G UEST VIEWPOINT
The Year We Held Our Breath In some respects, the last half of 2008 and almost all of 2009 was a time when the world collectively held its breath, as we watched the global economy come to a sudden halt and teeter on the brink of serious disaster. The money supply literally froze as banks stopped lending. The U.S. housing market dropped precipitously. The American automotive industry, a mainstay of U.S. manufacturing, also wavered on the edge, with two of the Big Three automakers going into bankruptcy proceedings. For the ranks of the employed, people worked with a certain grave persistence that comes knowing cuts are happening, and you might be one of them. For the unemployed, that same grave persistence was applied to indescribably frustrating jobs hunts. Leaders and owners of businesses hunkered down with what appeared to me to be an almost war-like mentality. Their approach: this is going to be ugly, but we must get through it. 2009 was the year that very little movement happened in the coatings industry. Fewer mergers and acquisitions, or even personnel changes, took place. And as the results for the PCI 25 and Global Top 10 show, with few exceptions, paint companies in the United States, as well as global leaders, had lower or, at best, stagnant sales for 2009. Quarterly statements and annual reports for the period revealed over and over the same story: the global economic crisis created serious challenges for coatings companies and their suppliers, and companies managed the crisis by quickly cutting costs and carefully managing their margins. But 2010 is beginning to look like the year where we all exhale and begin to slowly grow again. The economy is moving once more. It started where it slowed the least, in Asia, but it is also picking up in the United States. For example, the automotive industry is doing better. Ford Motor Co. reported a 22 percent increase in May for U.S. light-vehicle sales, and GM reported a 32 percent increase in domestic sales for the four brands the company kept after restructuring. Quarterly statements coming out for the first quarter of 2010 are almost all reporting a much more positive tone. For its first quarter, PPG reported a sales increase of 12 percent compared to 2008, with sales in the Industrial Coatings segment increasing 39 percent compared to the prior year. In its second-quarter report, Valspar reported a sales increase of 20.2 percent compared to the same period last year, prompting the company to increase its earnings guidance for 2010. AkzoNobel reported a six-percent increase in revenue for the first quarter of 2010, and the company continues to invest. So far this year, AkzoNobel has announced expansions in China and an acquisition in the United States. DuPont reported that sales in its Performance Coatings segment were up 23 percent for the first quarter of 2010, and Sherwin-Williams has already announced two new acquisitions in 2010. The positive news in quarterly statements reinforces what analysts are saying. According to a study by The Freedonia Group, demand for architectural paint is forecast to rise 3.6 percent per year into 2013. While this growth is recognized as less than the robust growth that was experienced in 2003-2008, it does indi6
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cate growth and worldwide demand for coatings, particularly in the world’s emerging markets. The other sign that gives me hope for the future is the continued commitment in the coatings industry to research and development. At PCI, we continue to receive, almost daily, news releases about new products developed by coatings suppliers and manufacturers. If there was a theme to the American Coatings Show, it was the industry’s emphasis on moving forward through innovation in areas such as waterborne technology, smart coatings and nanotechnology. In 2009, we all held our breath and hoped for the best. And while these last 18 months have been challenging for companies and individuals, the good news is that we survived. While companies struggled with cost cutting and reduced sales, they are still in business, ready to move forward and innovate. It is now time for us all to exhale and move forward. By Karen Parker, Associate Editor, PCI Magazine
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I NDUSTRY NEWS
Alliance Created to Promote Green Chemistry Awareness SAN FRANCISCO – Beyond Benign Foundation, Cytec Industries Inc. and Sopheon Corp. have formed the iSUSTAIN Alliance to promote green chemistry awareness in the global chemical industry. The alliance has launched a Web site, www.isustain.com, which allows chemical manufacturers and users to track their progress in developing greener products over time. Users will be able to assess the sustainability of new products using a systematic approach, which is both comprehensive
and simple, to help shape the formulation of these products. The site allows companies to test their green-product attributes and give each product an iSUSTAIN™ Green Chemistry Index
NCCA Debuts E-Learning Module CLEVELAND – Manufacturers can now learn all about the basics of prepaint and coil-coated metal by viewing the National Coil Coating Association’s (NCCA) new e-learning module, “Prepaint 101.” The free online tutorial highlights the origins of coil coating, explains the coating process, describes available coatings and their end uses, and illustrates why prepaint is the most efficient, durable and attractive method of applying coatings to metal products. To view the tutorial, go to www.coilcoatinginstitute.com.
GPU Routines Available From Numerical Algorithms Group OXFORD, UK – Chemists modeling fluid properties as part of paint and coatings development who are interested in achieving top performance from graphical processing units (GPUs) in diverse applications using Monte Carlo simulations can now obtain an updated version of NAG numeric routines for GPUs from the Numerical Algorithms Group (NAG), Oxford, UK. NAG’s numerical routines for GPU computing are available to academic researchers involved in collaborative research with the NAG organization. Commercial organizations can also get access to NAG’s GPU code and programming services by contacting the NAG office in their local area. Visit www.nag.com/contact_us.asp for additional information.
Vincentz Network Releases Adhesives and Sealants Book HANNOVER, Germany – The Vincentz Network, Hannover, Germany, has released a new book, “Formulating Adhesives and Sealants,” by Bodo Müller and Walter Rath. The book examines adhesives and sealants from the chemist’s viewpoint. It focuses on the composition and ingredients of the various types of adhesives, their chemical structure and functional groups, and clearly shows how these give rise to the resulting properties. The new publication teaches adhesive and sealant formulation in two steps. Each section first describes the application and chemical basis of the type of adhesive or sealant concerned. This is followed by formulation advice and, if possible, an analysis of 8
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rating that will be independently verifiable through a certification process. The academic community will be able to use the iSUSTAIN application free of charge, while company users will pay a small subscription fee. An advisory board for the alliance will be established in the coming months, which will include representation from the Web site’s user community. For more information on how to access the iSUSTAIN Green Chemistry Index, contact
[email protected].
existing recipes (e.g. guide formulations and patent examples). Analysis includes a calculation of the important characteristic values of the formulations. All calculations based on recipes and formulations are worked through step by step and should therefore be intelligible to beginners. As a further bonus, a separate chapter is devoted to the design and testing of adhesive joints.
New Web Site Indexes Epoxy-Floor Articles PITTSFIELD, NH – Progressive Epoxy Polymers Inc., an internet supplier of epoxy resins and coatings, urethanes, fillers and thickeners, is posting a new online index of epoxy-floor articles and links. The Web page, www.epoxyproducts.com/epoxy-floor-paint. html, lists Web links to articles relating to epoxy-floor systems. Topics covered on the Web index site include floor basics, color charts, epoxy-chip floors, non-slip issues and much more.
RadTech Names Student Award Winners BETHESDA, MD – RadTech has announced the winners of its student scholarship and graphic communications awards. Luke Kwisnek, a PhD student at the University of Southern Mississippi School of Polymers and High Performance Materials, and Kenny Mineart, a junior Chemical Engineering major from the University of Iowa, received the RadTech Experience scholarship. As part of the award, both students attended RadTech 2010. The first biennial TAGA/RadTech student poster competition was won by Alicia Juarez, a junior majoring in Graphic Communication at California Polytechnic State University San Luis Obispo. Juarez displayed her poster, printed by UV inkjet, at RadTech and received a cash award.
EMU Offers Certificate in Coatings Technology YPSILANTI, MI – Eastern Michigan University (EMU), Ypsilanti, MI, is offering an online Graduate Certificate in Coatings Technology. The program allows students from anywhere in the world to study at EMU. The Graduate Certificate in Coatings Technology is designed for those currently serving, or aspiring towards, technical and managerial positions in industries concerned with coatings. Upon com-
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I NDUSTRY NEWS pletion of this program, students will have a fundamental understanding of concepts, principles and applications in coatings materials. Students will also understand coatings composition and the significance of raw materials used in coatings technology. Additionally, students will gain
sufficient knowledge and understanding to: design, develop and process coating materials; analyze data; and provide solutions to technical problems. Completion of the program will give students adequate subject knowledge to pursue an advanced degree in coatings or related areas.
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OBITUARY Industry Loses Allen Buhovecky CLEVELAND – Allen Buhovecky, of Brunswick Hills, OH, passed away May 22. He was 66 years old. Buhovecky was employed as a research and development chemist at Cansto Paint/Varnish Co. in Cleveland. Earlier in his career, he spent time with Plastikote in Medina, OH, and was a member of the Cleveland Coatings Society. Buhovecky is survived by his wife, Judy, five children, and two grandchildren.
SSCT Announces Scholarship Recipients
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NORCROSS, GA – The Southern Society of Coatings Technology (SSCT) recently announced the recipients of the 2010 Thad T. Broome Scholarships. Recipients include: Casey Aultman, daughter of Phillip Aultman, Aultman Technical Sales, LLC; Nigum Dave, son of Dilip Dave, Benjamin Moore Co.; Christiana Mattice, daughter of Chuck Mattice, Permite Corp.; and Lauren Waldman, daughter of Randy Waldman, Lintech International.
Dates for India Coatings Show Announced NEW DELHI, India – The India International Coatings Show 2011 is set to take place Jan. 28-30, 2011, at Hotel Raj Hans, Surajkund, New Delhi, India. The Indian Paint Conference, organized by the Indian Paint Association (IPA), will take place alongside the exhibition. The conference will have a mix of marketing and technical sessions. For additional information, visit www. coatingsindia.com. To book space for the show, e-mail
[email protected].
Philadelphia Society Honors Two Members PHILADELPHIA – On May 2, 2010, the Philadelphia Society for Coatings Technology held its annual Awards Night at the Sedgley Club on Boat House Row in Philadelphia. Loyd Burcham of Stonhard Corp. was recognized with the Liberty Bell Award. Joseph McNiff of Monsey Products was recognized with a 25-Year Pin Award. Timothy Miller, President, presented the awards. 䡲
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C ALENDAR Meetings, Shows and Educational Programs 28-29 Professional Paint Formulation www.pra-world.com/nandl/training/courses
11-13 Polyurethanes 2010 Technical Conference www.americanchemistry.com/polyurethane
29 Fundamentals of Weathering Level I www.atlas-mts.com
12-13 Wood Coatings Congress www.pra-world.com/woodcoatings7
30 Fundamentals of Weathering Level II www.atlas-mts.com
12-14 COROSAVE www.corosave.com
OCT.
3-5 ASC Fall Convention www.ascouncil.org
13-14 North African Coatings Congress www.coatings-group.com
4-6 Radiation Curing Technology www.pra-world.com/nandl/training/courses
NOV. 9-11
27-29 CHINACOAT 2010 www.chinacoat.net
5-6 Coatings Trends and Technologies www.bnpevents.com/PCI/CTT
10-12 Spray Finishing Technology Workshop www.owens.edu
28 Ci4000/Ci5000 Weather-Ometer Workshop www.atlas-mts.com
11-13 UTECH North America www.utechnorthamerica.nl
15-18 Paint Technology www.pra-world.com
JULY 19-21 Coatings for People in the General Industry, Sales & Marketing http://coatings.mst.edu 19-23 Polymers and Coatings Introductory Short Course www.polymerscoatings.calpoly.edu
SEPT. 8-10 Spray Finishing Technology Workshop www.owens.edu 26-29 2010 SSCT Annual Meeting http://ssct.org
Fatipec Congress www.vilf.de/fatipec2010
AMAZING FINISHES DON’T JUST HAPPEN We’ve had years of practice to perfect ours. Few specialty chemical manufacturers can offer the same level of performance or experience in the coatings industry. That has given us plenty of practice at perfecting an extensive line of additives – from pigment dispersions and colorants to defoamers – to achieve that perfect finish. So don’t settle for anything less than a proven performer.
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JULY 2010 | W W W . P C I M A G . C O M
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C O M PA NY NEWS
NEI and Chisso Collaborate on Self-Healing Coatings SOMERSET, NJ – NEI Corp., Somerset, NJ, and Chisso Corp. of Japan have signed an agreement to develop a new class of self-healing coatings for flat-panel display and related markets. Under the terms of the agreement, Chisso Corp. will fund the effort. NEI Corp. will build upon its core competency in nanoscale materials and self-healing technology to develop self-healing coatings for the
intended applications. The initial term of the agreement is 12 months.
