The two parties will also carry out substantial collaboration in catalyst and carrier technology, membrane technology, as well as additives and other speciality chemicals. Evonik is focussing on solutions to China-specific megatrends, enhancing local innovation and helping Chinese and Asian customers improve their competitiveness.
Wacker polymer binders from renewable resources Wacker chemical company has said it is the world’s first manufacturer capable of using renewable resources to produce commercial quantities not only of dispersions based on vinyl acetate-ethylene copolymer (VAE), but also of further products based on vinyl acetate – all known by the VINNAPAS brand. To do so, the company uses acetic acid generated as a byproduct in the woodworking industry.
AkzoNobel helps save Edmund Hillary’s historic hut in Antarctica Explorer Sir Edmund Hillary’s historic Antarctic hut has been saved and restored thanks to a fundraising campaign and the application of coatings donated by AkzoNobel. A specialist team from the Antarctic Heritage Trust spent three months toiling in temperatures as low as minus 40°C to renovate the famous landmark.
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NEWS IN BRIEF
AkzoNobel releases Color of the Year 2019
Clariant to divest significant part of coatings SABIC has invested in Clariant, acquiring j24.99% of the business. The agreement underlines the long-term commitment of SABIC as a strategic shareholder. Shortly after the Saudi Arabian investor bought its share in Clariant, the company announced that it intends to divest its pigments, standard masterbatches and medical specialities businesses by 2020.
IMCD to acquire Velox IMCD NV, a leading distributor of speciality chemicals and food ingredients, has signed an agreement to acquire 100% of the outstanding shares of Velox GmbH, a group of companies with its headquarters in Hamburg, Germany. With an extensive commercial network across Europe and its long-standing relationships with global suppliers in the plastics, composites and other specialities markets, Velox is an excellent fit with IMCD’s existing operations. The transaction is subject to regulatory review.
Venator to close Pori, Finland site Venator intends to close its Pori, Finland TiO2 manufacturing facility. As a result of unanticipated cost escalation, Venator will transfer certain technology, and the production of select product grades, to other facilities within its current manufacturing network, which will become more efficient with greater flexibility. The Pori facility to continue to operate with up to approximately 25kt capacity (20% of site), with production reducing during the transition period, which is expected to last through 2021.
Spiced Honey has been unveiled by AkzoNobel as its Color of the Year for 2019. The shade was selected following expert research into global trends, insights and consumer behaviour. Perfectly capturing this year’s theme, “Let the light in”, the warm amber tone is being marketed under well-known decorative paints brands, such as Dulux, Coral, Levis and Flexa. AkzoNobel believes it’s a versatile and contemporary choice, complementing a wide variety of lifestyle and interior design preferences. It also feels it expresses the new sense of optimism felt
throughout the global trend research that was carried out. “Today’s reveal of Spiced Honey is another milestone in empowering consumers worldwide to choose paint colours with absolute confidence,” said Heleen van Gent, Creative Director of AkzoNobel’s Global Aesthetic Center. “It’s a colour that can be calming or nourishing, stimulating and energising, depending on the light and colours surrounding it.” Trend research is a vital part of identifying the Color of the Year and it plays a big role in helping AkzoNobel to meet the needs of its customers around the world. While Color of the Year is of major significance for the decorative paints market, the insight that is gathered is also highly relevant to the company’s coatings portfolio. For example, the Specialty Coatings business translates the annual trend research for customers in the consumer electronics and automotive markets. Meanwhile, colour stylists at Wood Coatings use the information to offer on-trend colour selections for product developers and designers in major markets, such as furniture, cabinetry, flooring and building products.
allnex and Bardese to promote waterborne UV coatings development in China allnex has signed a strategic co-operation agreement focusing on waterborne UV coatings with Guangdong Bardese Chemical Group, one of the “Top 500 Most Valuable Chinese Brands”, to jointly promote the centralised development of green coatings in China. Guangdong Bardese Chemical Group held a grand opening ceremony for its Boshi Home Funiture factory in Nankang, Ganzhou, Jiangxi Province. Nearly 50,000m2, the newly built factory is equipped with an advanced dust control system and a fully automated spraying production line imported from the USA and Italy. It will be the first environmentally-friendly waterbased paint factory in China. At the ceremony, which was attended by a number of industry players, Mr Xueping Fang, President of Guangdong Bardese Chemical Group,
and Matteo Vasconi, Global Business Director for Radcure at allnex, signed a strategic co-operation agreement on waterborne UV coatings. Through this new Boshi Home Furniture factory, the two parties will be aiming not only to explore and push the boundaries of water-based UV coating technology together, but also to establish a strategic partnership to further both the sustainable development of the industry as a whole and the regional economy. President Fang commented: “Sustainability is what we are aiming for. With that goal in mind, we want to challenge and explore the possibilities and opportunities to be found within the leading coating technologies in order for us to provide consumers with a wide array of high quality products. We aim to become the leader in the sustainable development of green coatings in China.”
India’s NTPC approves UK company The National Thermal Power Corporation (NTPC), which oversees the power generation industry across India, has turned to UK-based Indestructible Paint as part of its ongoing maintenance programme. The performance coating manufacturer has achieved approved supplier status for two products as part of NTPC’s industrial gas turbine overhaul programme. “We are now supplying our Ipcote Sacrificial Aluminium Basecoat, which has been extensively proven in the highly demanding aero engine and industrial gas turbine sectors, and which is designed to resist abrasion, corrosion and the action of operating fluids and chemicals,” said John Bourke, Global Sales Manager at Indestructible Paint. “Additionally, the coating system will include the associated Ipseal inorganic sealcoat, which provides a nonconductive barrier coating.”
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Nippon Paint introduces biocidefree antifouling technology Japan-headquartered Nippon Paint Marine has introduced, what is thought to be, the world’s first biocide-free, low friction self-polishing copolymer (SPC) antifouling technology. Aquaterras, a product name derived from the Japanese word for shining and the Latin for water is an entirely new type of marine coating developed using neither biocide materials nor silicone. Nippon Paint Marine Director John Drew said: “Typically ships’ antifouling paints have contained some form of biocide copper, tributyltin, co-biocides. “But the use of biocides today is strictly controlled by
BASF invests in HDO capacity at Ludwigshafen BASF intends to increase the production capacity of 1.6-Hexanediol (HDO) at its Ludwigshafen Verbund site by more than 50%. After the start-up in 2021, BASF’s global annual nameplate capacity of HDO will be more than 70,000t/yr at its production facilities in Ludwigshafen, Germany and Freeport, Texas, USA.
both national and international regulations, such as the BPR in the EU. While there are no immediate plans to further regulate the use of approved biocides, we cannot rule out the possibility that copper in antifouling will be regulated
in the near future.” The technology adopts an advanced antifouling mechanism based around the anti-thrombogenic polymers used in the construction of artificial hearts and blood vessels in the medical sector.
Paints and coatings market to reach US$191.9bn globally The paints and coatings market is expected to reach nearly US$191.9bn by the end of 2023, with a compound annual growth rate (CAGR) of 5%, according to the BCC Research report, Global Markets and Advanced Technologies for Paints and Coatings. The industry is experiencing strong growth due to increasing demand from developing nations. All manufactured products require a coating for decorative and/ or protective purposes, making the industry an integral part of maintaining the appearance, functionality and longevity of many buildings and products. Therefore, industrial growth in developing economies is a major driver for growth in the coatings industry. There is a major shift in the production of global paints and coatings, which is moving away from the developed regions, such as Europe
NEWS IN BRIEF
and the USA, to developing economies, such as China and India. Research highlights include: • Increasing demand from both the developed and developing countries is contributing to the overall expansion of the global coatings market; • The solventborne paints and coatings market is not declining as projected, thereby adding to the increase in the total market value of paints and coatings; • The powder coating and emerging technologies segment is expected to see the highest growth. New technologies focusing on pollution control and other environmental factors are being developed by major manufacturers. “Paints and coatings contribute to the aesthetics and utility of all manufactured products, but these
benefits must be weighed against environmental costs,” said BCC Research Analyst Srinivasa Rajaram. “Development of economically competitive new coating products and processes is a formidable scientific and engineering challenge. Such new products use minimal amounts of material and produce final defect-free coatings in actual production line operations without adverse environmental impact.” With environmental concerns at the forefront of industry advancement, coatings crafted with waterborne technologies are taking prominence. The transition away from solventborne coatings is occurring in the North American and European markets. Highsolids and radiation-cured technologies are experiencing reasonably good growth as these technologies are considered to be less polluting than solventborne technology.
Correction: On p.33 of APCJ August, ‘China welcomes APIC 2019’, we stated: “A high priority to both the UN and the World Health Organization (WHO), their recommended ‘safe’ level of lead in paint is 19ppm (parts per million), a figure yet to be attained by many Asian countries.” The recommended safe level is in fact, 90ppm.
PPG announces acquisition of Hodij Coatings PPG has announced that it has reached an agreement to acquire Hodij Coatings, a leading performance coatings distributor in The Netherlands. PPG will close the transaction as per October 1, 2018. Financial terms were not disclosed. Hodij Coatings, established in 1979, distributes a portfolio of well-known professional paint brands in the segments Automotive Aftersales, Protective and Industrial Coatings. Reported sales in 2017 were US$17.8M.
AkzoNobel acquires Brazil’s Polinox AkzoNobel Specialty Chemicals has completed its acquisition of Brazil’s Polinox, South America’s leading producer of ketone peroxides, an essential ingredient in the manufacture of polymers. The purchase expands the company’s footprint in South America, establishing it as one of the region’s leading producers of curing systems for polyester thermoset resins. AkzoNobel Specialty Chemicals acquires Polinox’s brands and trademarks, including Brasnox®, Perbenzox® and TecnoxSuper®, as well as its customer list and production knowhow.
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DIARY | REGULATIONS
DIARY OCTOBER 23-15, 2018 ExpoCoating Moscow Crocus Expo, Moscow, Russia www.expocoating-moscow.ru OCTOBER 24-25, 2018 North African Coatings Congress 2018 Hyatt Hotel, Casablanca, Morocco www.coatings-group.com OCTOBER 25-27, 2018 Adhesive & Sealant Eurasia Istanbul Expo Center, Turkey www.aseurasia.com OCTOBER 31 – NOV 1, 2018 Nanoaugmented Materials Industry Summit Poly Grand Theatre, Jiading District, Shanghai, China www.naum.world DECEMBER 4-6, 2018 ChinaCoat China Import and Export Fair Complex, Guangzhou, China www.chinacoat.net DECEMBER 5-7, 2018 Coating Japan Makuhari Messe, Tokyo, Japan www.coating-japan.jp/en/ JANUARY 23-26, 2019 IPPC 2019 Tehran Permanent Fairground, Tehran, Iran www.ipcc.ir FEBRUARY 26-28, 2019 Middle East Coatings Show Dubai World Trade Center, Dubai www.coatings-group.com MARCH 19-21 European Coatings Show Messe Nuremberg, Germany www.european-coatings-show.com MAY 14-15, 2019 Asia Coatings Congress InterContinental Hotel, Ho Chi Minh City, Vietnam www.coatings-group.com/acc/ JUNE 11-12, 2019 East African Coatings Congress Safari Park Hotel, Nairobi, Kenya www.coatings-group.com/eacc
REGULATORY ROUND UP — ASIA PACIFIC India paint sector exempted from key biocide controls By Jens Kastner, Poorna Rodrigo, Keith Nuthall and Raghavendra Verma, New Delhi; and Kathryn Wortley, Tokyo. India’s paint industry has been made
called upon its member companies
Thailand’s department of industrial
exempt from a mandatory biocide
to review the ministry’s proposal
works has announced that a planned
registration requirement under the
for an impact on the industry and
release of an Existing Chemicals
national Insecticides Act (1968), if
Inventory (ECI), covering chemical products on sale in the country,
the biocides are used as a dry film preservative. However, new guidelines
Taiwan’s Bureau of Standards,
including paint and coatings
issued by the Central Insecticide Board
Metrology and Inspection (BSMI)
ingredients, is now unlikely to be
and Registration Committee (CIBRC) in
is introducing amended inspection
released until 2020. The department
June have told the Indian paint industry
standard rules for coatings, entailing
had earlier planned to release the
that they must use registered biocide
more clarity in product labelling and
inventory by December 2017. It added
products at recommended dosages, or
stricter testing methods for emissions
that the delay was partly because of
protective labelling rules will apply. For
of formaldehyde and content of heavy
ongoing work developing a Hazardous
instance, “products containing more
metals. The updated standards cover
Substance Single Submission System
than 1000ppm [parts-per-million] (0.1%)
ready mixed paint; enamel paint;
(HSSSS) tool for chemical authorisation
carbendazim will attract ‘skull and
emulsion paint; solvent-based masonry
applications, which is expected to be
crossbones’ and ‘dead fish plus dead
paints; and fire-retardant paints. Under
available in 2019, Dr Knoell Consult
tree’ labels,” it said. The guidelines
the new rules, labels must list levels of
Thai Company Ltd has said in a report:
also require that paint and coating
formaldehyde emissions and hazardous
products do not carry labels claiming
heavy metal content, as well as VOC
biocides inhibit the growth of micro-
Malaysia’s newly elected government
organisms causing odours; inhibit the
(in power since May) is continuing work undertaken under the Eleventh
growth of mould and mildew; or repel or kill insects: http://ppqs.gov.in/
Japan has designated polychlorinated
Malaysia Plan (2016-2020) to
linear-chain paraffins with 10-13
establish a national inventory of
carbons and chlorine content more
existing chemicals authorised for use
than 48% of their total weight as “toxic
in the country and carrying out risk
Vietnam’s Ministry of Science and
for humans or other animals at the top
assessment of chemicals of prioritised
Technology has amended Decree
of the food chain” in the case long-
concerns. Malaysia’s environmental
No 127/2007, imposing new rules
term, persistent or accumulative intake.
management and climate change
affecting the paint and coatings sector
From October 1, 2018, firms in Japan
division, under the Ministry of Natural
within the country’s law on standards
will no longer be permitted to import
Resources and Environment, has said
and technical regulations to improve
items that contain the substance. Items
that a large percentage of existing
indoor air quality. Effective as of July
affected include paint with water-
chemicals have yet to be assessed.
