IPC-E Newsletter: August 2002  
  Welcome to the August edition of the IPC e-newsletter.

This edition of the newsletter contains:

News features.
The Powder Coating Manual (Part 5)
Exhibitions and Conferences in July and August 2002

If you have information you would like to have included in this newsletter, please contact the moderator using the details given at the end of each newsletter.

Powder Coating 2002

    Important Announcement  
  Change of email address

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    News Features  
Begun, the (Cy)clone war has.
New powder recovery technique using rotary cyclones from Mitsuba
(Based on the information provided by Mitsuba Systems)
Mitsuba introduces a completely  new powder recovery technique using rotary cyclones. This is the only system which offers super fast color changes plus 99% powder recovery.   Fast color change is achieved because the powder enters through a stabilizing chamber on top of  the cyclone instead of conventional side entry. Powder enters each clone through rotary wings which provide substantially enhanced  centrifugal force to the powder particle. This boosts the cyclonic action and results in 99% powder recovery. High air velocity also make the cyclone self cleaning and it is now no longer necessary to physically  clean the insides of the cyclone during color change.  Over and above this self cleaning  property, ducts work is completely eliminated and super fast color changes are generated. For further information please contact, Mitsuba Systems, 34-H, Laxmi Industrial Estate, New Link Road, Andheri (W), Mumbai - 400 053. India. Tel : 0091-22-631 8633 / 633 4735 Fax : 0091-22-631 6565 Email : mitsuba@vsnl.com Website : www.powdergun.com  

Tata Steel inks pact with TN for titanium dioxide project
(European Coatings Flash - July 15, 2002)
Tata Iron and Steel Co Ltd (Tata Steel) on 27 June signed an MoU with the Tamil Nadu Government to undertake a techno-economic feasibility study for a project to set up an integrated titanium dioxide plant using the mineral sands available in the State's southern districts. If the project comes through, Tata Steel will be investing close to Rs 18000 million in the venture, the first such foray into the South by the company, according to its Managing Director, Mr B. Muthuraman. The project involves separating the rutile and illuminite from the beach sand, and processing and enriching them to produce titanium dioxide. Currently, he said, India imported about 25,000-30,000 tonnes per annum of titanium dioxide, and as the economy grew, its consumption would also go up.
The first phase, which involved mining and beneficiation and the manufacture of synthetic rutile, would cost Rs 6000-7000 million. Synthetic rutile was used in the manufacture of electrodes. Two years after the first phase, the company would go in for the next stage, which involved the manufacture of 60,000 tonnes per annum of titanium dioxide, at a cost of Rs 10000 million. 

Asian Paints restructures foreign arms shareholding
(European Coatings Flash - July 22, 2002)

Paints major Asian Paints has restructured the shareholding of its various subsidiaries forming a part of its international operations. The company has transferred all the equity shares held by Asian Paints (India) in the subsidiaries at Fiji, Tonga, Solomon Island, Vanuatu, Australia, and the Sultanate of Oman to a wholly owned subsidiary in Mauritius. While the units in Fiji, Tongo, Solomon Islands, Vanuatu and Nepal have posted profits, the unit in Nepal has declared a bonus in the ratio of 1:1. However, the Australian subsidiary has continued to post losses in the last fiscal despite there being a sharp reduction compared with the previous year. The company has, however, forecast an optimistic outlook for the current year, compared with the previous year.

The units in Mauritius and Oman completed the first full year of operations in 2001, although the operations were not yet profitable. The plant being set up by the company's subsidiary in Bangladesh is in an advanced stage of construction and is expected to go on stream in the next quarter of the next fiscal.

