IPC-E-Newsletter:   April 2002


Welcome to the April edition of the IPC e-newsletter.

This edition of the newsletter contains:
1. News features compiled from various resources.
2. The Powder Coating Manual (Part 2)
3. Exhibitions and Conferences in January 2002
Site Activity
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    News Features  
Markus Vüllers, President
of the European Society
for Coating Technology (EGL)
Power coating technology established in Nürnberg right from the start

(Based on report from Ruby Vatcha, Indo German Chamber of Commerce)
Nuremberg, February 2002. Following two successful events in Amsterdam, POWDER COATING EUROPE, the International Exhibition and Congress for Powder Coating Technology, celebrated its première in the Exhibition Centre Nuremberg from 15-17 January 2002. 3,206 trade visitors1 (2000: 3,145) gathered information from 139 exhibitors (2000: 127) about a comprehensive range of products from the segments of powder coatings, application equipment, pretreatment, testing equipment, raw materials for powder coatings, production engineering for powder coatings, environmental protection, safety at work and services.
POWDER COATING EUROPE 2002 as international meeting-place for the powder coating community once again reflected the current situation in the growth market of powder coating. In addition to the wide spectrum of products displayed on the stands, trade visitors were able to obtain an accurate picture of the various aspects of this technology at live demonstrations of application equipment, at the discussion and presentation forum Powder Coaters’ Marketplace, at the presentation of powder-coated end products in the Powder Coaters’ Showcase and during the Powder Coating Live excursion to various powder coating facilities.

Robert Strouhal, Chairman Powder Coating Manufacturers’ Group of the European Council of Paint, Printing Ink and Artist's Colours Industry (CEPE), sums up favorably and sees the future of the event as optimistic: 'POWDER COATING EUROPE is the only exhibition and congress for powder coating technology for the whole of Europe.

After the two events in Amsterdam, Nürnberg has now passed the test as venue located centrally in Europe and therefore at the heart of the expected enlargement of the European Union. The previous success of POWDER COATING EUROPE, especially in terms of the interest of international visitors, shows that POWDER COATING EUROPE has become the focus of attention compared with regional events.

The congress excels The Solution is Powder!

Powder is the Solution! was the motto of this year’s congress parallel to the exhibition and which with 343 participants recorded appreciable growth of some 20 percent over the previous event. The around three dozen papers presented by internationally renowned experts from industry, research and development were aimed at employees from coating shops and powder coating manufacturers. For the first time, this year’s conference was clearly divided into theme blocks for formulators on the one side and powder coaters and custom coaters on the other; the great interest has shown that this is the right way, says Robert Strouhal. The themes are to be extended to cover other branches in the future and then provide the best survey of powder coating technology in Europe. The congress was organized by Vincentz Verlag in co-operation with the European Council of Paint, Printing Ink and Artist’s Colours Industry (CEPE), the Deutsche Forschungsgesellschaft für Oberflächentechnik (DFO) and the Europäische Gesellschaft für Lackiertechnik (EGL).

High quality and satisfaction among exhibitors and visitors
Well over 90 percent of the exhibiting companies were satisfied with their success at POWDER COATING EUROPE 2002. Almost all exhibitors welcomed international visitors 44 percent of the trade visitors came from countries outside Germany. Over 90 percent of the exhibitors made new business relationships and almost as many expect follow-up business from these contacts. The caliber of trade attendance at POWDER COATING EUROPE 2002 was convincing: The largest groups of visitors included heads of departments (30 %), employees (20 %), general managers and self-employed (some 14 % each), especially from the metal manufacturing industry (19 %), mechanical engineering (11 %), automobile engineering (9 %) and electrical engineering, building services and medical technology (9 %). Also out in force: custom coaters (13 %) and component suppliers of coating shops (coatings 21 %). Nine out of ten of these visitors are involved in purchasing and procurement decisions in their company. 90 percent of the trade visitors were satisfied with the products offered at POWDER COATING EUROPE 2002 in Nürnberg.