Exchange of data and samples over the course of several months between NEI and Chisso has culminated in this joint development agreement. NEI Corp. will synthesize and formulate the self-healing coatings at its laboratories in New Jersey. Engineers and chemists at Chisso Corp. will evaluate the samples developed by NEI and tailor the program to meet their customers’ requirements.
Buhler Group and Sigma-Aldrich Sign Agreement
Evonik to End Production of Polyethylene Waxes
UZWIL, Switzerland – The Buhler Group is making selected dispersions of inorganic nanoparticles accessible to materials science researchers through an exclusive distribution agreement with Sigma-Aldrich®. Buhler and Sigma-Aldrich have signed an agreement in which research volumes of nanoparticle dispersions from Buhler will be sold worldwide exclusively by Sigma-Aldrich. The agreement covers dispersions of nanoscale titanium dioxide, zinc oxide and hydrated iron oxide.
ESSEN, Germany – Evonik Industries intends to shut down its production of polyethylene waxes in Herne, Germany, at the end of December 2010. The modification and sale of Fischer-Tropsch-based waxes will continue. Evonik will use best efforts to achieve a controlled withdrawal of the polyethylene waxes from the business.
TRONOX Becomes crenox KREFELD, Germany – Tronox Pigments GmbH, Uerdingen, Germany, has changed its name. The international producer of white pigments and specialty products now operates under the new name of crenox GmbH. The name crenox was chosen as it connects the location (Krefeld-Uerdingen) with the product name (titanium dioxide) and simultaneously emphasizes continuity.
Arch Chemicals Opens Biocides Facility in Japan OSAKA, Japan – Arch Chemicals Inc. has opened its new Asia-Pacific Marine Laboratory in Osaka, Japan. The facility has been established to maximize technical expertise in the ongoing development of antifouling paint technology and will include work with self-polishing polymers and net coatings for aquaculture applications.
Hockmeyer Equipment Granted Fifth Patent ELIZABETH CITY, NC – Hockmeyer Equipment has received notice that its fifth patent covering immersion mill enhancement has been granted by the U.S. government. The patent covers the
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JULY 2010 | W W W . P C I M A G . C O M
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C O M PA NY NEWS deterrence of wear at a bearing construct in a basket media mill. The device involves the introduction of slots in the rotating peg hub within the basket. As the hub rotates, centrifugal force pulls the media and feedstock away from the polymer-bearing construct within the peg hub. This results in extended bearing life regardless of the media type or size and elimination of micro media escaping thru the clearance between the rotating drive shaft and the bearing construct.
Nubiola Expands Distribution with K&M BARCELONA, Spain – Nubiola has expanded its distribution agreement with Keyser and Mackay (K&M), a performance chemicals and equipment distributor based in Amsterdam. K&M Germany has been Nubiola’s exclusive distributor for the NUBIROX corrosion inhibitors range in Germany and Switzerland. The distribution agreement for the Swiss market now extends to the entire product range.
Dow to Build Emulsion Plant in China PHILADELPHIA – Dow Coating Materials has announced a new $17 million emulsion plant located at the company’s Zhangjiagang site in the eastern Chinese province of Jiangsu. Construction of the new plant is expected to begin in the fourth quarter of 2010, with an expected start-up date sometime in late 2011.
Cognis Opens New APG® Facility in China MONHEIM, Germany – Cognis has officially opened a new production facility for alkyl polyglucoside (APG) surfactants at its site in Jinshan, China. Along with its other two production sites for APG surfactants, the Jinshan facility will enable Cognis to better serve the increasing demand for green solutions in the Asia-Pacific region.
Sherwin-Williams to Acquire Wood Coatings Business
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CLEVELAND – The Sherwin-Williams Co. has signed a definitive agreement to acquire Becker Acroma Industrial Wood Coatings, a subsidiary of AB Wilh. Becker. Headquartered in Stockholm, Sweden, Becker Acroma is one of the largest manufacturers of industrial wood coatings globally and a technology leader in water, UV and other wood coatings.
Double Bond Chemical Names Brenntag Distributor SOUTH PLAINFIELD, NJ – Double Bond USA has selected Brenntag Specialties to be the exclusive U.S. distributor for Double Bond’s UV-cure raw materials. Brenntag’s Director of New Market Development, Mike Leahy, will lead the Double Bond USA project.
OMNOVA Solutions Acquires HPP Product Line FAIRLAWN, OH – OMNOVA Solutions Inc. has acquired The Dow Chemical Co.’s hollow-sphere plastic pigment (HPP) product line. Concurrent with the HPP closing, the companies will also terminate the RohmNova joint venture, a sales, marketing and technical service alliance that has served the coated paper and paperboard market since 2002. Following the termination of the joint venture, OMNOVA will market, sell and service its products directly to customers.
NETZSCH Acquires Premier Mill EXTON, PA – NETZSCH Fine Particle Technology LLC has acquired the Premier Mill business of SPX Corp. The combined products and services of NETZSCH and Premier Mill are now available under the new company name, NETZSCH Premier Technologies LLC. The combined product line enables NETZSCH Premier Technologies to offer a broader range of solutions to both current and new customers.
Eastman Acquires Genovique Specialties KINGSPORT, TN – Eastman Chemical Co. has completed the acquisition of Genovique Specialties Corp., a leading global producer of specialty plasticizers, benzoic acid and sodium benzoate. This acquisition includes Genovique’s manufacturing operations in Kohtla-Järve, Estonia, Chestertown, MD, and a joint venture in Wuhan, China.
AkzoNobel Acquires Powder Coatings Business A M S T E R DA M , T h e N e t h e r l a n d s – AkzoNobel has completed its acquisition of the Dow Chemical Co.’s powder coatings activities. The deal complements the paint producer’s position in key strategic markets especially the U.S., automotive and trade coaters markets. It also introduces MDF and thermoplastic capabilities to the company’s existing expertise. The powder coatings business operates factories in the United States, Europe and China. 䡲
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N AMES IN THE NEWS 䡲 Dario Aganovic has been appointed Global Quality Director at CPS Color and a member of CPS Color Group Oy’s Management Team.
䡲 Brookfield Engineering Laboratories has appointed Joe Murray to the position of Regional Sales Manager for Process Instrumentation. He will focus on application development of products for specific markets based on customer inquiries.
䡲 Color-Logic
has named John Charnock to the Color-Logic Advisory Board. Charnock is widely known for his color expertise and knowledge of various printing technologies.
䡲 Mark Giesen, President and CEO, Conti- Hansinger nental Packaging Solutions, has been named President of the National Association of Container Distributors.
䡲 Thermcraft Inc. has appointed David Hansinger to the position of Marketing Manager. Hansinger will be responsible for advertising, marketing and product development worldwide. He will also coordinate and train industrial sales representatives and distributors for the Expressline series of laboratory furnaces. 䡲 David Helsby is the new President of RadTech Europe. Helsby, Technical Director at Rahn AG, will serve a two-year term. 䡲 Jay Hirschberg
has joined Adhesive Applications as the National Sales Manager of Fenestration. Hirschberg will continue development of the fenestration and solar markets.
䡲 Mario Preissler has been appointed by Swissbased DKSH as Global Business Unit Manager, Performance Materials. He will ensure the busiMurray ness unit’s position as the preferred partner for market expansion services for specialty chemicals and ingredients. 䡲 NETZSCH Premier Technologies LLC has added two new senior staffers as part of the company’s acquisition of Premier Mill. Stewart Rissley has been named Midwest Regional Sales Manager. He will handle former Premier Mill key accounts for the central United States and Canada. John R. Sneeringer is the new Technical Advisor for dispersion and grinding in the company’s Sales and Testing Laboratory. 䡲 James Tovey
has joined New Brook International Inc. as Southeastern Regional Sales Manager. Tovey will be responsible for growing New Brook’s full line of pigments, fillers and anti-corrosive products in the territory. 䡲
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A Challenging Year for the Coatings Industry By Karen Parker, Associate Editor, PCI Magazine
This issue of PCI features the 18th annual listing of the top coatings manufacturers in the world. Following is a ranking of the Top 10 global leaders and a listing of the Top 25 North American companies. Coatings sales listed for each company include worldwide 2009 global coatings sales figures. For a more complete listing, visit our online edition at www.pcimag.com. This has been a challenging year for the coatings industry due to the global economic crisis. The industry has been impacted by the worldwide decline in manufacturing, the housing crisis in the United States and the challenges facing the automotive industry. These factors resulted in virtually across-the-board declines in sales. Of the Top 10 global leaders, every company posted lower sales for 2009 compared to 2008. Additionally, the majority of the PCI 25 posted lower or flat sales for 2009. While the numbers are down for 2009, there
is optimism for 2010, and the industry seems to be moving forward in a positive direction, with many companies posting more positive numbers for the first quarter of 2010. This year, some of the North American companies did not want to supply sales figures for 2009, which made ranking them impossible. Rather than omit them, it was decided to list the top 25 North American companies alphabetically instead of ranking companies according to sales numbers. For the most part, the list remains the same as our listing in 2009. The exception is BASF’s U.S. division, which requested to be removed from the PCI 25 and only be included as a global entity in our Top 10 global ranking. While the PCI staff made every effort to seek out the top companies in the industry, we may have inadvertently omitted some. Please contact Karen Parker at
[email protected] if you have interest in being included next year.
GLOBAL 1. Akzo Nobel nv Amsterdam, The Netherlands Chairman of the Board of Management: Hans Wijers Coatings Sales: $12.5 billion (€8.7 billion) AkzoNobel is one of the world’s leading industrial companies. The company makes and supplies a wide range of paints, coatings and specialty chemicals. 2009 revenue totaled $19.9 billion (€13.9 billion). The company is the largest paint and coatings producer in the world. The company has 57,000 employees based in more than 80 countries. AkzoNobel coatings brands include global and household names such as International®, Sikkens®, Glidden®, Dulux ®, Crown®, Interpon®, Levis®, Coral® and Sadolin®. Parent Company: AkzoNobel, Amsterdam, The Netherlands. Source: AkzoNobel Report 2009, press releases, company contact Recent Acquisitions and Divestments: In Decorative Paints, AkzoNobel acquired two distributors in Continental Europe. In Performance Coatings, the company divested Chemcraft Brazil and the nonstick businesses. The company also completed the acquisitions of SABA and Kronospan. In June of 2010, the company completed its acquisition of the Dow Powder Coatings assets. Notes: In January 2009, AkzoNobel’s Car Refinishes business was named the official supplier of paint solutions to the Vodafone McLaren Mercedes Formula One team. In December 2009, AkzoNobel announced, 22
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TOP 10
in partnership with The Home Depot in North America, the development of a new range of high-quality paints for the Martha Stewart Living Brand.
2. PPG Industries Inc. Pittsburgh Chairman/CEO: Charles E. Bunch Coatings Sales: Approx. $9.2 billion PPG’s global coatings businesses comprise coatings for auto OEM, auto refinish, industrial, architectural, aerospace, packaging, and protective and marine applications. PPG serves customers in industrial, transportation, consumer products, and construction markets and aftermarkets. It is the technology leader in coatings for the wood-flooring industry and a leader in the supply of paints for consumer electronics. PPG is the largest producer worldwide of transportation OEM and refinish coatings. Notably, the Asia-Pacific region posted record earnings for PPG in 2009 and now represents about 18 percent of PPG’s coatings portfolio. Coatings represented about 75 percent of 2009 corporate sales of $12.2 billion. Source: 2009 Annual Report, company Web site, company contact Recent Acquisitions and Divestments: While there were no notable acquisitions or divestitures by PPG in 2009, the company weathered challenging economic conditions by undertaking several restructuring initiatives and emphasizing operating discipline and cost control. Initiatives included closing several manufacturing and distribution facilities, and eliminating approximately 3,800 positions.