Indian import duty discussion
(July 2002 e-epoxy.NEWS letter)
The Indian epoxy market is witnessing a tussle between the importers and the domestic manufacturer of epichlorohydrin, the main raw material for epoxy. While the manufacturer of epichlorohydrin, TN Petroproducts, has sought a hike in the import duty from the present 25 to 33 percent, the consumers are seeking a reduction in the import duty. Currently, almost 40 percent of the domestic demand of epoxy is being met through imports. (Source: The Indian Express Online Media Ltd, Copyright 2002)

Powder Coating offers enormous Global opportunities for coating manufacturers, Raw material producers and Application Equipment constructors

The 2001 global thermosetting Powder Coatings market of over 900,000 Tonnes is valued at approximately EUR 3.6 billion (US$ 3.2 billion). Europe leads the way with approximately 43%, Asia 26%, North America with 23% and the rest of the world with 8%. Penetration of powder coatings differs by country and Region from 4% up to 15%. Irfab reports there is still plenty of room for increased penetration of Powder Coatings in the world paints arena. With growth rates that vary by region from 4,5 to 10% and more per year, by the year 2003, the global powder coatings market will reach the one Million Tonnes (2.2 billion lbs) mark. Polyester-epoxy Hybrids dominate the Powder Coatings industry, representing on a global scale approximately 55% of the market, followed by Polyesters, epoxies, polyurethanes and acrylics. Average country or regional prices across the board vary considerably, from highs of approximately EUR 6.40/kg to EUR 2.30/ kg. In certain areas prices are in free fall.

Remmers develop UV Based Window Coating

The German company Remmers Baustofftechnik, in conjunction with the Fraunhofer Institute in Braunschweig, has developed a water-based, UV-cured coating for wooden windows. The first international test results for this system are now available. (JOT, May 2002, 42 (5), 8)

"Twist & Pour " Easy to Open paint container from Dutch Boy Paint

Dutch Boy Paint has introduced the "Twist & Pour" paint container, an all-plastic gallon can featuring an easy twist-off lid, comfort side handle and convenient neat- pour spout. The new container eliminates the need for screwdrivers, paint keys or other tools frequently used to open paint cans while providing a tight seal when closed to extend the shelf life of any unused paint. The exterior moulded handle allows for a more controlled pour and easier carrying while the pour spout is designed to reduce the spilling and dripping typically associated with traditional paint cans. The "Twist & Pour" paint container is more lightweight and durable than typical paint cans, will not rust or dent over time and takes up less space to store due to the stackability of the new design. Initially available in the "Twist & Pour" paint container will be Dutch Boy's Dirt Fighter; a high quality interior and exterior coating that is tintable in over 900 colours. The new container will be available at paint retailers in the second quarter of 2002. (http://biz.yahoo.com, 10 June 2002)

DuPont Marks July 1802 Founding with Time Capsule, Other Anniversary Events

([Insider News] July 22, 2002 Issue )

DuPont Co. marked its 200th anniversary last week in ceremonies that included the dedication of a time capsule at Wilmington, DE, and the ringing of the closing bell at the New York Stock Exchange on Friday by DuPont's Chairman and CEO and several other employees. The company
traces its origins to July 19, 1802, when French immigrant Eleuthere Irenee du Pont began a small family business in Wilmington that manufactured black powder for guns and blasting.

The 8-cubic-foot time capsule, filled with artifacts, employees' and retirees' creative expressions and a CD-ROM viewer, was dedicated at the site where the company started operations. Presiding at the ceremony at the historic Hagley Museum and Library, DuPont Chairman and CEO Charles O. Holliday Jr., was joined by two former CEOs - Edgar S. Woolard and John A. Krol - and 12 employees from Asia, Europe, South America, and the United States.  The employees were grand prize winners in a company-wide contest celebrating the company's past, present, and future contributions to industry and society.

Other special guests included retiree Joe Labovsky, who worked on Wallace Carothers' team in the discovery of nylon; Bill Ulmer, the longest-serving DuPont employee in Delaware with 58 years' service; fifth-generation employees Fred and Kevin Best and Ray Conner; and
the DuPont Diversity Choir.

Contributing to the time capsule contents, the 12 employees provided unique creative expressions including wood carvings, a tapestry made of DuPont products, a "time machine," poems, and drawings.  They were selected from among 2,000 submissions, all of which have been captured digitally on CD-ROM and microfilm that were placed in the time capsule - along with devices for reading them when the capsule is opened on the company's 300th anniversary in 2102.

