Issue 4 | Volume 6 | 2018
We talk polymers
AND INDUSTRIAL TRADE NEWS
Mandy Linossi leaves SAPMA
10 YO U R
Top SAPMA Awards
D WA R E B U
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Issue 4 | Volume 6 | 2018
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Food for Thought: Why you should belong to SAPMA - dealing with officialdom
Farewell to Mandy Linossi
Feature: Key manufacturing trends for 2019
Product feature: Polymers
Q&A: Tara Benn
Technical: Novel sugar-based neutralising agent for ecolabel certified paints
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Be the change
or the coatings sector 2018 will be marked in the history books as a tough year. I cannot recall this industry ever facing the challenges as it does at the moment. In simple terms, the deck is stacked, and it is stacked against us. But we should embrace these challenges, as it is only once we are pushed out of our comfort zones that we can grow as an industry. These challenges are forcing us to think about our efficiencies, we are becoming more innovative and we have an opportunity to exceed expectations. Exceeding expectations is what we have to start doing. I read recently that the abnormal has become the normal in South Africa. Everyone drives on the sidewalk, taxis do whatever they want, crime is
normal, and so is being in a recession. It is not normal. And we need to change our minds and start striving for more. If your business is not growing, Johann Gerber what can you do differently? How can you force change? Be the change! Next year, we will all have to get our hands dirty and start pushing growth. We might have to kick a couple of doors down, but if we tackle every day to force change, to deliver better than the day before, we will deliver results beyond our wildest dreams! c
Protea Chemicals is all around you, from the coating of paint on the wall to the brush that painted it, and from the glue in your childâ€™s school project to the solvent you used to clean your hands after helping to build it. Inside every coating, adhesive, and sealant is Protea Chemicals.
Industry Sector: COATINGS, ADHESIVES, AND SEALENTS
Polyoak’s new fleet of electric folklifts are delivering energy-efficiency gains.
Polyoak cares passionately about the environment and is committed to improving environmental efficiencies, minimising waste and taking a leading role as a responsible producer.
ou can’t just say you want to help shape the future. You have to roll up your sleeves and get involved to really make a difference,” explains Jeremy Mackintosh, Polyoak group managing director. This year has been another productive year for Polyoak regarding its sustainability agenda. CLEAN-UP EVENTS On Saturday, 15 September 2018, Polyoak Packaging conducted its third annual clean-up programme with hundreds of dedicated employees and their families volunteering to collect litter for recycling at eight locations across the country in Gauteng, Durban, Cape Town, Port Elizabeth, East London, George, Middelburg and Polokwane. This year’s campaign theme, ‘Littering Kills’ highlights the responsibility of citizens to dispose of their waste responsibly, to prevent it from ending up in the environment where it poses a risk to marine life, wildlife and humans. Collectively these Polyoak volunteers removed almost 3.7 tons of litter,
that otherwise would have entered our waterways, ending up polluting the ocean. ENERGY-EFFICIENT FORKLIFTS In line with its ongoing commitment to having a positive and sustainable impact on the environment, Polyoak upgraded
to even more energy-efficient forklifts in August, to assist with the loading and offloading of its trucks. The new fleet includes the latest electric forklift models, said to be amongst the cleanest and quietest available on the market. These best-in-class forklifts have
Polyoak’s 3rd annual clean-up by volunteering employees and family removed almost 3.7 tons of litter across the country in September.
6 | Coatings SA
news enabled longer operating times between charges, and increased productivity, efficiency and safety. ZERO WASTE PROGRAMME The company is also nearing completion in the roll-out of its bespoke ‘Zero Waste’ programme, which has now seen almost all its employees trained on how to separate waste at source to optimise recycling, and ultimately eliminate waste sent to landfill. The programme includes installation and usage of purpose-designed recycling bins at its manufacturing plants and distribution centres nationwide. The implementation of this employee programme, as an extension to its existing waste management system, has already delivered significant gains in the amount of post-consumer waste being diverted for recycling. As one of South Africa’s first signatories to ‘Operation Clean Sweep’, the company’s ‘Zero Waste’ programme also includes a disciplined focus at each
of its manufacturing sites to prevent pellet loss into the natural environment. “We need to lead by example. We are proud to make plastic packaging that is convenient, prevents food waste and is too valuable to throw away as it can be recycled. With the help of our employees, our customers and community at large, we can grow the recycling industry which currently sustains nearly 60 000 informal jobs annually, and at the same time enjoy the benefits of plastic without harming our environment,” says Mackintosh. PACKAGING DESIGNED FOR RECYCLING The company offers a wide range of plastic packaging
including containers made from recycled material and plastic derived from renewable sources such as sugar cane. Its design experts are constantly exploring innovative new technology and materials, to provide and advise its customers about the most suitable and sustainable packaging options achievable to meet the demands of convenience, affordability and sustainability. c
On Saturday, 15 September 2018, Polyoak Packaging conducted its third annual clean-up programme with hundreds of dedicated employees and their families volunteering to collect litter for recycling at eight locations across the country.
7 | Coatings SA
Tawazon enters local market Industry stalwart, Denzil Mohanial, has partnered with Tawazon Chemical Company, a Dubai-based integrated chemicals supplier, representing the business in the SADC region.
awazon is a well-known raw material supplier to the paint and ink, construction chemicals, packaging, fibreglass, plastic, rubber and polyurethane industries. The core focus for Denzil and his team is to penetrate the ink and coatings market within the region. Denzil grew his reputation representing Ferro Coatings Resins, the unsaturated polyester resins and coatings manufacturer at Isipingo south of Durban. “Having worked in the industry for
over three decades, I have a high regard for customers and suppliers and look forward to continuing my association in the sector,” said Denzil. Established over 27 years ago, Tawazon has offices in the Middle East and South East Asia as well as Nairobi. Products are supplied direct from the country of origin or from its warehouses in Dubai, Jebel Ali, Riyadh, Jeddah, Nairobi, Chennai, Bangalore and Jakarta. c For more information, call 031-271-3135.
Government should heed value of coatings industry The beleaguered South African coatings market, which has struggled for government recognition and support for years, is part of a global industry expected to be worth US$178bn by 2020, an international analysis of this industry has found.
global study commissioned by the International Paint and Printing Ink Council (IPPIC) has found that world demand for coatings is currently growing at an annual rate of 4.3% and will result in a 2020 volume of 50-billion litres, with an international value of US $178bn. The newest market analysis for IPPIC, which is represented locally by the SA Paint Manufacturing Association, included comprehensive market research, covering the global paint and coatings industries in more than 175 countries. Deryck Spence, executive director of SAPMA, says it is hoped that the South African government would take note of the value of coatings globally and not continue to turn a blind eye to the needs
of the South African coatings sector, which locally employs over 15 000 people and contributes over R13bn annually to the national economy. “Here we have an industrial sector worth nearly $180bn a year globally – a market ripe for South African producers to enter and exploit via exports. Meanwhile our government shows little concern about assisting SAPMA with the funding for training of future technologists, providing adequate standards certification for our members, or protecting local coatings producers against dumped imports, to name just a few of the challenges of the past few years. “SAPMA’s protracted crusade to have high levels of hazardous lead banned from local paints has been uphill all the way,
8 | Coatings SA
It is time the government fully appreciates the contribution of the coatings sector to the national economy, Deryck Spence, executive director of SAPMA, has urged.
and still has to be fully legalised. SAPMA members who have voluntarily adhered to internationally-driven lead levels have had to wait for years for any government intervention to protect their profitability against cheaper, leaded paints. Members who have removed methanol from their production of thinners share a similar fate,” adds Spence. c
Doing more with less
top performing SAPMA students
The SA Paint Manufacturing Association (SAPMA) student award winners for 2018 have been announced.
