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

This edition of the newsletter contains:

News features.
The Powder Coating Manual (Part 9)
Exhibitions and Conferences in November and December 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.


    News Features  
Paint industry betting on festival demand for growth
(European Coatings Flash - October 14, 2002)

The coming festival season is a litmus test for paint manufacturers in India. The decorative paint segment is showing signs of a declining growth rate, which is the result of a slackening rural economy shaken by scanty monsoon (rainy season) this year. As a result, paint companies are going all out to woo the average Indian to part with some of his earnings for a bright and painted home. Companies such as Asian Paints, Goodlass Nerolac, Jenson&Nicholson and Berger Paints have launched several innovative schemes and 'value-added services' for the festival season, particularly Diwali.
Asian Paints, the largest paint maker in terms of market share in the decorative segments, has lined up a range of products. Not to be left behind, Goodlass Nerolac has launched a promotion campaign targeting the festival season. "We are kicking off a festival scheme shortly aimed at pushing forth the sub-brands that we focussed on building up in the past two years,'' Mr Anuj Jain, Vice-President-Sales and Marketing, Goodlass Nerolac, said.
Says, Mr Rajesh Kothari, research analyst, Khandwala Securities, "the decorative segment went through a bad phase in 2000-01 and has shown some upside in the first half of the year. But, currently it is showing a lacklustre growth at just 3-3.5 percent growth. In contrast, the industrial segment consisting of automotive paints, high performance coatings, powder coatings, marine paints and coil coatings is showing a growth rate of 7 to 8 percent.'' In the first half of this year, the growth rate was in the region of 8 to 10 percent. Companies are now trying to offset this dip by offering more services such as painting services.  The other factor that could have an impact on the industry is the raising raw material prices.

Major coatings producer to meet at The Coatings Summit
(European Coatings Flash - October 07, 2002)

Preparations for The Coatings Summit, the new strategy conference and networking forum scheduled for January 13-14, 2003, are well under way.. While the final program has been completed, registrations have been "pouring in at a remarkable pace", the organizers said. The CEOs of major manufacturers from Europe, the US, Africa and Asia have already signed on. All participants will be given access to an exclusive, password-protected online database of Summit speakers and delegates to further facilitate advance planning. Apart from the main conference venue, Summit participants will enjoy the opportunity of setting up targetted meetings with their peers. Spouse and social functions will add more benefits and also offer opportunities for networking.

Henkel acquires Solyplast
(European Coatings Flash - October 21, 2002)

On October 10, 2002, the Henkel Group, Düsseldorf, took over Solyplast S.A., Barcelona, Spain, a manufacturer of adhesives and sealants. Solyplast S.A. produces and markets acrylate and silicone sealants as well as adhesives for the craftsmen and DIY market. The company, which has 42 employees, recorded sales of some 14.6 million euros in 2001.
"By purchasing Solyplast the Henkel Group is not only strengthening its market position but also acquiring expertise that ideally complements our existing business," explains Alois Linder, Executive Vice President Consumer and Craftsmen Adhesives of the Henkel Group. "This acquisition gives us an opportunity to grow in this area in other regions as well." Founded in 1973, Solyplast S.A. is one of the market leaders in Spain for sealants, generating about 90 percent of its sales in the craftsmen segment. The company will be fully integrated in the Henkel Group company Henkel Ibérica, Barcelona, Spain.

Ferro completes sale of Powder Coatings
(European Coatings Flash - October 07, 2002)

Ferro Corporation has completed the sale of its Powder Coating Business unit. The sale consisted of two separate transactions with Akzo Nobel N.V. and Rohm and Haas Company. Akzo purchased the operations in the Americas and the Asia-Pacific region, while Rohm and Haas purchased the operations in Europe.

Chugoku invents "HOT" paint

Chugoku Marine Paints of Japan has developed an electro-conductive paint for exothermic applications. In the presence of an electric current, the coating film gives rise to a uniform surface exothermic effect which could melt snow and ice. Chugoku is hoping to commercialise the system, comprising both the coating and current control device. (Polym Paint Col J, Aug 2002, 192 (4455), 34)

Adhesive inspired by GECKO PHYSIOLOGY

An interdisciplinary team at the University of California and Stanford University has unlocked the molecular secrets behind the gecko's sticking ability, which in turn has opened the door for engineers to develop a new dry adhesive which works under water and in outer space. Behind the gecko's uncanny ability to climb up a polished glass wall, and support its entire weight with single toe, lie the weak molecular attractive forces, known as van der Waals bonds. Depending on geometry, not surface chemistry, the gecko's ability to adhere to smooth surfaces is due to the size and shape of the tips of gecko foot hairs, not their composition. One of its microscopic hairs - of which a gecko has millions - can lift the weight of an ant; a million of its hairs could lift a 45lb child, rising to a 280lb weight with the help of all its hairs. The findings have been published by Dr Kellar Autumn in the Proceedings of the National Academy of Science. (Daily Telegraph, 27 Aug 2002, 4)