3. Sherwin-Williams Co. Cleveland Chairman/CEO: Christopher M. Connor Coatings Sales: Approx. $5.31 billion The Sherwin-Williams Co. is engaged in the manufacture, distribution and sale of coatings and related products to professional, industrial, commercial and retail customers primarily in North and South America. The company has three operating segments: Paint Stores Group, Consumer Group and Global Group. Consolidated net sales in 2009 was $7.094 billion. It is estimated that between 70 to 75 percent of sales, or about $5.31 billion, represents coatings sales, with the remainder being related products, including wallcoverings, floor coverings and application supplies. In 2009, the company opened 53 stores in new markets and consolidated an additional 45 redundant store locations, for a net increase of eight new stores for the year. The company’s store count in the United States, Canada and the Caribbean now stands at 3,354. The company manufactures and sells coatings such as Dutch Boy®, Pratt & Lambert®, Martin-Senour®, Dupli-Color®, Krylon®, Thompson’s® and Minwax®, plus private-label brands to independent dealers, mass merchandisers and home-improvement centers. Sherwin-Williams produces coatings for original equipment manufacturers in a number of industries and special-purpose coatings for the automotive-aftermarket, industrial-maintenance and traffic-paint markets. Source: 2009 Annual Report, company Web site, press releases Notes: In March of 2010, the company
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GLOBAL closed an agreement to acquire the Industrial Wood Coatings business of Arch Chemicals Inc. In May of 2010, the company signed an agreement to acquire Becker Acroma Industrial Wood Coatings, a subsidiary of AB Wilh.
TOP 10
4. DuPont Performance Coatings Wilmington, DE Chairman/CEO: Ellen J. Kullman President: Terry Caloghiris Coatings Sales: $3.5 billion
DuPont Performance Coatings includes its core markets of automotive, collision repair and industrial coatings. The company offers high-performance liquid and powder coatings as well as high-performance specialty products. In 2009, global sales were 13 percent of 2009 corporate sales of $26.1 billion. Sales of $3.4 billion were down 21 percent when compared to the prior year. The price reflects a 20-percent decline in volume, due in large part to the global economic recession in the automotive industry. Parent Company: DuPont Source: Dupont 2009 Annual Report, company Web site, company contact Notes: Dupont Performance Coatings closed an OEM Coatings manufacturing facility in Lemans, France, an OEM Powder Coatings plant in Landshut, Germany, and a coatings lab in the United States. In addition, a plant was opened in Savli, India, serving the refinish markets, and industrial automotive plastic coatings.
5. BASF Coatings Münster, Germany CEO/President: Raimar Jahn Coatings Sales: $3.2 billion (€2.2 billion) BASF Coatings, the Coatings division of the BASF Group, develops, produces and markets a high-quality range of innovative automotive OEM coatings, automotive refinishes and industrial coatings as well as decorative paints. BASF has significant market positions in the coatings sector in Europe, North America, South America and the Asia-Pacific region. BASF Coatings is among the top-three global leaders of automotive OEM coatings. Parent Company: BASF SE Source: Company contact Notes: In 2009, BASF Coatings expanded its water-based coatings in Würzburg, Germany. Also in 2009, BASF Coatings opened the Refinish Competence Center (training center for spray painters) at its Münster, Germany, site. Additionally, BASF has expanded its coatings business in ASEAN, with Thailand at the center, to serve the large coatings market in the region for motorcycles, industrial coatings and the automotive industry.
6. The Valspar Corp.
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Minneapolis Chairman of the Board/CEO: William L. Mansfield Coatings Sales: $2.655 billion Valspar experienced a total sales decline of 17 percent in 2009. The company operates its coatings-related businesses in two reportable segments: Paints and Coatings. Sales in the Paints segment decreased 4.9 percent (2009 revenue of $1,072.4 mil3/27/09 4:12:19 PM
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lion) and 22.9 percent in the Coatings segment (2009 revenue of $1,582.8 million), for total coatings sales of $2,655 million. Despite the volume declines, the company reduced its cost structure, allowing it to remain profitable in all product lines. International sales accounted for approximately 38 percent of consolidated net sales. Source: 2009 Annual Report, company Web site
7. Kansai Paint Co., Ltd. Osaka, Japan President: Shoju Kobayashi Coatings Sales: $2.319 billion for fiscal year ended March 31, 2009 Kansai Paint Co. Ltd. is a manufacturer of paint and coatings used in Japan, Europe and the Americas, as well as China, India and other Asian countries. Core business areas include Automotive Coatings, Industrial Coatings, Decorative Coatings, and Marine and Protective Coatings. Source: Company Annual Report
Make Any Paint “Green” As environmentally friendly paints evolve from marketing concept to industry mandate chemists find the Brilliant Additions portfolio a valuable formulating resource. These functional mineral fillers excel when combined with next-generation resins to optimize the hardness, flexibility, and durability of ultra-low VOC coatings.
8. RPM International Inc. Medina, OH Chairman/CEO/President: Frank C. Sullivan Coatings Sales: $2.22 billion for fiscal year ended May 31, 2009 RPM is a holding company with subsidiaries that are leaders in specialty coatings, sealants, building materials and related services serving both industrial and consumer markets. Industrial products include corrosion-control coatings, flooring coatings and specialty chemicals. Major industrial brands are Stonhard, Tremco, illbruck, Carboline, Day-Glo and Dryvit. RPM’s consumer products are used by professionals and do-it-yourselfers for home maintenance and improvement, boat repair and maintenance, and by hobbyists. Consumer brands include Zinsser, Rust-Oleum, DAP, Varathane and Testors. Subsidiaries: A/D Fire, Agpro, Alteco Technik, Carboline, Chemical Coatings, Chemical Specialties, Compact Technology, DAP, Dane Color, Day-Glo, Dryvit, Ecoloc, Euclid Admixture, Euclid Chemical, Eucomex, Fibergrate, Flowcrete, Guardian Protection, Increte Systems, Kop-Coat, Mantrose-Haeuser, Martin Mathys, Modern Masters, New Parks, Nullifire, Paramount Technical, Productos Cave, Radiant Color, Republic Powdered Metals, RPM/Belgium, RPM Wood Finishes, Rust-Oleum, Star Maling, Stonhard, TCI, Testors, Tor Coatings, Toxement, Tremco, Universal Sealants, Vandex, Watco, Weatherproofing Technologies, Westfield Coatings, Wolman and Zinsser. Parent Company: RPM International Inc. Source: Company contact, 2009 Annual Report, press releases Recent Acquisitions and Divestments: Recent transactions include Stonhard’s acquisition of $5 million Australia business Ascoat Pty Ltd in September 2009; Carboline taking a majority interest in its $8 million Indian joint venture, CDC Carboline India Pvt. Ltd., in October 2009; Rust-Oleum’s acquisition of $3.5 million UK-based FibreGrid Limited in December 2009; RPM’s acquisition of $55 million UK-headquartered Universal Sealants Limited in January 2010; and Rust-Oleum’s acquisition of $6 million Netherlands-based Chemtec Chemicals in March 2010.
9. Nippon Paint Co. Osaka, Japan President: Kenji Sakai Coatings Sales: $2.1 billion Nippon Paint produces paint and coatings for the automotive market, the marine coatings market, as well as industrial products. It also makes paints for residential and commercial buildings and for the do-it-yourself market. Nippon Paint’s manufacturing operations are located principally in Asia, but the company also has facil-
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GLOBAL ities in North America and Europe. In the United States, it has two subsidiaries that manufacture and sell paints: NB Coatings (liquid automotive coatings for plastic) and NPA Coatings (automotive body coatings and powder coatings). Source: Company contact
10. Jotun Sandefjord, Norway
Ace Hardware Corp. Oakbrook, IL CEO/President: Ray A. Griffith Chairman of the Board: Dave Ziegler Coatings Sales: $128 million Ace Hardware is the largest retailer-owned hardware cooperative in the industry. Ace manufactures a full assortment of paints, stains, primers and light-industrial products with its primary business centered on the Ace ROYAL™ brand. The Royal brand has recently expanded to include Royal Finest™, the only paint on the market with Scotchgard™ protection. All Ace paintbranded products are produced in one of two facilities owned and operated by the Ace Paint division. Both facilities are located in the south suburbs of Chicago. In 2009, the company was recognized for its pollutionprevention initiatives by receiving the Illinois Governor’s Sustainability Award. Aside from manufacturing its own line of products, Ace Paint also manufactures privatelabel brands for third-party accounts. Source: Company contact
TOP 10
President/CEO: Morten Fon Coatings Sales: $1.79 billion The Jotun Group is a leading manufacturer of paints, coatings and powder coatings. It consists of four divisions: Jotun Dekorativ, responsible for Jotun’s decorative paints, stains and varnish deliveries in Scandinavia; Jotun Paints, responsible for decorative paints in markets outside Scandinavia; Jotun Coatings, a global seg-
ment responsible for marine protective coatings and decorative paints in local European and selected Asian markets; and Jotun Powder Coatings, responsible for powder coatings. Source: 2009 Annual Report, company Web site Notes: In November 2009, Jotun inaugurated a new paint factory in Yanbu, Saudi Arabia.
under the brand names Sayerlack® and LineaBlu®. Sales decreased $80.3 million, or 18 percent, in 2009. Source: 2009 10-K Form, company Web site Notes: In March 2010, The Sherwin-Williams Co. acquired the Industrial Wood Coatings business of Arch Chemicals.
CEO: C.A. (Al) Mordy Rodda Paint Co. Portland, OR COO: Bill Boone Coatings Sales: $212 million (combined) Cloverdale Paint Inc. and its subsidiaries, Rodda Paint Co., Fargo Paint & Chemicals Inc., and Guertin Coatings, Sealants & Polymers Ltd., operate through 107 corporate-owned locations covering western Canada as well as Washington, Oregon, Idaho and Alaska. The companies manufacture architectural paint and industrial coatings along with certain powder coatings, specialty resins and sealant products. Combined markets include sales to a wide variety of professional, commercial, industrial, marine, private-label and DIY customers, as well as a network supporting Cloverdale Paint and Rodda Paint independent dealers throughout the Pacific Northwest region. Source: Company contact, company Web site
Behr Process Corp. Santa Ana, CA CEO/President: Jeff Filley Coatings Sales: Approx. $1.714 billion Masco’s Decorative Architectural Products segment includes Behr Process Corp. and Masterchem Industries, LLC. A leader in the DIY market with The Home Depot, Behr also provides Behr Premium Select paint for professional application through Masco Contractor Services. Masterchem Industries sells under the brand names of Kilz®, Casual Colors®, Expressions®, Hammerite® and others. Parent Company: Masco Corp. Source: Masco Corp. SEC filing
Comex Group Arch Chemicals Inc.
Benjamin Moore & Co.