Powder has potential
Powder coating technology currently holds a share of some 10 percent of industrial coating tendency rising. Industry experts expect average annual growth of 7 percent in Europe until 2007 to reach an annual turnover of some 1.82 billion US dollars. The forecasts for other regions of the world are between 5 and 15 percent. An independent survey of trade visitors confirms the estimates: Just under 28 percent expect the economic situation in the industry to remain stable and almost 58 percent even expect improvements. Whereas the growth limit for wet coatings has been practically reached, the reasons for the good prospects for powder coating are especially its ecological and economic advantages: It is solvent-free and the overspray can be recovered. Powder coating with its low curing temperatures and IR curing is also slowly capturing new application areas such as wood coating. Other factors that will positively influence the growth of powder coating’s market share are the VOC directives of the European Union and the growing markets in Eastern and Central Eastern Europe with their rising standard of living and the demand for powder-coated products. The production of powder coatings has rapidly become established in these regions, but these countries are also increasingly interesting as users of powder coatings and not just as producers a trend that also emerged at POWDER COATING EUROPE 2002 and confirmed the change of location from Amsterdam to Nürnberg as an important decision.

World market leader Europe
The available figures for 2000 record a total annual production of 700,000 tons of powder coatings worldwide, of which 180,000 t are produced in Asia, 150,000 t in North America, 35,000 t in South America and 25,000 t in Africa. The list is, however, headed by Europe with 297,000 t, of which 71,000 t are produced in Italy, 54,000 t in Germany and 31,000 t each in Great Britain and France. These countries occupy the same positions in terms of consumption: Italy 80,000 t, Germany 60,000 t, Great Britain 36,000 t, France 30,000 t and Spain with 25,000 t. These are followed some way behind by Switzerland with 9,000 t, Austria with 7,500 t and the Netherlands with 7,000 t. The total consumption of powder coatings in Europe in 2000 was 269,500 tons.

The building sector especially aluminum facade components currently leads the European consumption statistics with a share of some 30 percent, followed by domestic appliances (mainly white goods such as refrigerators, washing machines and dishwashers) and metal office furniture with some 15 percent each, and automobile, heating and mechanical engineering at the top end of the single-figure percentage range.

The highest growth forecasts are 11 percent for automobile engineering, followed by 7 percent for household goods.

Nürnberg: Competence in state-of-the-art finishing technology
The next event in Nürnberg on the subject of coating is the EUROPEAN COATINGS SHOW plus Adhesives, Sealants, Construction Chemicals in the coming year from 8-10 April 2003. The next POWDER COATING EUROPE takes place in Nürnberg again from 20-22 January 2004. The organizers of the exhibition are Vincentz Verlag of Hanover and NürnbergMesse.

PPG earns PACE Award again
(European Coatings Flash - March 11, 2002)
 PPG Industries was the only automotive coatings manufacturer to receive a prestigious PACE Award Wednesday night when it was recognized for its environmentally friendly FrameCoat electrodeposition coatings for automotive and light-truck chassis components. This marked the third consecutive year PPG has been a winner in the PACE Awards program, sponsored by Automotive News magazine and Cap Gemini Ernst & Young to honor automotive suppliers around the world for product innovation and management excellence. PPG is the only coatings manufacturer to receive three awards since the program began in 1994.

Physicist David Ignat Joins Nordson Board of Directors
(WESTLAKE, Ohio, March 7 /PRNewswire-FirstCall/)