The time capsule was placed on a hillside overlooking the Brandywine River near the 1884 Power Plant restored with DuPont's help.

DuPont, the oldest industrial company listed on the Fortune 500, today has 79,000 employees and operations in 70 countries. The company's notable industrial inventions include nylon, Teflon non-stick coating, Stainmaster carpet, Lycra brand elastane, Kevlar fiber, Corian solid surfaces, Tyvek protective materials, and Solae soy protein. The company's businesses include DuPont Performance Coatings, which ranks as the world's biggest automotive-coatings producer and the fourth-largest coatings producer overall, and DuPont Titanium Technologies, the world's biggest producer of titanium dioxide (TiO2) pigments.

http://www.pra.org.uk/publications/newsofthemonth/nom-current.htm )

The following developments have taken place recently:

BS EN 13284-1: 2002: Stationary source emissions - determination of low range mass concentration of dust. Part 1. Manual gravimetric method

BS EN 13526: 2002: Stationary source emissions - determination of the mass concentration of total gaseous organic carbon in flue gases from solvent using processes - continuous flame ionisation detector method

For further information, please go to: http://www.bsi-global.com

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    Exhibitions and Seminars  
August 7 - 8, 2002 Exhibition; Buenos Aires/Argentina

More Information from: dmg world media, Queensway House, 2 Queensway
Redhill RH1 1QS Surrey Great Britain Fax: +44 (1737) 85 54 74
http://www.dmg.co.uk tickets@uk.dmgworldmedia.com

August 12 - 16, 2002 Short Course; Davos/Switzerland

More Information from:School of Chemical Engineering Georgia, Institute of Technology, Atlanta, Georgia 30332-0100, USA, Fax: +1 (605) 238-19 89, http://www.che.gatech./edu/~Davos/ joseph.schork@che.gatech.edu


25-27 August 2003, Copenhagen, Denmark
For further information, please contact Charles M Hansen, Force Institute, Park Alle 345, 2605 Broendby,
Denmark. Tel: + 45 43 26 74 86; Fax: + 45 43 26 70 11; or go to:

1-6 September 2002, Erlangen, Germany
For further information, please contact: European Society of Rheology, Martensstr 7, 91058 Erlangen, Germany. Tel: + 49 9131 85 28 593; Fax: + 49 9131 85 28 321:

2-5 September 2002, Newcastle upon Tyne, UK
For further information, please contact Melanie Boyce or Victoria Bowyer: Conferences and Events, IOM Communications Ltd, 1 Carlton House Terrace, London, SW1Y 5DB. Tel: + 44 20 7451 7303; Fax: + 44 20 7839 2289 or go to:

4 September 2002, Cheshire, UK
This conference is organised jointly by PRA and the Royal Society of Chemistry. For further information, please contact: Royal Society of Chemistry, 34 Beechfields, Doctors Lane, Eccleston, Chorley, PR7 5RE, UK

5–6 September 2002, Leeds, UK.
Organised by the Colloid and Interface Science Group of the Faraday Division of the Royal Society of Chemistry. For further information, please contact: B. S. Murray, Food Colloids Group, Procter Department of Food Science, University of Leeds, Leeds, LS2 9JT. Tel: + 44 113 233 2962; Fax: + 44 113 233 2982

9-11 September 2002, Dresden, Germany
For further information, please contact: Prof Dr Hans-Juergen P Adler, FATIPEC President, TU Dresden, Institute of Macromolecular Chemistry and Textile Chemistry, 01062 Dresden, Germany. Tel: + 49 351 463 3782; Fax: + 49 351 463 7122:

Klebtechnisches Forum: Praxisseminar Klebtechnik
September 10 - 12, 2002 Seminar; Hanover/Germany

More Information from: Zentrale Einrichtung für Weiterbildung der FH Hannover, Postfach 920251, 30441 Hannover Germany Fax: +49 (511) 92 96-10 25,
http://www.fh-hannover.de/zew weiterbildung@fh-hannover.de

