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  IPC-E Newsletter: January 2003  
  Welcome to the January edition of the IPC e-newsletter.

This edition of the newsletter contains:

News features.
The Powder Coating Manual (Part 11)
Exhibitions and Conferences in and January and February 2003

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    News Features      
  Advertisement feature  
Now you can spray direct from the box !

So why waste time and money unloading powder from a box to a hopper.

New Dipstick reduces powder wastage and hence 50% of manufacturers are now buying box feed systems instead of conventional hopper.

Users the world over confirm that the new patented dipstick is superior from conventional box feed systems. It contains a special powder submersible pump which vibrates at 16000 RPM !!!

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mitsuba@vsnl.com Website : www.powdergun.com


  Advertisement feature  
Revolution in Powder Coating

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A Light weight gun. (600 gms)

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For Further details contact
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307 Chetak Centre RNT Marg, Indore MP 452001
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  *50 INR = 1 USD (approx)

Akzo Nobel may cut more jobs
(European Coatings Flash - December 02, 2002)
Akzo Nobel said it may cut more jobs in its coatings and pharmaceutical businesses in addition to previously announced reductions, according to news reports. The company declined to provide specifics on the number of possible job cuts or when an announcement would be made. Akzo Nobel, the world's biggest coatings manufacturer, launched a cost-reduction program last year in its coatings and chemicals businesses. The company initially said it would cut 2,000 jobs in the coatings unit, and said earlier this month that 700 coatings positions had been eliminated so far.

Asian Paints to focus on emerging global markets
(European Coatings Flash - December 23, 2002)
Asian Paints has announced that the company will focus on the emerging markets for growth and that Berger International will be the main growth driver for its international operations. The company is transforming itself to become a major world player in the decorative paints business, with particular focus on emerging markets following its acquisition of controlling stake in Berger International Ltd, Singapore and SCIB Chemical SAE of Egypt. The total investment made by the company in both these acquisitions amounted to around $16.80 million.

Silver is the most popular vehicle color
(European Coatings Flash - December 23, 2002)
Silver was the most popular color throughout the world on vehicles manufactured in the 2002 model year, according to the DuPont Automotive Color Popularity Report. Silver also was the most-selected color in North America, where white took second place with 15 percent of consumers and black was the third choice at 12 percent. Blue continues to gain strength in North America as it replaces green. Silver/gray was tops in Europe, followed by blue and black. In Asia, gray was first, white second and black third. "DuPont spotted the potential of silver several years ago, even as green was the dominant color choice in the United States and blue and white led in Europe," says Bob Daily, manager, DuPont automotive color marketing.
"Gray, whether dark and mysterious or pale pewter, will extend the influence of this family of neutral colors because it conveys a sense of richness, especially for luxury SUVs and light trucks. "A color surge this strong generally runs a seven-year cycle, from its initial quick rise through its fall below the top three colors. We continue our watch on the interest of blue as a possible leading color. Blue is the lone chromatic color choice in the top rankings otherwise dominated by neutrals such as silver/gray, white and black."

Help in fight against superbugs
(EXPRESSANDSTAR.COM Dec 17, 2002, 12:05:00)
A Wolverhampton company which specialises in anti-bacterial powder coatings is helping hospitals in the fight against superbugs.

BioCote provides equipment which makes them immune to bacteria.

According to a study by the National Audit Office two years ago, 100,000 patients a year pick up the superbug MRSA and it kills about 5,000 patients annually in the UK.

BioCote's powder has been created to beat bacteria on objects such as handrails, hospital beds, showers, door handles and medical equipment where it is most likely to be passed on by direct contact.

The antibacterial agent is incorporated into traditional powder coating finish for metal and wood objects so that each item can effectively inhibit the growth of all major bacterial strains, including MRSA.

BioCote was developed after several years of research by BioCote Ltd in association with the University of Wolverhampton.

The company was founded in 1994 and is based at Wolverhampton Science Park.

A spokesman said they were currently working with a number of suppliers to the NHS and spraying beds with a coated powder which makes them immune to bacteria.

He said: "Powder coating has always been the product of choice on equipment where regular contact is made because it is so long lasting."