Hentie van Loggerenberg of SAPMA-member, SAPS (left, at back) who received the SAPS student certificates on behalf of the company at the Gauteng awards function, was pictured with SAPMA 2018 student awards winners: Danie Brink (on right, at back) and in front (from left): Veshalin Moodley, Rudine Brink, and Paul Hadjiapostolou. Inset: award winner, Belinda Clasen.
Gauteng award winners for the 2018 SAPMA training final assessments are: Belinda Clasen of The Beckers Group: BAMR Award for highest national marks for Basic Technology Module 1. Paul Hadjiapostolou of Rhine Ruhr: BAMR Award for second highest national marks for Basic Technology Module 1. Danie Brink of Air Products: Tag Solvents Award for highest national marks for Paint Application Module 2 and Technipaint Award for the highest overall practical marks for Paint Application Module 2, and joint winner of BAMR Elcometer Award for highest assignment mark in Paint Application Module 2. Hilton Greetham of Prodec Paints: Joint winner of BAMR Elcometer Award for highest assignment marks Paint Application Module 2.
Rudene Irwin of The Beckers Group: Rolfes Award for highest national marks for Pigments and Dispersion Module 4, and Lejn Award for highest national marks for Evolution Module 6. Veshalin Moodley of SAPS: Servochem Award for highest national marks for Convertible Media Module 7.
The KwaZulu-Natal award winners are: Kimona Chinsamy of Paintchem: Engen Award for highest national marks for Solvents and Media Module 3, and Acti-Chem Award for All-round Performance. Zama Ndaba of Resource Link Coatings: Ferro Coatings Resins Award for highest national marks for Modifiers Module 5. The Zimbabwe winner is Gabriel Ngadze of Kingdom Paints Manufacturing, Kansai Plascon Award for highest national marks for Basic Science.
10 | Coatings SA
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CO2 and sunlight!
he companies formed a partnership in 2014 to jointly work on a technology using cyanobacteria that mimics the way plants use photosynthesis to produce chemical building blocks such as organic acids from carbon dioxide (CO2). These have applications in biodegradable plastics, personal care products and as intermediates for the chemical industry. Photanol has closed a financing round with a group of Dutch investment firms that will allow the construction of the unit to go ahead; completion is expected in 2020. “The joint development of Photanol’s production capability is part of our strategic choice to collaborate with innovative companies to drive growth by developing more sustainable chemical platforms for our customers,” says Marco Waas, director RD&I and Technology – Industrial Chemicals at AkzoNobel
A demonstration plant for a groundbreaking technology to produce chemicals from sunlight will be built at Delfzijl, in the Netherlands by AkzoNobel Specialty Chemicals and partner firm Photanol BV.
Specialty Chemicals. for one of our businesses. This will allow us “The Photanol team is keen to prove to make a step change in profitability and to the world that we can make a big product quality. We are proud to support difference by producing clean chemicals Photanol making chemicals from sunlight at while reducing the CO2 burden on the scale, and to help grow a profitable, green environment,” adds Véronique de Bruijn, chemical cluster in Delfzijl,” concludes Peter CEO of Photanol BV. Nieuwenhuizen, chief technology officer, The new investors in Photanol are AkzoNobel Specialty Chemicals. c GROEIfonds, Innovatiefonds Noord-Nederland and Investeringsfonds Groningen. “The new investment and the continued support of existing shareholders and partners are a testament to the potential of Photanol’s CO2 -to-chemicals technology,” says de Bruijn. “This is the next step in our partnership, where Photanol will ultimately produce a new and low-cost intermediate Groundbreaking technology produces chemicals from sunlight.
SAPMA New appointments Tara Benn has been appointed administrative manager for the SA Paint Manufacturers Association (SAPMA). Kgomotso Mokubyane is SAPMA’s new Administrative Assistant. Tara Benn.
12 | Coatings SA
scoops 3 Gold Pack Awards
Olympic Paints won gold in the Household, Rigid Plastic and Gold Pack Trophy categories.
n each of the categories that Olympic Paints received its award, the packaging was supplied by Koogan Plastics. The IPSA Gold Pack Awards are about promoting innovation, identifying the best solutions that have met South African and regional packaging challenges and ultimately maximising exports and minimising imports for the continent. The awards are also about benchmarking the local industry and keeping pace with global technological developments, as well as recognising outstanding design, which includes construction, graphics, convenience, product protection and
ecological impact. The judges looked for excellent application and execution of any new, innovative and creative design, marketing and technology applied to packaging in South Africa. It is understood that the concept or technology may not necessarily be original, but it has been used in a manner that makes it stand out or is exceptional. The judges looked for packaging that demonstrates the ingenuity and competitiveness of the South African Packaging Industry. The scrutiny applied equally to the disciplines of design, marketing and technology, both individually and as a combination. c
13 | Coatings SA
StonCor leads lead-free While the SA Paint Manufacturing Associations (SAPMA) urgently awaits pending legislation that will make industrial paints lead-free, one of its members has already been producing lead free protective and industrial coatings for the past eight years.