10-13 September 2002, Glasgow, UK
For further information, please contact Lisa Bromley, Conference and Events, IOM Communications, 1 Carlton House Terrace, London. Tel: + 44 20 7839 2289; or go to:

Galvitech + Finishing Verona Fair
September 12 - 14, 2002 Exhibition; Verona/Italy

More Information from: Promax Srl, Via della Meccanica 1/R, 36100 Vicenza, Italy, Fax: +39 (444) 28 06 37,
http://www.galvitechfinishing.com, info@galvitechfinishing.com

16-19 September 2002, Moscow, Russia
For further information, please contact Messe Duesseldorf GmbH, Stockumer Kirchstrasse 61, 40474 Duesseldorf, Germany. Tel: + 49 211 45 60 77 42; Fax: + 49 211 45 60 77 40

Adhesives from Natural Resources
September 17, 2002, Cleveland/USA

More Information from: The Adhesive and Sealant Council, INC., 7979 Old Georgetown Road, Suite 500, Maryland, 20814 Bethesda, USA, Fax: +1 (301) 986-97 95,
http://www.ascouncil.org , wendy.yanis@ascouncil.org

Paint Defect Analysis Workshop
September 17 - 19, 2002, Troy/USA

More Information from: Paint Performance Consulting, 35585 Pound Road, Richmond 48062 Michigan, USA, Fax: +1 (586) 727-27 24,
http://www.paintperformanceconsulting.com techservices@paintperformanceconsulting.com

18-21 September 2002, New Delhi, India
For further information on this exhibition and conference, please contact: Federation of Indian Chambers of Commerce and Industry, Federation House, Tansen Marg, 110001 New Delhi, India. Tel: + 91 11 37 38 760; Fax: + 91 11 33 20 714; http://www.indiachem2002.com

IRaP 2002
21-26 September 2002, Sainte Adele, Canada
The fifth international symposium on ionising radiation and polymers, covering the broad range of all such applications and chemistries. Conference will be held in English and French. For further information, please contact: IRaP 2002, Curly Dog Communications; Tel: + 1 514 481 8086; Fax: + 1 514 481 9143; or go to:

23-24 September 2002, Minneapolis, USA
A call for papers has been issued for this conference. For further details, please contact: Joshua Barney, Continuing Professional Education, University of Minnesota, 352 Classroom Office Building, 1994 Buford Avenue, St. Paul, MN 55108, USA. Tel: + 1 612 624 0768; Fax: + 1 612 624 6225;

23-24 September 2002, Beijing, China
For further information, please contact: Michael Jardine, Chemical Week Associates, 110 William Street, 11th Floor, New York, NY 10038. USA. Tel: + 1 212 621 4978; Fax: + 1 212 621 4829 or go to:

23-26 September 2002, Darmstadt, Germany
For further information on this seminar, please contact: GDCh, Postfach 900440, D-60444 Frankfurt am Main. Tel: + 49 69 7917 364; Fax: + 49 69 7917 475 or go to:

23-27 September 2002, Granada, Spain
For further information, please contact: 15th ICC Secretariat, Viajes Iberia Congresos, San Bernardo, 20, 28015 Madrid, Spain. Tel: + 34 91 531 94 49; Fax: + 34 91 532 45 43; or go to:

24-26 September, 2002, Indiana Convention Centre, Indianapolis, USA
Further information from Goyer Management: Tel: + 1 513 624 9988;
Information also is available at:


24-27 September 2002, Lyon, France
For further information, please contact: CME, 50 Place Marcel Pagnol, 92100 Boulogne-Billancourt, France. Tel: + 33 147 61 76 89; Fax: + 33 147 61 74 65:

26-27 September 2002, Wuppertal, Germany
For further information on this seminar, please contact: Technische Akademie Wuppertal, Hubertus-Allee 18, D-42117 Wuppertal. Tel: + 49 202 7495-0; Fax: + 49 202 7495 216 or go to:

  Powder Coater’s Manual ------- (Part - 6)  