The directors of Nordson Corporation (Nasdaq: NDSN) today elected plasma physicist David W. Ignat to the company's board.
"We are delighted to welcome David, whose strong background of research, management and administration adds yet another perspective to our board," said Edward P. Campbell, president and chief executive officer. "As a significant shareholder, he is keenly attentive to the continuing transformation of Nordson Corporation and our ongoing efforts to build shareholder value. We look forward to his insight and counsel."
Ignat, 60, retired from the senior scientific and engineering staff of the Plasma Physics Laboratory at Princeton University in 1996 after a 19-year career there. He then became editor of Nuclear Fusion, a journal published by the International Atomic Energy Agency, a position he still holds. From 1999 to 2000, he was a part-time consultant to the Plasma Physics Laboratory at Princeton. Earlier in his career, Ignat was a program officer at U.S. Department of Energy headquarters and a researcher at the Center for Research in Plasma Physics, Lausanne, Switzerland, and Los Alamos National Laboratory, Los Alamos, New Mexico. He earned a bachelor's degree in physics from Carleton College, Northfield, Minnesota, and a Ph.D. in physics from Yale University.
Ignat succeeds his uncle, Evan W. Nord, on the 13-member Nordson board. Nord, a co-founder of the company, retired from the board today. As a teen-ager, Ignat helped his uncle, working in his basement on finish grinding of the tungsten carbide, flat-spray nozzle - a Nordson innovation that made possible the airless spraying of pigmented coating materials. He also had a summer job at Nordson while attending college. Nordson Corporation is the world's leading producer of precision dispensing equipment to apply adhesives, sealants and coatings to a broad range of consumer and industrial products during manufacturing operations, helping customers meet quality, productivity and environmental targets. The company also manufactures technology-based systems for curing and surface treatment processes. Headquartered in Westlake, Ohio, Nordson has direct operations in 31 countries.

Rohm and Haas to Build Manufacturing Plant in India; Ground Breaking Takes Place in Mumbai
(3/11/2002 MUMBAI, India, Mar 11, 2002 /PRNewswire-FirstCall via COMTEX)
- Rohm and Haas Company (NYSE: ROH) said today it is investing approximately US $20 million to build a manufacturing facility in Mumbai that will manufacture both emulsion polymers and adhesives.

This multi-purpose plant will be situated in Taloja, and will supply the domestic market and serve export needs elsewhere in the Asia-Pacific region. The state-of-the-art plant will be built to the company's global safety standards and will be commissioned early next year. Rohm and Haas has operated a wholly owned subsidiary in India for more than five years, and has enjoyed increasing sales in the area. "Choosing to build a plant here in India is the natural next step to our success," said Harish Badami, Country Manager for Rohm and Haas India.

Speaking at the ground breaking ceremony today, J. Michael Fitzpatrick, President and Chief Operating Officer of Rohm and Haas, said, "We are quite pleased to be able to expand our presence here. India presents a growing market for our Coatings and Adhesives and Sealants businesses, and is a key location for further growth throughout the Asia-Pacific region."

Tom Grehl, Asia-Pacific Regional Director for Rohm and Haas, also attended the ceremony. He noted that the company was making this strategic investment in the midst of a worldwide economic slowdown. "Our decision to invest is clear evidence of our commitment and confidence in the India market."

About Rohm and Haas: Rohm and Haas Company is a global supplier of specialty materials, with annual sales of US $5.7 billion. The company has had a presence in the Asia-Pacific region for more than 70 years, and in 2001 was responsible for 12 percent of company sales. The Coatings and Adhesives and Sealants businesses are among the company's largest and fastest growing operations in the world and together reported sales in 2001 of US $2.1 billion. Coatings makes intermediate products and additives that are used in latex paints, textile and paper finishes. The Adhesives and Sealants business makes products that are used in flexible packaging, building materials, and tape and label applications. Rohm and Haas worldwide employs more than 17,000 people and operates more than 100 research and manufacturing sites in 25 countries. The company's headquarters are located in Philadelphia, PA, USA. Raj L. Gupta is Chairman and CEO.