n 2010, Midrand-based StonCor Africa voluntarily introduced the removal of hazardous lead-based pigments and driers from its wide range of Carboline protective and industrial coatings, which represent the majority its local turnover. Nico van Eeden, managing director of StonCor Africa, says although leaded industrial coatings are still not banned in South Africa, the company realised that the coating of large industrial steel structures with leaded Carboline coatings at customers’ sites would pose a threat to the health of their staff and the environment. “In 2010 StonCor changed the formulation for Carboline products to meet American and European leadfree specifications. We knew that the removal of lead from our coatings would substantially increase the cost of our raw materials and that the unavoidable higher selling price would harm Carboline’s competitiveness in the local market, but decided to move to lead-free coatings before we had even learnt that anti-lead legislation was planned locally. Hopefully, the fact that we will already be totally compliant when the new law is applied will restore the competitive edge to StonCor Africa’s business,” states van Eeden. “From a sales point there are many inherent challenges in producing safer, but more expensive coatings. “Our
competitors still use lead pigments to make their coatings substantially cheaper so we had to launch a major educational drive among customers to spell out the dangers of leaded paint on structural steel elements. During application and maintenance, toxic leaded residues can end up polluting streams and rivers and leaded paint also endangers the health of staff working close to, and in contact with, the coatings,” explained Dave Thompson, StonCor Africa’s business manager – Steel Protection. Thompson says as far as StonCor Africa’s export market is concerned, the decision to go lead-free was nonnegotiable as leaded coatings are banned in some of the countries that import StonCor Africa’s Carboline coatings. South African steel fabricators who coated their products with leaded Carboline also would have lost their export markets. Jonathan Starmer, StonCor Africa’s technical resources executive and Sandra Olivier, the company’s QA and colour manager were tasked with the formidable practicalities of the switchover to lead-free Carboline coatings, say the reformulation and factory preparation posed immense challenges, calling for months of planning back in 2010. “Even then we encountered some teething problems, but our lead-free Carboline coatings production process
14 | Coatings SA
has now been running smoothly since then,” Starmer states. “It’s reassuring to know that legislation will hopefully by next year level the local market’s playing fields for StonCor Africa. We sincerely hope the new law will be adequately policed and enforced,” Olivier adds. Deryck Spence, executive director of SAPMA, says that the new legislation, scheduled to be introduced next year or early 2020, will amend the current Hazardous Substances Act’s to stipulate that industrial coatings’ lead content should be a maximum of 90ppm – currently there is no restriction at all on the level of lead pigments in industrial coatings. Decorative coatings are prohibited by law to have a lead content of over 90ppm compared to its previous permissible level of 600ppm. “It is gratifying to see that StonCor Africa took such a pre-emptive stand on a matter SAPMA has long and passionately campaigned for. SAPMA has particularly been concerned about the lead levels in industrial paint as there was absolutely no restriction on the amount of hazardous lead it could contain. The company’s environmental and social responsibility and concern for the consumer are therefore highly commendable and exemplary to all other producers in South Africa,” Spence adds. c
food for thought
Why you should belong to SAPMA – dealing with officialdom
I have discovered a strange anomaly in the concept of association membership – companies reluctant to pay annual subscriptions cannot find benefits or reasons why they joined the association in the first place – or should remain a member. By Deryck Spence
e experience it here at SAPMA every year when we try to renew memberships: “There is no benefit to me being a member” or “It’s a club for the big guys” are typical responses not to pay subs. So, putting myself in the shoes of a small manufacturer, which I have been, or a multi-national Chief opening a branch or factory in South Africa, or just being Joe Bloggs who is about to open a paint plant, why do I need to be part of a body representing my sector of industry? Firstly, logic tells me that I should know something about the market I want to enter, as well as the Regulatory and Legislative requirements such an entry may prescribe. My check list will probably include some of the following very basic information, not necessarily in the order below: I should enquire from the DTI
(Department of Trade and Industry) and ITAC (International Trade Administration Commission) about the importation of raw material and import duties on imported products, and the protection against dumping of products from other countries. Note: to do this, I would first have to establish how to contact this state body and all the ones listed below, and then find the right person to address your inquiry to – the extent of this obstacle is akin to trying to contact your local municipality. I should also contact the Department of Agriculture, Forestry and Fisheries (DAFF) for assistance regarding dangerous ‘agricultural remedies’ such as biocides, pesticides, formaldehyde and algaecides, and ask whether these are banned or illegal, so that they are not confiscated before they get to the market place. By contacting the Department of Labour, I should be put in the
picture about labour practices and Health and Safety. The Department of Environmental Affairs (DEA) should have input regarding environmental waste practices. Next, I would have to speak to the Department of Health about what is allowed, or not, in terms of the Hazardous Substance Act. I would have to find out whether I am allowed to use lead pigments or alternatively methanol, or any other toxic chemical in my manufacturing processes or formulations. The Department of Transport should be able to brief me about restrictions about the transportation of hazardous goods, so that I am not going to get stopped by the police on my first delivery. The SABS would be the target of my enquiry as to what quality standards I need to meet and how much SABS would charge for the testing of my products. The National Registrar of Compulsory Specifications should be approached for advice on my protection against unfair imports of sub-standard products. Now all SAPMA members who have tried to do all the above steps required to start and stay in business in coatings production, will urge you: “Rather join SAPMA and pay your membership fee. Your annual subscription will answer all of the above and keep you sane!” Makes you think, doesn’t it? c Deryck Spence executive director – SAPMA
16 | Coatings SA
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news Mandy Linossi has for 20 years passionately devoted herself to furthering the SAPMA cause. She is leaving the Association and relocating to Scotland. Here the respected and much-loved SAPMA Administrator looks back on a career that earned her the nickname “Mrs SAPMA.”
Mrs SAPMA to depart after two decades Q: When and how did your career at SAPMA start?
A: I started working for SAPMA in January 1999. The administration office had moved from Durban to Johannesburg and I took over from John Bryce of the Chamber of Commerce in Durban, who had performed the secretarial duties for SAPMA. At my first official meeting were Terry Ashmore, Mike Russell and Reg Hoddinott. I felt an immediate rapport with all three gents, little knowing that they would play an important role in my working life, and become close friends, throughout my career at SAPMA. Jan de Jong, retired technical director of Dulux was the first SAPMA Director, followed by Mike Hayes - with a chemical background from Engen Chemicals. During his five years of leading SAPMA, the development of the lead-free paint legislation was promulgated in 2009. I ran SAPMA for 18 months until Deryck Spence was appointed as executive director in 2009. Although a corporate veteran, Deryck is highly motivated and has the energy of a young man, which I have never seen in a SAPMA director. I had a motto in my office “Time to turn the ship around” and that’s exactly what Deryck has done. He introduced a
new belief system, new traditions, new constitution, new membership benefits, new management committee and changed the perception of an ‘Old Boys’ club to a fully-fledged industry Association. The rest is history.
Q: How does SAPMA compare today, to the one you first joint?
A: Initially, the industry was dominated by the three largest producers, however, the last decade has seen a more diverse membership and a better representation of the industry.
Q: How did the training provision start and what role did you personally play in its development?
A: In 1999, the SAPMA Paint Technology
course was already well established and well supported by the industry. The course was delivered by ‘Distance Learning’ with one tutor per region giving two lectures in a four-month timeframe, supported by an in-house counsellor or mentor for practical demonstrations to students. From about 2005, mergers and international acquisitions started, and the calibre of staff in the industry was changing. There was a slow, but sure migration towards classroom teaching. Both employers and employees
20 | Coatings SA
loved the personal interactions and the industry became converted to this method of teaching but the high costs involved forced us to revert to distance learning through the British Coatings Federation. Official accreditation of the surface coatings qualification started in 2000. It was a very long and painful process, with CHIETA forever changing the goal posts. In 2009, CHIETA appointed SAPITI for the accreditation of the surface coatings technology qualification as a pilot project. The qualification was eventually accredited by the QCTO in 2015, with SAPMA accredited and the Assessment Quality Partner (AQP). I was intimately involved in these processes and progress was painstakingly slow and frustrating. Reg Hoddinott played a pivotal role in the development and realisation of the accreditation. As with all the challenges we have had with government enterprises, we got there in the end, but it was a draining experience both physically and mentally.
Q: Roughly how many students did you help train and eventually see receive their certificates?
A: Between 1999 to 2018, over 4 300
modules had been taught to employees in the industry. I was heavily involved with
news the operations of the course and in 2013 we started to employ additional staff to help me cope with the administrative demands. I thoroughly enjoyed the financial and marketing aspect, liaising with the employers for registration of their staff, operational duties, presenting the induction of the course, monitoring the students’ progress and encouraging them along the way. I got to know our students personally and knew which module they had studied. The cherry on top was the training awards presented at functions at our major cities. I was so proud of each person receiving their certificate and in some cases, top achievers receiving trophy awards, because I knew how much hard work and dedication went into their achievement.
Q: What are your future plans? A: I realised I wanted to do something else with my life, so decided to go to my motherland in Scotland to settle in Edinburgh, where I hope to start a new career. I want to learn new skills, make new friends, have some fun and travel as much as my work allows. I would also like to catch up with relatives and visit historical places.
