cost pressures stick to industry; major producers expand

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6 DECEMBER 2006 FOCUS ON POWDER COATINGS lowest curing temperature (80°C). At higher temperatures they assume a circular shape, which does not alter as the temperature is increased. On most of the coating surfaces it was possible to distinguish the wax particles from the filler and pigments. The calculations of surface profile and average roughness showed that the average size of the wax particles is a significant parameter when neither fillers nor hardeners are used in the coating. Coatings with larger wax particles have a lower specular gloss. Single filler does not influence this relationship to a large extent. It becomes important in samples with two fillers, where the deviation in the influence of the wax on specular gloss is considerable. It can be concluded that the matting efficiency of waxes is larger than it is for fillers. All surfaces gave a semi- gloss appearance. Article entitled “Surface analysis of matt powder coatings” by Marta Klanjsek Gunde and co-researchers at the National Institute of Chemistry and the Jozef Stefan Institute, Ljubljana, Slovenia published in Dyes and Pigments, 2007, 74 (1), 202-207 INDUSTRY NEWS Paints and coatings: new automotive coatings from DuPont and Dow Corning DuPont Co’s new coating for automotive refinishing is expected to be sold in auto collision repair centres by 2008. The new coatings are fortified with biopolymers obtained partly from the process utilized to develop 1,3 propanediol (PDO). The plant being constructed in Tennessee, USA is designed to house the manufacture of the new line. Meanwhile, Dow Corning will launch its new PlasmaStream system for coating various surfaces. Touted as energy efficient and environmentally friendly, PlasmaStream utilizes no water, solvents or surfactants. It needs no drying, and waste disposal and recycling are minimal. Chemical Engineering Progress, Nov 2006, 102 (11), 6 Vitracoat builds a new plant in Indiana Global company Vitracoat is setting up a modern production facility for powder coatings at its main site in Elkhart, IN, USA, with start up slated in 4Q 2006. Plant output will be marketed in the North American powder coatings market. Paint & Coatings Industry (PCI), Nov 2006, 22 (11), 20 2005 coatings industry report: product OEM coatings Product OEM coatings remained almost stagnant in 2005, with a slight drop in shipment volume of less than 1.0% year-on-year to almost 400 M gallons. Value of products shipped rose by 2.0% to $5944.8 M, an all-time high since 2000. By category, the results were somewhat varied in 2005. Both automotive coatings and powder coatings registered reductions in 2005, following an upturn in the previous year. Nearly all sub-types of powder coatings fell behind. Coatings for wood, non-wood furniture and related applications improved. Other OEM coatings, including general metals dropped, while all other coatings for the transportation industry grew. A table lists the top 10 categories in the Product OEM segment for 2005, based on volume shipped and product value. Paint & Coatings Industry (PCI), Nov 2006, 22 (11), 32 Company coats historic pipeline: Akzo Nobel’s powder coatings used Powder coatings supplied by Akzo Nobel have been used on the world’s longest underwater gas pipeline, the Langeled, which recently began delivering gas to the UK. A total of 64 tonnes of the company’s Resicoat R-743 product was used on part of the 1200 km pipeline, which carries gas to the UK from the North Sea. Norway’s Statoil and Hydro are the companies behind Langeled, which is set to deliver up to a fifth of all the gas consumed in the UK. Having its products specified for major projects such as Langeled highlights Akzo Nobel’s position as the worlds leading manufacturer of powder coatings. The southern half of the piepline was recently completed, with the northern section (which connects to the giant Ormen Lange gas field off the coast of Norway) due to come onstream in Oct 2006. Russian energy giant Gazprom has also expressed interest in the project. The company plans to roll out a $4 bn, 1200 km-long gas pipeline across the Baltic Sea to Germany. Akzo Nobel News and Views, 22 Nov 2006, (Akzo Nobel nv, PO Box 9300, 6800 SB Arnhem, the Netherlands, tel: +31 26 3665760, fax: +31 26 3665850, website: http://newsandviews.akzonobel.com) Cost pressures stick to industry; major producers expand Suppliers to the global paints and coatings industry are expecting to generate higher margins in 2007, mainly as a result of price hikes, cost-reduction measures and expansion in fast growing regions, including China. Cost pressures however, will continue to be a key problem. One of the most recent developments in the $71.3 bn/y industry is the completion of Engelhard’s integration into BASF, enabling BASF to have the largest range of products for coatings. 3M has added new equipment, and modernized its paints and coatings laboratory at St Paul, MN, USA. The company is also looking into building a similar facility in China, and in either Germany or France. Meanwhile, Dow Corning and Wacker Chemie have started

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Page 1: Cost pressures stick to industry; major producers expand

6 DECEMBER 2006

F O C U S O N P O W D E R C O A T I N G S

lowest curing temperature (80°C).At higher temperatures theyassume a circular shape, whichdoes not alter as the temperatureis increased. On most of thecoating surfaces it was possibleto distinguish the wax particlesfrom the filler and pigments. Thecalculations of surface profile andaverage roughness showed thatthe average size of the waxparticles is a significant parameterwhen neither fillers nor hardenersare used in the coating. Coatingswith larger wax particles have alower specular gloss. Single fillerdoes not influence thisrelationship to a large extent. Itbecomes important in sampleswith two fillers, where thedeviation in the influence of thewax on specular gloss isconsiderable. It can be concludedthat the matting efficiency ofwaxes is larger than it is forfillers. All surfaces gave a semi-gloss appearance.