Powder Particle Size

The size of the powder particle can have an influence on the behavior of the material in the delivery system, the charging system and the final film characteristics. The original grind size is determined by the manufacturer to provide certain deposition and appearance characteristics. The powder coater must understand the role of particle size in the electrostatic process and maintain a consistent blend when reclaimed powder is used. The consistency of powder flow from the gun begins in the feed hopper. Steady, uniform fluidization is required to achieve a consistent flow through the pumps and out of the gun. As the concentration of fine particles increases the powder coating material will begin to clump together and resist fluidization. Finer particles fill the voids between the larger particles and force the operator to use higher air pressure. The air entering the fluidized bed will follow the path of least resistance and higher pressure will often cause geysering. The surface of the fluidized powder is inconsistent with large bubbles and dead spots. This condition will cause the air to surge and deliver inconsistent amounts of powder to the pick-up tube. If the condition is not too severe the operator may continue to spray but the parts will have uneven film thickness and possibly surface blemishes. If the condition is severe the gun will spit a large volume of powder onto the surface and leave a blotchy mound of powder.

Higher delivery pressures may also be needed to move the compacted powder through the hose. This higher pressure will cause excessive impact fusion at contact points throughout the delivery system, particularly in bends of the hose or around the deflector tip. Higher delivery pressures will also result in higher velocity, which can reduce powder transfer efficiency. Higher pressure will also cause more grinding action as the powder travels through the system, breaking down the powder and adding still more fines.

Finer particles have more surface area per given weight than larger particles so they tend to pick up more moisture. The higher moisture content contributes to clumping.There are physical and chemical properties of powder materials that can affect the transfer efficiency. If a powder seems to perform below the level of the other powders run on the same line the powder supplier should be consulted to see if it can be altered so that it will charge more efficiently.

The range and concentration of particle size can also affect transfer efficiency. Smaller particles carry more charge per unit weight and become self limiting at thinner films. Since back-ionization occurs at the self limiting point, a higher concentration of fine particles will contribute to surface disruptions at thinner films. Smaller particles also have less mass and are more likely to be influenced by the air flows and weaker electrostatic lines. Larger particles are more likely to have straight line motion and be affected by strong electrostatic force lines or gravity. This particle size related behavior has an impact on electrostatic wrap and penetration of faraday cage areas.

The electrostatic field lines generated from the corona gun will tend to concentrate on the external edges and bend around to the back of the part. Since the finer particles tend to be more influenced by the weaker field lines that connect to the back of the part they will contribute more to wrap. The fines also deposit on the edges more readily and become selflimiting at thinner films, making it more difficult to penetrate Faraday areas when there is a high concentration of finer particles. Larger particles, since they are slower to self limit and have truer straight line motion, are more successful in penetrating inside corners.

When film builds are drifting lower and penetration is becoming more difficult the powder particle size blend may
have too many fines.

Smaller powder particles are easily influenced by air flows in the application area and more likely to drift away from containment. Since uncontained powder is a dirt source the finer particles can be a contributor to dirt rejects. Because of the ability to collect over-spray for reuse, some operators are not overly concerned about first pass transfer efficiency. However, recycling of powder has a negative impact on the material. It alters the classification of the particle size, it degrades application performance, contamination may be added to the reclaimed material and some over-spray will need to be scrapped. Good practices in application must be designed to provide high first pass transfer efficiency to reduce over-spray.

Reclaimed powder is mixed with virgin powder in a consistent volume for consistent performance. It is important to maintain a consistent ratio of virgin to reclaim powder for the best possible transfer efficiency.

Experience with a given powder will help to determine what the ratio should be. A sensible starting point is 50/50. If the deposition is good then 50/50 is a good ratio of virgin to reclaim. If the deposition is worse than the virgin material it may be necessary to reduce the volume of reclaim in the blend. Film characteristics, such as thickness and smoothness, are also affected by the grind size. In general, an overall coarser blend will build a thicker film and a finer grind will provide a thinner film. Film smoothness is partly dependent on an even distribution of various sized powder particles. Larger particles take longer to melt and they may not completely level out during the cure cycle. If a grind is too coarse it may cause excessive texture called orange peel. An excess of fines will cause the film to reach the self limiting point faster and start back ionization, resulting in "electrostatic orange peel."