Q: Some closing thoughts about the
challenges facing the coatings sector and SAPMA in future?
A: The industry faces many challenges.
The first is general apathy, which I believe stems from uncertainty, fear, nervousness and unfair red-tape created by our Government, preventing business from flourishing and creating more jobs. I believe BBBEE
and tariff parity do not promote local manufacturing growth and international investment, which probably contributes to high unemployment and transgression. Statistics and determininng the scope of the is another challenge. SAPMA is inundated with enquiries about the size and statistical data relating to the industry and it is frustrating that we are unable to provide meaningful information, because of members’ lack of cooperation. Those paranoid about disclosure should learn to trust professionals and the strict confidentiality measures in place. SAPMA needs input to collate valuable market and business confidence trends. Trying to work with the SETAs, especially our CHIETA is another challenge, the constant moving of the goal posts, staff changes, disorganised administration and processes and denial of training funding are crippling the industry. SETAs were put in place to serve the industry, not the other way around. SAPMA also has to constantly chase membership subscriptions and training fees to add to our chores of lobbying with Government and the daily demands of the Industry. In closing, I wish SAPMA could become a professional body in the near future, so the organisation can offer more benefits to members. However, this means more committed participation from member companies, which is the main reason why SAPMA has been unable to make application as a professional body. Members should remember that SAPMA is not owned by management
or the executive committee nor the chairperson or executive director. SAPMA is a branch of your business − would you ignore your branch? Instead of relying on 20% participation to get the work done, let’s have 80% participsation, which spreads the load more evenly. So, when you receive a request to participate on a certain chamber or committee or statistical scheme and so forth, try to comply. I believe in the old adage ‘United we stand, divided we fall’ this is how we can overcome challenges. I am leaving SAPMA, SAPITI and the Surface Coatings Employers Association at the end of October 2018, leaving part of my life behind. I made a personal investment into SAPMA and saw myself as a guardian of the industry. I wish to thank SAPMA management, staff, and chairpersons of the various committees and you, dear member, for your support over all the years. I value the experience, knowledge and memories gained over the past two decades. But I have learnt one can’t control everything. Sometimes one just needs to relax and have faith that things will work out. Let go a little and just let life happen. This is what I’m trying to do in taking a very big leap in faith. I trust that the new chapter in my life will be good and hopefully have some fun along the way, and I will face any adversities, bravely. I’m sure our paths may cross sometime in the future, and then we can look back fondly of times gone by. Take care all of you. I shall follow your progress and hope that SAPMA and the coatings industry will have only happy times ahead. c
WILL BE SORELY MISSED
Mandy Linossi (seated), SAPMA administrator, has left the Association to move to Scotland. Pictured with her for a farewell picture were colleagues (from left): Tara Benn, Deryck Spence (executive director) and Kgomotso Mokubyane. Her other colleague, Michael Masalesa, was at a meeting when the picture was taken.
Mandy has throughout her career at SAPMA been a major contributor to the growth of the Association, earning her the affectionate title of “Mrs SAPMA”. Her contribution to not only SAPMA and SAPITI, but the coatings industry as a whole, has been significant. She has decided to join her daughter, Lisa, now domiciled in Scotland, and on behalf of the SAPMA management and staff, we would like to thank Mandy for the tremendous commitment and time that she has dedicated to the organisation. We wish her great success in her relocation to the UK where we have no doubt she will be equally successful in any business field she is led to. Mandy shall be sorely missed not only by her employers, but by everyone she dealt with on our behalf over nearly two decades – Deryck Spence, executive director, SAPMA.
21 | Coatings SA
Kansai Plascon was kind enough to share what they believe the key trends in coating manufacturing will be for 2019.
ABOUT KANSAI PLASCON Kansai Plascon is the largest coating supplier in southern Africa operating in the market for over 128 years and supplies decorative, professional, industrial and automotive products. The company’s ethos, to design products through constant innovation and ground-breaking technologies, is what drives Kansai Plascon’s growth and has cemented the business as a leading coatings manufacturer in South Africa and Africa. The continuous technical advancements have enabled Kansai Plascon to be the first coatings manufacturer to confidently raise the bar on product guarantees. Dedicated to being a catalyst for change, Kansai Plascon is committed to service and delivering worldclass products throughout the full value-chain of the business. In 2012 Plascon South Africa, as it was then known, was renamed Kansai Plascon, after an acquisition by Japanese company Kansai Paint, who at the time, was the world’s sixth largest coatings company. Today, the company continues to drive innovation and excellence in the various coatings markets in southern Africa from four strategically placed manufacturing sites in Mobeni, Krugersdorp, Port Elizabeth and Cape Town. Kansai Plascon’s integrity-based relationships mean the business is able to strategically position itself within specific markets, in a way that benefits both the brand and the customer.
Q: What manufacturing trends do you see making an appearance in 2019? A: To ensure manufacturing sustainability, people, process and technology need to come together effectively to maximise productivity and efficiencies in manufacturing. Automation is a vital aspect of the manufacturing industry’s future, to cope with the more tedious, repetitive or unsafe manufacturing tasks. In this way, automated tasks become a complement to the workforce and brings about new jobs. As such, the workforce may require re-training and upskilling. With multiple manufacturing sites across Africa, there is a high focus to obtain the right data at the right time to make the right decisions. The effective introduction and use of digital platforms to collate information from customers to directly impact the performance on the production line is becoming increasingly vital. For example, customers’ expectations of delivery times have increased, and so the responsiveness and flexibility
22 | Coatings SA
of the production lines’ must also increase to remain competitive. Data analysis and interpretation is core to ensure focused improvements. To remain competitive, technology is increasingly being leveraged to reduce waste in various forms. For example, with ever-rising energy costs, the energy consumption of electronic devices is at the forefront of procurement decisions. With the reduced cost of solar PV solutions, manufacturing companies are also increasingly involved in the roll-out of green energy alternatives, which in turn creates new and sustainable jobs in this sector in the process.
Q: How far behind with regard to specific international trends is the SA manufacturing sector? A: South Africa’s coatings manufacture has been knocked back by factors such as a weakening economy, increasing cost and short supplies of electricity, and water scarcity in parts of the country.
Images sourced from Shutterstock
Key manufacturing trends
IMCD AND COLORS & EFFECTS HAVE JOINED FORCES “Our ability to technically drive and add value to the BASF Colors & Effects product portfolio has been a key factor in joining forces.” Otto Brinkmann, Managing Director, IMCD South Africa.
IMCD, a leading distributor of speciality chemicals and food ingredients, has concluded an agreement with BASF Colors & Effects to distribute their range of colourants and special effect pigments for South Africa and its neighbouring countries, effective the 1st of October 2018. The BASF Colors & Effects brand encompasses BASF’s broad portfolio of colourants and effect pigments for use in Coatings, Plastics, Printing Inks, Cosmetics and Agricultural markets. IMCD South Africa, headquartered in Johannesburg, provides national market coverage with branches and warehousing in all major cities throughout South Africa. For more information, visit www.imcdgroup.com. To find out how our experienced team can develop the best solution for you, please contact your local IMCD representative.
IMCD South Africa Tel.: +27 (0) 11 293-2000 or Toll Free: 086 136 6019 imcdgroup.com
feature Increased competition from international companies has forced South African companies to focus on efficiencies, optimising processes, reducing costs using internationally recognised production methods and processes. Increased levels of automation and upskilling of labour continue to close the gap to international manufacturers.