Asian Paints net sales rise by 15.4 %
(European Coatings Flash - October 28, 2002)

Asian Paints (India) Limited announced that their net sales for the six-month ended September 30, 2002 has increased by 15.4 % from INR 6,194.05 million to INR 7,145.13 million (1 EUR = 47 INR). Other income for the company was INR 92.60 million compared to INR 48.49 million for the corresponding period of the previous financial year. Profit before depreciation, interest and tax for the six-month ended Sept 30, 2002 was INR 1407.21 million as against INR 1054.88 million, registering an increase of 33.4 %. Profit before tax for the company increased by 45 % to INR 1129.35 million compared to INR 778.61 million in the corresponding period of the previous financial year. Profit After tax for the six-month period ended Sept 30, 2002 was INR 701.38 million compared to INR 494.01 million, registering an increase of 42 %.

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

BS EN 13523-6: 2002: Coil coated metals - test methods. Part 6. Adhesion after indentation (cupping test)

BS EN 13523-8: 2002: Coil coated metals - test methods. Part 8. Resistance to salt spray (fog)

BS EN 13523-18: 2002: Coil coated metals - test methods. Part 18. Resistance to staining

BS EN 13523-23: 2002: Coil coated metals - test methods. Part 23. Colour stability in humid atmospheres containing sulphur dioxide

For further information, please go to:

Quick Links www.ipconweb.com
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Happy Pushya Nakshtra

On October 29On October 29th, the moon passed through the Pushya Nakshtra (A part of the Cancer Constellation). Eight days before the Diwali festival, this is considered to be an auspicious occastion for the purchase of new account books. As seen from the earth, the moon passes through this circle of the 27 Nakshatras in about 27 days. Thus it takes the moon about one day to pass through one Nakshatra. In southern parts of India the star is also known also Pooyyam.

Pushya Nakshatra is headed by the star Asellus Australis (Southern Donkey), Delta Cancri, magnitude 3.9, which is about 100 light years away. For a change, try to locate the Pushya Nakshatra in the cancer constellation which lies between the Leo and the Gemini constellation. As a bonus, you may have a chance to see the planet Jupiter which is in the same constellation at present.



    Exhibitions, Seminars, Course, Lectures  
ICE 2002
(30 October - 1 November 2002, New Orleans, USA)
FSCT Annual Meeting and International Coatings Expo. For further information, please contact FSCT, 492 Norristown Rd, Blue Bell, PA 19422; Tel: + 1 610 940 0777; Fax: + 1 610 940 0292 or go to: http://www.coatingstech.org

(3-6 November 2002, Florida, USA)
Conference and exhibition addressing all aspects of the protective coatings
industry. For further information, please visit SSPC online at:
http://www.sspc.org or contact Tera Lynch. Tel: + 1 412 281 2331 ext 217;

(5-6 November 2002, Dresden, Germany
For further information on this conference, please contact: Deutsche Forschungsgesellschaft fuer Oberflaechenbehandlung, Adlerstrasse 94, D 40215, Duesseldorf, Germany. Tel: + 49 211 370457; Fax: + 49 211 370459 or go to

(5-6 November 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
: http://www.taw.de

(5-7 November 2002, Katowice, Poland)
For further information, please contact: Marketing Department, dmg world
media ltd, Queensway House, 1 Queensway, Redhill, Surrey, RH1 1QS. Tel: + 44
1737 855488; Fax: + 44 1737 855474;

(5-8 November 2002, Katowice, Poland)
The list of papers for this conference is now available. For further details, please contact: Institute of Plastics and Paint Industry, ACT '02 Organising Committee, Ms Anna Pajak - Conference Manager, ul. Chorzowska 50, 44 100 Gliwice, Poland. Tel: + 48 (32) 231 90 41; Fax: + 48 (32) 2312674

6 November 2002, York, UK
This one-day symposium is arranged by the Oil and Colour Chemists' Association (OCCA). For further information, please contact: Yvonne Waterman, OCCA, Priory House, 967 Harrow Road, Wembley, HA0 2SF. Tel: + 44 20 8908 1086; Fax: + 44 20 8908 1219

4-5 December 2002, Edinburgh, Scotland
For further information, please contact: Jo Stone, Conference Coordinator,  PIRA International, Randalls Road, Leatherhead, Surrey, KT22 7RU, UK. Tel: + 44 1372 802044; Fax: + 44 1372 802243 or go to:

(6-8 November 2002, Lund, Sweden)
For further information on this international symposium, please go to:

Highly Predictive Accelerated Weathering
(November 7, 2002, Virtual course: location your home or office, international access is free)
Dr. James E. Pickett, for further information please contact: Peter Patsis papatsis@ims-np.org, Institute of Materials Science, 52 South Manheim St., New Paltz, NY 12561; Tel: + 1 508 981 0146; or go to http://www.imsvip.com/  

(12-13 November 2002, Birmingham, UK)
For further information on this 2-day international conference and exhibition, please go to
: http://www.piranet.com