Article entitled “Surface analysis of mattpowder coatings” by Marta Klanjsek Gundeand co-researchers at the National Instituteof Chemistry and the Jozef Stefan Institute,Ljubljana, Slovenia published in Dyes andPigments, 2007, 74 (1), 202-207

INDUSTRYNEWS

Paints and coatings: newautomotive coatings from DuPontand Dow Corning

DuPont Co’s new coating forautomotive refinishing is expectedto be sold in auto collision repaircentres by 2008. The newcoatings are fortified withbiopolymers obtained partly fromthe process utilized to develop1,3 propanediol (PDO). The plantbeing constructed in Tennessee,USA is designed to house themanufacture of the new line.Meanwhile, Dow Corning willlaunch its new PlasmaStreamsystem for coating varioussurfaces. Touted as energyefficient and environmentallyfriendly, PlasmaStream utilizes no

water, solvents or surfactants. Itneeds no drying, and wastedisposal and recycling are minimal.

Chemical Engineering Progress, Nov 2006,102 (11), 6

Vitracoat builds a new plant inIndiana

Global company Vitracoat issetting up a modern productionfacility for powder coatings at itsmain site in Elkhart, IN, USA,with start up slated in 4Q 2006.Plant output will be marketed inthe North American powdercoatings market.

Paint & Coatings Industry (PCI), Nov 2006,22 (11), 20

2005 coatings industry report:product OEM coatings

Product OEM coatings remainedalmost stagnant in 2005, with aslight drop in shipment volume ofless than 1.0% year-on-year toalmost 400 M gallons. Value ofproducts shipped rose by 2.0% to$5944.8 M, an all-time high since2000. By category, the resultswere somewhat varied in 2005.Both automotive coatings andpowder coatings registeredreductions in 2005, following anupturn in the previous year.Nearly all sub-types of powdercoatings fell behind. Coatings forwood, non-wood furniture andrelated applications improved.Other OEM coatings, includinggeneral metals dropped, while allother coatings for thetransportation industry grew. Atable lists the top 10 categories inthe Product OEM segment for2005, based on volume shippedand product value.

Paint & Coatings Industry (PCI), Nov 2006,22 (11), 32

Company coats historic pipeline:Akzo Nobel’s powder coatings used

Powder coatings supplied byAkzo Nobel have been used onthe world’s longest underwatergas pipeline, the Langeled, which

recently began delivering gas tothe UK. A total of 64 tonnes ofthe company’s Resicoat R-743product was used on part of the1200 km pipeline, which carriesgas to the UK from the NorthSea. Norway’s Statoil and Hydroare the companies behindLangeled, which is set to deliverup to a fifth of all the gasconsumed in the UK. Having itsproducts specified for majorprojects such as Langeledhighlights Akzo Nobel’s positionas the worlds leadingmanufacturer of powder coatings.The southern half of the pieplinewas recently completed, with thenorthern section (which connectsto the giant Ormen Lange gasfield off the coast of Norway) dueto come onstream in Oct 2006.Russian energy giant Gazpromhas also expressed interest in theproject. The company plans to rollout a $4 bn, 1200 km-long gaspipeline across the Baltic Sea toGermany.

Akzo Nobel News and Views, 22 Nov 2006,(Akzo Nobel nv, PO Box 9300, 6800 SBArnhem, the Netherlands, tel: +31 263665760, fax: +31 26 3665850, website:http://newsandviews.akzonobel.com)

Cost pressures stick to industry;major producers expand

Suppliers to the global paints andcoatings industry are expecting togenerate higher margins in 2007,mainly as a result of price hikes,cost-reduction measures andexpansion in fast growing regions,including China. Cost pressureshowever, will continue to be akey problem. One of the mostrecent developments in the $71.3bn/y industry is the completion ofEngelhard’s integration into BASF,enabling BASF to have thelargest range of products forcoatings. 3M has added newequipment, and modernized itspaints and coatings laboratory atSt Paul, MN, USA. The companyis also looking into building asimilar facility in China, and ineither Germany or France.Meanwhile, Dow Corning andWacker Chemie have started

Page 2: Cost pressures stick to industry; major producers expand

DECEMBER 2006 7

F O C U S O N P O W D E R C O A T I N G S

constructing a silicones unit atZhangjiagang City, China, slatedfor completion by end of 2010.Other suppliers like ICE, Huber,Omya, BASF Catalysts andImerys have hiked prices tobalance costs and improveprofits. Huber will reduce itscapacity for paper-grade kaolin to250,000 tons/y at its plant inMacon, GA, USA, to concentrateon more cash-generatingindustrial markets. In Oct 2006,Imerys relaunched two calcinedkaolin grades for paint, whichwere taken out in 2005 becauseof increasing processing andenergy costs. A figure illustratesbreakdown of global paints andcoatings industry.