Q: Do you see the South African coatings sector catching up? A: With exports into 10 African countries, Kansai Plascon has developed a roadmap to become Africa’s fastest growing coatings company and thus enable Kansai Paints growth globally. For South African manufacturing to stay relevant and cost competitive, automation in this sector will speed up over the next few years to drive up efficiency and drive down the per unit costs.
Q: Which manufacturing trends do you believe are important for SA to adopt urgently? A: Amid these conditions, Kansai Plascon is taking steps to continuously improve the cost position of the company and continues to maximise global procurement benefits. The current focus is to bring flexible manufacturing methods and processes to reduce inventory and optimise costs.
Key manufacturing facilities are being upgraded to maximise production efficiencies and minimise waste. Strides have been made to balance supply and demand in all regions, and there are ongoing efforts to reduce working capital. The responsiveness of manufacturing facilities to changing market demands will be a key trend going forward, this includes small batch manufacture, colour dispensing accuracy as well new dispersion technology to further maximise the efficiency of key raw materials such as titanium dioxide.
Q: With the global coatings industry growth set at above 4% can SA exceed this in the near future? A: The current economic climate of low economic growth and low construction activity is affecting the coatings industry negatively. Without an upturn in economic activity it is unlikely that growth targets will be exceeded in the near future. With the 2019 elections, the government has put strong measures in place to bring state owned enterprises back on track. Hopefully, this will mean investor confidence in South Africa is growing.
Q: Locally, we have seen a move towards specifically lower quality coatings. Is the premium market still growing or have we hit a plateau?
A: There is a combination of factors at play, a combination of financial pressure, stagnant paint market as well as changing consumer needs. With a stagnant coatings market and consumers are under financial pressure, there has been a move to more economical lower quality coatings, resulting in a stalling premium market.
Q: How will manufacturers overcome this challenge? A: This is a reaction to a short term financial problem, the effect of which will only be felt in a few years’ time when premature repainting will be required. The cost of applying the coating is significantly higher, five to six times higher than the actual cost of the paint. So, in the long term the value proposition for premium high quality paint will always exist. The Plascon brand is a strong and recognisable paint brand in South Africa, known for its premium product positioning. The brand continues to weather the storm and when consumers are faced with low disposable income a brand that they can trust becomes most relevant. The premium market has been stagnant with some volumes migrating to the mid-tier products. This trend will continue in the short term and then stabilise. Manufacturers will have to stay relevant by improving their cost competitiveness.
Q: When do you think premium brands will make resurgence? A: Despite the premium market being under pressure the premium brands are still resilient as they offer customers peace of mind and confidence in their investments. Traditionally quality and performance have driven these brands but as consumers come to accept these qualities as the norm, innovation and services are becoming more and more important. Premium brands will remain a strong feature in the South African coatings market segment. This sector will however, remain flat for the next few years as the upper as the middle class expands. The growing lower quality market will increase in volume and become a strong volume driver for manufacturers who can harness this to reduce the overall cost of manufacturing. c
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The polymer that creates colour Synthetic Polymers produces high-quality polymers for various myriad sectors such as decorative coatings, automotive coating, medium to heavy industrial coating and wood coating etc. Solvent based polymers are Synthetic Polymers core focus; however, our plant also has the capability of producing water-based polymers. A wide variety of resins including acrylics, aminos, saturated polyesters and the more popular alkyd resins as well as some specialist resins are produced using the strictest quality standards in our plant. Research and development take place in our state-of-the-art laboratory with the latest equipment and highly qualified polymer chemists. Convenient delivery with our twenty-metric ton bulk delivery vehicle with lead times between twenty-four and seventy-two hours.
• Long oil alkyds • Medium oil alkyds • Short oil alkyds • Short & Medium chain stopped alkyds • Urethane alkyds & Oils • Styrenated alkyds • Hydroxy functional acrylics • Thermoplastic acrylics • Specialty alkyds • Amino resins • Thermoset acrylics • Saturated oil free polyesters
010 596 4444 | firstname.lastname@example.org | www.syntheticpolymers.co.za
Ferro and Sancryl feature their polymers available to the South African coatings manufacturing sector. Sancryl Sancryl is a privately owned manufacturer of polymers and speciality industrial chemicals based in Durban, South Africa, with sales offices and distribution warehouses in the major areas of Gauteng, Durban and the Western Cape. The company supplies its products to the southern African region with local demand accounting for the majority portion. Continual growth since its humble beginnings in 1991 has resulted in ever expanding projects to build on capacity and manufacturing capability. Sancryl’s active and forward thinking technical departments have been in the forefront of this growth and influential in ensuring continuous business strength from new products, new markets and innovative business designs. Sancryl plans to continue its growth in the paint and coatings industry in the main, whilst maintaining its market involvement in the water treatment, detergent, mining and related industries. The company currently manufactures a range of acrylic binders, speciality binders, dispersants, defoamers, deflocculants, antiscalants, sequestrants, biocides and other speciality surfactants and additives. After much research, the company now offers the South Africa market a complete range of green products needed in the manufacture of water based paints that safely satisfies all the requirements of an environmentally friendly paint, as per the European Decopaint Directive 2004/42/EC, for VOC, APEO, ammonia, heavy metals and isothiazalone free along with other added environment friendly advantages. The business is currently an ISO9001:2008 and ISO 14001:2004 accredited facility. Further, in keeping with management desire to conform to clean manufacturing, Sancryl
is a signatory to the Responsible Care Initiative. It is also involved at a strategic level with Durban Chemicals Cluster in helping to promote the competitiveness and development of its chemical sector and employment in general within the sector.
enviro-cryl PA 64 enviro-cryl PA 64 is a new high performance, waterborne pure acrylic polymer that is designed to provide very good colour development and enhanced durability. It allows the paint formulator the luxury of designing a variety of different paints using one emulsion. Paints formulated using enviro-cryl PA 64 will conform to the VOC regulations of European directive 2004/42/EC. Enviro-cryl PA 64 is recommended for the manufacture of zero to low VOC coatings. Another very significant feature is its excellent hydrophobicity. It can be used for both interior and exterior wall coatings. Envripol SP14 Enviropol SP 14 is an environmentally friendly, APEO free, water reducible solution polymer designed for use in bonding liquids and masonry primers. Enviropol SP 14 possesses the following characteristics: Its use on masonry and concrete surfaces offers the following on the coating: • Exceptional water long term durability • Water repellence • Breathability. Enviropol SP 14 offers the following advantages of a conventional solution polymer coupled with the ease of formulating, equipment washability and dilutability of an Acrylic emulsion: • Adhesion • Penetration • Breathability.