1, the detailing concerns the sampling
proofing or flame retarding properties
The government is concerned
of nitrogen dioxide and carbon
and adhesives: http://www.meti.go.jp/
about human and environmental
dioxide; mould detection and spore
exposure from toxic substances and unregulated chemicals used in a wide
counting; evaluating the reduction of formaldehyde concentrations
The New Zealand Environmental
range of chemical products. Eleventh
and volatile organic compounds;
Protection Authority (EPA) has banned
Malaysia National Plan: http://www.
measuring flame retardants and
anti-fouling paints containing the
plasticisers on organic phosphorus
chemicals diuron, octhilinone or ziram.
compounds; plus determining
Following a June decision, such
surface dust and odour emissions. It
products can no longer be imported
Indonesia’s Centre for Human
furthermore sets new standards for
or manufactured in New Zealand
Resource Planning & Development
assessing the presence of phthalates
after the EPA decided they were too
and the Human Resources
by gas chromatography and mass
toxic to marine life. These paints are
Counselling & Development Agency,
slow-release toxic coatings and the
of the country’s Environment and
substances build up to concentrations
Forestry Ministry, are working with
that can affect people and the
chemical product manufacturers
South Korea’s Ministry of Environment
environment. However, retailers “can
to draft new Indonesian national
has proposed measures to reduce
continue to sell and use remaining
work competency standards for
domestic fine dust emissions by
stock,” said Dr Stephen Cobb, from the
managing ‘B3’ hazardous and toxic
30% by 2022, lowering the fine dust
EPA’s hazardous substances group.
environment standard from 25µg/m3
From June 2023, anti-fouling paints
to 1525µg/m3. South Korea’s paint
containing thiram will also be banned:
association, the Korea Paint & Printing
Ink Cooperative, on August 8, 2018,
8 APCJ • October 2018 www.coatingsgroup.com
October diary.indd 1
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Terry Knowles looks at three reports that focus on whitening minerals for the coatings industry
All white now Author: Terry Knowles Freelance Writer Email: firstname.lastname@example.org
ecent publications in the market research sector have offered up a useful crop of titles targeting particular minerals of especial significance to the coatings industry, so this is a great opportunity to pull together some of the latest findings on titanium dioxide, calcium carbonate and kaolin.
nnTITANIUM DIOXIDE Titanium dioxide is the daddy of all pigments in the coatings industry so let’s start with that first and Ceresana’s new Titanium Dioxide (3rd Edition) report; this is a report that reviews and previews quite a lot in the titanium chain, including the upstream companies working in the mineral processing area, before progressing to the more traditional areas of end-use markets. Hence, with a databank that contains a total of 73 profiles of companies working in the titanium chain it appears a more comprehensive overview of the entire industry sector than just the consolidated TiO2 players as we know them. Inevitably, these profiles include the major companies, such as Chemours, Iluka, Group DF, Kenmare, Kronos, RioTinto, Tronox, TiZir and Venator. Regarding facts and figures, not too many teasers have been released but the main figures of interest are that the Asia Pacific industry occupied almost 46% of global demand last year, with North America and Western Europe following with almost 17% respectively. A breakdown of the end-uses shows that TiO2 pigments find their greatest level of consumption in the paint and coatings sector at 56%, followed by plastics, paper and other pigment uses (eg sunscreens and foods).
nnCALCIUM CARBONATE Calcium Carbonate Market Size, Share & Analysis Report By Application, By Region, and Segment Forecasts, 2018 – 2025 is new from Grand View Research. This title valued the global calcium carbonate market at US$20.69bn in 2016. The use of precipitated calcium carbonate (PCC) as a filler is witnessing growth at a
phenomenal rate, especially in the uncoated papers segment. Using PCC in papers results in better printing surfaces and brighter papers. Enhanced gloss and opacity are other significant attributes, enabling a broader application scope of PCC in various segments. In the broad realms of coatings definitions, within the paint sector per se, the functional benefits that encourage the use of calcium carbonate in paint and coating applications include high brightness, weather resistance, ability to disperse, gloss level tweaks, sheen adjustment and opacity. Meanwhile, in the sphere of adhesives and sealants production, calcium carbonate is chosen for its low cost. Use of CaCO3 fillers reduces the dependency on polymer-based binder products in formulations, which also helps reduce carbon footprint and greenhouse gas emissions. These fillers are also used as a replacement for mineral fillers and pigments with high oil absorption. • Asia Pacific is expected to emerge as the largest and fastest growing market for calcium carbonate globally and this is rooted in the rapid growth of the plastics and paper industries. Demand is also higher in this region, owing to factors like the establishment of new paper mills, increases in paper production and high mineral loadings in paper to reduce pulp usage. • The North American calcium carbonate market should flourish over the forecast period thanks to rising use of paper in the production of several day-to-day utilities, such as coffee cups, tissues, printing paper and packing material. Large-scale consumption of high-quality alkaline paper, increased demand for coated papers and the growing agricultural sector in Mexico are expected to fuel demand for calcium carbonate. One of the key strategies adopted by market players is the establishment of on-site production facilities, primarily to supply highquality PCC to paper mills. The major market players include Omya, Mineral Technologies, Imerys Pigments and Parchem Specialty & Fine Chemicals.
10 APCJ • October 2018 www.coatingsgroup.com
Terry 01 October APCJ .indd 1
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BUSINESS REPORT nnKAOLIN A separate report, also from Grand View Research, examines the global kaolin market, valuing it at US$5.04bn in 2017. According to Kaolin Market Size, Share & Trends Analysis Report, the market is expected to grow at a CAGR of 8.8% over the next seven years. Paints represent the third-largest area of kaolin consumption at less than 10% (see chart) with ceramics and paper being key applications. Nevertheless, the connection between paint and paper is a close one here, as kaolin confers better gloss, smoothness, brightness and paint absorbency where paper is concerned. All these factors also improve surface printability and are likely to sustain demand from the paper and packaging sectors. Furthermore, companies have been focusing on advancements in technology and on tapping unexplored applications, such as printing inks. • In 2017, the Asia Pacific region was the leading geographical market in revenue terms and this is expected to continue its dominance over the forecast period. Rising demand for packaging paper due to new and stringent government regulations is the main driver, having led to significant penetration for products manufactured using kaolin. On a broader basis, the greater affordability of consumer goods, such as paints and to some extent rubber goods, as well as construction demand, creates a cumulative rising demand drawn from China, India, Japan, Malaysia, Vietnam, Indonesia and South Korea.
Source: Grand View Research
• Growing demand for ceramic products is expected to be one of the primary market drivers. In addition, rapid industrialisation in emerging economies from Asia Pacific, Central and South America, and the Middle East is expected to fuel product demand across a breadth of applications over the forecast period. • Europe accounted for a significant market share in 2017. The greater need for environmentally-friendly products in Europe arising from strict regulation, coupled with expanding application scope, is expected to see new avenues of growth flourish in the coming years. Furthermore, investments (particularly in Germany) in construction projects are expected to drive demand for both paints and metakaolin.
Many major companies are expected to initiate exploration for kaolin in various untapped regions, especially in the Asia Pacific region. Some of the key manufacturers present in the industry are LB Minerals, BASF SE, Kaolin AD, AKW Ukrainian Kaolin Company, Sibelco, KaMin LLC and Thiele Kaolin Company. n Report details 1. Titanium Dioxide (3rd Edition) was published by Ceresana in September 2018. A single-user licence for a soft copy costs €3300. For more information on this title, email firstname.lastname@example.org. 2. Kaolin Market Size, Share & Trends Analysis Report By Application (Paper, Ceramics, Paint, Fiberglass, Rubber, Metakaolin), By Region (North America, CSA, Europe, APAC, MEA) and Segment Forecasts, 2018 - 2025, is from Grand View research and costs US$5950 for a single user licence. 3. Calcium Carbonate Market Size, Share & Analysis Report By Application (Paper, Paints & Coatings, Plastics, Adhesives & Sealants), By Region (North America, Europe, Asia Pacific, MEA, CSA) and Segment Forecasts, 2018 2025 is from the same publisher and is available at the same single user licence price. For more information on either report, email email@example.com.
Researchers at the University of Akron have studied how the glue made by orb spiders can help the adhesives industry
Improving adhesives with spider glue The effect of humidity or water on the strength of adhesives has long been one of the great challenges for those designing adhesive materials. Now, researchers at the University of Akron, USA, have used orb spiders as an inspiration to improve the stickiness of adhesives, even when exposed to interfacial water. When water comes into contact with an adhesive material, it forms a slippery and non-adhesive layer between the glue and the surface to which it is meant to stick. This makes it less likely to stay in place and more prone to slip off. To overcome this, researchers at the university, including graduate student Saranshu Singl, studied spiders (and in particular, orb spiders) and how they create one of
the strongest materials found in nature: spider silk. “We were intrigued by how effortlessly spiders catch prey in their webs using the sticky capture glue in both dry and humid environments, as opposed to most conventional synthetic adhesives that fail at high humidity,” she said. The spider capture glue is a complex mixture of glycoproteins—a protein with pendant sugar groups—along with a cocktail of hygroscopic, or water-attracting, compounds and water, Singla explained. “These hygroscopic compounds make the spider glue soft and tacky by absorbing atmospheric water. Therefore, we designed a study to understand how spider glue maintains its stickiness at high humidity even though the capture glue itself
is full of water, like a hydrogel.” Common examples of interfacial water’s effect on adhesives include paint peeling off the wall in climates with high humidity. Continued Singla: “In contrast, spider capture glue is able to perform in both dry and humid environments. Thus, understanding the reasons behind the success of the capture will initiate the design of better synthetic adhesives.” From the investigation, the team discovered that the liquid-like water in the material is completely excluded from the contact boundary by the hygroscopic compounds found in it. Singla said: “This unravels a previously unknown and surprising role of hygroscopic compounds in preventing adhesive failure by pulling water away from the contact boundary.” n
12 APCJ • October 2018 www.coatingsgroup.com
Terry 01 October APCJ .indd 2
MARKET REPORT CHINA
Mark Godfrey looks at how the Chinese paint sector is looking to become more environmentally sustainable, even as growth is still robust
Putting sustainability at the forefront
nvironmental enforcement and product safety improvements were top priorities for the President of the China National Coatings Industrial Association (CNCIA), Sun Lian Ying, when addressing her organisation’s annual summit, held in March, 2018 in Jiangsu province. The meeting launched a ‘Green Development – Six Actions of China’s Coatings Industry Plan’ for the industry, which included pledges to reduce pollution in production plants while increasing the industry’s range of environmentally friendly, highly innovative products. This comes as China introduced an environmental tax from January 1, which taxes emissions of air, water and soil pollutants. Also on the environmental theme, the association is co-ordinating the draft of a series of standards, ‘Technical Specifications for Green Design Product Evaluation’, which aims to drive green-washing out of the industry. “Standardisation of China’s coatings sector has a long way to go,” noted Sun at the March conference.
nnDELIVERING EXPECTATIONS Such ambitions will not be easy to deliver – the sector has consolidated but remains highly fragmented and characterised by large numbers of firms competing in similar products on a low-margin basis. The summit was given data indicating that mainland China’s paints and coatings sector had 1380 incorporated larger companies in 2017, accounting for 20.3Mt of output – up 12.38% yr-on-yr. Earnings, however, were up 5% to CNY/ RMB417bn (US$60.9bn) on a sampling of 2057 companies, including mediumsized businesses. Upstream input prices continued to rise in 2017, according to Sun, while the Chinese government’s policy goal of poverty alleviation, partly through
encouraging home building, has ensured demand for construction materials, including coatings. “The demand growth tendency will remain strong into the future,” said Sun: 2018’s projected output at 22Mt will be up 8% yr-on-yr in volume terms and 6% up regarding value. Sales of paints and coatings are highly dependent on China’s turbulent real estate market. A government drive to encourage corporate de-leveraging has slowed an investment boom that had been driving the Chinese economy (and coatings sales): China reported yr-on-yr GDP growth of 6.7% in Q2 of 2018, down from 6.8% in the previous quarter.
