EDITOR’S LETTER

Sherwin-Williams, Axalta, Tiger Drylac and Europolveri. Organic market growth was predicted to wane over the next two to three years. U.S. manufacturing had hit a ten year low in September 2019 due to lower consumer demand and the uncertainty caused by Trump’s trade war with China. Some experts, me included, foresaw an economic recession on the horizon. In addition, scant market growth was expected in the automotive market. OEMs had committed to waterborne technologies and the “compact” process which neither entail any use of powder coatings. Slow growth that tracks overall automotive production was expected to occur in under-the-hood applications and alloy wheels. As we all know, the world economy came crashing down at the onset of the coronavirus. The rebound, however, has varied depending upon how each region and country fared in fighting the pandemic. China instituted an aggressive and draconian shutdown and emerged remarkably quickly. As the rest of the world struggled with containing the virus, China experienced an unprecedented “V-shaped” economic recovery. Globally the industry saw an overall growth rate of 17% in Q1 2021 versus Q1 2020, however it was mainly due to a spectacular 23% expansion in Asia. Europe rebounded with a 6% growth tally; however, North America has only experienced a meagre growth rate of 1.5% versus Q1 2020.

What are the sector’s current priorities, in general, and from a legislative point of view, in particular, in the US?

Current priorities in the US and much of the rest of the world centre around meeting current customer needs in light of raw material price increases, continuing supply chain disruptions and exorbitantly long lead times. Key raw materials are in short supply due to plant shutdowns around the world, a scarcity of chemical building blocks due to the February freeze in Texas and the Gulf Coast and a dearth of shipping containers to move product around the world. Legislation has been hinted at by government regulators regarding titanium dioxide and BPA (Bis-Phenol-A), however nothing concrete has emerged in the last year. TGIC (Triglycidyl Isocyanurate), the polyester curing agent aggressively regulated in the EU, remains off the EPA’s list of Chemicals of Special Concern, therefore no active legislation is anticipated in the near future. Interestingly, TGIC is in short supply due to the shutdown of a couple of Chinese production facilities. This has created a new demand for HAA (hydroxy-alkyl amide), an alternative curing agent commonly used in Europe.

© The Powder Coating Research Group

Kevin Biller.

Competence in Shot Blast Technology

20 years

As a full-range supplier, we design and manufacture shot blasting machines including filter and transport technology. ➜ New shot blast machines ➜ Second hand machines ➜ Service and spare parts ➜ Reparation & maintenance ➜ Inspection & consulting ➜ Performance improvement AGTOS | GmbH | D-48282 Emsdetten info@agtos.de | www.agtos.com

At present sustainability is one of the drivers of the entire industrial field. What future do you foresee for the powder coatings industry with respect to this issue?

Sustainability is alive and well in the powder coating industry and can take many forms. Obvious examples are the use of recycled polymers and raw materials based on renewable feedstocks such as plants. In addition, sustainability can be engendered with products requiring less energy to process or produce. Furthermore, more highly durable products can enhance sustainability. The powder coating industry has technology represented in all of these categories. Sherwin-Williams recently debuted the Powdura® ECO Hybrid Coatings line. The polyester resins used in these powders contains 25% pre-consumer recycled plastic (rPET). SW touts these coatings as being easy to apply, having wide cure capability, and can align with third-party certifications such as LEED, GreenGuard and BIFMA (the Business and Institutional Furniture Manufacturer’s Association). Battelle Memorial Institute has recently developed a bio-based powder resin that checks two boxes of sustainability – renewable plant-based feedstocks and low temperature cure. This polyester-amide resin boasts an 85% bio-based content and is capable of cure as low as 130°C. In addition, it exhibits excellent UV resistance as evidenced in laboratory testing (4000 hrs. QUV-B). Prototypes have been submitted to a few powder manufacturers for their support in eventual commercial scale-up potential. Rilsan Fine Powders, a division of Arkema, has developed a high-performance polymer designed for thermoplastic powder coatings. Rilsan® 11 is a member of the nylon family of polymers and is based on a monomer derived from castor beans. It can be used for a variety of coatings requiring durability including dishwasher racks, auto parts, potable water pipelines, outdoor furniture, medical instruments and commercial grade outdoor lighting. Low temperature cure is an important subgenre of sustainable products. Reducing the energy requirements to cure coatings reduces their carbon footprint and saves operating costs. AkzoNobel recently introduced the Interpon Low-E collection of polyester powder coatings which are designed to reduce the curing temperature and/or curing time, without sacrificing the quality and properties of the coating. These powder coatings can be cured between 150 and 170°C, from 8 to 40 minutes. By using this range, coaters can reduce energy consumption and/or increase the productivity of their application process. This contributes to lower costs and also improves their ecological footprint. Axalta debuted a similar polyester product line called Alesta BE+ in Mexico in 2020. More highly durable powders increase the longevity of a coated item leading to more sustainability. The need to refresh or repaint products is costly, labour intensive and can involve field applied coatings with high VOC content. Additionally, coating failures that instigate the replacement of a coated item incurs the high costs of disposal and ultimate replacement. The powder coating industry recently introduced “hyper-durable” technology that significantly increases the longevity of a coated asset.