26 | Coatings SA
Enviropol SP14 should be formulated as for water based acrylic Paint. The Millbase should be traditionally prepared using standard Polyacrylate dispersants, defoamers, biocides and surfactants. The viscosity of the paint based on Enviropol SP 14 may be adjusted with an acrylic thickener in an alkaline medium. The use of Sancryl’s environmentally friendly additives is recommended in the preparation of the grind phase. No coalescing solvent is required in the paint based on Enviropol SP14. Water should be used for the washing of utensils and brushes Enviro-cryl PA65 Enviro-cryl PA 65 is a high performance, APEO free, zero VOC, water borne pure acrylic emulsion polymer, designed for a variety of coating applications offering an environmentally friendly advanced option to traditional pure acrylics. PA 65 exhibits excellent water resistance and very good flexibility. PA 65 can be used in areas where low to zero odour is a prerequisite. Suitably formulated coatings will conform to the VOC regulations of European directive 2004/42/EC. Advantages: • APEO free • Ammonia free • Formaldehyde free • Zero VOC • Low odour • Iso-Thiazalone free • Improved flexibility • Improved alkali resistance • Improved water resistance • Improved hiding power. Physical properties: Appearance: Milky white liquid Solids content: 49% PH: 8.0 Viscosity: ± 2000cps SG: 1.03 MFT: 0 °C
product feature Processing PA 65 should be used in the traditional manner in paint manufacture. The pigments and extenders should be dispersed in an alkaline medium using dispersants and wetting aids, prior to the addition of the binder. Envirosperse SS 70 a sodium polyacrylate and Envirowet BD are the recommended dispersants and wetting aids. Envirofoam SB 20 is the defoamer of choice.
Ferro South Africa Group Ferro Coating Resins, Ferro Dispersions and Arkem are all part of the Ferro South Africa group, which is in turn part of the Bud Group. These companies cover a broad range of polymer solutions for several markets and have more than 60 years’ experience operating in South Africa, SubSaharan Africa and the Indian Ocean Islands. The companies manufacture and supply a complete package of solvent-borne resins, dispersions and additives to the architectural and industrial coatings, vehicle refinish, construction, adhesives, detergent, textiles, graphic arts and water treatment industries. Its two manufacturing plants are located close to each other in Jacobs and Isipingo, south of Durban. Classified as Major Hazardous Installations, these plants meet the highest safety and legal compliance standards, including ISO 9001:2015 and ISO 14000:2015.
Ferro Dispersions Ferro Dispersions offers a vast range of water-based acrylic polymers. Aquafer The new trade name Aquafer has been trademarked and all Ferro Dispersions products are being branded with the Aquafer name. All Arkem Grades will also be included in this branding exercise, but the original product codes will still be used to keep ordering
simple for customers. The Ferro range of products include high performance binders, including styrene acrylics, pure acrylics, and vinyl acetate home polymers and copolymers. With many improvements made to these technologies, water-based polymers now offer the formulator an alternative to solvent-based technologies, in both decorative and certain industrial applications, with the added benefits of reduced VOC levels and significantly lower environmental impact. Ferro’s water based polymer dispersions are successfully used in areas such as light industrial coatings, high-gloss finishes and high-performance decorative finishes. The benefits of using water-based acrylic polymers in your formulations include: • Improved adhesion to porous and non-porous surfaces • Excellent finish, gloss and clarity • Outstanding durability and weatherability • Exceptional alkali-resistance • Anti-corrosion properties. The following chemistries are produced under the Ferro Dispersions Aquafer brand: Styrene Acrylics: Diverse range providing excellent binding for decorative interior paints, waterproofing and cement additives. Pure Acrylics: Highly durable range used for UV-resistant roof coatings, water-based gloss enamels, water based wood finishes, and pure acrylic pressuresensitive adhesives used in ready-mix ceramic and vinyl tile adhesives. Vinyl Acetate: Vinyl acetate homopolymers used in the laminating wood and furniture industry, high-solids adhesives for use in compounding and packaging adhesives. Polyacrylates: Large range of polyacrylates used as a dispersant
27 | Coatings SA
and deflocculates for decorative coatings, mining slurries and detergents. Specialties: APEO and ammonia-free styrene-butadiene copolymers, used in repair mortars and cement-based sealing slurries. In-can preservative biocides: Used in water based coatings, PVA adhesives and acrylic polymers, providing protection against bacteria and fungi.
Ferro Coating Resins Ferro Coating Resins offers a comprehensive range of highquality solvent-borne resins and additives. Product offerings include alkyds and modified alkyds, acrylics, saturated polyesters, polyamides, rheology modifiers and surface modifiers. The products are all marketed under well-established registered trademarks, namely Synolac, Synocryl, Crayamid, Crayvallac, Gelkyd and Super Gelkyd. South African resins are recognised by the XSA codes. The following chemistries are produced under the Ferro Coating Resins brands: Alkyds: A range of conventional and modified alkyds providing top quality enamels, primers and for the architectural and industrial markets. Gelkyd and Super Gelkyd: A range of thixotropic resins providing structure to coatings designed primarily for the decorative market. Acrylics: A range of thermoplastic and hydroxy acrylics providing quality solid colour topcoats, primers and clears for the vehicle refinish and industrial markets. Saturated Polyesters: A unique range of OPFEs for the coil and can coating markets. Polyamides: The Crayamid range of reactive and thermoplastic
product feature polyamides for the heavy-duty coatings, adhesives and graphic arts markets. Additives: A diverse range of rheology and surface modifiers as well as flow and levelling agents for the coatings market.
Synthetic Polymers Synthetic Polymers specialises in the manufacturing of synthetic resins and polymers for the coatings industry. The company entered the industry in late 2015 and has grown to become an integral part of the southern African coatings market over the last three years. Driven by a goal to push the limits and its vision to redefine the industry, Synthetic Polymers believes in taking manufacturing to a new level. The business is proud to be associated with leading paint manufacturers and have a key focus on export markets throughout Africa. It boasts a team of highly-skilled Polymer Chemists in the laboratory and at the plant to ensure quality control and superior standards of resin. Adding to the mix is its maintenance team of qualified engineers, fitters, welders and electricians.Â The vision is to redefine the coatings industry with its QCCP (Quality, Consistency and Competitive Prices) theory.
Long Oil Alkyds (LOA) LOA for manufacture of decorative high gloss enamels for interior and exterior, varnish floor sealers (high build as well), porch and deck enamels, wood stains, penetrating varnishes and many others with various non-volatile content and viscosities to suite specific applications.
Medium Oil Alkyds (MOA) MOA for manufacture of
economical industrial and architectural enamel paints. Excellent resistance to yellowing and good balance between brushability, drying and gloss. Water reducible medium oil has also been developed to assist paint formulators to formulate paint with high dosages of water.
Short Oil Alkyds SOA non-drying or non-oxidising for manufacture of stoving or baking enamels, nitrocellulose lacquers for automotive and industrial wood finishes and acid catalysed wood finishes. Castor and Coconut Oil alkyds for non-yellowing AC & NC lacquers have also been developed earlier this year SX1060 and SX2060.
Urethane Alkyds and Oils Urethane alkyds and oils for manufacture of varnishes for parquet floors, furniture, marine, wood and as sole binder for floor coatings.
Chain stopped medium and short oil alkyds Chain stopped SOA and MOA for manufacture of fast dry metal primers and finishes as well as truck and tractor or coach enamel and roadmaking enamel.
Modified Alkyds Gloss enamel coatings that dry and have capabilities of two-coats in a day have pushed the company to develop a resin specifically for this market segment â€” MLW160.
Styrenated and Modified (Copolymerised) Alkyds Styrenated alkyds for manufacture of quick drying paints with good gloss, primers and hammer finishes. Modified alkyds for fast curing enamels and varnishes for metal decorating with good flexibility and excellent adhesion. Recently the company
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has developed a 60% solids styrenated alkyd VX60 specifically for road marking enamels and high build QD Enamels. Specifically, for Hammertone paints is product VX7050.