nnTHE LEADING COMPANIES Nonetheless, the growth in revenues being reported by key domestic players is remarkable. Local company San Ke Shu, based in Fujian, claims to have racked up US$400Min revenues in 2017, a doubling of the figure for 2014 and a trebling of the 2011 figure. The firm has run a billboard campaign in bus and train stations around China this summer touting its “healthy, green, natural” home décor products, among them the ‘cool tec’ range, which claims to reduce heat impact on homes. Other key local players are Hunan Xiang Jiang Paint Ltd, based in the province’s city of Changsha and focused increasingly on coatings for appliances and new energy equipment. The firm reported revenues of US$700M in 2017, well ahead of the country’s second-placed (domesticallyowned) player, Dong Fang Yu Hong (also known as Oriental Yuhong), based in Shenzhen, with US$537M in 2017 revenues – up from US$220M in 2015 - just ahead of Guangdong-based Carpoly on US$502M in revenues. However, multinationals remain entrenched as leaders in the Chinese coatings sector. One-quarter of China’s
US$30bn sales in 2016 went to a coterie of multinationals headed by AkzoNobel and including the USA’s Axalta, PPG and Valspar, Germany’s BASF, Japan-based Kansai and Nippon and Norwegian-run Jotun. The six Chinese companies in the top 20 ranked by US-based chemical consultancy Kusumgar, Nerlfi & Growney took only 6% of market share based on revenues. This is despite the fact that the government has, for the past decade, sought to shift Chinese coatings production upmarket through higher levels of innovation and technology, as well as upskilling staff. Prodded by government, the CNCIA has, over the last decade, opened 50 coatings talent training bases, as well as a series of advanced research centres.
nnSCOPE FOR GROWTH Decorative coatings offer the biggest scope for growth according to Liu Jie, Deputy Secretary General at the CNCIA, speaking at the China Art Paints Tint & Texture Trends Fair in Guangzhou this June. Decorative coatings account for 3540% of sales in the China coatings market, compared to 50% in the European Union (EU) and USA, according to Liu. Consumers are becoming far more discerning according to leading interior designer Shen Yi, also speaking in Guangzhou: he pointed to “more differentiation” of products among Chinese consumers and the onset of colour trends, such as the Gobi shade which is “natural and calming”. The biggest obstacle to future growth for domestic firms may, however, be higher environmental compliance costs: net profit margins across the industry in the first four months of 2018 averaged 5.95% but growth in margins dropped 6.69% on the same period last >16
13 APCJ • October 2018 www.coatingsgroup.com
Terry Knowles looks at the two largest paint manufacturers in Asia Pacific, Japan’s Nippon and Kansai Paint
Momentous times for Kansai and Nippon Author: Terry Knowles Freelance Writer Email: firstname.lastname@example.org
ith the August publication of Kansai Paint’s annual report there is considerable good news to report in the company’s development, which is especially fitting as in May 2018 it celebrated its centenary of operation. This period in Kansai’s modern evolution finds it still in the throes of a three-year strategy targeting increased global presence through consolidation and rising profitability. Kansai Paint enjoyed record sales and record net income in its fiscal 2017 year, which ended in March 2018. Putting some values to those performance attributes, Kansai Paint’s consolidated net sales for the last fiscal year amounted to ¥401,978M (US$3,784M), up 21.7% yr-on-yr. Operating income was ¥35,802M (US$337M), up 1.4% yr-on-yr, due to a rise in raw material prices and an increase in selling and general administrative expenses. Kansai’s largest revenue generator continues to be the automotive sector with 34%, as seen in the pie chart.
nnREGIONAL SKETCHES FROM KANSAI
Source: 2018 Corporate Report, Kansai Paint
Looking over the last year, the company saw that China and emerging countries in Asia continued to enjoy economic recovery on the back of varying influences. Even in Japan, the economy witnessed some mild recovery owing to improvements in the wider world economy, as well as improving income and employment
scenarios at home. European economies have experienced an upswing on the back of rising consumer spending, while the USA saw an upturn in business sentiment and employment. Looking across the current year and into the near term, many of these positive forces will shape progress, with India expected to demonstrate strong economic growth in particular. In Asia, its native Japan benefited from rising car and machinery output, translating into growth for the automotive and industrial segments, while the protective coatings markets also rose. These improvements were set in stark contrast against the Japanese refinish, decorative and marine sectors, which all decreased in yr-on-yr terms. Collectively, net sales in Japan ended at ¥155,553M (up 2.7%) and ordinary profits culminated in a total ¥19,051M (down 19.1% yr-on-yr). In India, where the company has a strong hand in the industrial sector in the form of Kansai Nerolac Paints, and thereby also a sizeable presence in the growing Indian decorative market, there were good growth prospects in both of these spheres, although rising raw material costs dented profitability somewhat. In India, the company’s net sales reached ¥83,433M (up 11.7% yr-on-yr) and ordinary profits resulted in ¥13,366M (up 15% yr-on-yr). In China, car production was robust, resulting in sales of the automotive coatings sector holding steady with the previous year’s level. Sales of the industrial coatings sector saw growth in paints for construction machinery, leading to an annual increase in sales in China as a whole. On the other hand, equity in earnings of affiliates decreased due to sluggish sales to local car manufacturers. Indonesian sales in the automotive and decorative coatings sector were higher than the previous year owing to a robust economy, while in Thailand, operating results fell short of the previous year’s level, despite recovery in car production. Performance in the Middle East was sluggish despite aggressive sales activities. In the Europe and Africa region, a huge boost was derived from the acquisitions of the Sloveniabased Helios Group and Turkey’s Polisan Boya. In
14 APCJ • October 2018 www.coatingsgroup.com
TERRY industry October APCJ.indd 1
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INDUSTRY OUTLOOK trading patterns in China and Japan, net sales of trade-applied decorative paints have also been strong across Singapore, Malaysia and Vietnam. • The Americas and the USA most notably, saw a decline in coatings sales to the automotive industry – a squeeze being felt as automotive output was seen to fall during the first six months of this year, while at the same time the company redoubled its efforts to push further into the sector. On the other hand, Nippon’s takeover of DunnEdwards Paints saw it tap favourably into the trade paints area, at a time of increased construction activity. 2018 has been the first time that the DunnEdwards business has contributed to a complete half-yearly result. • Finally, in Europe automotive output in the EU region boosted automotive coatings sales, mainly as a result of sales to French car manufacturers. Unusually, operating profits were an astonishing 95% lower here at ¥21M due to rising raw material costs and product mix changes exacerbating the overall result. n
Meanwhile, Kansai’s larger rival, Nippon Paint is making adjustments to the reporting of its results, which has led to a short-year nine-month period in 2017 to give a year of results finishing with the calendar year. This realignment of reporting has brought in its wake a half-year result to June 2018 for the first time, which is to be welcomed here. Nippon Paint’s consolidated sales for the first six months of 2018 were up by 6.6% over the same period in 2017, moving from ¥271,748M to ¥310,996M, while its operating income, compared on the same basis, fell from ¥35,493M to ¥34,597M.
Covering this latest period up to June 2018, the following performance notes have been taken: • In Japan, there was better performance as a result of more premium-level automotive coatings and those with higher values being pushed, at a time when the level of automotive output was otherwise flat. The other main area of growth, also resulting from a strong push in otherwise static markets, was in trade-applied decorative paints. Those segments aside, other segments like industrial and marine appear to have been weaker. Consequently, consolidated net sales in Japan decreased by 0.5% from the previous year, to ¥86,657M. Consolidated operating income decreased by 0.8% from the previous year, to ¥27,601M due to the effects of an increase in raw material prices and an increase in selling, general and administrative expenses. • China in 2018 has delivered Nippon higher sales in the automotive coatings sector as a result of both the output level and greater penetration into the automotive component finishing sector in China. Similarly, trade paints in the Chinese decorative market also returned higher sales at a time when the interior decorative market and the real estate segment was sluggish. Coatings for construction materials in China were also slow-movers, echoing the same performance as Japan. • Extra to those two major markets but still remaining in Asia, automotive coatings in Thailand has continued to flourish in the first half of this year as a result of rising production levels on the part of both Indian and Japanese car manufacturers in the country. Mirroring
<13 year, according to the CNCIA, which (in a statement publishing the data) put the slide in profitability down to higher environmental compliance costs including a pollution tax introduced by China in 2018. But given the country will remain the world’s largest coatings market, China looks set to be a focus of intense competition in the future. Growing opportunities in appliances, motor vehicles and renewable energy equipment create “huge market space” for the future, according to a Beijing-based European business consultant who advised several multinational coatings firms on establishing coatings manufacturing and ingredients sourcing facilities in the Tianjin region. In its ‘Made in China 2025’ strategy, the government lists sectors like renewable
energy equipment – including wind, solar and nuclear power equipment – as areas where China will seek international competitiveness, using Chinese inputs. “This will obviously call for coatings developed at home, but most Chinese companies remain in a volume game; they are far behind the research and development capacity of multinational peers,” said the consultant, who requested anonymity. He foresees a rise in Chinese exports of chemical-based products including coatings, which remains a government focus under the One Belt One Road infrastructure blueprint with the greater Eurasian connectivity it is building continuing to open up overseas markets. Economic growth across the
neighbouring ASEAN (Association of South East Asian Nations) region remains higher than in mature markets, such as Europe. Worry about the economy at home also continues to drive Chinese companies to invest overseas. Energetic overseas M&A activity is to continue in 2018 as underlying driving factors, “especially low growth prospects and meagre return on assets, are still intact,” according to Alicia GarciaHerrero, Asia Pacific Chief Economist at the Hong Kong offices of French investment bank Natixis. n
the Turkish market, domestic sales of paints for automotive components were strong, owing to an increase in car production, but yen exchange rates from the Turkish lira brought down the final result. Collectively in Europe itself (including Turkey), Kansai’s turnover rose by more than 250% in the year, largely on the back of these two sizeable acquisitions. In Africa, there were rising sales to be had on the back of Kansai’s new venture into East Africa, while South Africa and its neighbouring economies remained slow. Tightening the African squeeze further were rising raw material costs and increased competition on price. Overall, this led to a 25% increase in sales in the African region, which was accompanied by an operating loss too. In other regions – chiefly North America – slowish car production and rising competition led to a decrease in earnings in some affiliates, but with the inclusion of the US Paint Corporation’s results, net sales in this area more than doubled, although operating profits were 4% lower.
PLACE AT NIPPON PAINT
For more information, contact: Keith Nuthall, International News Services www.internationalnewsservices.com Tel: +44 (0)207 193 4888
16 APCJ • October 2018 www.coatingsgroup.com
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APCJ spoke to Michael Olosky, Henkel, to find out about how the leading global adhesives company is focussing its attention on the Chinese market
Innovation and sustainability in China
Michael Olosky, President of Henkel Asia Pacific
What operations does Henkel currently have in China? We currently operate more than 10 adhesives manufacturing locations in China. Since establishing our first office in China in 1988, Henkel has been providing high-impact, tailored adhesives, sealants and functional coatings to a wide range of local industries, such as automotive, electronics and packaging — to list a few. China is among Henkel’s top three markets globally and contributes significantly to our growth. Last year, our Asia Pacific sales reached €3.4bn, with organic sales growth of 5.9%. The China market contributed significantly to this positive result. Based on our strong 2017 performance, we will bolster our China market investment. As the trend of smart manufacturing accelerates, we will increasingly integrate our local manufacturing sites with Industry 4.0 technologies and solutions. We have already incorporated the Manufacturing Execution System in five of our China plants, a system that utilises cutting-edge technologies, such as big data, cloud computing and Internet of Things to enable end-to-end automation, transparency and operational efficiency. Furthermore, we have strengthened our product portfolio and expertise through targeted acquisitions. Last year, we acquired Darex Packaging Technologies and Sonderhoff Group, leveraging their China operations and products to build our market position and better serve local customers. We have also designated our Henkel Management Center in Shanghai as our new Asia Pacific and Greater China Headquarters in 2017. This reflects our long-term commitment to our customers in China and our confidence in China’s market growth potential.