SOURCE Rohm and Haas Company

Akzo Nobel announced 140 job losses in Stuttgart
(PRA News of the Month - March 2002)
In connection with its current restructuring measures, Akzo Nobel is to lose 140 of the 600 jobs at its Stuttgart site. Some of the production, particularly in the primer / surfacer lines, is to be transferred to Barcelona in Spain. Thirty jobs are to go in the automotive refinishing business in the wake of tough competition. In future, the Stuttgart site is to concentrate on service-intensive products. In 2001, reorganisation in the German deco business had resulted in 90 job losses in Cologne and Wunstorf. (Farbe Lack, Feb 2002, 108 (2), 11)

BASF experiments with constellations colours.
(PRA News of the Month - March 2002)
BASF has launched Constellation Colours, an experimental line for automotive applications, which will make vehicles more visible at night. The new concept was first used on a racing car in the Le Mans race in France last June. Two coating systems are currently being explored by BASF, using either retroreflection or electroluminescent pigments. A retroreflection pigment illuminates cars when exposed to a light source, as in street signs or safety markers. Colour visibility is achieved through combining the pigment's refractive index with a special reflective coating on one side of the pigment. The coating 'lights up' when hit by headlights. The second approach uses electroluminescent pigments, which produce coatings which glow with different long- lasting colours at night and are capable of being turned on or off via a low-voltage electrical charge. (Coatings World, Jan 2002, 7 (1), 10)

Non toxic paint stripper:invented by UK's female inventor of the year.
(PRA News of the Month - March 2002)
The inventor of a non-toxic, environmentally-friendly paint remover, Ithiel Mogridge, has been declared the UK's female inventor of the year. Her invention easily shifts water- and oil-based paints without using acid or methylene chloride. The product is ethanol-based and biodegradable. (Chem. in Brit., March 2002, 38 (3) p 17)

Bayer: Opening of Major Powder Coatings R&D Center
(European Coatings Flash - March 18, 2002)
Bayer Corp. announced the opening of its $1.5-million Powder Coatings Global Research and Development Competency Center, located at the company´s Pittsburgh campus. The 1,600-square-foot application and testing facility will be used for customer support, evaluation of new company said. The center houses three separate application lines that can operate simultaneously and equipment that includes laboratory-scale extruders, grinders, particle-size classification instruments, and standard spray and oven-bake systems. Operations at the center also receive technical support from Bayer facilities in Columbus, GA, and Leverkusen, Germany, the company said

The following developments have taken place recently:

BS EN ISO 119988: 2001; BS 3900-F17: 1998: Paints and varnishes: determination of wet-scrub resistance and cleanability of coatings.

BS EN ISO 4623-1: 2002: BS 3900-F13: 2002: Paints and varnishes - determination of resistance to filiform corrosion. Part 1. Steel


2-4 April 2001, Tokyo, Japan
For further information, please contact: The Japan Society of Colour Material. E-mail:
jscm@blue.ocn.ne.jp or go to: http://wwwsoc.nii.ac.jp/jscm

3-5 April 2002, Orlando, Florida, USA
This conference will address electrodeposition, coatings application and related topics. For further information, please contact: The Electrocoat Association, 6915 Valley Ave, Cincinnati, OH 45244; Fax: + 1 513 527 8950; Tel: + 1 513 527 8977. Alternatively, go to:

4-6 April 2002, Tokyo, Japan.
For further information, please contact: Japan Paint Manufacturers Association, 3rd Floor, Tokyo Toryo Kaikan, 3-12-8, Ebisu, Shibuya-ku, Tokyo 150-0013. Tel +81-3-3443-2011 / Fax +81-3-3443-3599; E-mail:

23-26 April 2002, Munich, Germany
For further information, please go to:

9-11 April 2002, London, UK
For further information, please contact the Institute of Materials: Tel: + 44 (0) 20 7451 7320

11-14 April 2002, Munich, Germany
For further information, please contact GHM Gesellschaft fuer Handwerksmessen mbH, Willy-Brandt-Allee 1, 81829 Munich, Germany. Tel: + 49 89 9 4955 161; Fax: + 49 89 9 4955 169. Alternatively, please go to:

2002 45th Annual Technical Conference
(April 12-17, 2002 Orlando FL)
Society of Vacuum Coaters
Tel: 505-856-7188 Fax: 505-856-6716

14-17 April 2002, Los Angeles, USA
For further information, please contact The Adhesive and Sealant Council, Inc., 7979 Old Georgetown Rd., Ste. 500, Bethesda, Maryland 20814. Tel: + 1 301 986 9700; Fax: + 1 301 986 9795 or go to: http://www.ascouncil.org