Meanwhile, Financial Times Internet edition (ft.com Monday Dec 30 2002) informs that Flintstone Technologies, an investor that specialises in bringing Russian technologies to western markets, will announce tomorrow that one of the companies it has invested in, BioCote, will seek to float on Aim in the first half of 2003.

BioCote has developed an anti-bacterial powder coating for surfaces used in hospitals. Flintstone has a 40 per cent stake in the company.

MDF Powder Coat Systems
Press Release

MDF Powder Coat Systems announces the opening of their three hundred foot coating line and R&D Test Facility in Portsmouth, Rhode Island. MDF Powder Coat Systems applies powder coating to medium density fiberboard, or MDF, as an alternative to other paint and laminate technologies.

The systems designed and installed by MDF Powder Coat Systems are high speed, energy-efficient lines utilizing automatic powder coating equipment and catalytic infrared curing ovens to apply and cure electrostatically charged powders to engineered wood products such as MDF. By testing products in thermal and thermal/UV cure ovens, customers are able to select an individually designed system that will best suit their needs. Powder coating is an environment-friendly method of painting, as there is little wasted powder and no V.O.C (Volatile Organic Compounds) emitted from the process.

The pre-conditioned MDF passes through the powder-coating booth where the reciprocating spray guns apply the charged powder onto the board. The over-sprayed powder is reclaimed and recycled via a highly efficient multi-pack cyclone system.

The collective technologies offered by MDF Systems are a major departure from the methods used to date. Central to the systems are the multiple catalytic ovens that are key to a production facility for coating medium density fiberboard. MDF Powder Coat Systems is a leader in this area with their experience including installations of MDF lines in Europe and New Zealand. MDF Powder Coat Systems is located at 300 High Point Avenue, P.O. Box 840, Portsmouth, RI 02871. For further information, call (401) 683-7525, fax at (401) 683-6450, or send an email to MDFPowderCoating@aol.com.

Using its paint developed for cars and factory roofs, the Nagashima Special Paint Co has launched, jointly with the Nippon Hodo Co, a material capable of reducing road surface temperature by up to 30 degrees C by reflecting the sun's rays. Nippon Hodo, the country's top road paver, will market the material to local authorities to produce 'cool' pavements. (Surface Coatings Austral, Oct 2002, 39 (10), 13)

Nippon Paint developes silicon-based water repellent coating
(European Coatings Flash - December 16, 2002)
Japans leading paint producer Nippon Paint has succeeded in developing a silicon-based super water repellent coating possessing equivalent properties to existing fluorine-based materials. Because fluorine compounds are expensive, fluorine-based water repellent paints have been less than satisfactory from a cost viewpoint. Nippon Paint claims, that the new coating solves former problems and enables water repellency to be delivered at relatively low cost.

BASF Coatings offers solutions for coil coating
(European Coatings Flash - December 16, 2002)
BASF Coatings AG developed new products for use in the coil coating segment: with the innovative materials, BASF is offering a new coating which reflects heat and is thus able to conserve energy. The other products improve the coatings performance in the building and construction sector. "Ultra-Cool", a coil coating which is based on a fluoropolymer resin system and which is used to coat metal roofs can help to keep buildings cooler in the heat of summer and save on the costs of air conditioning. In contrast with energy-intensive air conditioning, Ultra-Cool from BASF Coatings offers a particularly eco-efficient solution.
Two product versions that go under the "First Coat" product name are intended for the pre-treatment of metals: what sets both of these innovative products apart is their combination of inorganic acids and organic resin material. In conjunction with a suitable primer and topcoat, these components provide exceptionally good anti-corrosion properties and additional surface protection for galvanized steel and aluminum. The high performance nature of the product provides the basis for several novel uses.
High resistance and durability also distinguishes the two coil coatings formulations "Fluoroceram" and "UltraMet": these coatings contain at least 70 per cent fluoropolymer resin and are therefore particularly suitable for building and construction applications. They are highly UV-resistant, abrasion-resistant, flexible and colorfast. The ruggedness in extreme weather conditions, acid rain and air pollution without bleaching or flaking makes these paints virtually maintenance-free.