A recent report predicts the Chinese adhesives & sealants market is expected to grow at a CAGR of 5.91% during the forecast period, 2018 to 2023. Is Henkel also predicting this kind of growth for its own operations in China? The total global market for adhesives, sealants and functional coatings we are operating in accounts for about €65bn. Due to its rapid economic growth, Asia Pacific is a major growth driver in this segment. Furthermore, emerging strategic industries are driving market development and creating new growth opportunities. For example, our global electronics business generated double-digit growth in revenue last year, while our automotive business segment supplies solutions that enable up to 15% of car weight reduction. These trends have enabled our Adhesive Technologies business unit to achieve an organic sales growth of 5% in 2017. In tandem with China’s ongoing industrial development, continued strong market demand and government support for strategic emerging industries will drive further growth for high-impact, tailored adhesives, sealants and functional coatings. We are confident that our leading innovations, brands and technologies will enable us to grow with the market. The same report noted that the Paper, Board and Packaging industry dominates the Chinese adhesives market, accounting for 43% of its revenue. Which enduser segments are currently driving the most demand for Henkel? China’s packaging industry, especially the food packaging industry, is a major source of demand for us. By providing customers with highperformance adhesive solutions, Henkel seeks to help improve the safety and quality standards of
18 APCJ • October 2018 www.coatingsgroup.com
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Henkel’s Dragon plant, Shanghai
the food industry. The electronics industry in China is another significant source of demand for us, and a key success factor for our global electronics business, which has grown to more than €1bn last year. As China pursues industrial upgrading and smart manufacturing, emerging strategic industries, such as new energy vehicles, 5G, and 3D printing are rapidly developing and driving new growth opportunities. Recently, the electric vehicle (EV) market has been booming, with 777,000 EVs sold in China in 2017, up 53% yr-onyr1. Henkel supplies the EV industry with a slew of solutions, including surface treatments, noise, vibration and harshness (NVH) solutions, thermal management, magnetic bonding and sealing, just to name a few. More significantly, products like our electroconductive pastes will enable Henkel to improve the performance and longevity of EV batteries. As China drives the development of the 5G mobile networks, we see great potential of China’s 5G industry. This is where Henkel can contribute: we provide highly thermally conductive pads, liquid gap fillers and gels for telecoms equipment including base stations, routers, switches and server infrastructure. 3D printing is another emerging industry that is generating new growth opportunities. Henkel has recently partnered with HP and Carbon to develop 3D printing materials and equipment to drive the adoption of the technology beyond prototyping to final parts production. We have launched a European hub for 3D printing in Dublin and we also plan to establish a 3D printing training centre in Shanghai to drive growth and better serve our customers in Asia Pacific.
How is the Chinese government’s recent emphasis on environmental sustainability affecting Henkel’s operations in the country? As China seeks to balance economic growth, social well-being and environmental health, the country is increasingly emphasising sustainability and ‘productivity enhancement’ over ‘productivity expansion’. This aligns perfectly with Henkel’s commitment to leadership in sustainability, which includes “creating sustainable value with everything we do” and reducing our environmental footprint. We are delighted to witness China enacting sustainability policies and view them as vital for driving healthy economic growth — both nationally and for the manufacturing industry. Henkel aims to triple the value of its operations, products and services by 2030 (base year 2010) while reducing our environmental footprint — in other words, achieving more with less. We have already implemented policies aimed at realising this goal. For example, our Dragon Plant utilises technologies, such as enclosed chilled water recycling systems, solid waste recycling and special translucent roofs to enhance energy efficiency and reduce waste. Henkel is also dedicated to advocating for sustainability amongst its partners along the entire value chain. We are working with product packaging suppliers to minimise waste and utilise easily recyclable materials to reach our 2020 target of reducing packaging weight by 20% compared to 2010. Furthermore, as a member of the Together for Sustainability initiative, we advocate for sustainability standards throughout the entire supply chain. In addition, we aim to both serve our customers and lower carbon footprint by supporting lightweight and hybrid vehicles to phase out heavy metals.
Environmental sustainability aside, are there any other key trends that you are observing in China at the moment? China is currently shifting towards an innovation-driven economy, which, in turn, is driving market demand for Henkel’s highimpact and tailored solutions. In response, we’re investing in strengthening our manufacturing and innovation capabilities. Since establishing our largest adhesives plant — the Dragon Plant — in Shanghai, we have launched the Shanghai-based Henkel Adhesive Innovation Center in 2015 to foster crossindustry collaborations and fulfill customer and consumer needs. Moreover, we have partnered with leading local companies to jointly develop innovations. For example, we’ve worked with China’s top home appliances companies to integrate our cuttingedge NVH technology with their home appliances to enhance product quality and consumers’ experience. Furthermore, as China aims to realise a ‘Digital China’ by investing in the development and widespread integration of next generation information technology, digitalisation is inevitable. This is in line with Henkel’s 2020+ strategic priority of accelerating digitalisation, which includes driving our digital business by digitising our interaction with customers, consumers, business partners and suppliers along the entire value chain in both its consumer and its industrial businesses. As such, in China’s booming e-commerce market, we have partnered with Alibaba to open flagship stores to better serve our consumers and industry partners. Additionally, our leading brand Loctite has utilised WeChat to drive consumer engagement and offer services, such as after sales follow-up and accepting new product requests. Do you expect the Chinese market to continue to dominate in the way it has over the last decade? As a global company with employees from 120 nations and locations, we regard every market as integral. China is among our top three markets globally and we are confident in its future. n References 1. www.scmp.com/business/companies/ article/2143646/chinas-ev-market-growingtwice-fast-us-heres-why
Michael Olosky, Corporate Senior Vice President, President of Henkel Asia Pacific, Head of Adhesive Technologies Asia Pacific Website: www.henkel.com
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2019 14 – 15 May 2019 InterContinental Hotel Ho Chi Minh City, Vietnam
THE PREMIER FORUM FOR THE COATINGS INDUSTRY IN ASIA
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Sarah Gibbons reports on the reasons behind the current growth in the global wallpaper market and reviews some of the latest products
Innovations in wallpaper driving a resurgence in market
emand from two key generations is driving resurging sales in the global wallpaper market: Millennials and their quest for a sustainable lifestyle coupled with embracing all things technological, together with the baby-boomer generation’s affection for heritage preservation. Sales for the past five years have been growing steadily amidst a wealth of promotional material boasting wallpaper’s environmentally-friendly credentials, a connection to traditional cultural influences or how technological advances can transform a simple wall covering into a dynamic home or workspace. Researchers Euromonitor International depict the international wallpaper market leaping from a value of US$5.5bn in 2012 to almost US$6.7bn in 2017 – itself a 4% increase on 2016 figures.
nnMILLENNIALS VS BABY BOOMERS
Millennials are moving into their prime working and spending years and shaping the industry with their demands for sustainability, convenience and personalisation. However, brands will need to keep in mind the older generation for more than a while longer, as Millennials are also increasingly having to delay their financially independent adulthood, staying or returning to live with their parents, she said.
nnPEEL-OFF WALLPAPER Ideal for the younger generation is the trend in peel-off wallpaper, that can be updated and replaced. A spokesman for New York-based Chasing Paper, producers of removable wallpaper made from polywoven fabric rather than traditional vinyl, said: “Wallpaper is an extraordinary way to transform an environment and removable wallpaper removes that fear of commitment many people have.”
Adeline Ho, Senior Research Analyst at Euromonitor, said: “Two demographics currently stand out in importance for the home and garden industry – Millennials and Baby Boomers, with companies and brands finding themselves at the crossroads of catering to two generations that hold vastly different values.” She highlighted how technologically-savvy
Woven Ivory Barkskin™. Image: barkskin.com
NLXL Shabby Scrapwood effect wallpaper by The Longest Stay. Image: The Longest Stay
Boasting low chemical emissions from latex ink, Chasing Paper’s target audience is USA urban women aged 25-45 who follow interior design trends. A company note said: “Created from conversations with serial movers, stylish mamas, renters who feel like anything but, DIYers and, of course, commitment-phobes, Chasing Paper is simple to hang and easy to remove.” The spokesman said: “Wallpaper is making a resurgence,” and added that the company’s sales figure reflected that trend.
nnPVC-FREE Another eco-line wallpaper is Ecodeco, developed by Lithuanian company Veika, which has the appearance of conventional vinyl wallpaper but is PVC-free, made without chemical plasticisers. It makes “functional, washable and printable wallpapers…without harmful chemicals.” said Dr Aleksey Etin, the Ecodeco’s founder. He said its wallpapers are produced from an environmentally friendly polymer composite material, both odourless and fully recyclable. Dr Etin said such new lines could keep wallpaper sales growing, noting that “for years, there has not been any real innovation in the market.” Meanwhile, Len-Tex Wallcoverings, from New Hampshire, USA, boasts certificates
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WALLPAPER 3D wallpaper is another trend
relating to environmental standards and stressed in a note that the company takes indoor air quality seriously. Its products use “clean vinyl technology” containing no phthalates, heavy metals or formaldehyde. “Our innovative Clean Vinyl Technology (CVT) formulation addresses the chemicals and associated health risks typically found in vinyl wallcoverings,” said the note. New Jersey, USA-based J Josephson also sells wallpaper with environmental marketing, explaining how its printing inks are recycled and its industrial systems generate energy as they operate, “reducing dependence on outside energy supplies”. As for wallpaper materials suppliers, Barkskin, by Caba, based in New Mexico, USA, makes an organic, hand-pounded bark material popular in wallpaper designs, offering a natural look and feel. Moreover, the emphasis on ‘going green’ spreads from the wallpaper market into the closely-related adhesives sector. The Emsland Group, from Emlichheim in Germany, has developed an extensive range of wallpaper adhesive products based on potato starch, offering “particularly high adhesive strength”. Other advantages of this type of wallpaper paste, the company claims, include lower consumption, ease of movement of the paper on the wall and quick and easy removal.
As for the Baby Boomer side of the growing sales equation, and older buyers desire to preserve visual cultural traditions, one company tapping into this trend is Norwegian firm Biri Tapet, founded by current General Manager Ingeborg Semb’s grandmother in 1938. It still uses traditional weaving methods to create wallcoverings using waste oat straw.
Colours are introduced using dyed threads to create a timeless form of wallpaper. “The production is “innovative” in the sense that we are using old techniques making modern designs,” Ingeborg said told APCJ. “The really special thing about our wallcovering is that we are using straw (that is normally just waste) to produce a wallcovering that lasts ‘forever’,” she noted. “One of the first wallcoverings my grandmother made is still in the house where I grew up – looking just as beautiful as it did 80 years ago. Living in a world where there is so much waste, I think this is great!” While used mainly in residential homes, Biri products also hang in international hotels and in the Security Council chamber at the United Nations building in New York, USA.
nnFIRE-RESISTANT WALLPAPERS Then at the opposite end of the design spectrum is the dynamic products combining aesthetic and practical features. Scientists at the Shanghai Institute of Ceramics at the Chinese Academy of Sciences, have developed a fire alarm wallpaper made of environmentally friendly, non-flammable materials – including nanowires made from hydroxyapatite, found in bone and teeth – that can detect a fire, prevent fires from spreading and give off an alarm when a blaze breaks out. When exposed to heat, the graphene oxide-based ink coating the paper is transformed from an electrically insulating state into an electrically conductive one, causing it to automatically trigger an alarm embedded in the paper, activating loud sounds and warning lights. Researcher Professor Ying-Jie Zhu told APCJ: “The fire-resistant wallpaper has a white colour, mechanical robustness and high flexibility; it can be processed into various shapes, dyed with different colours, and printed with any design or colourful patterns or words. Therefore, the fire-resistant wallpaper has promising
applications in high-safety interior decoration of houses to save human lives and reduce the loss of property in a fire disaster.” Thermochromic inks are also used in some wallpaper designs so a room can be transformed according to the temperature – for example, a product by London, UK-based designer Shi Yuan is based on flowers which change colour when exposed to heat, such as a radiator. Intelligent wallcoverings can be personalised with interactivity. Tori Deetz, co-founder and Vice President of New York-based Visual Magnetics, explained how several layers of magnetic paint, a flexible magnetic liner and a surface layer containing iron produce a dynamic wallcovering capable of holding shelves and other accessories, ideal for corporate brainstorming sessions, “workplace innovation” or children’s play areas, designed according to customer preferences to include corporate logos or bespoke images. The surface area can be written upon or have items attached via magnets, which can be removed easily and transported to another wall. And then there are products referred to as “digital wallpaper” but are, in truth, electronic boards using a variety of display technologies, although NanoLumens, based in Georgia, USA, has now devised its lightweight Nixel Series which is “remarkably thin” and curves allowing it to be wrapped around columns and mounted into any space. n
For more information, contact: International News Services www.internationalnewsservices.com
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Asia Pacific Coatings Show 2018 opened its doors on September 13, and welcomed more than 2100 visitors from 40 countries over the course of the two day event
Coatings success in Kuala Lumpur
he Asia Pacific Coatings Show 2018 (APCS) returned to the Kuala Lumpur Convention Centre, proving once again to be an international hub for the coatings industry as it welcomed 2132 attendees from 40 countries around the world over the course of the two day event. With more than 130 exhibitors from numerous countries, such as China, Australia, the UK, Germany, Italy, India and Korea, to name a few, the buzzing mood in the hall reflected the opportunities available to businesses present in the Malaysian market. With Asia Pacific remaining the world’s dominant and fastest growing coatings market, companies present at the show were able to meet with both new and familiar contacts, see the latest industry trends and secure business contracts with local and international suppliers and manufacturers to the coatings industry. This year was also the inaugural event for the Asia Speciality Chemicals Show, which was held alongside the main exhibition. Companies, such as Troy Corporation, were present and able to take advantage of the numerous links between the coatings and the speciality chemicals markets. Vincent Abran of Troy also gave a presentation within the free to attend Business Solutions Hub, entitled ‘Advanced biocides for architectural paints and coatings’. The business presentations were were held on day one of the show. Other companies that gave presentations included Germany’s Hoffmann Mineral, ‘Advantages of using Neuburg siliceous earth in coatings – an overview’; China’s Shandong Landu New Material Co Ltd, ‘Biocides’; and China’s Biuged Instruments, who presented a paper
entitled ‘Multi-function high speed dispersing machine’.