Norwalk, CT President/CEO/Chairman of the Board: Michael E. Campbell Coatings Sales: Approx. $379 million The Wood Protection and Industrial Coatings business unit of Arch Chemicals produces wood-treatment products. Brand names include Wolman®, Dricon®, Tanalith®, Vacsol™ and Resistol™. Principal customers are sawmills and treaters of softwoods. The company also manufactures a range of industrial wood coatings for markets primarily located in Europe. Products include stains, polyester-based and polyurethane-based coatings, and water-based coatings and UV systems sold primarily
Montvale, NJ President/CEO: Denis Abrams Coatings Sales: Not available Benjamin Moore & Co. is primarily a North American paint company. Its products are sold nationally through independent paint stores. It specializes in architectural coatings with some industrial-maintenance coatings. The company has a small amount of sales overseas. Parent Company: Berkshire Hathaway Inc. Source: Company Web site
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Mexico City CEO: Marcos Achar Coatings Sales: $1.33 billion Comex Group was formed with the consolidation of Professional Paint Inc. and Comex. Professional Paint Inc. now operates as the U.S. and Canadian division, and Comex Paint as the Mexico division. Comex Paint is the leading architectural paint brand in Mexico. In addition to architectural paints, Comex manufactures industrial coatings, automotive paints, roof coatings, wood-care products and aerosols. Subsidiaries: Comex, Color Wheel, Frazee, General Paint, Kwal, Parker and Duckback Source: Company contact
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Dow Powder Coatings
DuPont Performance Coatings
Reading, PA Coatings Sales: Not available Dow Powder Coatings offers a portfolio of powder coatings that are utilized within the consumer, automotive, architectural, industrial and general metal-finishing industries. The company has powder coatings operations in Europe, South America and Asia. The business was formerly the powder coatings business unit of Rohm and Haas, which was purchased by The Dow Chemical Co. in April of 2009. In November 2009, Dow announced plans to sell the business to AkzoNobel. The sale to AkzoNobel was finalized on June 1, 2010. The company will become part of AkzoNobel’s powder coatings activities. Source: Press release, company Web site
Wilmington, DE Coatings Sales: $3.5 billion
Dunn-Edwards Corp. Los Angeles CEO: Kenneth N. Edwards Coatings Sales: Not available Dunn-Edwards is a manufacturer and supplier of architectural and industrial coatings, providing a complete line of paints and professional painting supplies. The company caters to architects, designers, painting contractors, homebuilders and property managers in the Southwest. It also serves do-it-yourselfers, although professionals account for a majority of sales. Source: Company Web site, press releases
ELANTAS PDG Inc. St. Louis, MO CEO/President: Susan W. Graham Coatings Sales: $100 million ELANTAS PDG Inc. is a premier supplier of specialty polymers for the electrical and electronic industries. The key products of ELANTAS PDG include magnet wire enamel, insulating varnishes and encapsulating resins. It also produces tubing and sleeving varnishes, pultrusion resins, laminating resins, adhesives, and conformal coatings. Parent Company: ALTANA AG, of Germany Source: Company Web site, press releases, financial report, company contact
Ennis Paint Inc. Ennis, TX Chairman: W. Bryce Anderson Coatings Sales: $372 million Ennis Paint Inc. continues a long history of pavement markings that dates back to the 1960s. Ennis Paint is a world leader in both traffic paint and thermoplastics. Source: Company contact
Kelly-Moore Paint Co., Inc.
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San Carlos, CA President/CEO: Steve DeVoe Coatings Sales: $240 million Kelly-Moore is one of the largest employee-owned paint companies in the United States. A leader and innovator of waterborne coatings technology, Kelly-Moore was the first company to offer recycled paints. Kelly-Moore operates 163 company-owned stores in eight states: Arkansas, California, Idaho, Nevada, Oklahoma, Oregon, Texas and Washington. Source: Company contact Notes: In 2009, Kelly-Moore Paints partnered with independent paint dealers, making its entire paint product line available to over 100 stores nationwide.
Nippon Paint U.S. Subsidiaries Manufacturer of organo modified & reactive silicones. SILTECH CORPORATION 225 Wicksteed Avenue, Toronto, Ontario, Canada, M4H 1G5 Tel: (416) 424-4567 Fax: (416) 424-3158 www.siltechcorp.com
Coatings Sales: $190 million (combined) NB Coatings Inc. Lansing, IL COO/President: Tim Ruberry A subsidiary of Nippon Paint Co., NB Coatings is the leading supplier of liquid coatings for plastic automotive parts in North America. It provides a complete line of custom coatings for fascia, exterior trim, interior trim and lens applications. In addition to automotive paint, NB Coatings also offers resins and liquid dispersions to a variety of end markets. NPA Coatings Inc. Cleveland President: Masaru Sumida NPA Coatings manufactures and sells powder coatings, automotive body coatings, pretreatment chemicals and transit film to customers in the general industrial and automotive markets. Source: Company contact
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Ask the Expert Mike Peck Senior Research Chemist
Q
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A
Selecting the right dispersant-pigment combination can be very challenging, as pigments vary widely from source to source and region to region, even within the same color index number. To help our customers save time and testing, we’ve developed an online product selection tool, F.A.Z.T., that instantly recommends a dispersant and calculates a starting point formulation based on a choice of a specific pigment grade from over 1800 products. Developed from empirical testing, pigment properties, and theoretical understanding, the F.A.Z.T. helps a formulator select a pigment dispersant and accelerate product development. To learn more and see how the F.A.Z.T. tool can help you, visit www.airproducts.com/fazt.
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Quest Specialty Chemicals, Inc. Detroit CEO: Fred Quinn COO: Gerry Loftus Coatings Sales: $104 million Quest Specialty Chemicals is funded through private equity by Huron Capital Partners of Detroit and TBG Capital of Dover, MA. The company acquires and builds specialty chemical companies in the coatings arena. It is organized into two principal divisions focusing on transportation, industrial and construction coatings. Subsidiaries Matrix System Automotive Finishes LLC and Raabe Co. LLC form the Specialty Coatings division, while United Coatings Manufacturing Co. and HydroStop LLC form the Quest Construction Products division. Quest Construction Products offers a full line of premium-quality protective coatings for a wide range of architectural, industrial and roofing applications. Matrix System Automotive Finishes LLC is the largest independent manufacturer and distributor of automotive refinish paint products in the country, marketing paints, primers, clearcoats, hardeners and solvents, while Raabe Co. LLC manufactures custom-matched branded touchup paint and provides private-label aerosol and liquid-paint filling services. Source: Company contact, company Web site
RPM International Inc. Medina, OH Coatings Sales: $2.22 billion for fiscal year ended May 31, 2009
Sherwin-Williams Co. Cleveland Coatings Sales: Approx. $5.31 billion
Spraylat Corp. Pelham, NY CEO: Michael Borner President: Raymond T. Chlodney Coatings Sales: $102 million Spraylat Corp. is a supplier to the productfinishing market, offering both decorative and functional coatings. Spraylat offers powder coatings for a wide variety of applications including architectural powder coatings that exceed AAMA specifications. It offers high-technology coatings, including electrically conductive coatings for EMI/RFI shielding and polymer thick film (PTF) inks for membrane switches and printed antennas. Spraylat’s Liquid business unit provides high-performance coatings for heavy equipment, automotive, sign coatings, specialty OEM applications, as well as solutions and coatings for the manufacture of mirrors. Spraylat’s global operations include locations in North America, Europe and Asia.
Subsidiaries: One Shot LLC, Spraylat GmbH (Germany), Spraylat Coatings Ltd. (Shanghai), Spraylat Boya Ltd. (Turkey). Source: Company contact
TIGER Drylac U.S.A., Inc. Reading, PA CEO: Larry McNeely Coatings Sales: $180 million TIGER is one of the largest powder manufacturers in the world with sales of over $180 million and more than 800 employees. It offers the largest selection of top-of-the-line powder coatings in every type of chemistry, serving the architectural, automotive, lighting and furniture industries. The U.S. operations were established in 1984 and in 2009 reported North American coating sales of $64 million. The North American production network includes three facilities in the United States, in California, Illinois and Pennsylvania. Source: Company contact
Tnemec Co., Inc. Kansas City, MO CEO/President: Peter Cortelyou Coatings Sales: $112 million Tnemec Co. manufactures more than 100 architectural and industrial coatings, from premium epoxies and polyurethanes to specialized fluoropolymer products, formulated specifically for extreme durability, enduring performance and enhanced aesthetics. Tnemec is a leading supplier of interior and exterior coatings for waterstorage tanks. Tnemec’s StrataShield brand consists of resinous floor and wall coatings. The company’s Chemprobe subsidiary offers water-repellent and stain products for concrete, masonry and wood. Subsidiary: Chemprobe Coating Systems Source: Company contact
True Value Co. Chicago President/CEO: Lyle G. Heidemann Coatings Sales: Not available True Value Co. manufactures exclusive paint brands for its retail identities as well as private-label brands for third-party accounts. Paint is manufactured under the EasyCare and Weatherall brands in Cary, IL, and distributed nationally to its core hardware stores. Source: 2009 Annual Report, press releases
The Valspar Corp. Minneapolis Coatings Sales: $2.655 billion
Vogel Paint, Inc. Orange City, IA
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President/CEO: Drew F. Vogel Coatings Sales: $125 million Vogel Paints was established in 1926 as a manufacturer of barn paints and creamery maintenance enamels. It entered the liquid industrial coatings market in the 1950s and began to build a fleet of company stores selling architectural paints and heavy-duty maintenance coatings in the 1970s. The company formed the Peridium powder coatings division in 1998 and built a new powder coatings production facility in 2003. Today, the company operates over 70 company stores and seven manufacturing plants and distribution centers in 13 states. Source: Company contact
Whitford Corp. Elverson, PA President: David P. Willis, Jr. Coatings Sales: In excess of $199 million Whitford Corp. was founded in 1969 as the outgrowth of a compounder of solid PTFE materials. Whitford has dedicated itself to nonstick coatings for both industrial and
consumer markets. Whitford’s first venture into the international market took place in 1971 with the opening of Whitford Plastics Ltd. in the north of England. Current products include Xylan®, Xylac®, Dykor®, Xylar ®, Ultralon®, Excalibur ®, Eterna®, Eclipse®, QuanTanium®, Quantum2® and Suave®. Whitford has global manufacturing facilities, including sites in Elverson, PA, Brazil, Italy, the United Kingdom, China and Singapore. Source: Company Web site, company contact Notes: In May 2009, Whitford purchased the Akzo Nobel Non Stick Coatings LLC division (ANNS).
Yenkin-Majestic Paint Corp. Columbus, Ohio President: Jonathan M. Petuchowski COO: Andrew O. Smith Coatings Sales: $105 million Yenkin-Majestic is a vertically integrated manufacturer of paint and coatings resins. Its full line of architectural paints includes interior and exterior products and a variety of specialties, including a complete farm
program, low-VOC oil-base floor paints and a unique acrylic enamel line (Diamond Hard). Its industrial division manufactures waterborne and solventborne products, including urethanes, epoxies and polyesters. Its OPC Polymers operations serve the United States, Canada and other markets, with expansion in 2010 by the acquisition of SI Group-Canada Ltd. Source: Company contact
Honorable Mentions: California Products Corp. Andover, MA CEO/President: Peter Longo Coatings Sales: $71 million California Paints manufactures coatings for architectural, consumers and contractors. California Products produces interior and exterior architectural paints. Source: Company contact, Web site Notes: In August 2009, California Products Corp. acquired the customer base and certain assets of Progress Paint Manufacturing Co.
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Deft Inc. Irvine, CA Coatings Sales: $42 million Deft produces a full line of professionalquality, easy-to-use interior wood stains and finishes, as well as commercial and military-specification primers and coatings. Source: Company contact
Farrell-Calhoun Inc. Memphis, TN President: John A. Ward Jr. VP Sales & Marketing: Anthony Ward Coatings Sales: $31 million Farrell-Calhoun manufactures architectural and industrial-maintenance coatings. Source: Company contact
ings, aerosol products and touchup materials for the architectural wood-finishing market. Parent Company: Gemini Industries Source: Company contact
patch and repair products. Subsidiaries: Elder and Jenks Inc., Synkoloid, and Graham Paint and Varnish Co. Source: Company contact
LORD Corp.