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Coating longevity requires a combination of UV durability and corrosion resistance. Outdoor durable powder coating technology is well positioned to take on the high-performance architectural market. The North American architectural market abides by the AAMA specifications: 2603 (one year Florida), 2604 (five years Florida) and 2605 (ten plus years Florida). Powder coatings meeting the AAMA 2604 specification have been around for decades and have a sterling track record of performance in the field. These are typically based on “superdurable” polyester binders combined with high performance pigments, fillers and additives. Powder coatings that meet the more stringent AAMA 2605 and Qualicoat Class 3 requirements have recently been commercialized and are gaining momentum in the architectural market. These powders are based on FEVE (fluoro ethylene vinyl ether) polymers and can last up to twenty years in UV intense environments such as South Florida and parts of the Middle East. Leaders in this arena are IFS Coatings, PPG, Axalta, ProTech and AkzoNobel. Prominent building projects have touted the use of AAMA 2605 powder coatings including the PNC Plaza in Pittsburgh (PPG Coraflon), 55 Hudson Yards (PPG Coraflon) and 10 & 30 Hudson Yards (AkzoNobel Fluromax) in Manhattan.

Digitalization is another important and recent theme. What do you think about its development in your industry?

As for digitalization, powder coating equipment makers have introduced more sophisticated coating application control software in the form of user-friendly apps. GEMA’s OptiStar® 4.0 controls crucial coating parameters such as pneumatic and electrostatic parameters. These relevant coating data can be then accessed to a mobile device with their Electrostatic App. Moreover, their DVC technology ensures precise and reproducible powder output and ensures consistent film thickness. Finally, GEMA’s PCC and SuperCorona software improves penetration, reduces back ionization, orange peel and picture framing. Nordson’s latest gun control software is aptly named Encore® Engage. It features an easy-to-understand, 15-inch touchscreen with modern graphics and intuitive symbol-driven navigation. In addition, a guided recipe feature provides step-by-step navigation with pre-set options to help operators confidently create new recipes. Video tutorials and guided instructions provide greater visibility to key information and give additional support for critical tasks. For operators around the world, Encore Engage® includes several screen language options and its controller interface delivers easy navigation and enables industrial internet of things (IIoT)/ Industry 4.0 functionality for powder coating application. Parker Ionics has focused on their exclusive Pulse-Power gun

control technology. Their new GX8500A powder application system features a 3G patented Super Pulse Power - corona charging technology that provides superior first pass transfer efficiencies (FPTE) on all shapes and substrates. In addition, it is fully digital with simple controls featuring 250 recipe capacity. Parker explains that the GX8500A is excellent for coating boxes, wheels, piping, MDF and extrusions and that it possesses the highest transfer efficiency in the industry resulting in lower operating costs.

The health crisis has stopped all events and face-to-face meetings, like exhibitions and training courses. You have attended numerous events around the world, and you have organized the Powder Coating Kitchen, a short course that introduces formulators, chemists and scientists to the fundamentals of creating a powder coating from the ground up. How do you think the events sector will change?

Because of Covid, we have had to modify our approach to training. Our popular formulators’ short course, the PC Kitchen, originated as a live, hands-on experience held in the PCR Group laboratory. It consists of lectures spanning the spectrum of formulation fundamentals, powder processing and application technology. Live lab demonstrations are intermingled with presentations enabling the student to participate in powder processing, application and evaluation techniques. Social distancing and travel restrictions compelled us to shift this two-day course to a series of four consecutive Thursday afternoons of live broadcast via Zoom meetings. We delivered live presentations including animated question and answer sessions. Pre-recorded videos were made demonstrating the powder coating manufacturing process as well as application techniques. In both the live and broadcast versions of the course we had the students break into small groups to tackle a formulating exercise. Each group was given a specification to meet along with a list of various raw materials in which they had to use to formulate a powder that met the requirements. PCR Group lab technicians took these “new creations” and made powder coatings based on their newfound formulating skills. Test panels were sprayed followed by evaluation and critique of their powders in a live broadcast. In addition to repackaging the PC Kitchen we developed a regular podcast. The Ask Joe Powder “powdcast” provides the listener to the latest news and information in the powder industry in an entertaining and enlightening manner. The mythical Joe Powder then answers technical questions from people in the industry. On occasion the podcast consists of an interview with industry leaders. This podcast just posted its 28th episode.

Today it’s difficult to make a forecast of the economic situation over the next years. From your point of view, could you give us some indications of future developments both in the US and in all the world?