nnNEW PRODUCTS, NEW EXHIBITORS This year’s APCS welcomed first-time exhibitors Basil Commodities of India, which displayed its range of dyes and pigments. The company has been active in its domestic market and international markets for more than three decades but APCS 2018 marked its debut into the Malaysian market. Speaking about the company’s success of APCS 2018, Preeti Pillai, Export Manager – Chemicals, said: “Looking at the number of visitors, we are hopeful to do some good business in Malaysia. We had a good number of inquiries for different usages of pigments, including a few traders. The Asia Pacific region is of interest to us because it is the fastest growing region, with so many important surrounding countries like Thailand.” KH Chemicals, headquartered in The Netherlands, also made an appearance at an exhibition in Asia for the first time and with an office in Shanghai, the company is well placed to meet the demands of the Asian market. The company supplies various hydrocarbon and chemical solvents, acrylates and monomers, which were on display at the show. New products on display at the show included the Dyno-Mill UBM from Switzerland’s Willy A Bachofen. The recently launched Universal Bead Mill is for dispersion and ultra-fine grinding and is best for aqueous, solvent-based and contamination sensitive products in production facilities throughout the industrial sectors. The
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APCS REVIEW company also had its new Dyno-Mill Unilab on display, which allows high efficiency at laboratory- and pilot-scale. Also hailing from Switzerland, Bühler Group was present with its high performance bead mill, the MicroMedia+TM. The wet grinding and dispersing machine allows for a wide parameter range concerning bead size, power density and flow rate. Leau Jun Wei, Area Sales Manager for Bühler Malaysia, said of the show: “It has been successful. We were able to generate positive, good potential leads and interact with our existing clients who visited us. We are happy with the amount of prospected business that we procured at the show. For this year, the most important reason to attend the exhibition was face-to-face meetings with clients and potential clients.” Also on display at APCS 2018 was a broad range of equipment, technology and products that cater to the entire supply chain and production of coatings ingredients. This included products, such as the Russell Self Cleaning Eco Filter, from Malaysian company Repassa Engineering; tinting and mixing machines from China’s Santint; a range of high torque/output twin screw extruders from the UK’s Xtrutech; and filling machines from Belgium’s J De Vree & Co. This was on top of a diverse range of organic and inorganic pigments, additives, chemicals and waterborne and solventborne technology.
‘High performance corrosion resistant coatings using graphene’, from Prof A S Khanna of IIT Bombay; and the very popular ‘Bio-based architectural wall paint’, from Dr Nurudin Budiman of Connell Bros. Reflecting the range of trends in the Asia Pacific market at the moment, the conference was both informative and interesting for delegates and provided a platform for attendees and speakers to exchange ideas, research and solutions for problems regularly encountered throughout the coatings industry. Those interested in speaking at next year’s Asia Pacific Coatings Conference can get in touch with Kieran Proverbs, kieranproverbs@ dmgevents.com, to discuss possible subjects and details of availability. The conference will take place alongside the Asia Pacific Coatings Show 2019 in Bangkok, Thailand, on September 4-6.
nnDATES FOR YOUR DIARY The Asia Pacific Coatings Show is organised by The Coatings Group, dmg events. Other events organised by The Coatings Group include: • North African Coatings Congress 2018 Hyatt Hotel, Casablanca, Morocco October 24-25, 2018 • Middle East Coatings Show 2019 Dubai International Convention & Exhibition Centre, Dubai February 26-28, 2019 • Asia Coatings Congress 2019 InterContinental Hotel, Ho Chi Minh City, Vietnam May 14-15, 2019 • East African Coatings Congress 2019 Safari Park Hotel, Nairobi, Kenya June 11-12, 2019 n
nnSHARING KNOWLEDGE This year, the conference was entitled ‘Coatings for the Future’ and it was held above the exhibition floor over the two days of the show. Attendees were able to hear presentations on a wide range of topics relevant to the coatings industry, including a talk on ‘Epoxy resins and coatings, market and trend’ from IHS Markit; ‘Eliminating lead paints in Asia’ from Hatijah Hashim, of the Consumers Association of Penang;
Asia Pacific Coatings Show 2019 will take place in Bangkok, Thailand, on September 4-6. Email: firstname.lastname@example.org Website: www.coatings-group.com
Below and above: Scenes from the exhibition floor, including the Business Solutions Hub and the Asia Pacific Coatings Conference
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PIGMENTS & DISPERSIONS
Julie Bostock, Smithers Rapra, discusses how new applications will add value as the world’s high-performance pigment market blossoms
High performance pigments
n 2018, the market for high-performance pigments (HPPs) and speciality pigments (SPs) is an increasingly globalised and competitive business environment. The border between high-performance and commodity pigment has in the past been indistinct. But as application requirements have become increasingly demanding, this has helped to refine more clearly a definition of HPPs. Producers of HPPs are increasingly striving to produce products with excellent durability, high colour strength, excellent dispersibility in a range of resin systems, chemical stability and low solubility. Such performance commands a premium price. Exclusive research from Smithers Rapra published in its new market report ‘The Future of HighPerformance Pigments to 2023’, shows that the market for HPPs and SPs will reach US$6.73bn in 2018. In addition to superior production technology, contemporary HPPs are compatible for a diverse range of applications, as well as meeting increasingly stringent regulatory requirements – especially in the EU – which further adds to the value of topend pigments. Smithers analysis forecasts the growth of 14 HPPs and SPs – including complex inorganic coloured pigments (CICPs) – and
tracks how the overall market will reach US$7.97bn in 2023; a yr-on-yr growth rate of 3.4%. Volume consumption will rise across the same time period from 239,120t to 282,694t.
nnASIA Asia is already the largest regional geographic market for HPPs. It will consume 87,136t in 2018 and be worth US$2.36bn. Asia’s share of the world market will rise significantly across the next five years. This can mostly be attributed to China as it continues to dominate new growth in high-performance pigments, as it already does in commodity pigments; and new sales into the relatively underdeveloped Indian market. Both have forecast growth rates in excess of 6% for 2018-2023. The combined markets of China and India in 2018 are estimated to be 32,689t and will grow to 44,679t in 2023, surpassing the USA market. Major pigment and coatings manufacturers have continued to invest heavily in China, especially in the automotive production sector, underpinning medium-term growth. For example, Axalta is building a new plant in Nanjing, which will hit full production of primers, basecoats,
clearcoats and resin intermediates in 2020. And BASF Coatings has recently opened a world-scale automotive coatings plant at the Shanghai Chemical Industry Park. In the short term, two new environmental protection laws enacted at the start of 2018 are having a major impact on the cost of raw materials in high-performance pigment manufacture and the supply chain – both in China and further afield. For example, the raw material of phthalocyanine blue and phthalocyanine green is copper(II) phthalocyanine; and the main materials of copper(II) phthalocyanine are phthalic anhydride, urea, ammonium molybdate and cuprous chloride. The price of phthalic anhydride increased from RMB6100/t (US$920) to RMB9000/t across 2017. The production capacity of urea in 2017 dropped, causing the price of urea to increase to about RMB300-500. The RMB13,000 increase in the price of cuprous chloride is a direct consequence of the price increase of copper during 2017. Pigment manufacturers in India are catching up fast in terms of productivity and technology. They are changing their product mix with an increased contribution from HPPs and are developing a global presence. Meghmani Organics, for example, has fostered local markets – especially in the textile, paper, plastic and rubber industries. It exports 55% of its total production and controls 10% of the global market in copper phthalocyanine crude blue and beta blue pigments.
nnMARKET INNOVATION The capacity for HPPs to innovate and offer extra functionality in end-use products is an important factor for continued profitability. Smithers’ analysis identifies the following key growth areas across 2018-2023 that capitalise on this and parallel innovations. Nanopigments – super-fine pigments where individual particles are in the nanometre range – will be central to feeding the technical cutting edge of the market for special effect pigments.
End-use market shares for HPPs in 2018, by volume (%)
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PIGMENTS & DISPERSIONS The automotive industry will be central in driving much of this innovation. There is a growing demand for organic nanoHPP products, which are fine enough to avoid scattering effects and give very high transparency. These products still need to maintain high light fastness and durability, while giving high chroma, saturation and, above all, transparency like conventional dyes. When mixed with effect pigments, these nanopigments can generate an extended portfolio of colours with dramatic face and flop effects embraced by designers and consumers to accentuate shape and design. Nano-technology pigment platforms, such as PPG’s Andaro Tint Dispersion, developed initially for the automotive industry, are now finding uses in other high-performance coatings. This includes luxury goods and high-end colour coatings for home appliances, such as washing machines and refrigerators. Future growth will continue as and where segments can be identified where consumers are willing to pay a high price to differentiate themselves using colour. Demand for these very small particle sizes is also stimulating innovation in bead mill construction and design from the likes of Bühler, Netzsch and Hockmeyer.
nnDISPERSION INNOVATION The relative high cost of high-performance pigments is continuing to prompt producers to refine their products to increase their cost-effectiveness wherever possible. Innovation in another direction is looking to eliminate the time and financial costs associated with bead milling. Ease of dispersion is one area of special attention that can offer a significant potential cost saving to the user and therefore most pigment suppliers are now offering easy dispersing pigment powders. For example, Shepherd Colour has its Dynamix range of easily dispersible pigment powders. It reports these have excellent behaviour in both solventborne and waterborne paints and are now finding applications in some ink formulations. Clariant has developed and is marketing easily dispersible (ED) pigments and sells an expanding line of easily dispersible highperformance organic pigments. These are marketed as easily dispersible waterborne (EDW) pigments.
nnCOOL PIGMENTS Cool buildings – structures that employ coatings to reflect heat from the sun – is a major trend in construction, helping reduce running costs from air conditioning and
meet new energy efficiency standards for buildings. Furthermore, cool coatings result in less thermal degradation and reduce expansion across the building structure, improving its lifecycle and cutting the need for the site owner to conduct maintenance. Many manufacturers now offer specific pigment lines with infrared (IR) reflective properties: Ferro (Cool Color), Heubach (Heucodur IR), Merck (Iriotec 9000), Shepherd Color (Arctic), Venator (Altiris). Significantly, this emergent class of HPPs can offer dual functionality – marrying colour durability and IR-reflection – in a variety of colours, including blacks, to be produced. The same functionality of paints with IR-reflective HPPs is also gaining ground in automotive coatings. In March 2018, BASF’s work in this area was recognised with an iF Design Award at the BMW Welt centre in Munich. Its passive temperature management system utilises a basecoat that is transparent to IR-radiation and an IR-reflecting filler. In this combination, the paint is reported to reduce a vehicle’s surface temperature by up to 20°C in bright sunlight, offering similar durability and energy savings as seen in cool building coatings. Nano-technology is being harnessed to optimise IR reflectance. Decoration of mica flakes with nanorods of the mixed iron/titanium oxide has generated a new family of pigments. The near-infrared solar reflectance of these composite pigments can be as high as 80%. These pigments could be lower cost, near-infrared reflective yellow pigments for use in solar reflective coatings for the future.
nnCOATINGS FOR DRIVERLESS CARS The automotive industry is increasingly fitting advanced driver-assistance system (ADAS) to vehicles with the goal that fully autonomous vehicles may be on the road sometime in the next decade. ADAS relies increasingly on a suite of specialised sensors fitted to cars to help the driver to navigate traffic and other hazards. For real-time feedback, many of these are focussed on employing Light Detection and Ranging (LiDAR) technology; this in turn is stimulating demand for further enhancement in vehicle coatings. PPG has led in this area with a coating technology that allows fine management of the reflectivity of the coating to specific wavelengths. It expects to market this before 2020. PPG also wants to produce improved coatings that enhance the radar reflectivity and transmission properties of plastic and composite substrates.