United Gilsonite Laboratories
Cary, NC CEO/President: Richard L. McNeel Coatings Sales: Not available LORD Corp. designs, formulates, manufactures and markets adhesives, polyurethane coatings, and devices and systems to manage mechanical motion and control noise. Source: Company contact
Dunmore, PA CEO/President: Thomas White Coatings Sales: $40 million United Gilsonite Laboratories (UGL) manufactures over 80 paint-specialty and home-maintenance products. Its main brands are Zar and Drylok. Source: Company contact
The Muralo Co. Inc. Bayonne, NJ President: James S. Norton CEO: Edward F Norton Jr. Coatings Sales: $22 million Muralo manufactures a broad line of architectural coatings sold through independent paint stores, supplying its customers nationally. Muralo also offers Spackle® spackling compound and brush,
Gemini Industries El Reno, OK CEO/President: David Warren Coatings Sales: $40 million Founded in 1964, Gemini Industries is an employee-owned company that manufactures and distributes an extensive line of coat-
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Moving Beyond With New Technology, Coatings Join the War on Germs
T
hee b bad ad news ad new ewss out out of of W Washington ashi as hing hing gton ton these to theesse th d h h state off the h days is more than the economy. We are also losing the battle against germs, specifically in terms of HAIs — hospital-acquired infections. In its March 2010 quality report to Congress, the U.S. Health and Human Services (HHS) Department found “very little progress” in eliminating HAIs and called for “urgent attention” to the problem. A recent study conducted by the Washington, D.C. think tank, Resources for the Future, indicates that 48,000 Americans die of infections caught while in the hospital each year, and that is probably a conservative figure. HAIs also hit the bottom line of hospitals. Medicare has reduced or eliminated reimbursements to hospitals for HAI treatments, and the mean cost of treating HAIs is estimated to exceed $13,973 per incidence. With an average hospital-acquired infection rate of 5% of admissions, reducing this rate to even 4% could translate into millions of dollars in savings per hospital. Conversely, a continued increase in this rate means millions of dollars of additional cost per hospital. When the known impact of infection-causing germs is extrapolated to other locations where both healthy and ill people gather – doctors’ offices, rehab and extended care facilities, fitness and recreational facilities, educational facilities, dorms, day cares, public transportation, hotels, prisons – the HHS call for urgent attention to the problem may prove to be an understatement. Clinical studies have shown that even with proper hygiene practices the potential for infection-causing bacterial outbreaks still exists. Fortunately, advances in antimicrobial technology are providing the health care sector and other areas concerned with transmission of infections with new opportunities to control the growth and spread of germs. Standard infection prevention practices, such as hand washing and disinfection will continue to be critical, but some hospitals are now expanding the role of antimicrobial agents from therapeutic to preventative. In short, they are providing built-in antimicrobial protection for the entire patient environment from the scrubs the care givers wear to every element in the patient room including the architectural paint, floor and furniture coatings, curtains, bathroom
ffixtures, fi i xt xtur ureess, patient pa attiien entt bed, bed be d, and d, and any any ny other oth o ther the er patient pat atient atie ient high-touch ie hig hig igh h-to touc uch uc h h success off this h preventative approach h depends d d points. The primarily on using an antimicrobial agent that is effective, safe, durable, cost efficient and adaptable to a variety of materials. Silver, revered for thousands of years as a natural healing metal and preservative, is an excellent fit for this set of requirements.
Silver: Trusted Protection Not Tarnished by Time Silver’s inherent antimicrobial properties have a long historical track record. As early as 1200 B.C., the ancient Phoenicians stored water in silver bottles to prevent spoilage from microbes. By 500 B.C., Greeks and Romans routinely used silver vessels for water purification. In the fourth century B.C., Hippocrates, the father of modern medicine, noted the healing benefits and anti-disease properties of silver. As they trekked westward, 19th century American pioneers used silver to keep their water safe and prevent common ailments such as dysentery, colds and flu. They also used silver dollars in their milk containers to slow bacterial growth. The 1800s also saw silver used directly for medicinal purposes: as silver sutures for surgical wounds, as a silver nitrate solution to prevent blindness in newborns, and to treat typhoid and anthrax. Before the onset of antibiotics, silver compounds were used to prevent infection during World War I. During the 1920s, over 3 million prescriptions were written annually for medicinal silver. Silver’s impressive history continues today. Because it is recognized as one of the most non-toxic and safest of nature’s metals, silver is routinely used in neonatal eye drops to prevent eye infection. It is the preferred antimicrobial in wound care because silver’s oligodynamic biocidal action enables it to reduce infections without promoting antibiotic resistance. Silver sulfadiazine is the most popular treatment for burns in U.S. burn centers. Outside the health care sector, silver is used in surfaces such as cutting boards and table tops to help protect against food contamination, in sport and military clothing to reduce bacteria-causing odors, in outdoor furniture and rugs to prevent material degradation, and in water purification filters used by international airlines and NASA.
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the Aesthetics Nanotechnology: Less is More Various antimicrobial technologies have been commercialized for some time. These older technologies, however, have inherent limitations in terms of meeting today’s high-performance demands of health care facilities and other locations where infection is a concern. The latest breakthrough in silver antimicrobial products – nanoscale silver additives – effectively resolves these issues. Nanotechnology combines engineering and science to make materials that are smaller than 100 nanometers. To put that size into perspective, the width of a human hair is about 100,000 nanometers while the average size of bacteria and viruses is generally 2,000 and 100 nanometers, respectively. When materials are engineered at nanoscale, they exhibit unique properties not present in their bulk form. The key to nanoscale silver’s antimicrobial advantage is found in how it works. Ionic silver is the active form of silver that is most effective at eliminating bacteria, mold and fungus. Moisture activates silver nanoparticles, which release silver ions that attack microbes. These silver ions inhibit bacteria by stopping bacterial energy metabolism and electrolyte transport, by slowing or stopping DNA replication or by binding to the bacterial cell wall causing it to collapse or burst. As such, silver ions are active against a broad range of gram-positive and gram-negative bacteria, have a low risk for bacteria resistance, and are effective in low concentrations. Reducing silver to nanoscale sizes provides several important benefits not found in silver’s bulk form. The first is related to antimicrobial performance. The key to optimizing the use of silver as an antimicrobial is to maximize the production of the silver ions that target and eliminate microbes. This is achieved by reducing the average size of the silver particle, which exponentially increases the collective surface area available for silver ion production (Figure 1). Hence, unlike bulk silverbased antimicrobial solutions that depend on adding increasingly more silver to be effective, nanoscale silver can achieve the same or better levels of efficacy using considerably less silver, thereby reducing cost and the potential for environmental impact. Nanoscale size brings other advantages to silver. Silver nanoparticles can be covalently bonded to molecules in the products in which they are integrated. In this way, the silver particles are less susceptible to being washed out or worn off over time. Under the proper application techniques, their antimicrobial capabilities are effective for the expected life of the host material. In addition, silver nanoparticles are so small that they don’t impact mechanical properties (Figure 2). And because silver nanoparticles are metallic, they retain a number of key
attributes of bulk silver, such as thermal stability during processing and UV-color stability. Finally, nanoparticle silver additives can be produced in integration-ready formulas, compatible with virtually any manufacturing process across a wide variety of host materials, including coatings, foams and engineered plastics as well as natural and synthetic fibers and fabrics. Specific to coatings, nanoparticle silver additives for liquid systems enable formulators to “just add and mix” at numerous steps during the manufacturing process. Powder additives are also available for integration with other performance
FIGURE 1 | Nanoscale silver particles have relative large surface areas that produce a significant number of microbe-fighting silver ions from a very small amount of silver. Surface Area to Volume 400,000 350,000 300,000 250,000 200,000 150,000 100,000 50,000 0 5
35
65
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FIGURE 2 | Silver nanoparticles (left) are 1000x smaller than typical foam cell walls (right) so they won’t negatively impact physical properties.
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Moving Beyond the Aesthetics
additives typically compounded into powder coatings, such as flame retardants and colorants.
Nanoscale Silver: Proven Performance with New Breakthroughs While recent advances in nanotechnology have improved its performance and flexibility, nanoscale silver itself has an established track record of use and a proven safety record with respect to both human health and the environment. The FDA has approved the use of silver nanoparticles in medical products such as wound care dressings and catheters to prevent bacterial colonization in the devices. Also, the International Oeko-Tex® Association, a respected independent testing institution, has tested and classified nanoscale silver additives as not harmful to human health. In non-public health applications, nanoscale silver colloids have been FIFRA registered and used safely to control algae over six decades. And carbon filters impregnated with nanoscale silver are commonly used to protect our drinking water supply. In fact, it is estimated that over 50 percent of EPA-registered silver products are based on nanoscale silver. These longstanding uses provide a clear understanding of the life-cycle and “downstream” speciation of nanoscale silver; silver in waste or natural environments is immediately converted to inert silver minerals such as silver sulfide, thus mitigating the risk of unintended environmental impacts. That said, manufacturers of antimicrobial products must ensure that the claims and use patterns of their products are in compliance with appropriate regulatory policies if the benefits of antimicrobial protection are to be fully realized.
TABLE 1 | Typical silver add rate by chemistry type. Chemistry
Typical Silver Add Rate (ppm)
Aliphatic epoxy Water-based fluoropolymer Silicone Solvent-based acrylic Unsaturated polyester/styrene gel coat Solvent-based alkyd Polyester powder coating Solvent-based polyester/melamine Aliphatic polyurea Water-based epoxy Plastisol Vinyl acrylic emulsion PUD 100% solids 2K urethane Solvent-based TPU Solvent-based polyester
2000-750
1000-500
500-250
TABLE 2 | Aging data on solvent-based polyester bake coating. Antimicrobial Additive
Accelerated Aging of Solvent-Based % Reduction Against Polyester Bake Coating Test Specimen
None
None 1 week salt spray and 100 double clean wipes 1 week salt spray and 100 double clean wipes
None Silver Nanoparticles
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99.9% No Reduction 99.9%
Breakthroughs in dispersion technology now enable nanoscale silver to be readily integrated into many common coating systems, resulting in durable antimicrobial performance in dry film. Laboratory tests have shown that levels as low as 250 ppm (0.025% w/w) of nanoparticle silver are effective in flexible and breathable systems. Harder, less breathable and more hydrophobic systems require higher loadings (Table 1). Various blooming agents can improve the surface activity of silver in systems. Due to the effectiveness of silver nanoparticles at very low concentrations, there is no impact on dry times, film formation, gloss, or abrasion resistance. In addition, since silver nanoparticles do not thermally or UV degrade, the applicator does not need to make any changes to post curing processes.
Antimicrobial Landscape in Coatings Given their broad facility-based applications, coatings with antimicrobial performance can play an increasingly important role in protecting high-touch surfaces against the spread of infection-causing bacteria. Antimicrobial products, such as silver zeolites, silver halides salts and organic biocides, have been incorporated into coatings for a number of years. However, current antimicrobial performance standards, particularly in the health care arena, are substantially higher than in the past in terms of durability, efficacy and safety. These traditional antimicrobials have been challenged in meeting these tougher standards. Zeolite-based antimicrobial technology has been available since the 1980s. Zeolites are ceramic cages, typically 2-200 µm in size and filled with 1-10% pre-ionized silver. Because silver zeolites quickly release their silver ion reservoir via ion exchange in the presence of sodium, this technology provides relatively short-term antimicrobial protection when cleaned regularly with traditional sodium-laden detergents. In addition, the larger particle size of silver zeolites can cause them to settle out of solution and negatively impact dry film properties such as UV stability and abrasion resistance. Silver halide salts are also used as an antimicrobial but tend to have limited efficacy due to their low solubility. As a consequence, silver halides tend to require high add rates to achieve significant performance. At these levels, the salts also have a significant negative impact on dry film properties, especially UV color stability. This is not unexpected as silver halides are the basis of traditional photographic chemistry. Organic biocide additives are used in the majority of water-based coatings for the protection of the emulsion itself. Organic biocides are effective against specific algae and fungus that can contaminate and degrade the emulsion during processing and in-can storage. However, these biocides are not always equally effective against a broader range of bacteria. They typically degrade or deactivate during application or are wiped away from the dry film once the coating is applied, providing only several months of antimicrobial protection. Some of the organic biocides have the potential to be harmful to humans and Congress is currently considering a consumer ban for one such organic biocide, triclosan.
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Moving Beyond the Aesthetics
TABLE 3 | Aging data on unsaturated polyester gel coating. Antimicrobial Additive
Accelerated Aging of Unsaturated % Reduction Against Polyester Gel Coating Test Specimen
None None Silver Nanoparticles
None 100 h at 65 º C in water 100 h at 65 º C in water
99.9% No reduction 99.9%
Organic biocides along with residual solvents, leveling/flow agents, plasticizers, and catalysts can yield a coating that has antimicrobial properties right out of the can. It is very important, therefore, that formulators develop and perform accelerated weather/aging on the dry films in order to determine the effectiveness of an antimicrobial additive. Tables 2 and 3 provide data on aged and unaged polyester coatings. The results demonstrate the importance of aging tests in identifying the durability of antimicrobial effects among competing antimicrobial solutions.