Thermoplastic acrylic resins Thermoplastic acrylic resins for manufacture of plaster primers, masonry paints as well as high build road marking enamels.
Thermoset Acrylic Resins Thermoset acrylic acrylamide resin for high build metal coatings have good flexibility, detergent resistance and excellent adhesion.
Hydroxy Acrylic Resins Hydroxy Acrylic Resin 2K for manufacture of automotive refinishes top coat and clear coats, primers and as protective coat on metal structures like off-shores, cranes, rigs and many others and on difficult metals such as galvanised steel and aluminium. Due to market pressures Synthetic Polymers has developed an economical 2K hydroxy for the refinish market OHXE360.
Amino Resins Amino Resins both Urea Formaldehyde and Melamine Formaldehyde for manufacture of AC lacquers and heavy-duty stoving enamels or baking enamel.
Saturated Polyester Resins Saturated oil free polyesters for general purpose coil and can coatings as well as metallised basecoats, automotive finishing systems and stoving finishes in conjunction with amino resins. c For more information Ferro: Call 031-910-3500 Email email@example.com Sancryl: Call 031-902-1422 Synthetic Polymers: Call 010-596 4444.
Tara Benn -
Ready to break new ground Tara Benn is tasked with taking the reins from Mandy Linossi and she is more than ready to tackle many of the issues facing SAPMA head-on. Coatings SA had a moment to chat with her and she shares her ideas with our readers.
Q: What do you view as your
immediate challenges taking over from Mandy at SAPMA?
A: Whilst Mandy was still employed
with SAPMA, I worked closely with her in terms of training, attending various quarterly meetings as well as event management. I see the finance side of the business as a small challenge at the moment, as this is not something I have worked with before. I am sure with the guidance and assistance from our bookkeeper and auditors we will have a system in place that works for both them and me in terms of finance and invoicing.
Q: What are the opportunities you’d like to focus on for 2019?
A: I would like to grow and develop SAPITI training and see the industry benefit from the revised training programmes we have to offer. We have revisited our training programmes and will be marketing these to the industry in 2019. I would also like to see the SAPMA membership increase as there are significant benefits of being a member of SAPMA.
Q: Briefly, what are the key
objectives SAPMA would like to achieve during the coming year? • Marketing SAPITI training programmes to our members • Online training development (more videos) to educate the retail sales personnel • Increase SAPMA membership • Develop good, ethical working
relationships with the CHIETA, SETA and CETA institutes • The SAPMA Golf Day in May • Maintaining and updating the industry database.
Q: How, in your opinion, can
SAPMA stimulate more industry involvement?
A: I believe SAPMA can stimulate the industry to become more involved with negotiations with various government departments, CHIETA, CETA and SETA’s. The way we hope to achieve this, is through regular meetings with the members, both on a one-on-one basis as well as quarterly meetings with executive members. We need to educate them as to what is happening within the industry in order for them to get more involved.
Q: Mandy mentioned, member
apathy as a big concern, do you have specific ideas how you believe you can tackle this head-on?
Q: Describe SAPMA in five words Successful: Our success is determined by how hard we work to keep the industry informed constantly about changes both locally and internationally. This in turn, ensures our members are successful. Ambitious: We have an ambitious team of people working at SAPMA, to assist members timeously, effectively and to the best of our ability. Personalised: We believe personalised interaction with our members is important in building strong, ethical, working relationships in order to succeed. Membership: We have a solid membership base of manufacturers, suppliers, contractors and retailers. We hope to build on this each year and increase our membership database. Attitude: It is the right attitude at the beginning of a task that will determine your success or failure!
A: This is a difficult one to tackle. The
Q: Where do you see yourself
members are very busy with their dayto-day operational issues within their businesses. Unfortunately, it has become a ‘way of life’ to constantly follow-up and nag to receive feedback, however, the same goes for our members. I believe that building solid relationships with people and more interaction with our members will assist with this relationship development and will help the flow of information when it is requested. Hopefully members will be more forthcoming supplying the association with information.
No, I see this position as a long term role and would love to see both SAPMA and SAPITI grow from strength to strength both with regards to membership as well as the internal staff that run SAPMA and SAPITI. I believe that staff development is the key to a successful business. If your staff is motivated and willing to learn, you will only have success. I would like to be part of the growth and success of SAPMA and SAPITI in the years to come. c
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in five years? A: Sitting on a beach, drinking cocktails!
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technical Neutralising agents are used in only small quantities in water-based paints. However, they can have a significant effect. Not only do they regulate the pH-value, they also make a positive contribution to the storage stability of the paint by reducing the interaction between the paint ingredients. If neutralising agents also comply with health and environmental-relevant aspects, such as being VOC-free and hazard label-free, they are of particular interest for ecolabel certified paints.
Novel sugar-based neutralising agent for ecolabel certified paints
by Silvia Ziebold, Jörg Rüger
ver the course of a human lifespan, it is estimated that up to 90% of that time is spent indoors. As people desire to live in healthier indoor surroundings, they increasingly demand water-based paints that are free from air pollutants, hazardous substances and allergens. For consumers, it can be difficult to keep track of the different critical substances, therefore they rely on ecolabels in their buying decisions. With currently available raw materials and additives, it is no easy task for a paint formulator to develop a high-quality paint that offers performance advantages, is easy-to-use and at the same time fulfils the stringent ecolabel criteria. Formulators therefore consider not only function but also environmental profile when it comes to selecting paint ingredients. Additives should be multifunctional and universally applicable in order to reduce formulation complexity, raw material handling and logistics costs. In addition, they need to comply with regulatory requirements, safety and environmentally-relevant aspects. This article introduces the novel, sugar-based amine (glucamine) Genamin ® Gluco 50 that was developed specifically for use as a multifunctional performance additive in eco-friendly, water-based paints. In the course of the article, the application and performance profile is discussed in detail in comparison to common neutralising agents on the market.
How sustainable are neutralising agents? Environmental, health and safety apects play an increasing role in the selection of suitable ingredients. To fully assess a product’s sustainability profile, a variety of aspects need to be taken into consideration. To support this, Clariant, developed the EcoTain® label a few years ago. EcoTain is a sustainability concept at product level that helps to evaluate a product’s impact on three dimensions: people, planet and performance. Hereby products are screened against 36 sustainability criteria, overarching the complete product lifecycle and are also benchmarked against market standards. A selection of important sustainability aspects are listed in Table 1.
Standard versus multifunctional neutralising agents? Neutralising agents can generally be classified as standard or multifunctional. Standard neutralising agents are only used to adjust the pH to the range of 8-10 and thereby provide a stable paint system with little interaction between the different formulation components such as thickeners, binders, fillers and biocides. Multifunctional neutralising agents also offer other properties that would normally be provided by other additives in a paint formulation. For example, they can act as a wetting agent or compatibilizer for pigment pastes or can significantly improve the paint’s storage stability. Thus, they enable paints with superior quality and performance. Reducing the number of paint components in the formulation is a great advantage for the manufacturer as it means lower formulation complexity, less raw materials handling and lower logistics costs. There are various neutralising agents available to the paint industry. The most common neutralising agents on the market are standard products such as caustic soda (NaOH) and ammonia or the multifunctional additive 2-Amino-2-methylpropan-1-ol (AMP). Clariant has developed a sugar-based specialty amine that is new to the market. In order to create a comprehensive assessment of these neutralising agents, environmental, health and safety aspects have been considered in addition to performance characteristics.