nn3D PRINTING Additive manufacturing, commonly known as 3D printing, is poised to revolutionise production in some industries/segments – principally those requiring low production runs, ease of customisation and/or complexity in design. 3D printed products or components are not cheap, typically. The fact they can command a premium price means there is a corresponding need for high-quality effects, which can be realised by adding HPPs into the polymer mixes that a 3D printer uses. Both Clariant and BASF have started businesses specifically tailored to supplying this market with premium and customised 3D printer filaments. There is great growth potential. Smithers analysis shows that the global market for 3D print equipment and consumables will be US$8.67bn in 2018. This will triple to reach US$20.14bn in 2022 and double again to US$55.82bn in 2027. This is seeing pigment business build new partnerships with additive manufacturing technology suppliers. BASF and industrial inkjet company Xaar are collaborating to refine a photopolymer jetting (PPJ) process. This relies on curing the plastic with a UV light source, creating an opportunity to colour the photopolymers resins with HPPs. Schlenk Metallic Pigments and filament producer Herz have collaborated to create 3D printing filaments that they report have ‘a silky, homogeneous surface that is free from visible glitter particles [combining] deep shine with an authentic metallic look.’ Working with polyterephthalate glycolmodified (PETG) matrix polymer, five 3D print grades are now available – in metallic gloss blue, red, black, brown, and fir tree (green) – and can be processed up to 240°C. The impact of these, other innovations and commercial market trends are examined and quantified in the new Smithers Rapra report ‘The Future of High-Performance Pigments to 2023’. This strategic business forecasting tool is available for purchase now on the Smithers Rarpa website. n
Author: Julie Bostock, Marketing Manager, Smithers Rapra. Details on how to obtain the complete report can be found at : Website: www.smithersrapra.com/marketreports/raw-materials-industry-marketreports/the-future-of-high-performancepigments-to-2023
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PIGMENTS & DISPERSIONS
Bernhard Stengel-Rutkowski and Stefan Ohren, Clariant, look at how Quinacridone pigments containing raw materials that are derived from renewable sources produce brilliant colours that are more environmentally friendly and on par with petrochemical-based pigments
Quinacridone pigments based on renewables: where sustainability meets high performance
ustainable architecture, demand from consumers for healthier indoor environments, stricter segment regulations and manufacturers’ own efforts to improve the sustainability profile of their companies and their products are contributing towards sustainability across the paints and coatings industry. It is impacting production processes through to the final customer product and is leading, for example, to an increasing use of organic pigments, commitment to waterborne technologies, interest in renewable-based ingredients and expansion in speciality powder coating systems. However, certain facets remain fundamental to manufacturers in their choice of formulation ingredients and technologies. These include maintaining the same level of colour strength and fastness, avoiding performance deficits and staying at the fore of design and colour trends. Clariant’s forward-looking step of switching ever more of its quinacridone pigments production from petrochemicalbased to renewable-based succinic acid offers a major in-road into improving the ecological footprint of organic pigments. These quinacridone pigments deliver on customer requirements of renewable raw materials and low carbon footprint products. Importantly, there are no downsides. Both the properties and the quality remain the same as their crude oilbased equivalents1. This advance enables manufacturers to continue to deliver the high-performance, bright and chromatic colours demanded for today’s architectural, industrial and automotive applications. Around 40% by molecular weight of the pigments can be produced using renewable-based succinic acid, which considerably improves their sustainability profile. Not only are fewer fossil fuels used as a result of the renewable-based
production of succinic acid but harmful greenhouse gases are also reduced by 94% in the production process.
nnQUINACRIDONE PIGMENTS According to Smithers Rapra, quinacridone pigments constitute an important group within the organic high performance pigments – more than 4300t of these pigments were sold worldwide in 2013 and it is forecast that around 5120t will be used as colourants in 2019, which equates to an annual growth rate of almost three percent. These pigments are of particular interest for the production of metallic effects in the automotive industry, where they are used to produce unusual colour tones that boast a high degree of colour intensity and light resistance despite their transparency. They are also very popular in the construction paints and industrial paints sectors, as well as for conventional and digital print colours. Analysts predict a successful future, in particular for environmentally sustainable pigments from this group, which satisfy the growing demand for products with a better carbon footprint 2, 3.
nnRENEWABLE-BASED PIGMENT RED 122 AND VIOLET 19
Clariant, the first global pigment manufacturer to produce quinacridone pigments from renewable raw materials on a large scale, uses bio-based succinic acid to manufacture the industrially-important high performance pigments Pigment Red 122 and Pigment Violet 19. These pigments produce very high colour tones in the red, pink and red violet ranges. Succinic acid from renewable sources is produced by a fermentation process using natural sugars extracted from carbohydrates. Succinic acid occurs in all living creatures and is, like other simple mono and dicarboxylic acids, safe to use. Clariant has a comprehensive range of Pigment Red 122 including special purpose grades for maximising chromaticity and transparency (Hostaperm® Pink EB Transp., Hostaperm® Pink E Transp. 01). Clariant’s multipurpose grades (Hostaperm® Pink E, Hostaperm® Red Violet ER02, Hostaperm® Red E3B, Hostaperm® Red E5B 02) of Pigment Red 122 and Violet 19 have been established industry standards for decades. Products
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PIGMENTS & DISPERSIONS with even better processing properties are currently under development. Known as easily dispersible (ED) pigments, they can be dispersed simply with just a high-speed dissolver, yet they deliver the same colour intensity as the usual grades after beadmilling. As a consequence, the use of such pigments allows further reduction of the carbon footprint of paint manufacturing.
nnECOTAIN® LABELLED – FOR
Such is the positive sustainability contribution to paint manufacturing, Pigment Red 122, Pigment Violet 19 and all of the products of the ED paints range carry the Clariant EcoTain®label. The company awards this label to products that offer outstanding sustainability advantages. EcoTain® labelled products have undergone a systematic, in-depth screening process using 36 criteria in all three sustainability dimensions: social,
environmental and economic. They significantly exceed sustainability market standards, have best-in-class performance and contribute overall to sustainability efforts of the company and customers. To date there are more than 150 EcoTain® labeled products coming from all of its Business Units. There is a general trend towards more sustainability and smaller carbon footprint triggered by global concerns. At Clariant, we address this trend by regularly reviewing our raw materials for alternatives from renewable sources, reinforcing the general target of a more sustainable production. Our high-performance pigments based on renewable raw materials show exactly the same outstanding quality properties as petrochemical-based pigments. Therefore, becoming more sustainable has never been easier for our customers. n
References 1. Cf. Clariant: Discover Value. Discover quinacridone pigments based on renewable materials, 2016, www. clariant.com 2. Cf. Trevor S. B. Sayer (Smithers Rapra): The Future of High Performance and Specialty Pigments to 2019, 2014, pp. 23-25, www. smithersrapra.com 3. Cf. Persistence Market Research: Quinacridone Pigments Market: Global Industry Analysis and Forecast to 2015 to 2021, September 2016, www. persistencemarketresearch.com
Author: Bernhard Stengel-Rutkowski, Senior Global Technical Marketing Manager, and Stefan Ohren, Head of Product Management High Performance Polycylic Pigments, at Clariant Website: www.clariant.com/quinacridone
Global powder coating market estimated to be worth US$10bn by 2023
rost & Sullivan’s recent analysis, Global Powder Coatings Market, Forecast to 2023, finds emerging economies, such as Asia Pacific (APAC) will propel the global powder coatings market to US$10bn by 2023. Developing markets like Asia Pacific and Rest-of-World (ROW) are following the footsteps of developed markets, such as North America and Europe and are increasingly replacing liquid coatings with powder coatings. End-user markets, including automotive, construction, appliances and industrial, are shifting to higher-performing powder coatings in these regions due to the rising purchasing power of citizens and the subsequent demand for technologically superior products. The growth of these sectors is expected to steer the US$7.88bn global market toward US$10.61bn by 2023. The analysis explores the key powder chemistries of epoxy, polyester, epoxy-polyester hybrids, acrylic, PVC, polyamide, polyolefins and fluoropolymer. It also analyses the growth opportunities for these chemistries in the application segments of appliances, automotive, architectural, furniture, industrial, agriculture, construction, mining equipment (ACME) and pipe in the North American, Europe, APAC and ROW markets.
“An important driver for getting the powder coating market over the US$10bn line is technological advances,” said Soundarya Gowrishankar, Visionary Science Industry Analyst at Frost & Sullivan. “Most of the innovations have been aimed at resolving the challenges in powder [being able to coat] difficult surfaces like non-conductive moulded parts. “There has been heated R&D activity in the areas of attractive finishes, lowtemperature cure coatings, as well as selfhealing, self-cleaning, heat-reflective and energy-efficient coatings.” Although there is some resistance to the adoption of powder coatings due to the competition from alternate techniques like anodising and the price sensitivity of customers, the market will enjoy huge growth opportunities created by: • Regulatory trends, because powder chemistry very-low/no-solvent formulations exempt them from volatile organic compound (VOC) emission and hazardous air pollutants (HAP) regulations. • Powder coatings’ aesthetic, functional, environmental and cost advantages over liquid coatings. • Smart coatings that respond to colour shifts, are corrosion resistant, water repellant and have tribological and
electrical properties. These coatings are particularly popular in electrical processes, food and beverage handling equipment and fire detection systems. • The low manufacturing costs across regions and increasing focus on quality in the APAC and ROW markets. China and India will be the key growth engines in APAC owing to the rapid growth of their appliance sector, while the Middle East will be a lucrative market for coating suppliers to the construction industry. “When looking to make the most of the significant opportunities in the global market, powder coating manufacturers need to offer products with unique functionalities to stand out,” noted Gowrishankar. “Although APAC and ROW will drive volume shipment, North America and Europe will continue to be the hub of R&D activity.” n
Frost & Sullivan’s report Global Powder Coatings Market, Forecast to 2023 can be found online: Website: https://go.frost.com/MENASA_PR_ AChandhoke_K211_PowderCoatings_May18
30 APCJ • October 2018 www.coatingsgroup.com
PIGMENTS & DISPERSIONS
Wai Ling Loong, Venator, outlines the basics of dispersing TiO2 pigments
The basics of titanium dioxide dispersion
igment dispersion is a key factor when it comes to determining a coating’s performance. A coating where the pigment is poorly dispersed will invariably be inferior in terms of its optical properties, its weatherability and its storage stability performance. So how can you ensure consistent dispersion and measure the results you are achieving? From picking a suitable pigment and the dispersion differences between lowand high-quality grades, this article will explore the three key fundamentals of the pigment dispersion process: wetting, disruption and stabilisation. It will also examine the options available to coating manufacturers wanting to measure pigment dispersion quality. It will focus on fineness of grind, one basic and one more advanced and scientific method, pioneered by Venator almost 20 years ago and still helping customers today.
nnPICKING THE RIGHT
TITANIUM DIOXIDE GRADE
and labour intensive, reducing productivity. They also require the use of solvents for the cleaning of equipment, which can have an environmental impact. With ballmilling techniques no longer considered a practical option in modern coating manufacture, sourcing a lower quality titanium dioxide grade on this basis can be a false economy. In recent years, premium titanium dioxide producers have made significant advances in the dispersion capabilities of titanium dioxide grades. Investments in plant engineering mean that aggregate formation at the crystal forming stage is now largely preventable. Milling technique improvements have also had an impact, as has the development of novel products, such as granular free-flowing pigments, which can disperse faster than conventional powder products. So wherever possible, it’s best to pick the best quality pigment you can afford.
nnTHE FUNDAMENTALS OF
TITANIUM DIOXIDE DISPERSION
Successful pigment dispersion is as important to the optical and protective properties of a coating as selecting the correct raw materials – so picking a suitable grade and knowing how to process it properly is essential. When choosing a titanium dioxide grade, formulators face a wide range of options. Some formulators pick pigment purely based on raw material price/kg. However, given the impact titanium dioxide can have on the performance of white and tinted paints, the priority should be on selecting a pigment that can be easily dispersed and utilised properly. As with anything, you get what you pay for and there are big differences in the price and quality of titanium dioxide pigments, with the latter having a direct bearing on dispersion. Some people would argue that lower quality titanium dioxide grades can achieve similar dispersion results as higher quality pigments if you use ball-milling equipment. However, ball-milling techniques are time
Once you’ve chosen your titanium dioxide grade, you need to think about the pigment dispersion techniques you’ll use to integrate it into your formulation. Compared to other pigments, titanium dioxide is relatively easy to disperse – if you know what you are doing. To achieve the right degree of dispersion, formulators must consider all stages of the pigment integration process. From charging raw materials into dispersion equipment to the formation of the final film, every step has the potential to affect quality so there
is little margin for error. Broadly, the key stages of dispersion are: • Wetting; • Disruption; • Stabilisation.
nnWETTING There are three stages to the pigment wetting process as per Figure 1: • Adhesion – where the medium comes into contact with the pigment particle (the change from a to b); • Immersion – where the medium permeates into the pigment article pores (the change from b to c); • Spreading – where the particle is surrounded by the medium (the change from c to d). When pigments are immersed in a resin solution, they enter as air flocculates, which contain a complex network of pores and channels between and inside the agglomerates. The permeation of resin solution into this complex structure is much more difficult than the wetting of a smooth surface. Penetration can be assisted by high surface tension of the binder, a low contact angle, and low viscosity. Bear in mind that reduction of the contact angle by surfactants will make wetting more rapid; fine particles of pigment will be wetted more slowly than large ones; and charging a mill with fine particle pigments will always be more difficult, especially when highly viscous media is used; the last small amounts of pigment will often take as long to charge as all the rest. Also remember the wetting of titanium dioxide never proceeds spontaneously. Complete displacement of air is possible only if the entire surface of the pigment is exposed to the binder – so wetting and disruption may need to proceed concurrently.
nnDISRUPTION Maximising the separation of pigment particles is necessary to take full advantage of the opacifying power of titanium dioxide. When the pigment has been
31 APCJ • October 2018 www.coatingsgroup.com
PIGMENTS & DISPERSIONS occur after storage and can be accelerated by higher temperatures.
nnMEASUREMENT When it comes to measuring dispersion, there are many methods for studying how pigments are scattered throughout a liquid paint or a dried film. For the purpose of this article I have focused on methods for measuring fineness of grind, which give only a partial but very important measure of dispersion.
partially wetted, the next step is to break down agglomerates by mechanically induced force – generally either by shearing or impact. Impact techniques use a perpendicular grinding motion and presuppose a millbase of low viscosity plus high velocity at the point of impact. Conversely, for shearing, the motion is parallel to the pigment and a high viscosity millbase is preferable, with velocity (at the point of impact) much less critical. These opposing factors are responsible for some of the problems that can be encountered during dispersion. Obviously, different results will be achieved if you try to disperse a low viscosity millbase via shearing and vice versa. In terms of particle separation techniques, there are different types of equipment available that use distinct shearing and impact techniques. Figure 2 shows the main options available. Forty years ago, when titanium dioxide particles contained more aggregates, ball mills were the most popular method of disruption. Today, thanks to engineering advances and general improvements in pigment technology, high-speed impeller mills are the most commonly employed technique. With high-speed impeller mills, stabilisation can be controlled more easily, making it possible to increase production rates even with a highly pigmented millbase. Figure 3 shows the ideal set-up for high-speed impeller mills. When the equipment setup is correct and the millbase has been formulated correctly, a doughnut effect should be achieved during milling.