New Role, New Opportunities The growing financial and human impact of microbecausing infections in the hospital and beyond is creating new opportunities for the coatings market sector. Their presence in a variety of high-touch point products that
can harbor germs opens up a new role in providing preventative antimicrobial protection wherever the public gathers but most particularly in the health care arena. Performance gaps in older antimicrobial technologies, especially in terms of durability and flexibility, have, up to now, prevented coatings formulators from becoming a part of a comprehensive solution to prevent the spread of infection-causing germs. Nanoscale silver additives that use the latest advances in nanotechnology can bridge these gaps. Silver nanoparticles are integrated at the molecular level and designed for controlled ion release, thereby permitting long-term local silver concentrations above the antimicrobial threshold. They continue to work effectively against microbes – bacteria, mold and fungus – for the expected life of the product. In addition, nanoscale silver is stable, will not thermally or UV degrade, has no impact on other physical properties of the product, and can be easily integrated into the manufacturing process. Most importantly, they have been proven safe and eco-friendly. The combination of coatings with silver nanoparticle-based antimicrobial protection can present a strong line of defense in locations where infection control is of concern. 䡲 *Figures and tables courtesy of NanoHorizons Inc. For more information, visit www.SmartSilver.com or e-mail
[email protected].
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Antimicrobial C
T
he term ‘antimicrobials’ is generally defined as substances – or mixtures of substances – used to destroy or suppress the growth of harmful microorganisms whether they be bacteria, fungi, or virus, in or on a substrate or article where it is not desired. This article makes an attempt to simplify antimicrobials for readers in the industry and explain various ways an antimicrobial is referred, used, evaluated and/or promoted in several markets, particularly focusing on coatings and building products applications. Some of the government regulations on the claims and uses of antimicrobials in products are briefly reviewed, taking excerpts from published articles and cited websites.
Terminology Historically, the term ‘antibiotics’ is used in reference to controlling bacterial infections, specifically in humans. For substances that control or inhibit yeast and fungi, the term used is ‘anti-fungal’ whether on animate or inanimate substrates. Similarly, for inhibiting viruses, we refer to anti-viral substances. Besides these various terms for anti-microbial concepts, in many industries terms like bactericides, fungicides, algaecides, virucides, preservatives and biocides are commonly used. For example, in the coatings industry, the term ‘biocide’ is historically employed to indicate preserving a wet formulation from microbial spoilage which, in most other industries like personal care or household markets, would be defined as a ‘preservative’. In addition to these various terms to indicate chemicals that inhibit or destroy microorganisms, we are also exposed to layman’s terminology of ‘mildewcide’ or ‘moldicide’ to refer to chemicals controlling unsightly biological defacement on surfaces that are ‘black’. Even though it is implied primarily for fungal growth, it can also be caused by a consortium of other microorganisms including lower forms of algae, moss, amoeba, protozoa, etc. For non-microbiologists, these terms may be confusing with each term meaning different things depending on the implied uses and claims by different suppliers. Simply put, can all of these chemicals be referred to as antimicrobials irrespective of their applications, target organisms and mode of activity? The answer is yes, all of them are antimicrobials against one or another class of microorganisms under a given condition.
Regulatory Aspects With the defacement of buildings and paints following hurricane Katrina, there has been increased interest in either using or promoting products that are termed ‘antimicrobial’, particularly in the U.S. surface treatment coatings industry. In doing so, by extrapolating the functions, some public health claims are being attributed to products. Government regulations on treated articles, including coatings with antimicrobials, and guidelines on claims come under the Federal Insecticide Fungicide and Rodenticide Act (FIFRA), EPA and FDA. Under FIFRA, an antimicrobial product that claims to control microorganisms such as bacteria and fungi requires registration. According to the EPA, an article or a substance that is treated with, or containing, a registered pesticide is defined as a treated article and is limited to protecting the article itself from microbial spoilage or contamination (for example paints supplemented with fungicides or bactericides to protect the paint in storage or after application, or preservative treatments used in wood to protect wood against insects or fungal infestation). The sole purpose of the treatment is to protect the articles themselves.1 Concerned with the increasing claims of treated products in the market having implied or explicit public health claims from many manufacturers beyond the intended and permitted purpose of protecting the article itself, thus giving a false sense of security to the public against disease-causing harmful bacteria, the EPA in 2000 issued a Pesticide Regulation Notice 2000-1 to clarify the Agency’s policy with respect to the scope of the treated article exemption. It is a guidance document that focuses on the various types of antimicrobial claims that the EPA considers acceptable or unacceptable. It simply classifies antimicrobial-treated products into two categories, 1.) Public health claim products are intended to control microorganisms infectious to humans in any inanimate environment. The most commonly used public health antimicrobial products include the following: sterilizers (sporicides), disinfectants, sanitizers, antiseptics and germicides. 2.) Non-public health claim products are used to control growth of odor-causing bacteria, algae, mildew, bacteria that cause spoilage, deterioration or fouling of materials and microorganisms infectious only to animals. This general category includes products used in cooling towers, jet
By Lakshmi Sadasivan, Ph. D. | Siva Microbiological Solutions LLC, Bristol, PA 40
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l Coatings f l paints, fuels, i treatments for f textiles il and d paper products. d The EPA considers terms such as “antimicrobial,” “fungistatic,” “mildew-resistant” and “preservative” as being acceptable for exempted treated articles or substances, provided that they are properly, and very clearly, qualified as to their intended non-public health use. They also restrict use of these terms in product names or elsewhere in the labeling in bolder text than accompanying information. The EPA also considers trademarked product names of treated articles or substances (or reference to trademarked names of registered pesticides) as a potential public health claim and makes it ineligible to qualify under the “treated article exemption”.2
iinclude l d the h chemical h i stability in the formulation, pH compatibility, heat stability, color acceptance, shelf storage longevity, exterior weather sustainability, etc., in addition to testing for its bio-availability to function as an antimicrobial throughout the process.
Methods for Antimicrobial Testing in Coatings
With so many scenarios for defining an antimicrobial, the challenge becomes how to test and what test methods to use for demonstrating and claiming broadly the ‘antimicrobial’ property of a treated article such as a coating. ASTM D 5589: Standard Test Method for Determining the Resistance of Paint Films and Related Coatings to Algal Defacement. This test method is for Testing for Antimicrobial Products antimicrobial testing of dry coating films with respect Antimicrobials used in public or nonto algae including cyano bacteria/blue green public health claim products have to algae and green algae.3 ASTM D 5590: Standard Test go through a battery of testing Method for Determining the using acceptable microbiologiResistance of Paint Films cal methods to show efficacy and Related Coatings to in the product in use. There Fungal Attack. This is an are many test methods in agar-based method evalumicrobiology described ating coated surfaces for to demonstrate the antitheir resistance to commicrobial nature of a monly occurring indoor substance and when and exterior fungi such it is incorporated in an as Aspergillus niger, Peniarticle. There are various cillium sp. and Aureobascreening stages adopted sidium pullulans.4 that may include primary, ASTM D 3273: Stansecondary and in-use final dard Test Method for testing. A typical primaryResistance to Growth of screening protocol involves Mold on the Surface of Intetesting for the minimum Anti-fungal effect of three different coatings. rior Coatings in an Environinhibitory concentration (MIC) mental Chamber. An accelerof the chemical to be incorpoated antimicrobial test for determining rated in an article. Normally the MIC is the resistance of interior coatings to mold determined in an in-vitro system like growth growth; useful in estimating the performance of coatmedia against a set of bacteria, fungi, virus and/or algae ings designed for use in interior environments that prodepending on the target microorganism. After getting mote mold growth.5 selected in the primary screen, the substance enters the ASTM D 2574: Standard Test Method for Resissecondary screening process in an in-vivo system, meantance of Emulsion Paints in the Container to ing the application matrix in which it is expected to be Attack by Microorganisms. An antimicrobial test incorporated. Because not all selected antimicrobial method to demonstrate resistance of the wet products substances are expected to be universally acceptable to bacterial contamination (spoilage) during long term in varied systems, they next go through the rigor of storage prior to application. Typically, select environcompatibility, stability and efficacy testing evaluations. mental microorganisms are grown and challenged Some examples of this rigor in coatings applications PA I N T & C O A T I N G S I N D U S T R Y
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Antimicrobial Coatings
(introduced or inoculated) weekly into the product which is then tested for their total elimination or absence of their growth in 24, 72 and 96 hours.6 The Japanese Industrial Standard JIS Z 2801-2000: Antimicrobial Products – Test for Antimicrobial Activity and Efficacy. This method was originally
developed to test the antibacterial activity of silver ions impregnated in rigid hydrophobic polymers. This method was developed by a consortium of workers comprised of manufacturers of silver-based antimicrobial agents, government-based research organizations and universities, and under organizations such as the Soci-
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ety of Industrial Technology for Antimicrobial Articles (SIAA).7 This method is a quantitative measurement method that tests survival of low-dose bacterial inoculum deposited between the tested antimicrobial surface and a thin plastic film that keeps the inocula wet and nourished in a nutrient-rich environment throughout the 24 h incubation at 35 ºC. This differs from other traditional methods of testing antimicrobial resistance in coatings surfaces where the surface is not kept deliberately wet or moist with a nutrient medium. Inoculum survival and growth in the other methods depends only on the moisture from either media or humidity created in the incubated unit, so only microorganisms that can survive some level of desiccation on the surfaces in 24 h can be recovered and can be compared to the non-treated surface. In this respect, the JIS Z 2801 method is so severe it is not necessarily a realistic surface contamination model for dry walls and other coated vertical surfaces. In spite of this limitation, JIS Z 2801 has emerged as one of the industry standards for perhaps the ‘worst case scenario’ of a surface that retains wetness and permits microbial survival. Following the method as written for hydrophobic coatings surfaces, yields results that may provide useful information, but for hydrophilic and porous substrates and surfaces, a deviation in the inoculum delivery and validation for each different substrate would be required to get useful data. There is no one universal test protocol or one pesticide product that can demonstrate all the antimicrobial properties on all surfaces.
Reynolds Dual Shaft with patented helical blade design
The EPA has focused its efforts on evaluating registered products that are most crucial to infection control such as sterilants, tuberculocides and hospital-level disinfectants. The manufacturer of any product bearing a public health claim is required to submit efficacy data to the Antimicrobials Division of the Office of Pesticide Programs (OPP) to substantiate the product’s effectiveness. The focus of the OPP Microbiology Laboratory is centered on the efficacy of antimicrobial products used to kill or suppress the growth of infectious microorganisms on inanimate objects and surfaces. The EPA also collaborates with the Organization for Economic Co-Operation and Development [OECD] on developing harmonized
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test guidelines for hard surface dard Test Method for Determining disinfectants and treated articles. the Resistance of Paint Films and The OECD is an intergovernment Related Coatings to Fungal Defaceorganization working with ~30 ment by Accelerated Four-Week industrialized countries including Agar Plate Assay. 5 ASTM D 3273-00 [2005] Stanthe EPA in North America on issues of mutual concern, to harmonize dard Test Method for Resistance to Growth of Mold on the Surface of policies and work to respond to Interior Coatings in an EnvironAnti-bacterial effect of three different coatings. international problems. They cremental Chamber. ated the Pesticide Programme in 6 ASTM D2574 - 06 Standard Test Method 1992 with a goal toward harmonizing the for Resistance of Emulsion Paints in the Container pesticide registration process including review to Attack by Microorganisms. procedures, evaluating pesticides and working toward 7 Japanese Industrial Standard JIS Z 2801: 2000 (E) Test for reducing risks associated with pesticide use. In 2008, OECD Antimicrobial Products: Antimicrobial test and Efficacy. issued a guidance document that focuses issues exclusively IMSL White Paper 2005. on microbiological efficacy testing for treated articles with 8 Antimicrobial Testing Methods & Procedurre: http://www. claims for external effects.8-10 䡲
References 1
2
3
epa.gov/oppbead1/methods/atmpindex.htm. Guidance Document on the Evaluation of the Efficacy of Antimicrobial Treated Articles with Claims for External Effect. 2008, ENV/JM/ Mono, 27, OECD Environment, Health and Safety Publication Series on Biocides. 10 EPA Antimicrobial Division 2009 OECD Work Plan: http:// www.epa.gov/oppad001/pdf_files/adworkplan2009.pdf. 9
Tesh, E.M. The Regulation of Antimicrobials in Paints and Surface Treatments. Paint and Coatings Industry 2004, 7. Consumer Products Treated with Pesticides : www.epa.gov/ pesticides/factsheets/treatart.htm. ASTM D 5589-09 Standard Test Method for Determining the Resistance of Paint Films and Related Coatings to Algae Defacements.