Particle Size Measurement

Because of the impact that particle size has on the coating process it is important to be able to accurately measure the grind size for specification of a material and for adjustments to the coating operation.

Many coaters do not have this capability and must rely on the coating supplier to perform the test for them. Understanding the measuring process and the how the data is organized and analyzed can help a coater develop process control measures.

The grinding operation in powder manufacturing produces particles of varying size and shape. This collection of particles is called the particle size distribution. A sample of the virgin material is used to determine the particle size distribution as received. Collection of the sample should consider the natural separation that can take place in the container. Coarser particles tend to migrate to the top while the finer particles settle at the bottom. In order for the sample to be a true representation of the bulk material it should be taken from a level somewhere in the center of the container. The scoop that is used for the sample should be metal rather than plastic to help avoid frictional charging and the relative humidity should be between 40 to 60%. These measures will help provide a truly representative sample.

In order to compare the reclaimed powder to the virgin material or a mix of the two to the virgin material, a sample is compared to the original bulk powder as received. The results are used to construct a graph, a table or a statistical summary for comparison. There are several methods by which particle size distribution can be measured. Different methods measure different attributes so it is difficult to compare results from two different methods. Optical methods that are used may not always be completely accurate but they are useful for comparing relative particle size differences.


It is important to understand the influence of powder particle size on the application of the coating. The particle size from the manufacturer will be altered by the application process and these changes must be managed to provide consistent results. Effective communication of particle size data can help define the best powder and provide information for process control.

  To be Continued.....  

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Mr Siddiq writes in his email, "I visited your web site www.ipconweb.com. I came to know that you publish a news letter regarding powder coating market in india. please send it to me through mail."
Moderator: We have added your email address to our mailing list.
M Rawat Manager Product Development, Asian paints (I) Ltd writes "Its always a pleasure to read and contribute to your news letter".
Mr Sidhart writes in his email "Could you provide us the following details: What is the installed capacity of the powder manufacturers of India and what is the present consumption."
Moderator: We have covered this issue in our earlier newsletter. We have sent you a copy of that newsletter".
Gary M. Cohen Executive Director RadTech International North America, writes in his email "Wow!!!  Vivek, I never took a good look.  This is excellent!  Love the UV Powder info.  Congratulations, I am a little jealous!!! 
Moderator: :-)
During a Telephonic conversation from Mumbai, Mr. Muthukumar informed us about the recent changes at Sames.
Mr. Murli called us from Mumbai informing about the features of the Gema powder coating gun.
Mr Ganesh Narayan, Sr. Manager, Nissho Iwai Corporation subscribes to our enewsletter saying, "We at Nissho Iwai have identified Indian Coating Industry as a progressive segment having tremendous potential for growth.  Hence wish to keep close relation with the whole industry and contribute in our own humble way to its growth in India.  This is in line with our company's logo ' More for the world "
Moderator: Welcome aboard.
In response to the email interview with Mr Jasud of Raj Systems, which appeared in our earlier newsletter, Mr Desai of Mitsuba Systems raised doubts on the claims made by Mr Jasud. In his email Mr Desai writes, "The information provided by Mr. Jasud is wrong and may mislead prospective buyers"
Moderator: We appreciate your concern about the possible incorrect technical statement made by Raj Systems. We have forwarded your reaction to the concerned person.
Dilshan Ferdinando, of Sri Lanka writes in his email, "I am looking for a low cost small powder coating equipment and plant to coat steel panels".
Moderator: We have posted your query in our e-biz-newlsetter and we hope you must have received offers from the plant manufacturers by now.
Mr. Sameer from Super Coats Delhi writes in his email, "My name is Sameer Verma and I am doing Powder Coating job work at Delhi. I am regular visitor to your web site India powder coating but I feel you are not updating it regularly with latest updates but in any case it is a good effort."
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