Checking your millbase formulation If you do not see the doughnut effect, it is worth checking your millbase formulation. The flowpoint curve is a useful tool for calculating the composition of a millbase containing titanium dioxide – giving a measure, albeit empirical, of the relationships between paste composition, flow and the equilibrium state of dispersion.
nnSTABILISATION After disruption is complete, the next task is to ensure particles remain separated. If they are not adequately stabilised after disruption, titanium dioxide particles suspended in a polymer will re-flocculate. There are two key ways to overcome this: either through electrostatic or steric repulsion. Electrostatic repulsion reduces the risk of flocculation by giving particles the same electrical charge. While steric repulsion uses a resin or additive adsorbed on the particle to form a protective layer that prevents flocculation. During production, the process of let down can increase the risk of pigment reagglomeration. As a concentrated polymer solution is added to a millbase, solvent will diffuse from the vicinity of the pigment particles into zones of high polymer concentration. This increases the volume concentration of the pigment locally, leading to reagglomeration – also known as colloidal, pigment or resin shock. To avoid this, dilution should be carried out in a way that ensures the concentration of pigment particles is reduced gradually. Also remember that the onset of flocculation can
The grind gauge The quickest, most convenient form of measurement is the fineness-of-grind gauge. There are several types of gauge but basic designs are similar. One or two wedge-shaped channels are cut into the top of a hardened steel block. The channels usually taper from 50 or 100μm depth to zero over a distance of 12-18cm. The gauge is marked with an arbitrary numerical scale and/or in micrometres, indicating the depth of the channel. A test is then made by putting a small sample of the dispersion into the deepest part and drawing it down with a steel scraper blade to fill the channel. The gauge is viewed immediately at grazing incidence and the point at which particles protrude through the wet film is recorded. This testing method is inexpensive and easy to replicate if the prescribed method is followed strictly. However, it does have its drawbacks. A grind gauge will only display the largest undispersed aggregates and gives no indication of particle size or particle size distribution. Dispersions of fine pigments are often beyond the resolution limits of the gauge. Fineness-of-grind gauges also require trained operators to produce the drawdown and rate the results. Rating is, of course, a subjective process. You can get large differences in readings, depending on how results are interpreted. Plus, with a standard gauge, there is no record of actual dispersion – just a number. With these limitations in mind, finenessof-grind-gauges are recommend for the routine control of production and for the visual assessment of a dry paint film, with the caveat that results must be scrutinised carefully and consistently. The TIDAS system If you want a more advanced and scientific dispersion analysis method, using a TIDAS machine could be an option (Figure 4). Invented by the Venator team almost 20 years ago, TIDAS stands for the TIOXIDE Instrumental Dispersion Assessment System and is an instrumental means of producing images of grits on a fineness-of-
32 APCJ • October 2018 www.coatingsgroup.com
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PIGMENTS & DISPERSIONS nnCONCLUSION
Figure 4 (above) and Figures 5 (top right) and 6 (bottom right)
grind gauge and then deriving reproducible dispersion ratings from the images. The system works by taking an average rating over a minimum of two draw-downs. Outlying results are discarded and a rating is then given based on a consistent set of data. In this way, rogue results caused by air bubbles or dust are eliminated. One of the main benefits of TIDAS is that it allows analysis of aggregate size and distribution. There are other benefits, too: • With a TIDAS machine, the same rating is always provided for a given drawdown; • You get a pictorial record of dispersion in the form of a computer-stored image; • Rating is not operator dependent, thereby eliminating the risk of user error or misinterpretation. When it comes to disadvantages, TIDAS has one main limitation: obtaining correct, consistent dispersion readings depends on correct paint preparation, a good drawdown technique and a clean working environment.
nnMEASUREMENT IN PRACTICE At the Venator Innovation Centre in Wynyard, England, a TIDAS machine is available to help customers assess dispersion and trouble-shoot any problems
they may be experiencing. Recently, the team worked with a coatings customer that was experiencing problems with measuring dispersion and characterising the particle size distribution of dispersed pigments. The customer supplied six different coatings and asked Venator’s titanium dioxide experts to measure the dispersion of each. The first step was to measure the pastes received but the team could only get a reading from one sample. The viscosity of the other pastes was too high to achieve a good quality film on a grind gauge. The film surface had a tendency to drag and create an uneven surface, which the TIDAS instrument couldn’t really read (see sample A in Figure 5). To get round this, the team diluted the pastes with resin (50:50 mix resin:paste) and homogenised them in a speed mixer. This gave the reading shown in Figure 6 (with resin). The team was also able to use the TIDAS data to generate dispersion particle size distribution graphs (Figure 7) that showed the differences between samples. Having demonstrated that TIDAS could be used with the customer’s samples, the company in question hired a TIDAS unit to conduct further in-house tests and subsequently, bought their own instrument.
To conclude, in practice, it is not difficult to disperse titanium dioxide, as long as the limitations imposed by the pigment and the binder are carefully considered and the right equipment and techniques are selected. Remember to check: • If your titanium dioxide pigment is fit for purpose; • If you picked the best quality pigment you can afford; • If your wetting process is optimised for success; • If you are using the right disruption method; • If you formulated your millbase correctly; • If you achieved the doughnut effect during milling; • If the process of dilution is causing pigment reagglomeration; • If you’d be better using a TIDAS machine rather than a subjective visual assessment of a grind gauge to measure results. Assuming you’ve sourced your titanium dioxide pigment from a reputable supplier, they should be able to help you assess the results you are achieving and work through any issues experienced, either during production or with final film quality. If you need further information about dispersing titanium dioxide or have a coating formulation challenge to discuss, email: firstname.lastname@example.org n
Author: Wai Ling Loong, Senior Technical Service Manager, Venator, Malaysia Website: www.venatorcorp.com
34 APCJ • October 2018 www.coatingsgroup.com
LABORATORY & TEST EQUIPMENT
Richard Johnson, Xtrutech, details how powder coating manufacturers can accurately scale-up their operations on extruders
t is not always clear how scale-up methods will affect the performance of the extruder; at Xtrutech, we strive to produce the most reliable scale-up procedures. One question we are asked regularly is: ‘What operating parameters would you keep the same?’ The simple answer is, as many as possible. Primarily RPM, torque and barrel temperature should be set so that the machine is, in theory, adiabatic. The reasoning for this is that these parameters do not scale up in the same way as throughput, which is the function of the ratio of the diameters cubed, while heat transfer is only a function of the square of the diameter ratios. In contrast, we are also often asked: ‘What operating parameters would you change?’ The answer is even simpler: In theory, none. One of the problems that can be encountered when evaluating a scale-up is the colour, as there will be an increase in colour development on a smaller machine in comparison to a larger machine operating under the exact same conditions. This is due, partly, to the particle size of the product being the same but the machine clearances being different. You will also never get a true adiabatic ideal operation and you will proportionally get a larger heat transfer acting on the product on a smaller machine. Clearances are maintained on machines ranges, generally, as a function of the diameter, eg the D/100 particle size of the raw material remains constant. You will always get more of a grinding effect on a smaller machine due to this, regardless
of which machine you decide to invest in. This, therefore, means that you will generally find better colour development on a smaller extruder than on a large production sized machine. Customers tend to quickly learn the difference in colour development between the machine sizes and, thus, know that if colour X is achieved on a lab machine, then colour Y will come from the production machine. Additionally, for similar reasons, you find there is less of a ‘matting effect,’ on smaller machines then on production machines. This is because the matting agent finite particle size is acted upon slightly less in the production machines than in the lab machines. Again, this is due to a law of physics and true for all twin-screw extruders, not just the XTS range produced by us here at Xtrutech. We also get asked how well the XTS19 scalesup to a XTS24 and on to larger extruders. In theory, the throughput doubles while the heat transfer area only increases by 1.5X. However, if, for example, you were moving from a 19 to a 56, throughput would be increased by around 25X whilst the heat transfer area only increases by 8.68X. From these numbers, you can see why it is important on any manufacturer’s machine not to run too much cooling (or heating for that matter) on the smaller machines, as it will not scale-up. There are many questions to be asked when investing in a scale-up of a machine, however Xtrutech can promise the closest replication of the outputs of the original machines.
XTS 19 bench top and XTS 24 lab R&D allow sampling and testing of new, more demanding formulations, and scale-up to production units
35 APCJ • October 2018 www.coatingsgroup.com
LABORATORY & TEST EQUIPMENT nnPOWDER COATING PRODUCERS FACE FRESH CHALLENGES
Powder coating manufacturers have a customer base that continues to demand products for thinner film application, with tighter specifications, on faster delivery deadlines and improved service. The list goes on, but many readers would say that this is no different from any other sectors of the coatings industry. Companies making powder coatings may find themselves, at times, short of help to enable them to keep on hitting these requirements. This may be because their own in-house expertise has been streamlined and more widely spread and the recent spate of mergers and acquisitions will not have helped in this respect. It has been said that many modern production facilities have efficiencies in the region of only 50-60%. There are three main causes for this: 1. Maintenance demands (planned and unplanned) of production machines 2. Down-time for cleaning between production runs 3. Older machines that perform below their original production output To some extent, European machine designers have met this production gap. Xtrutech has incorporated a number of equipment and processing developments to boost output and mixing efficiency, by using new designs of extruder with longer extruder barrels that operate at higher speeds. This not only increases the output of any given size of extruder but improves processing performance on newer, more demanding formulations.
nnPRICE VERSUS QUALITY The emergence of Chinese-built extruders over the past 10 years or so has further complicated the choice of extruder.