Dow discontinues BLOX
( November 2002 e-epoxy.NEWS letter)

The Dow Chemical Company has announced that it is discontinuing production of BLOX* thermoplastic resins and is evaluating divestiture or licensing options for the materials, which are made via the company's patented reactive extrusion technology. BLOX thermoplastic resins, which were launched in December 1999, are a family of polymers that offer the adhesion and durability of epoxy resins with the flexibility and processability of thermoplastics.

After evaluation, Dow determined that BLOX resins do not fit in the company's current growth strategy and product mix. "We remain fully committed to the epoxy resin industry and will redirect knowledge and resources toward other growth opportunities, including the recently commercialized epoxies and epoxy acrylates for UV curable applications," said Phil Cook, business vice president for Epoxy Products & Intermediates.

Dow currently manufacturers BLOX resins at its Freeport, Texas facility. The company will establish a timeline for ceasing production only after meeting with all BLOX resins customers. Further information about the product can be found at www.bloxthermoplasticresins.com.

The following developments have recently occurred in the field of standards:

BS ISO9038: 2002: Test for sustained combustibility of liquids

For further information, please go to:

ASTM has recently published a list of 23 standards which are set for withdrawal because they have not been re-approved within the required fiveyear time frame. Some are listed below - the remainder will be listed in next month's News of the Month:

- D237-57 (1997): Standard specification for orange shellac and other lacs;
- D563-88 (1996) e1: Standard test method for phthalic anhydride content of alkyd resins and resin solutions;
- D1306-88 (1996)e1: Standard  test method for phthalic anhydride content of alkyd resins and esters containing other dibasic acids (gravimetric);
- D1615-60(1996)e1: Standard test methods for glycerol, ethylene glycol and pentaerythritol in alkyd resins;
- D1639-90 (1996)e1: Standard test method for acid value of organic coating materials;
- D1647-89 (1996)e1: Standard test methods for resistance of dried films of varnishes to water and alkali;
- D1652-97: Standard test methods for epoxy content of epoxy resins;
- D1725-62 (1996)e1: Standard test method for viscosity of resin solutions;
- D1726-90 (1996): Standard test methods for hydrolyzable chloride content of liquid epoxy resins;
- D1979-97: Standard test method for free formaldehyde content of amino resins;
- D2455-89 (1996)e1: Standard test method for identification of carboxylic acids in alkyd resins.

For further information, please go to:

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January 2002
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February 2002
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March 2002
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April 2002
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May 2002
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June 2002
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July 2002
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August 2002
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September 2002
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October 2002
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    Exhibitions, Seminars, Course, Lectures  

13-14 January 2003, The Bahamas
For further information on this conference, please contact Vincentz Verlag, Post box 6247, 30062 Hannover, Germany; Fax:+ 49 511 9910 299  or go to
: http://www.coatings.de/TheCoatingsSummit/

17-19 January 2003, Agra, India
For further information on this conference, and exhibition, please contact P K Khanna or G N Tewari, The Indian Paint Association, c/o Punjab Paint Colour & Varnish Works (P) Ltd, 123/529 Fazalganj, Kanpur, 208012 India. Tel: + 91
512 296867; Fax: + 91 512 218435 or go to
: http://www.indianpaintconference.com


17-19 January 2003, Agra, India
This exhibition will run alongside the 21st Indian Paint Conference: the product range on display will include chemicals and raw materials, plant and machinery, paint, and test equipment. For further information, please contact: Services International, B-13, IIIrd floor, A Block, LSC, Naraina Vihar, New Delhi - 110028 India. Tel: + 91 11 5707715, 5707684, 5793211, 5790212: Fax: + 91 11 5798876 or go to
: http://www.servintonline.com

21-22 January 2003, Florida, USA
The final programme has now been issued for this conference: For further information, please go to:

28-29 January 2003, Las Vegas, USA
For further information, please go to
: http://www.pdra.org/TradeShows.asp or call PDRA. Tel: + 1 636 326 2636