Innovation in powder technology will open new markets in the heat sensitive substrates and hyperdurable markets. Major furniture makers have expressed strong interest in converting liquid paint lines to powder for their MDF (medium density fibreboard) based product lines. As they make major conversions, competitors are expected to follow suit. Hyperdurable end-uses will slowly convert to powder especially in the demanding markets in the US and Middle East. Supply chains for critical raw materials, such as TiO2, pigments and base resins, will take some time to get back to a modicum of normality. R&D staffs are challenged to replace retiring formulators with the fresh minds of new graduates. Innovation is sluggish with the trend toward an oligopoly of behemoth producers who are bogged down in bureaucratic management. For decades powder coatings’ pillars of efficiency, economy, excellent performance and environmental compliance have compelled finishers to replace solventborne coatings. The potential for explosive growth of powder coatings has always been tempered by barriers to entry mostly centred around fear of radical change and the potential for failure. Liquid coating technology is still superior to powder coatings for large scale articles such as earth-movers, farming equipment and aerospace/aviation. Regardless powder growth will be driven by conversions in the finishing of heat sensitive substrates such as engineered boards, composites and plastics. In addition, hyperdurable powders will gain market share at the expense of more traditional liquid coatings due to the ability to meet everchanging environmental and sustainable goals of regulators. And finally incremental improvements in corrosion resistance and durability will be realized especially in the pipeline coating market which will drive modest growth.

March and April in review

Two months with important changes, starting from the new website up to a new section in our magazines… and a new colleague.

As anticipated, after months of work, on March 1st our new website went online (www.myipcm.com)! Available in 5 languages, the website features new graphics, an enhanced user experience, a responsive layout that optimises the navigation via mobile, new features and new tools to promote your brand and products. The News section of the website features all the latest news on sector trends, products and technologies, research and development, fairs and events and much more, and ipcmPedia allows you to get all the information you need on the major sector players, and is also a powerful search engine that crawls all the pages of our website to provide answers to your queries.

The most important international trade shows

To stay up-to-date with the scheduled trade shows and discover where you can grab a copy of our magazines, we have created a dedicated fair calendar (www.ipcm.it/en/exhibitions.aspx). Moreover, in the Exhibitions section (www.ipcm.it/en/calendar/2021-05.aspx), it is possible to find all the information on the trade fairs represented by us: PaintExpo, PaintExpo Eurasia, DeburringExpo and FABTECH México.

New edition, new section

In March, the issue no. 68 of ipcm® International Paint & Coating Magazine was also published. It not only covers a variety of topics and applications spanning several manufacturing fields but it also includes a comprehensive supplement devoted to the coating of architectural profiles and design objects, with a wealth of innovations especially in the powder coating sector. The March/April issue of ipcm® launches also a new section – How It’s Coated – inspired by the well-known tv program “How it’s made” and aimed at describing the production cycle and the coating phase of particular products. The first of these that we presented is MAMBO (www.ipcm.it/en/open/ipcm/2021/68/34-36.aspx), the first 3D-printed fiberglass boat in the world.

The month of April has always been dedicated to the preparation and release of the first issue of the year of ipcm®_Protective Coatings (www.ipcm.it/en/magazine/protective-coatings/2021/37.aspx). In this issue we have found how the pandemic has brought out new needs in the industry, which force companies to push on the accelerator of Research and Development. These include the demand for greater efficiency, durability and effectiveness of paint products and the need to reduce dependence on oil derivatives for the formulation of coatings, as well as VOCs.

The new session of the ipcm® Academy training courses has begun

On April 8 we started the first session of the ipcm® Academy training

course aimed at training the new professional figure of Technician of Industrial Surface Finishing Processes, included in the QRSP (Regional Framework of Professional Standards) of the Lombardy Region and recognized at national and European level. In the first three training days, the 13 students addressed the topics of corrosion, pre-treatment and waste water treatment and purification. Finally, in the last days of April, the participants of the 2020 edition of our training course received the certificate of competence as Technician of Industrial Surface Finishing Processes.

ipcm® at the “Alluminio&Acque” conference

On Wednesday April 14, the editor-in-chief of the ipcm® magazines, Alessia Venturi, participated in the digital conference “Alluminio&Acque” with a presentation entitled “The role of an international magazine in the dissemination of innovative technologies: promoting dialogue between suppliers and users”. The conference was organized by CIE Srl and MST Chemicals with the collaboration of ipcm® and the AITAL Association with the aim of getting deeper understanding of the technologies, processes, chemicals and plants to save, purify and recycle the water coming from metal finishing lines and anodic oxidation of aluminium.

eos’ tree

On the occasion of the international day dedicated to our Planet, celebrated globally on Thursday 22 April, we presented the lime tree that was given to us last Christmas by the girls of our editorial staff. The tree is planted in Bollate (province of Milan) in “Il bosco dei ricordi”, a project that involves the annual absorption of over 210,000 kg of CO2.

The new partnership with Assovernici

eos and ipcm® strongly believe in the importance of associations and networking for business development. To this end, we have established a new partnership with Assovernici - Produttori Italiani Vernici, an association that represents the main manufacturers of construction and industrial paint and coatings with the aim of promoting the Italian sector, enhancing its excellence and specificity.

A new special colleague

Last but not least, this month we welcomed a new friend/colleague: Falcor, a 3-month-old Miniature Schnauzer puppy. His work within the editorial office is very demanding: allowing cuddles here and there, playing and accompanying the girls of the editorial office on their coffee break every day.