Although the gap in price is clear to see, the gap in build and processing quality is not so apparent at first. Xtrutech designs, manufactures and sources components for its extruders in the UK and Europe, highlighting the need for buyers to review more closely the new process innovations and technology improvements. Xtrutech uses a high volume 1.8D/d screw geometry, which originates from the early 1980’s, closely matching the ‘megavolume’ geometry now promoted by Coperion. Coupled with a high torque AC drive system, this provides the optimum blend of screw volume to processing power for powder coating materials. Issues related to the intake of the extruder are dealt with by a combination of optimising the feed-port and feed screw design and possible use of a side-feeder to minimise air entrainment with the premixed raw materials. The XTS has been designed with a wide range of processing capabilities and can be configured for optimal mixing of products as diverse in their mixing requirements as acrylics, clearcoats, thin film and textured or leatherette finishes and the capability to recycle 100% fines with only a simple change of screws. Xtrutech has the clamshell barrel, which has been further developed by incorporating the stuffing box into the barrel and opens with the top barrel half, to expose the shaft couplings. This makes the removal of the shafts that much easier and simpler. The traditional gland packing and followers have been replaced with oil impregnated split bushes, which prevent fine feed powders from leaking into the shaft coupling area and eliminate the need for regular maintenance. The new barrel has been designed with a single-piece, robust, backing block and fewer clamping bolts to save barrel opening
times, offering quick access to the screws during cleaning or maintenance. The barrel is also fitted with a split chilled discharge arrangement that also improves the barrel opening time. Temperature control is achieved through optimising the screw profile and the highly efficient water cooling channels located in the barrel backing blocks. A combination of wear-resistant steels and strategically-designed lengths of insert type liners, maximise the wear life of the XTS barrel and minimise future replacement costs. It is aimed to minimise abrasive wear and to place a user in the best possible position to economically maintain the screws and barrel within the decided tolerances through its production life. In addition, Xtrutech offers wear solutions for all other makes of twin screw extruder alongside an inspection service, which can be part of a preventative maintenance plan. n
Author: Richard Johnson, Director Xtrutech Ltd Email: email@example.com Tel: +44 (0) 1782 621 122 Website: www.xtrutech.com
36 APCJ • October 2018 www.coatingsgroup.com
LABORATORY & TEST EQUIPMENT
Norbert Kern, Buhler, discusses how the company is using digital services to increase the productivity of its wet grinding equipment
Optimising the wet grinding process with digital services
ühler’s digital services enable manufacturers of printing inks or functional coatings to increase their competitiveness. SmartPro Cockpit aggregates all process parameters in a data cloud and makes them accessible from anywhere any time. SmartPro Statistics allows a chronological view of process data and intelligent analyses. SmartPro Optimization monitors quality and automatically adjusts production parameters if necessary using algorithms. It is common for bead mills to be used in the manufacture of printing inks, functional coatings or conductive pastes. Such systems work by putting countless small grinding beads into relative motion, resulting in intense grinding, through the use of a rotor. This rubs the colour pigments into very fine particles and disperses them into a carrier. To achieve higher quality and, at the same time, save energy, wet grinding systems use micro-grinding beads for many applications. These beads are only between 50 and 500 micrometres in size. Since many more beads can fit into such systems, the number of mechanical frictions required is significantly higher than in mills with larger grinding beads. Particle agglomerates are broken up more quickly and the rotor doesn’t need to accelerate the bead package as much. Depending on the application, micro-grinding beads can make it possible to lower energy use by up to 30% and to increase productivity by about 50%. However, the use of small grinding media, high throughput rates and maximised specific
Production module with MacroMedia™ predispersing unit and MicroMedia+™ bead mill
energy input mean that many wet grinding systems operate at the limit of their capacity. However, the use of small grinding media, high throughput rates and maximised specific power input mean that many wet grinding systems are operated at the limit of their capacity. For production to remain sustainable at this level, a new generation of machine control systems is needed. Smart solutions for automation are in demand, with which all important process parameters can be continuously monitored. Bühler has paved the way for intelligent process control by using the possibilities of IoT (the internet of things) with its digital services bundled under the ‘SmartPro’ label. • SmartPro Cockpit aggregates process data from multiple machines or sites and loads this up to a secure data cloud where it can be made available from anywhere and for a variety of devices. SmartPro Cockpit is already available today. • SmartPro Statistics puts the data that has been gathered over a longer period of time into a chronological, historical relationship, prepares statistics, identifies deviations and proposes measures for optimisation. SmartPro Statistics is planned for release at the end of 2018. • SmartPro Optimization integrates an inline quality assurance that constantly monitors production with a smart algorithm and, if necessary, automatically adjusts the process. SmartPro Optimization is currently planned for release in 2019.
Cockpit view with mid- and long-term statistics
37 APCJ • October 2018 www.coatingsgroup.com
LABORATORY & TEST EQUIPMENT n
PROCESS DATA MADE AVAILABLE FROM ANYWHERE
The visualisation solution, SmartPro Cockpit, bundles all important machine data, such as power input, and loads it up to the data cloud. The cloud storage meets the highest requirements for security and has been certified according to the ISO 27K standard. By storing the data in the cloud, it becomes available from anywhere and from any end device. This means an operator can monitor whether production is working as desired on a certain system on a tablet while at home. SmartPro Cockpit can compile data from multiple machines and multiple sites and display it clearly structured. The information layout can be modified for individual preferences. Thanks to its clear visualisation, SmartPro Cockpit makes it possible to compare the most important performance indicators at a glance. The operator can see if a plant falls noticeably under the level of other plants and immediately take action. Because production is being monitored in a timely manner, productivity increases. In addition, unnecessary service visits to sites are avoided. That reduces service costs. Another central aspect is the traceability it allows: SmartPro Cockpit identifies all recorded data with the product category and badge number. And lastly, any alarms triggered by individual machines are archived. This builds the foundation for proactive or predictive maintenance.
USEFUL STATISTICS OPEN POTENTIAL FOR OPTIMISATION
The SmartPro Statistics module makes it possible to observe data recorded over a longer period of time in its historical context, to compare it and to intelligently evaluate it. It can be determined faster and more easily if individual parameters or parameter groups deviate from a defined process window. For instance, if the power intake drops at a mill while the rotor speed stays constant, it can be an indication of bead wear or a change in the ﬂow properties. SmartPro Statistics make it possible to also compare data between multiple sites. If significantly more specific energy is being used for producing a tonne of suspension at one site compared to another, the operation can look into factors like bead size, rotation speed, bead volume, recirculation rate or temperature and, based on that information, make decisions that optimise the situation. Because the process data is collected over a longer period of time, the inﬂuence of seasonal factors on production, such as ambient humidity or the temperature of cold
Internal machine benchmarking visualisation
Easy traceability of production via key performance indicators
The future of the wet grinding industry
water can be studied. The combination of collected data and diverse analytical and assessment options, puts manufacturers using SmartPro Statistics in a position to compare the performance data of their machinery and sites in terms of internal benchmarking, as well as where there may be weak points. SmartPro Statistics can also be configured so that when certain threshold values are reached, alarms are triggered on a mobile phone or the settings of a machine are automatically adjusted.
SmartPro Optimization constantly monitors parameters, such as the particle size distribution or the viscosity and evaluates this with smart algorithms. These algorithms can detect important relationships and, in turn, suggest process optimisations to the operator. For instance, SmartPro Optimization can detect bead wear early on or send notifications when a wear part, such as a mechanical seal, is about to break down. Bühler can also monitor the production processes remotely, if the customer wishes, and suggest improvements. The intelligent process control enables manufacturers to align their production even more precisely to the required product quality. Thanks to smart plant control, operators can achieve maximum quality with minimal specific energy input and do not need a safety margin any more. Especially in times when cost pressure increases and many manufacturers produce at the limit of their capacity, this is a decisive advantage. Digital services like SmartPro Cockpit, SmartPro Statistics and SmartPro Optimization contribute significantly to growing a company’s competitiveness. n
SMART ALGORITHMS MONITOR AND OPTIMISE THE PROCESS
SmartPro Optimization is the last step in completely digitalising the wet grinding process. This intelligent process control expands every mill with an inline quality assurance system. This service does not just access data collected with SmartPro Cockpit and evaluated with SmartPro Statistics, it also accesses an extensive database from countless process tests at the Bühler laboratory.
Author: Norbert Kern, Head of Process Engineering in the Business Area Grinding & Dispersion Technologies at Bühler Website: www.buhlergroup.com
38 APCJ • October 2018 www.coatingsgroup.com
LABORATORY & TEST EQUIPMENT
Fritsch GmbH has launched its latest universal cutting mill with variable rotational speed
Fine and powerful comminution
he new Universal Cutting Mill from Fritsch is ideal for size-reduction for a wide range of different materials due to variable adjustment of the rotational speed of the rotor, various knife geometries, replaceable blades, practical sieve cassettes and excellent ease of cleaning.
nnVARIABLE 300-3000 RPM
an exhaust system that can be ordered alongside. The strong airflow ensures simple feeding, increases throughput, reduces the thermal load of the samples and enables the use of finer sieve cassettes to achieve a higher final fineness – even for materials that are otherwise difficult to comminute finely. The result: an especially fast and efficient comminution.
FOR FINE COMMINUTION
The high-speed Universal Cutting Mill Pulverisette 19 comminutes up to 60lit/hr of soft to medium-hard sample materials and fibrous materials at a torque of up to 30Nm with reliable reproducible results. A great advantage is that the variable rotational speed adjustment in increments of 10 between 300 and 3000rpm enables fine tuning of the comminution process for each sample within a very wide range of applications.
nnFRITSCH HIGH-PERFORMANCE CYCLONE SEPARATOR
The Fritsch high-performance Cyclone separator is made completely of stainless steel 304 and is particularly useful in the analytical sector, the food and pharmaceutical industries and for the processing of heterogeneous mixtures of
nnFRITSCH SMALL VOLUME CYCLONE SEPARATOR
Especially for exhaustion of small sample quantities, Fritsch designed the compact small volume Cyclone separator. It is made of plastic, can be dismantled completely and cleaned in a dishwasher for reliably preventing contaminations. The comminuted sample is collected in a screwed-on sample glass of 250 or 500ml volume.
nnVARIABLE 50-700 RPM FOR
The low-speed Universal Cutting Mill Pulverisette 19 with variable rotational speed adjustment between 50-700rpm and a torque of up to 67Nm enables, due to the combination of low cutting rate and extreme cutting forces, a very powerful comminution of hard, tough-elastic samples and small sample quantities. At the same time, it is the ideal solution for all cases where things like thermal damage, the loss of highly volatile substances or an excessively high fine share need to be avoided. The Universal Cutting Mill Pulverisette 19 is also available in both variable rotational speed versions in a corrosion-resistant stainless steel 316L version. All materials have an increased resistance to alkalis and acids and conform to the guidelines of the food and pharmaceutical industry.
material, eg in the cement industry. Due to its high surface quality, it offers enhanced resistance to corrosive media, such as alkalis and acids and is especially easy to clean with a wide range of possible cleaning agents, without leaving any residues. In addition, it can be completely dismantled, fully emptied, flooded and sterilised and thus, offers reliable protection against cross contamination. Especially convenient is that the comminuted sample is drawn directly into the screwed-on sample glass or in a larger collecting vessel of up 60lit, in which it can also be transported and stored.
nnEASE OF CLEANING
Universal Cutting Mill PULVERISETTE 19 with variable rotational speed adjustment
For residue-free cleaning, all grinding parts of the Cutting Mills can be removed within seconds without tools. The result is a completely open, empty grinding chamber with minimised dead space and smooth interior walls for quick and easy cleaning and reliable protection against cross contamination. n
nnFRITSCH CYCLONE SEPARATORS Combine your Fritsch Universal Cutting Mills Pulverisette 19 with a Fritsch Cyclone separator for sample exhaustion and
Universal Cutting Mill PULVERISETTE 19 with new FRITSCH high-performance Cyclone separator
39 APCJ • October 2018 www.coatingsgroup.com
Applied Graphene Materials discusses its Genable® 3000 series; graphene-based, active non-metallic, anti-corrosion additives
Tomorrow’s anti-corrosion material, today
arlier in 2018, Applied Graphene Materials (AGM) launched its latest dispersion range – the Genable® 3000 series. Genable 3000 dispersions are graphene-based, active non-metallic, anti-corrosion additives that are proven to be capable of delivering leading performance through numerous extensive test programmes. Like all Genable dispersions, they are formulated to enable the full benefit of graphene materials to be accessed by coating industry formulators seeking a step change anticorrosion performance. AGM is now reporting results from further testing, which not only underlines the potential for significant anti-corrosion performance gains but also the product’s commercial attractiveness – particularly under harsher C4/C5 corrosive environments. Incorporated into the formulation of an industry standard C3 epoxy primer system and tested under representative cyclical salt spray testing (ASTM G-85-94 Prohesion), Genable 3000 series materials have been shown to deliver a 5-fold extension in coating lifetime, based on a single 60μm dry film thickness (Figure 1). These exciting results are supported by a detailed mechanical dataset and studies incorporating combination with a PU topcoat exploring intercoat adhesion and overcoating intervals. All results confirm the product’s attractiveness for development into commercial anti-corrosion systems.
nnFURTHER TESTING Further investigating Genable 3000 series potential for applications in harsher C4/C5 environments, AGM has embarked on another Control*
Genable 3000 Series
extensive test programme looking at the performance of a higher build primer system. The thickness of this high build primer is around 110μm and is, therefore, typically thinner than many comparative industry standard systems in the C4/C5 category (ISO12944). The properties of the Genable 3000 series make it an ideal toolbox additive for formulators seeking to significantly enhance coating performance in a range of environments. As an additive capable of offering metal free systems with extended durability, it is anticipated that the Genable 3000 should find multiple applications in industrial areas subject to high humidity and aggressive atmosphere, including inshore areas of medium to high salinity. Extended durability and thinner flexible coatings are directly equitable to significant cost savings in both initial coating system application, as well as maintenance and repair for commercial end users. Genable 3000 series dispersions are available initially in epoxy resins but with a range of solvent- and water-based dispersions under nearterm development. All of AGM’s Genable dispersions are formulated for long term stability and engineered to aid easy incorporation into existing manufacturing processes. The new range follows on the heels of the recent launches of the Genable 1000 series (for enhancing existing anticorrosive additive performance) and the Genable 2000 series (specifically for corrosion inhibition on aluminium substrates). n Tel: + 44 (0)1642 438 214 Email: firstname.lastname@example.org Website: www.appliedgraphenematerials.com
Figure 1. More than five times extension to the primer coating lifetime under cyclic salt spray (ASTM G-85-94 Prohesion) with the use of Genable 3000, AGM’s formulation-ready active corrosion inhibitor, in place of Zinc Phosphate *Control is an in-house primer typical of a standard industrial C3 ZnPO4 based system
40 APCJ • October 2018 www.coatingsgroup.com
Applied Graphene Materials.indd 1
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The October issue of APCJ contains a market report on China and technical features on adhesives, laboratory & test equipment and pigments &...
Published on Oct 24, 2018
The October issue of APCJ contains a market report on China and technical features on adhesives, laboratory & test equipment and pigments &...