wood compositesconference
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International Coating Wood & Wood Composites Conference
September 13-14, 2011Charlotte, NC
UV-Curable Powder Coatings for MDF Substrates
Michael KnoblauchDVUV Holdings, LLC
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Discussion Overview
Market & Applications Why UV Powder? UV Curing Process Advantages Value of Powder Coating Environmental Benefits Questions
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Coatings Market
Paints and coatings marketNorth America paints and coatings market is valued at $21.2 billion.
In 2008, powder coating was a $6.5 billion industry.
Powder manufacturing is a $5 billion industry worldwide.
UV-cured coating marketUV-curable coatings will grow at a 7.5% rate to $2.41 billion by 2014.
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Industrial Coatings Market
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Powder Coating MDF MDF or Medium Density Fiberboard
Hardboard made from wood fibers which are glued under heat and pressure.
Excellent substrate for UV powder coatingDense & flat
Low porosity
Homogenous
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Powder Coating MDF Heating the board draws moisture to the surface, making it conductive for
electrostatic powder application. 2 Types of Application
Corona SprayPowder passes through highly charged & ionized corona field, powder picks up negative chargeHigh transfer efficiency and applies quickly
Tribo ChargingPowder develops a static charge due to frictionProvides better penetration into recesses Slower application and lower transfer efficiency
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UV Powder Applications for MDF Markets
Retail displays, fixtures and P-O-P
Healthcare and medical equipment
Storage and cabinetry
Specialty furniture
Excellent Finish and ProcessSuperior wear characteristics
Visual appeal and design innovation
Fast, efficient manufacturing
Environmentally safe production and end-products
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Why Powder Coat MDF? Increased design flexibility
No edge banding
Seamless 360° coverage Demand for environmentally
friendly products and processes.No VOCs, HAPs, or solvents
Superior wear characteristicsStrong cross-linked finish
Withstands high traffic environments
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Why Powder Coat MDF? Fast and efficient production
20 minute process
1 coat finish Ease of material handling
No messy liquids
Ability to reclaim waste powder Fast color changes
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Productivity & Innovation
Melamine
- 1 0 +1
+1
0
- 1
Productivity
Waterborne
UV
High
Pressure
HPLSolvent
Based
Vinyl
(membrane
press.)
Vinyl
Flat
PaperThermoset
UV Powder
Liquid
Lamination
Powder coating
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UV CuringUltraviolet curing (commonly known as UV curing) is a photochemical process in which high-intensity ultraviolet light is used to instantly cure or “dry” inks, coatings or adhesives.
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Cross-Linked UV Curing
Separates gel/flow stage from cure
Ensures complete cure for extended finish life
Expands potential gloss range
Enables smoother textures
Eliminates cracking
Creates cross-linked and bonded molecular finish
Produces superior surface that resists damage and maintains ideal appearance
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UV-Cured Powder Coating Process
Melt & Flow1 min
UV Cureseconds
Powder Deposition
Finished Product
Substrate Pretreatment
Raw Component to Finished Product: 20 Minutes
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14 Windy City Coatings ConferenceApril 27 & 28th, 2011
UV Powder Application System
• A UV powder application system
Parts are loaded and prepared
Pretreatment
Electrostatic powder application
Flow/Melt oven
UV Cure oven
Powder Coating Application
Environmental Room
UnloadArea
LoadArea
Pretreatment
MeltOven
UV CureOven
Prep
200 feet line – cycle 20 minutes
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UV Powder System Video
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UV Finishing Advantages Increases production speed & productivity
Liquid finishing requires flash off
Thermal curing requires 30 minutes or more
Thermoset higher temperatures require extra cooling time
Requires less energy and plant footprint
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Reduced Manufacturing Footprint
Typical thermal powder plant size >15,000 sqft
Typical UV powder plant
size2,050 sqft
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UV Finishing Advantages Reduces reject rates
Shorter line –– faster response time to fix issues
Reduced number of parts on line
Improved product performanceLess thermal exposure
Reduces outgassing
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Speed Wins!
0 10 20 30 40 50 60
Finish Time (min)
Liquid Coatings
Thermoset Powder
UV Powder
Part Cycle Time Anaylsis Thermal Cure Coating Systems (Powder & Liquid)
vs. UV Powder CoatingsCoating Application
Melt & Flow
UV cure
Solvent Flash
Thermal Cure
Cooling
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The Value of Powder Coating Applied material cost advantage
No solvents or liquids
Up to a 95% material utilization Shorter process time
Increased finishing capacity, faster ROI
Lower energy consumption
Shorter set-up times, less down time Efficient
Requires less energy and plant space
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The Value of Powder Coating Energy Productivity
Requires 1/4 to 1/8 less oven capacity than a solvent borne system
Utilizes gas to power ovens and electricity to power the UV lamp system
Solvent - FreeSavings associated to solvent incineration
Reduced waste disposal cost Less energy per part
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ROI Example
System Productive Capacity 3,000,000 Sq/ft/shift
Selling Price $4.00 Per/sq ft
Total Revenue $12,000,000 1 shift
Operating Margin 10%
Net Operating Margin $1,200,000
Net Investment $1,000,000
ROI Year 1 20%
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Environmental Benefits
Green Finish Formulation:
No VOCs (volatile organic compounds)
No HAPs (hazardous air pollutants)
No PVC (polyvinyl chloride)
No Solvents
Powder overspray can be reclaimed up to 95% MDF components can be recycled into mulch
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Environmental Benefits
Environmentally Sustainable Process:UV curing is extremely energy efficient
Fast, single-step process
20 minutes from raw MDF to finished parts Smaller manufacturing footprint
¼ - ⅓ the size required for other finishing processes Reduced energy consumption
40-60% energy savings compared to other finishes
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MDF and CARB ComplianceCARB(California Air Resources Board)
In 2007, the California Environmental Protection Agency implemented limits on the formaldehyde emitted from composite wood panels.
UV powder coating for MDF meets all CARB phase I and II compliances.
Phase I limits emitted urea-formaldehyde to <.21 ppm and <.11 for phase II.
UV-cured powder coating seals in remaining formaldehyde.
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Breadth of Pallet - Color & Effect
Metallic
Multi- Component
Full Color Pallet
Opaque
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Custom Color Matching Excellent scratch resistance hardness and chemical resistanceare all possible; together with a wide range of colors.
UV powder can be matched to meet any color standardRAL
Pantone Matching System (PMS)
Laminate Finishes
Liquid Paints
Any Supplied Sample
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Examples
Interactive Retail Display
Healthcare Component
POP Display
Educational Lectern
Architectural Element
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Conclusion
UV-cured powder coating for MDF provides:
High speed finishing and increased productivity Greater ROI Energy and space savings Environmentally friendly finishing option Durable and high quality product
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Thank You!
Questions?Michael KnoblauchPresidentDVUV Holdings, LLC4641 Hinckley Ind. Pkwy.Cleveland, OH [email protected]