18-19 April 2002, Brussels, Belgium
Organised by the European Association for the Self Adhesive Tape Industry, a call for papers has now been issued for this seminar. For further information, please contact: The European Association for the Self Adhesive Tape Industry: http://www.afera.com or e-mail:

21-24 April 2002, Paris, France
For further information, please contact: Industrial Minerals Conference Department, Park House, Park Terrace, Worcester Park, Surrey, KT4 7HY, UK or go to:

23-24 April 2002, Luxembourg
for further information please contact: Deutsche Forschungsgesellschaft fuer Oberflaechenbehandlung e.V., Arnulfstrasse 25, 40545 Duesseldorf, Germany. Tel: + 49 211 938895 70; Fax: + 49 211 938895 71; E-mail:
service@dfo-online.de or go to: http://www.dfo-online.de

28 April - 1 May 2002,
Indiana Convention Center, Indianapolis, USA For further information, please contact: RadTech International North America, 3 Bethesda Metro Center, Suite 700, Bethesda, MD 20814, USA. Fax: + 1 917 464 81 73; E-mail:
aygoyer@one.net or go to : http://www.radtech.org



  Powder Coater’s Manual ------- (Part - 2)  
2 Thermoset Powders

Thermosetting powders are much more widely used than thermoplastics.They are primarily composed of relatively high molecular weight solid resins and a crosslinker. Thermoset powders are used for a wide variety of decorative and protective applications. They are applied by the electrostatic spray process, heated to the necessary temperature and cured.

The primary resins used in the formulation of thermosetting powders are:


These primary resins are used with different crosslinkers to produce a variety of powder materials. Many crosslinkers, or cure agents, are used in powder coatings, including amines, anhydrides, melamines, and blocked or nonblocked isocyanates. Some materials also use more than one resin in hybrid formulas. When a thermoset powder is applied and subjected to heat it will melt, flow and chemically crosslink to form a finished film. The chemical reaction in the cure cycle creates a polymer network that provides excellent resistance to coating breakdown. A thermoset powder that has cured and crosslinked will not melt and flow again if subjected to heat a second time.


Epoxy powders were the first commercially available thermoset materials and they are the most commonly used of the thermosetting powders today. They are available in a wide range of formulations for thick film functional applications and thin film decorative applications. They provide excellent toughness, chemical resistance, corrosion resistance and flexibility. The primary drawback with epoxies is that they will chalk when subjected to UV radiation. For this reason they are rarely used for outdoor applications.

Functional Epoxy Powder Applications
Functional epoxies are commonly used for electrical insulation and corrosion protection. Some typical applications for functional epoxies are electric motors, alternators and electrical control junction boxes, taking advantage of its insulating properties. Because functional epoxies also have very good chemical resistance, they are used in a variety of applications where corrosion resistance is required, such as piping, under the hood automobile components and concrete "rebar."

Decorative Epoxy Powder Applications
Epoxies are often used for decorative applications. They can be formulated to provide a variety of glosses, colors and textures and applied in relatively thin films of 0.5 to 3 mil, still providing the toughness and durability of the functional coatings. Typical applications include metal office furniture, shelving, interior car parts, and toys.

Epoxy Polyester Hybrids
Epoxy-Polyester (Hybrids), like the name implies, combine epoxy resins with polyester resins to form a powder with most of the same properties as epoxies. Although some hybrids are less resistant to chemicals and solvents, they are tough, flexible and competitively priced.
Hybrids are likely to be used in many of the same applications as epoxies. In addition to the slight improvement in weatherability, the polyester resin sometimes provides some improvement in charging characteristics for electrostatic application.

Polyester Powder
Polyester resins are used to formulate urethane polyesters and polyester triglycidyl isocyanurate (TGIC) materials.