29-30 January 2003, Florida, USA
For further information, please contact ASTM International, 100 Barr Harbour Drive, PO Box C700, West Conshohocken, PA 19428-2559, USA. Tel: + 1 610 832 9677 or go to:

29-31 January 2002, Las Vegas, USA
For further information, please go to:

3-4 February 2003, Florida, USA
For further information, please go to:

TIO2 2003
3-5 February 2003, Miami, USA
This conference will address various topics, including regional TiO2 consumption rates and the effect of rising prices, industry rationalisation, and end-user developments on pigment demand in paper, plastics, paints, ink and textiles. For further information, please contact: Scott Stephenson, at Intertech: tel: + 1 207 781 9800 or go to: http://www.intertechusa.com

6-7 February 2003, Berlin, Germany
For further information, please contact: Dr Dirk Meine, Vincentz Verlag, Schiffgraben 43, 30175 Hannover, Germany. Tel: + 49 511 99 10 212; Fax: + 49 511 9910 279 or go to
: http://www.coatings.de

15-20 February 2003, New Delhi, India
For further information, please contact: Messe Duesseldorf GmbH, Stockumer Kirchstr. 61, 40474 Duesseldorf, Germany. Tel: + 49 211 45 60 01; Fax: + 49 211 45 60 7740 or go to:

17-19 February 2003, Sparks, USA
For further information on this exhibition and symposium, please contact: Los Angeles Society, 11 Duboce Avenue, 94103 San Francisco, CA, USA. Fax: + 1 702 492 15 78

24-28 February 2003, San Diego, USA
For further information, please go to: http://www.piasd.org/printweek1.html

25-26 February 2003, Cairo, Egypt
For further information, please contact: dmg world media (uk) ltd, Queensway House, 2 Queensway, Redhill, RH1 1QS, Surrey, UK. Tel: + 44 1737 855488; Fax:+ 44 1737 855474;

26-28 February 2003, New Orleans, Louisiana, USA
For further information, please contact Dr Robson F Storey, or Dr Shelby F Thames, Co-Organisers, WHS&PC Symposium, Department of Polymer Science, The University of Southern Mississippi, Box 10063, Hattiesburg, MS 39406-0063. Fax: + 1 601 266 6262;

  Powder Coater’s Manual ------- (Part - 11)  


Phosphating, or conversion coating, is the application of an iron or zinc phosphate coating to the substrate. Conversion coating can be a very critical part of the pretreatment process, adding significantly to the performance of the finished coating. A phosphate coating converts the metal substrate to a uniform, inert surface, which improves bonding, minimizes the spread of oxidation if the coating is scratched and improves the overall corrosion resistance of the final part.

A conversion coating can be iron, zinc, polycrystalline, chromate, or manganese phosphate film. They are developed on both ferrous (iron based) and non-ferrous surfaces (zinc, aluminum, terne and manganese). Parts are subjected to an acidic bath and a chemical conversion forms a complete film on the part surface, changing the chemical and physical nature of the metal surface.

Iron Phosphate
Iron phosphate is the thinnest of phosphate films. In the application process, an iron oxide base is developed, followed by a flat or amorphous metal phosphate topcoat. The treated metal surface will typically have a gray to blue iridescent or blue-gold iridescent color, depending on the coating weight and the base metal. A typical iron phosphate consists of:

phosphate acid base


surfactant package (optional)

In an iron phosphate solution, the metal surface is etched, releasing some iron into the bath. When metal ions are etched from the part surface, the surface becomes positively charged. The metal ions in the bath are converted to iron phosphate, negatively charged. A pH rise occurs at the interface of the solution and the part, causing the iron phosphate ions to deposit an amorphous coating on the metal surface.

The acid salt content, type and amount of accelerator, and the type and amount of acid etchants varies from one compound to another. These compositions are all moderately acidic. Although crystal site activators are not typically required prior to application of iron phosphate coatings, formulations commonly contain oxidizers and/or accelerators.

The oxidizers, such as nitrite or chlorate, act to initiate attack on ferrous parts, providing the iron for the iron phosphate coating. Accelerators, such as molybdate or vanadate, provide active sites for iron phosphate deposition. Choice of oxidizer or accelerator in a particular product may affect the performance or appearance of the final coating.