For more information contact Siva Microbiological Solutions LLC at www. sivams.com; or 215-499-1983; or
[email protected]
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New Micro/Macro Hardness Testing Line Extended Load Range and Extremely Fast, Efficient and Fully Automatic Test Cycles
A
new state-of-the-art micro/macro hardness testing product line, the DuraScan, has been introduced by Struers. With its extensive features and benefits, the DuraScan is a natural complement to Struers existing and extensive range of hardness testers. The DuraScan, designed in five basic models, each with varying levels of automation, has a unique test load range of 10 gf - 10 kgf, providing a level of versatility and flexibility with multiple test methods and application usage. Based on a patented combined load cell and dead weight system, the DuraScan takes advantage of both technologies, giving users the most functionality, the highest degree of accuracy and reproducibility possible in a single machine. The compact and revolutionary asymmetrical design with a patented V-concept – a motorized test head and vertically fixed stage – allows for greater vertical testing capacity (260 mm or 10.2”), resulting in an increased testing height for large and taller samples. Additional advantages include faster testing on a large sample area, constant working height providing ergonomic working
conditions, and a precise indent positioning allowing for more accurate and reproducible testing results. The DuraScan can have up to a six-position automatic turret with multiple indenters and objective lenses, eliminating the need for manual exchange, consequently reducing frequent re-calibration of the machine. This instrument eliminates the need for manual evaluation or surface adjustments, with its automatic image evaluation and surface setting providing a fast and fully automatic testing cycle. Intuitive ecos Workflow™ software lets the user execute hardness testing procedures in a step- by-step process for simplicity and ease of operation. Users can perform high-quality hardness testing with minimal training. Additionally, professional reports including statistical information can be easily generated utilizing the built-in report editor.
The main features of the DuraScan line include: • unique test load range from 10 gf - 10 kgf, providing versatility in testing applications; • available in semi- and fully automatic versions; • vertical test head and fixed stage for highest positioning accuracy; • overview camera for easy positioning of test points; • automatic image evaluation and autofocus eliminates manual intervention while testing; and • intuitive workflow-oriented software for ease of operation.
For more information, visit http://www.struers.com. 44
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Exterior Coatings Producer Blends Abrasives –
No Shaft Seal Wear
S
ince its founding in 1987, contractors have applied over 100 million square feet of Master Wall Inc. products – stucco, coatings, and exterior insulation and finish systems (EIFS) – on residential, commercial and industrial buildings. Master Wall founder and President Steve Smithwick says the company’s Aggre-flex EIFS system is “one of the most common commercial cladding in the country.” Also termed “synthetic stucco,” it consists of a water barrier, adhesive, insulation, mesh, basecoat and Master Wall’s “Superior Finishes” topcoat – layered with a trowel.
Similarly, Master Wall® “Superior Finishes over Stucco” systems consist of a water barrier, a basecoat and Superior Finishes topcoat. Superior Finishes over Stucco enhances building exteriors with custom colors and textures, ranging from fine to coarse sand, to “Aggre-Flex Superior Stone Finish” resembling cut stone. The topcoats are a challenge to blend, and require a durable, heavy-duty blender, explains Glen Smith, Manager of Process Engineering at Master Wall. The highdensity topcoats, up to 100 lb/cu ft (1600 kg/cu m), are comprised of heavy, abrasive aggregates – coarse particulates of sand and marble – blended with pigments in an acrylic polymer binder. The material caused the shaft seals of Master Wall’s blenders to wear and leak.
A Succession of Blenders Master Wall’s original mixer was a small, two-speed propeller-type blade unit placed atop a 30-gal (114 L) stainless steel pot, producing only three, 5-gal (19 L) pails of stucco per batch. Master Wall soon acquired a 150-gal (568 L) ribbon blender, and over the next 13 years added two more ribbon blenders (450 gal [1703 L] and 900 gal [3407 L]) to the Lithonia, GA, plant. The ribbon blenders combine the ingredients producing the water barriers, base coats and Superior Finishes topcoats. Today the plant produces thousands of 5-gal (19 L) pails of products in one shift. In 2006, Master Wall opened a plant in Payson, UT, to better supply the western United States. The company specified a Munson HD-48-SS ribbon blender having a 750gal (2839 L) capacity equivalent to 150 5-gal (19 L) pails per batch, to handle the heavy-duty coatings mixing jobs.
Ribbon Blender Performs Heavy-Duty Task
Operator adds pre-weighed aggregates from self-dumping hopper to the Munson HD-48-SS ribbon blender. 46
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When blending the coatings, ingredients are added to the 100-cu-ft (2.8 cu m) ribbon blender in several steps. First, liquid acrylic polymer and water are metered by a pumping system. While the blender is running, 50-lb (23 kg) bags of pigments and fillers, together with various pre-weighed chemicals, are manually dumped into the blender. Next, pre-weighed aggregates are added from self-dumping hoppers using a forklift. Typically, the blend contains about 25% liquids and 75% solids. The blender runs at full speed for the entire mix time of a batch, which is usually about 1 hour. Once mixing is complete, a sample is taken for quality control. An operator measures viscosity and pH, and visually
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Exterior Coatings Prod Producer od duc u er B Blen Blends nds Abra Abrasives ra asivess – No S Shaft haft S haft Seal eall We ea W Wear ar
compares the sample to a control. When the batch is approved, material is discharged through a manual butterfly valve into 5-gal pails, which are palletized for shipping. The 1/16 to 1/32 in. (1.6 to 0.8 mm) clearance between the ribbon blades and blender trough minimizes residual material after discharge. “The Munson blender blades sweep closer to the wall than our other blenders, resulting in less waste,” reports Smith. Cleaning between batches is not usually needed (production is scheduled so that products with increasingly larger aggregates follow those with smaller aggregates); the blender is simply washed out at the end of the day. While batch sizes vary, the largest batch size is 750 gal – about 10,000 lbs (453 kg) of material – utilizing the blender’s full working capacity. The blender’s double helical ribbon agitator design is energy efficient and offers faster blend times than other ribbon configurations. “With our other blenders we sometimes have to go longer than the desired time to fully homogenize the powders, but with the Munson we can sometimes mix in less than the set time due to the 2-to-1 length-to-width ratio of the double helical ribbon agitator,” says Smith, noting that the 40-hp (30 kw) motor maintains consistent speed when heavy materials are added.
Tight clearance between ribbon blades and blender trough minimizes residual material after discharge. The double helical ribbon agitator blends rapidly.
Air-Purge Seals Solve Leakage Problem According to Smith, “We run our machines hard.” The blender withstands non-stop, all-day mixing of abrasive material without premature seal leakage. In ribbon blenders, packing glands create a mechanical seal where the shaft penetrates the blender wall. The abrasive material in Master Wall’s blends was wearing away the braided Teflon® packing of the blenders in the Georgia plant, allowing material leaks, requiring packing to be replaced monthly and shafts to eventually be replaced, incurring two to three days of downtime. To prevent the problem, the new blender is equipped with air-purge shaft seals that apply positive pressure to drive abrasive particulates away from the seals, which show no signs of wear or leakage two years after installation.
At the top of the 750-gal-capacity ribbon blender, negative-pressure dust collectors pull dust into a bag house as the blender fills 5-gal pails of exterior coatings products.
Improving Operator Safety
Specifying a Blender
Master Wall specified four safety grates that cover the top of the ribbon blender and trip “kill switches” if moved, enhancing operator safety. The safety grates and switches are integrated into the machine with a flush-mount sensor. Master Wall also specified lids with dust-collection ports on the back half of the blender top that rest on heavy-duty stops when open. Negative-pressure dust collectors pull dust out of the blender into a bag house, so that little dust escapes into the work area, despite the quantities of dusty material being used. Low noise levels are another plus for operator safety. The chain that transfers power from the helical gear motor to the blender’s agitator sprocket runs through an oil bath, providing an added measure of safety by reducing noise.
In planning the construction of the Payson, UT, plant, Munson representative Bob Jeremias of TEC Engineering helped engineer the blender and dust collection system while Steve Knauth of Munson configured a model to meet Master Wall’s needs, including safety features and the air-purge shaft seal system. Smith says, “We needed a durable machine. Just looking at the blender you can tell it’s a heavy-duty machine because of its sturdy construction.” The company plans to purchase the same brand of ribbon blenders for its Georgia plant. 䡲
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For more information, visit
[email protected] or www.munsonmachinery.com.
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New, Renewable
Non-Ionic
G
oing “green” is a reality: the sustainability trend has hit store shelves and magazine covers. Everywhere you look products are competing to be “natural,” “biodegradable” and “environmentally friendly.” Consumers’ greater environmental awareness combined with more stringent regulation is increasingly driving manufacturers to look for innovative, “green” solutions and market-ready concepts. Obviously, these need to offer similar or superior performance to conventional alternatives. When talking about Green Chemistry it is always difficult to define what exactly is green. In 1998, Dr. Paul T. Anastas published his 12 Principles of Green Chemistry,1 and in 2003 the 12 Principles of Green Engineering,2 which are generally accepted today. Cognis has adopted these internationally recognized principles as a compass for the development of concepts, products and processes, and has taken these principles as the basis to define seven benefit dimensions in line with relevant market demands in order to provide genuine green chemical solutions.
Green and High-Performing Surfactants In our efforts over the last few years, we have demonstrated that it is possible to develop renewable-based products that offer higher performance levels than their fossil-based counterparts and represent true green alternatives for the industry. Already 50% of the raw materials Cognis uses are renewable, i.e., natural oils and fats and plant extracts. New renewable non-ionics are highly efficient surfactants that offer benefits for the emulsion polymerization process as well as in end-users’ applications. They are readily degradable and do not contain any toxic compounds. They are FDA approved and add to the safety and health protection of workers who have contact with them.
Non-Ionic Surfactants in Emulsion Polymerization Emulsion polymerization is a radical chain growth reaction of water-insoluble mono-
mers that are emulsified in an aqueous phase. The end product is a high-molecular-weightpolymer or copolymer that consists of billions of submicron micelles dispersed in water and stabilized by surfactants – a so-called “latex.” Latices are mainly used as film-forming substances or binders in coatings and as thickeners or rheology modifiers. Usually the surfactants used during the polymerization process also provide the final colloidal stability to the latex through electrostatic repulsion between the micelles. Yet, to improve the long-term stability of a latex, non-ionic surfactants are added at the end of the process. Non-ionic surfactants consist of a hydrophobic part and a long-chain hydrophilic part that are linked together in the same molecule. While the hydrophobic extremity of a non-ionic surfactant incorporates into the micelle, the long hydrophilic chain points away from the micelle and provides steric stability against other micelles. Also when it comes to the application of a latex, surfactants play an important role. Since the application of a latex usually means its destabilization and subsequent formation of a polymeric film or phase, surfactants must be able to allow this coagulation without affecting the properties of the polymer particles. It is even better if the surfactants are designed in such a way as their properties synergistically enhance the properties of the chosen polymer.
No Gel Non-ionic surfactants usually undergo a dilution with water when applied in the emulsion polymerization process. Manufacturers usually provide non-ionic surfactants having a high active matter content in order to reduce transportation costs. Some latex manufacturers tend to cut the active matter content by adding water to the surfactant solution prior to addition of the surfactant to the latex. Others apply the surfactant to their process as it is and take advantage of a dilution effect provided by the water in the latex. In any case, when applied, the concentration of the surfactant in its aqueous environment usually changes significantly.