Urethane Polyesters
Urethane cured polyester powders have excellent resistance to outdoor environments, toughness and very good appearance characteristics at 1 to 2 mil film thickness. A smooth, thin film that resists weathering and physical abuse makes the urethane polyesters a popular finish for high quality products.
It is common to block the crosslinker in urethane polyesters with ecaprolactam. To begin the crosslinking process, the material must reach a temperature above the blocking agent threshold. With ecaprolactam, unblocking occurs at approximately 360 °F (182 °C). Therefore, temperatures must be higher than 360 °F to start the melt phase of the cure cycle.
Powders containing eap are usually sensitive to films thicker than 3 mils. Thicker films with these urethanes may lose some of their mechanical properties and they may exhibit outgassing effects due to ecaprolactam evolution. They are used for exterior applications such as patio furniture, automotive wheels and trim, lawnmowers and a wide range of other products requiring high quality, decorative finishes comparable to wet coatings.

Polyester TGIC
Polyester TGIC coatings use the epoxy functional crosslinker triglycidyl isocyanurate (TGIC). TGIC’s have very good adhesion characteristics, corrosion resistance and exterior durability. They can typically be cured at lower temperatures than urethanes and/or have shorter cure cycles. In the cure cycle, they have good overbake characteristics and they are less sensitive to outgassing. They also provide good edge coverage and tough, thick films (3-5 mil/75-100 m) due to the inherent higher melt viscosity of the nonblocked TGIC crosslinker. They have equal corrosion resistance to urethane polyesters but they are somewhat less resistant to chemicals. Some typical applications are automotive wheels, air conditioners, lawn furniture, and air conditioner cabinets.

Acrylic Powders
Like the polyesters, acrylics give excellent exterior durability. Common acrylic-based materials include urethane acrylics (hydroxyl functional resins), acrylic hybrids (acid functional resins) and glycidyl methacrylate acrylics (GMA) (epoxy functional resins). Urethane acrylics require cure temperatures of 360 °F (182 °C). Like urethane polyesters, they may exhibit problems with outgassing at thicker films (3 mils/75 m). They offer excellent thin film appearance, good chemical resistance and hard films. Flexibility and impact resistance is usually poor. GMA acrylics can be cured in less time or lower temperatures than the urethane acrylics and they also can provide superior weathering characteristics. They make excellent clear coats over brass or chrome due to their exceptional clarity. Like the urethane acrylics, flexibility is somewhat limited. They can be applied in films greater than 3 mils (75 m) without the risk of outgassing that is characteristic with the urethanes. GMA acrylics are typically not compatible with other resins and are run in systems that are isolated from other powders.

Acrylic hybrids combine the acrylic resin with an epoxy binder. They are somewhat better than a polyester/epoxy hybrid but still not considered acceptable for outdoor use. The mechanical properties that are characteristic in epoxies are a benefit of these materials and they have much better flexibility than other acrylics. Because of their good appearance, tough surface, exceptional weatherability, and excellent electrostatic application characteristics, acrylics are frequently used for applications on products that have very high quality standards. Appliances, automobiles and other products that require durability and long life in a harsh environment are good candidates for acrylic powder coatings. Typical applications include automotive wheels, plumbing fixtures and vending machines. Research has been conducted to determine the suitability of acrylic powder coating as a clear coat on automotive bodies. While the United States automobile manufacturers continue to evaluate this application, one European manufacturer is using it in production.
  To be continued........  



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In a recent email, Teknofiniture s.r.l. of Italy informed us about their masking hanging and finishing products through their website.
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Mr. Ajay Mahule called in from Amravati, Maharashtra, India to inform that he is planning to set up a powder coating plant. Mr. Mahule plans to powder coat wood.
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Through their website Mr. Gianni informs that "tsa Industriale" are specialist in manufacturing twin screw extruder lines for laboratory and small production of capacity from 10 to 300 kg/hr. These systems are designed for the production of masterbatch, compound, powder coating, toner, pharmaceutical and medical compound.
Mr. T Christopher of Leo Systems inform from Pune, India "We are turn key suppliers of painting systems and we are into this market for the past 2 years"

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