In a three-stage iron phosphate treatment process, the cleaning and coating are combined by incorporation of a detergent surfactant package in the iron phosphate solution. A source of fluoride ions may be added if aluminum is also being processed to increase the etching effect on the oxide surface of the aluminum.

Iron phosphate coatings can be applied by hand wiping, with a handheld spray wand, immersion, or a spray washer. The number and type of process stages is directly dependent on finished part requirements. A cleaner/coater combination followed by a rinse is the typical minimum chemical cleaning and phosphating process used. The addition of stages in the process can provide enhanced performance. The most effective and commonly used method is a multi-stage spray washer. Spray washers are built with as few as two stages and as many as eight.
Two Stage: clean/coat, rinse
Three Stage: clean/coat, rinse, rinse/seal
Four Stage: , clean/coat rinse, rinse/seal, DI rinse*
Five Stage: clean, rinse, phosphate, rinse, rinse/seal
Six Stage: clean, rinse, phosphate, rinse, rinse/seal, DI rinse
Seven Stage: clean, clean, rinse, phosphate, rinse, rinse/seal,DI rinse
Eight Stage: clean, rinse, clean, rinse, phosphate, rinse, rinse/seal, DI rinse

* Deionized water; water that has been filtered to remove negative and positive ions.

Phosphate Coating Weight

Iron phosphate is measured in mg/ft2, or grams per square meter. Coating weights vary with the different levels of pretreatment. The quality of paint adhesion and corrosion resistance will be affected by the phosphate coating weight. The chart above shows typical results of additional steps in the process.

To determine the coating weight, test panels should be run through the washer with all of the process variables under control. After a clean, fresh panel is run through the washer, it should be removed and tested with the procedure described below. Clean cotton or surgical gloves should be worn to avoid contamination of the sample with skin oils.

Determine the square feet of the panel:
1. Weigh the panel, correct to three places (.000), and record the first weight.
2. Immerse the panel in 10 % chromic acid (CrO3) in water by weight at 160 0F (71 0C) for 10 minutes.
3. Rinse with tap water or D.I. Water if it is available.
4. Weigh the part again correct to three places and record the second weight.

Then complete the formula:
(1st wt. in grams – 2nd wt. in grams x 1000)/(Area in square foot) = mg./sq. ft.

(1st wt. in grams – 2nd wt. in grams)/(Area in square meters) = grams/sq. m

Iron Phosphate Controls

In addition to the number of process stages, the factors that will affect the weight of an iron phosphate coating are time, temperature, concentration, acid consumed (pH), the condition of the substrate and the spray pressure.

Time in Process - The more time that the chemistry has to work, the more work it will do. The process must be long enough to allow the chemistry to form to a uniform coating on the surface.
Temperature of the Solution - Soils become more reactive in a heated solution and the chemicals become more aggressive.
Concentration - A higher concentration of chemical will provide more total acid, more accelerators and it can provide more coating weight.

Acid Consumed - A higher pH will give less acid and less coating, while a lower pH will give better cleaning and more acid. More acid gives more pickling, providing heavier coatings. Excessive acid can cause too much pickling and the excess acid can dissolve the phosphate coating. The pH that works best for iron phosphate is between 3.5 and 6.0, with most running around 5.0. If the pH is too high (above 6), the parts will not get enough coating weight and they may flash rust. If the pH is too low (below 3.5), the parts will be cleaned and pickled but they will not have any phosphate coating. The ”blueness“ of the phosphate coating is related to the coating weight. An iridescent blue indicates a coating weight of 30-35 mg/ sq.ft. As the coating weights go up the color will change from blue to blue-gray to gold.

It is also important to maintain consistent control of these variables. Alkaline solutions can be carried into the phosphate solution and cause a rise in pH, or the operators may not make the adjustments to the solution often enough to maintain consistency. This can cause the coating to be spotty in some areas and flash rusting can occur. Solutions should be monitored frequently (3 times per shift) to make sure that they are in good condition.

  To be Continued.....  

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