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Surfactants
Low Foaming Foam formation is a general concern in industrial production. In the emulsion polymerization process foam may occur through agitation throughout the whole process and in particular at the end of the polymerization reaction when unreacted monomers are distilled off the reactor under reduced pressure. The presence of foam can significantly slow down a process, especially when its collapse proceeds very slowly. Cognis’ new class of nonionic surfactants provide a rapid foam collapse in both the surfactant solution and the finished latex.
FIGURE 1 | Phase behavior of non-ionic surfactants with 30 moles of EO. 50
Temperature ºC
40 liquid
30 20 10 0 -10
solid
-20 -30 0
10
20
30
40 50 60 Active Substance (%)
70
80
100
New non-ionic surfactant Standard surfactant iso-Tridecyl-OH 30EO
40
Temperature ºC
30 liquid
20
New non-ionics with
10
10 EO 20 EO 30 EO 40 EO
0 -10 solid
-20 -30 0
10
20
30 40 50 60 70 Active Substance (%)
80
90
100
FIGURE 3 | Collapse of foam. 400 350 300 250 New non-ionics with
200
10 EO 20 EO 30 EO 40 EO 30 EO low foaming iso-Tridecyl-OH 20EO
150 100 50
0 00:00 02:24 04:48 07:12 09:36 12:00 14:24 16:48 19:12 21:36 Time [min:sec] PA I N T & C O A T I N G S I N D U S T R Y
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90
FIGURE 2 | Phase boundaries of new non-ionics with different moles of EO.
Foam Column [mm]
Plant operators are well aware of the fact that the dilution of surfactants is often accompanied by a formation of liquid-crystal gel phases that occur either in a multitude of solid particles of varying sizes or in the form of a massive block that can even stop the stirrer of the vessel. In either case, gel phases destroy the homogeneity of the latex and usually do not re-dissolve except very slowly. The new class of Cognis non-ionic surfactants is designed to specifically avoid the presence of liquid-crystal gel phases in aqueous surfactant environments over the whole concentration range at 20 °C or above. Figure 1 provides phase limits between solid and liquid states of non-ionic surfactants with 30 moles of EO. The new class of non-ionic surfactants is compared to a standard non-ionic surfactant and to iso-tridecyl alcohol with 30 EO. The active substance of each surfactant was diluted with water and thus adjusted to various concentrations in steps of 10%. For each sample the gelation temperature was determined in a freeze/thaw experiment. As shown in Figure 1, the new non-ionic surfactant with 30 EO, which Cognis will deliver at a concentration of 70% active matter, can easily be diluted with water at temperatures above 10 °C without the appearance of gel phases. In contrast, a standard 30 EO non-ionic will gell at 55% active matter when diluted from 70% at the same temperature. Even more so the iso-tridecyl alcohol 30 EO that forms liquid crystal particles between 60% and 40% active matter at temperatures as high as 30 °C. In the case of the latter products, an addition of a small amount of water can cause severe problems in the production process. Figure 2 provides the phase boundaries for the new class of non-ionic surfactants with the different degrees of ethoxylation that will be available in the market. Due to the excellent phase behavior of the new class of non-ionic surfactants, plant operators can benefit from process advantages through easier handling by adding non-ionic surfactants much more rapidly to their process without taking the risk of gel formation. They are also more flexible with regard to the temperature at which surfactants are added to the process.
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New, Renewable Non-Ionic Surfactants
FIGURE 4 | Electrolyte stabilities of latices.
1% NaCl 10% NaCl 1% CaCl2 10% CaCl2 1% AlCl3 10% AlCl3
New Non-Ionic
Benchmark 1
Benchmark 2
Y Y Y Y N N
Y Y Y Y N N
Y Y Y Y N N
FIGURE 5 | Low foaming performance of Cognis’ new non-ionic surfactants in exterior paints. Density of Exterior Paint 1,200 1,100 1,000 0,900 0,800 0,700 0,600 0,500 0,400 0,300
were evaluated for their stability against addition of aqueous solutions of electrolytes. The same latices have been tested for their freeze-thaw stability. Each sample had been cooled five times to -5 °C and re-heated to room temperature. After each cycle the sample was analyzed for its homogeneous aspect. After the fifth cycle, the next series of cycles was started with -10 °C and -15 °C, respectively, as the minimum temperature. The latices that were prepared using the new nonionic surfactants were able to withstand 5 cycles at -15 °C without losing their homogeneity. These tests, as well as further examinations, underline the suitability and excellent performance of the new non-ionic surfactants as poststabilizers in the emulsion polymerization process.
Low Foaming Performance in Exterior Paints
fresh after 30 min after 90 min after 20h
S-Ac / S-Ac / S-Ac / Standard New Non-Ionic Standard New S-Ac Emulsion Emulsifier [D] LF [C] Non-Ionic [B] [A]
Figure 3 provides the collapse of a foam column versus time of the new class of non-ionics against ethoxylated iso-tridecyl alcohol. The foam column was generated by stirring a 1% solution of the surfactant in de-ionized water at 1100 rpm for 1 minute in a SITA foam tester. The actual height of the foam column was detected by electrodes. According to Figure 3, those new non-ionics having at least 20 moles of EO build less foam than ethoxylated isotridecyl alcohol. In addition, the decay of the foam column is much faster. In particular, the foam of the new nonionic that was developed to have significantly low foaming properties collapses completely in less than five minutes.
The benefits of the new non-ionic surfactants in easier handling have been pointed out as well as their excellent performance as latex stabilizers. Their low-foaming properties are not limited to the emulsion polymerization process itself, but are also reflected in end-user applications, e.g., in paint for outdoor applications. A standard pre-mix was made and pigmented with TiO2. Based on this pre-mix, four exterior paints have been prepared by adding four different styrene acrylate polymer emulsions that differed in the non-ionic surfactants used for their preparation. While emulsion (A) was a commercial styrene acrylate emulsion, (B) was prepared using the new non-ionic surfactant with 30 EO units, (C) using the new non-ionic surfactant specially designed for low-foaming properties and (D) using a standard non-ionic surfactant. Air was entrained into the finished paint by stirring for 3 minutes at 3000 rpm with a 40-mm-tooth wheel. The foaming properties of each paint were determined via density measurement directly after stirring as well as after 30 and 90 minutes and after 20 hours. The higher the density and the faster a high density is reached the better the defoaming properties. Figure 5 shows the significantly higher defoaming properties of the paint that contains the new non-ionic surfactant specially designed for its low foaming properties.
Low Pour Point Low pour points of raw materials are of importance for production plants that are geographically located in areas with cold winter days. For those plants it is desirable to use raw materials with pour points lower than the ambient temperature during transport and storage since only such material remains liquid and homogeneous and can therefore be used for processing without additional heating or stirring. The new non-ionic surfactants generally provide low pour points with one specially designed product having a pour point of -22 °C.
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Conclusion The new non-ionic surfactants developed by Cognis offer convincing easier-handling properties by forming no gel phases, showing low foaming behavior and having low pour points. These benefits are accompanied by an excellent stabilization performance. Their advantageous properties help manufacturers to optimize and speed up their processes and even improve final applications. They are characterized by their high content of renewable green material and thus support the trend for going “green”. 䡲
Stabilization of Latices
References
Besides these advantages in easier handling, the new non-ionic surfactants show high performance in micelle and latex stabilization. Figure 4 shows electrolyte stabilities of styrene acrylate latices that were made with an ethoxylated C12/14 fatty alcohol sulfate (30 EO) as anionic surfactant and post-stabilized with a new non-ionic surfactant or a standard surfactant, respectively. The latices
1
2
Anastas, P.T.; Warner; J.C. “Green Chemistry: Theory and Practice”; Oxford University Press: Oxford , UK , 1998. Anastas, P. T.; Zimmerman, J.B. Design through the Twelve Principles of Green Engineering. Env. Sci. and Tech. 2003, 37, 5, 94A – 101A,
This paper was presented at the American Coatings Conference, Charlotte, NC, 2010.
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GREEN SHOWCASES
䡲 Mixer Cartridges
SULZER MIXPAC USA, INC. New B Series 50 mL cartridges provide an innovative interface for the mixer and a pre-assembled built-in piston retention feature for easier use. The cartridges have a rectangular back, which fits the industry standard for dispensers. They are available in 50 mL, fully assembled, 1:1- and 2:1-ratio polypropylene cartridges. Benefits include a removable cap, a stronger attachment flange, separated outlets to minimize cross contamination, pre-assembled pistons with or without o-ring and an innovative interface with the mixer. Visit www.sulzermixpacusa.com.
䡲 Pigments CLARIANT
P RODUCTS 䡲 Selector Guide DYMAX CORP.
The Industrial Adhesives Selector Guide provides detailed guidance for selecting the best DYMAX adhesive and curing equipment for glass, metal and plastic bonding applications in the various manufacturing and assembly markets. Selector tables in the guide list glass, metal and plastic bonding adhesives, their properties and the unique applications for each product. The tables detail typical substrates and the bonding capabilities of the company’s products. Visit www.dymax.com.
䡲 Vinyl Emulsion
The ED Pigments range has been expanded to simplify the pigment dispersion process for all paint systems by removing the need for a milling step. The product allows manufacturers to add the ED pigment into their paint system by only using a dissolver. As the ED pigment surface is already coated with the dispersing additive, the shear forces in the dissolver are sufficient to develop good fineness of grind and suitable color properties for industrial and decorative paints. Visit www.clariant.com.
䡲 Additive
MICHELMAN Michem Lube 190 is an anionic polyethylene wax emulsion additive that significantly improves the mar and scratch resistance, and water repellency, of architectural and decorative paints, stains, sealants and numerous other interior and exterior coatings. It is commonly used in exterior wood coatings when abrasion resistance is required along with water beading, and can provide blocking resistance as well. This low-VOC surface modifier is also used in rub-resistant, high-gloss OPVs and topcoats where water sensitivity is important. Visit www.michelman.com.
䡲 Ribbon Blender
CHARLES ROSS & SON CO.
Elcometer 99 adhesion tape has been developed as a replacement for Permacel tape. These tapes are widely used to comply with the ASTM D3359 Method B cross-hatch inspection routines. Elcometer 99 is currently available for customers involved with paint and coating inspection. E-mail
[email protected].
The model 42NSD ribbon blender features a discharge screw positioned across the entire bottom of the trough with very close tolerances between the screw and the trough. The screw runs forward only during the discharge cycle and in reverse during the blending cycle. This helps to eliminate dead zones and enhances mixing. The advantages of this design include: the ability to discharge continuously at variable rates to match downstream packaging operations; removable screw for cleaning purposes; less dead space, thus more thorough blending; and complete discharge. Call 800/243.ROSS.
䡲 Grinding Mill
䡲 Dust and Fume Collector
This ultrafine grinding mill is capable of processing materials at throughputs ranging from just a few kilograms to over 1000 kilograms per hour. Licensed from Lehigh Technologies, Inc., the mill can produce a high yield of micron-scaled powders with a narrow particle-size distribution, while maximizing production rates and minimizing overall operational costs. Call 800/654.4567.
The Zephyr® III pulse-cleaned dust and fume collector combines portable three-stage filtration with versatility and ease of use. The portable collector is ideal for handling industrial process contamination, source capture or periodic dust collection at various locations. Applications include welding fumes, grinding dusts, dry dusts, soldering fumes and other airborne particles. E-mail
[email protected]. 䡲
CELANESE
The vinyl emulsion EcoVAE® 405 boasts even greater durability over EcoVAE 401, allowing formulators to develop products for use in tough environments such as kitchens and playrooms where frequent washing occurs. In numerous lab tests, interior flat paints made with EcoVAE 405 demonstrate better wet scrub resistance than paints based on 100-percent acrylic emulsions. Visit www.celanese.com.
䡲 Adhesion Tape ELCOMETER, INC.
AIR PRODUCTS
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CAMFIL FARR AIR POLLUTION CONTROL
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