Chemical Week, 15 Nov 2006, (Website:http://www.chemweek.com)

Akzo Nobel 3Q 2006: Delivering onprofitable growth

For its 3Q 2006, Akzo Nobel NVhas reported turnover of €3449M, (€3299 M for its 3Q 2005),operating income of €364 M,(€319 M), and net income of€313 M (€175 M). There isdiscussion of the business,including: development ofasenapine (joint development withPfizer), Organon (turnover of€626 M a rise of 6%), Intervet(turnover of €276 M up 7%),coatings (acquisitions, operatingprofit of €83 M – no change),and chemicals (sales of €912 M,slightly down due to divestments,and operating income, whichreported no change at €83 M).

Akzo Nobel 3Q 2006: Delivering onprofitable growth, 18 Oct 2006, 1-3 (AkzoNobel NV, Velperweg 76, PO Box 9300,6800 SB Arnhem, The Netherlands, tel: +3126 366 4343, fax: +31 26 366 4940,website: http://www.akzonobel.com)

Protech: powder coatings for life

Protech Chemicals Ltd is one ofthe world’s leading manufacturersof powder coatings. The companywas established in 1976. Today,Protech sells its products inEurope, Asia, the Middle East,

Central and South America, aswell as the US and Canada.Protech currently has fivemanufacturing facilities – two inCanada, one in the US, one inBrazil, one in Belgium (Oxyplast)and a distribution networkthroughout the Americas. Thesefacilities are designed to allowproduction of both large andsmall runs. Protech’s annualcapacity now exceeds 40,000tonnes. Protech employs morethan 400 people. Of theworkforce, 20% is involved intechnical services, includingresearch and development.Protech manufactures a widevariety of powder coatings in allthe basic chemical systems:epoxies, hybrids, urethanes,polyesters in TGIC and non-TGIC, and acrylics. While manypowders for general consumptionare kept in stock, much ofProtech’s production is gearedtoward custom formulations;developed and tailored for aparticular customer or application.Besides the traditional thermosetpowder coatings, Protech alsocarries six speciality lines eachdesigned for a unique application.Heliocoat is a line of powdercoatings that offers heatresistance up to 900°F andcomes in a wide range of coloursand textures. These powders arecompatible with conventionalpowder systems and haveexcellent application properties.Heliocoat is ideal for BBQs,industrial heaters, enginemanifolds, chimneystacks,halogen fixtures, etc. Nuvocoat isa flexible and environment-friendlyline of UV curable powdercoatings that offers significantcost savings to the end user.Nuvocoat is available in a rangeof colours and textures and issuitable for a variety of substratesincluding wood and engineeredwood products such as MDF.Permaslip is Protech’s line of low-friction powder coatings. Theyprovide an excellent applicationfor shopping carts, drawer slidesor any other type of interlockingor meshing process. These

powders are also available in awide range of colours andtextures. Ebond is Protech’s lineof metallic powder coatings.These powders are manufacturedusing proprietary processes thatensure a consistent finish in awide range of colours andtextures. Ebond powders showoptimum metallic effects and haveexcellent application characteristics.Thermolam is a line of low-temperature cure, thermosetpowder coatings ideal for woodand other heat sensitivesubstrates. The powders areextremely durable and areavailable in a wide range ofcolours and textures. Sol-ar isProtech’s line of high performancepowder coatings for architecturalapplications. These powders areformulated using a fluoropolymerresin that provides superiorweathering performance andexcellent UV resistance. Sol-arpowders demonstrate excellentabrasion and mar resistancewithout the use of primers. As aprivate corporation with a soleinterest in manufacturing andmarketing powder coatings, themanagement at Protech isdirectly involved in all aspects ofthe coating business, whether itis technical development,production or customer service.

Protech Chemicals Ltd, 2006, (Website:htpp://www.protechpowder.com)

EVENTSuv.eb WEST 2007

Radcure, the association for UVand EB technology, will holduv.eb WEST 2007, a two dayconference and tabletopexhibition, on 6-7 Mar, 2007, atthe Sheraton Gateway Hotel atLAX in Los Angeles, US.Presentations and demonstrationsby leading industry suppliers andusers will target theenvironmental, economic, energysavings and performance benefitsof UV and EB, and how thetechnology enables manufacturers