Table 1: Evaluation of neutralising agents based on environmental, health and safety aspects
Due to their hazardous substance labeling and the VOC/SVOC content, many common neutralising agents have limitations when used in a modern and environmentally-conscious formulation. Matters such as labeling or VOCs play an important role, especially in light of eco-labels such as the German Blue Angel, the EU Eco Flower, the Nordic Swan and the French Décret seal. It is no easy task for a paint formulator to develop a high-quality paint that fulfills stringent ecolabel criteria. The VOC/SVOC-limits of the German Blue Angel for example represent a real challenge. Even by using low VOC/SVOC ingredients, the formulation might already exceed the limit of 1 g/L for indoor paints or 2 wt.% for lacquers. In the evaluation of the neutralising agents’ suitability for ecolabels, glucamine as a multifunctional neutralising agent stands out as it is the only one that can be used in unlimited amount in paints which are certified with the Blue Angel, Nordic Swan, French Décret and the EU Ecoflower. Although the renewable content is not yet a criteria for ecolabels, another advantage of glucamine is that it consists of up to
31 | Coatings SA
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technical 75% glucose and is therefore very much in line with the trend of renewable raw materials. The multifunctional aminomethyl propanol (AMP) on the other hand is only allowed to <1% in lacquers and <0.07% in interior paints labeled with the Blue Angel. For the Nordic Swan the usage concentration is limited to 4.5% for gloss lacquers and only 1.1% for matt paints. The EU Ecoflower is even stricter and the dosage should be below 0.5% for class A,B,C. The picture for the standard neutralising agents looks varied. Ammonia cannot be used at all in indoor paints with the Blue Angel seal or is limited to <1% for lacquers. For the EU Ecoflower, the maximum dosage concentrations are between 0.5%-1% depending on the paint category. Caustic soda on the other hand can be used in unlimited concentrations for the EU Ecoflower, but is also limited for the Blue Angel lacquers to <1% and for the Nordic Swan to <2% due to the labeling.
In addition to storage at room temperature and in heat, frost is a further factor that can affect paints and, in the worst case, make them unusable. To assess the freeze-thaw stability, the paints were first frozen for 12 hours at -18°C and then thawed at room temperature for 12 hours. Afterward, it was evaluated whether the paints were still technically flawless. Figure 2 shows that both glucamine and AMP have withstood the maximum number of five cycles and contributed additional stabilising properties to the paints. The coatings with the standard neutralising agents NaOH and ammonia were unstable after three cycles.
Neutralising agents put to the test In addition to the environmental, health and safety aspects, the performance of the products was also evaluated. Hereby, the neutralising agents were formulated into standard acrylic gloss and semi-gloss lacquers, both low PVC paints, as well as in high PVC indoor and outdoor paints, and in pigment preparations. In the following graphs, mainly the results for the low PVC acrylic lacquers are shown, as it is here that the influence of the various neutralising agents is most pronounced and therefore ideal for visual representation. The influence of the neutralising agents on both the liquid paint as well as on the dried paint film that was applied, was studied.
Storage stability Figure 1 shows that it is possible to formulate stable paints with all neutralising agents. When stored for 28 days at 50°C, which corresponds to two years’ shelf life at room temperature in the Central European climate, none of the lacquers showed the appearance of syneresis or more pronounced sedimentation. Likewise, the pH level remained stable. With regard to rheology, there are clear differences, especially in the semi-gloss system. Immediately after manufacturing the lacquers, the viscosity remained nearly the same between the different neutralisation agents. However, after 28 days warm storage, the viscosity of the glucaminecontaining lacquer increased only slightly compared to the other neutralisation agents.
Dried and hard-dried coatings In addition to influencing the stability of the liquid paint, the ingredients also affect the dried film and therefore the decorative and protective functions of the coating. VOC-containing paint ingredients notoriously migrate from the coating and can therefore have an effect on the drying behavior of the coating. The König pendulum hardness was tested1 in order to evaluate both the drying behavior and the hardness of the paint films. Figure 3 shows the results of the pendulum hardness tests, measured in seconds,after different drying times over a period of 1–4 weeks, which corresponds in practice to the drying and complete drying of the coating. A comparison of both multifunctional neutralising agents – the VOCcontaining AMP and the VOC/SVOC-free glucamine – shows that the products have no significant effect on the drying rate, either to achieve the final film hardness or on the film hardness itself. Therefore, replacing AMP in a formulation with the nonmigrating glucamine neutralising agent will have no negative impact on the drying process.
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technical Flash rust Regarding the drying behavior on metallic substrates, the neutralising agents show different behaviour in the rust formation and discolouration of the paint. A 120 µm thin wet film was applied on a metal plate (Q-Panel type S-46) and then immediately stored at 23°C and 50% relative humidity for 24 hours for drying. As shown in Figures 4 and 5, the rust film appears as brown rust spots and the discoloration appears over the entire paint film. Glucamine showed the lowest tendency to initiate rust and create a discoloration in the film.
Shift of shades in tinted systems Paints are currently not only used as white or colourless coatings, but are tinted to various shades in construction and professional markets. The effect of the neutralising agent on colouring was therefore evaluated. During evaluation, acrylic gloss coatings neutralised with ammonia tinted in blue, green, red and black shades were set as a standard and compared to the alternatives. Figure 6 shows that the multifunctional
neutralising agents AMP and glucamine demonstrate a comparable shift of shades in the L and +b axis for all pigment pastes used and therefore allows these products to be interchangeable in mixing systems. (Note: a shift of shade of 0.1–0.2 is not evaluated as a significant deviation since it is still in the measurement tolerance.)
Pigment compatibility It was initially described that multifunctional neutralising agents could also act as a wetting agent or compatibilizer, for example when tinting a high PVC emulsion paint with pigment pastes. For the test, a standard low VOC emulsion paint with various neutralising agents was adjusted to a pH-value of 8.5 and subsequently tinted with a water-based iron oxide red pigment paste (3% each). After the homogenisation using a paint shaker, the paints were stored for 24 hours; then 200 µm was applied and subjected to a rub-out test. As can be seen in Figure 7, glucamine increases the tinting strength in the water-based paint system by more than 50%
SUMMARY Neutralising agents are only used in small quantities in water based paints. However, their effect is of significant importance. Not only do they regulate the pH-value, they also interact with paint ingredients and influence the stability of the paint during storage. There are a number of neutralising agents for the paints and coatings industry. The most frequently used neutralising agents are caustic soda, ammonia and AMP. Glucamine from Clariant is new to the market. It consists of up to 75% renewable raw materials, does not require labeling and is VOC/SVOC free and is therefore especially suitable for eco-label certified paints. From a performance point of the view, glucamine as a multifunctional additive improves the storage and freeze-thaw stability, reduces flashrust discolouration and enhances the compatibility with pigments. These properties can be achieved in low PVC acrylic paints, high PVC indoor and outdoor emulsion paints, and pigment paste preparations. Thanks to this multi-functionality, the glucamine Genamin® Gluco 50 helps to reduce the number of components in the paint formulation and thus contributes to process and logistics cost savings. Credit: This article has also been published in the European Coatings Journal, Issue 03, 2017; Farbe und Lack, Issue 03, 2017; PPCJ September 2017 and PCI Magazine, June 2018.
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