13 November 2002, Sheffield, UK
This one-day seminar is organised by the Yorkshire Branch of the Institute of Corrosion. For further information, please contact: The Institute of Corrosion, Corrosion House, Vimy Court, Leighton Buzzard, LU7 1FG, UK. Tel
: + 44 1525 851771; Fax: + 44 1525 376690 or go to
: http://www.icorr.org

(13-15 November 2002, Guangzhou, China)

For further information on this exhibition, please contact: Sinostar International Ltd, 185 Wanchai Road, 2101-2 Connaught Commercial Building, Wanchai, Hong Kong, China; Fax: + 852 28 04 22 56 or go to:

13-14 November 2002, Birmingham, UK
This exhibition is sponsored by Surface World. For further information, please contact Nigel Bean at Hill Media Ltd, 119 High Street, Berkhamsted, Herts, HP4 2DJ, UK. Tel: +44 (0)1442 878787; Fax: +44 (0)1442 87944

(10-13 November 2002, Adelaide, Australia
This 42nd Annual Conference of the Australasian Corrosion Association (ACA) will be held in conjunction with the Blast Cleaning and Coating Association (BCCA). This synergy will present many opportunities to bring together experts from a wide range of activities from the industry. For further information, please contact: Australasian Corrosion Association, PO Box 634, Brentford Square, Vic 3131, Australia. Tel: + 61 3 9874 0800; Fax: + 61 39874 4800, or go to
: http://www.corrprev.org.ua/caphome.htm

(13-14 November 2002, Birmingham, UK)
For further information, please contact Nigel Bean at Hill Media Ltd, 119 High Street, Berkhamsted, Herts, HP4 2DJ, UK. Tel: +44 (0)1442 878787; Fax: +44 (0)1442 879447

(14-15 November 2002, Berlin, Germany)
For further information, please contact Dr Dirk Meine, Vincentz Verlag, Schiffgraben 43, 30175 Hannover, Germany. Tel: + 49 511 9910 212; Fax: + 49 511 9910 299; or go to
: http://www.coatings.de

(18-19 November 2002, Amsterdam, The Netherlands)
For further information on this conference, please go to: http://www.finechemicalsconference.com

21 Nov 2002, Liverpool, UK
This event is organised by the UK Health and Safety Executive, and further information can be obtained from: Alison Wightman, Biocides and Pesticides Assessment Unit, Health and Safety Executive, Magdalen House, Bootle, M
erseyside, L20 3QZ, UK. Tel: + 44 151 951 3927; Fax: + 44 151 951 3317

6 December 2002, Edinburgh, Scotland
For further information, please contact: Jo Stone, Conference Coordinator,  PIRA International, Randalls Road, Leatherhead, Surrey, KT22 7RU, UK. Tel: + 44 1372 802044; Fax: + 44 1372 802243


  Powder Coater’s Manual ------- (Part - 9)  
Blast Media
In selecting a specific media it is helpful to understand some of the materials used and how they compare. Blast media can be made of natural material such as silica, sand, mineral sand, flint, garnet, zircon, and other mineral products. It can be made of some natural byproducts such as walnut shell or corncob. And it can be manufactured of a variety of metal and non-metal compositions such as steel, iron, aluminum oxide, silicon carbide, plastic, wheat starch, and glass bead.

In selecting a media, the comparative features that are the most important size of the product, how well it will cut, how well it will recycle and how much it cost. It is also important to know if there are any health and safety issues, such as lung problems associated with silica, and if the media will leave by-products on the surface, such as oils from walnut shells. The chart shows some common blast media and their comparative characteristics.

In addition to the comparative issues listed in the table above, it is a good idea to test different media to have a visual idea of the effect that they will have on the part.

Hard grit media such as aluminum oxide will cut faster and deeper than soft, angular media such as plastic or agricultural grit. Mineral, ceramic, or metallic grit media are used in air-blast systems. Iron and steel media are more often used in turbine-blast equipment. Materials that are more prone to fracture, reflected in the chart by friability, are not good materials for recycling. Recirculation of these materials will produce wide variations in the surface condition.

Ultrasonic Cleaning
Ultrasonic cleaning combines the chemical cleaning capability of a detergent or solvent solution with the mechanical action of ultrasonic waves. Transducers located at the bottom or sides of the cleaning solution tank generate the ultrasonic waves. The ultrasonic energy causes a cavitation process to take place at the part surface. The agitation of the solution at the part surface creates a scrubbing action that lifts and removes soils from the surface.

Ultrasonic cleaning is used in small systems with a series of immersion tanks. The equipment is fairly expensive but it can enhance the level of cleaning on parts that require special processing. It is often used to process brass parts prior to application of a clearcoat. The ultrasonic waves to help remove soils that are hard to get out of the porous surface of the brass.

Parts that are dipped into an ultrasonic cleaner should provide good access to all surfaces to allow the cavitation to work. If parts are grouped to tightly together the process will not be effective.

Vibratory or Tumbling Cleaning Methods

Vibratory systems use an abrasive media in a cleaning solution to remove burrs, rough edges and surface contamination. They are very useful to prepare castings for coating. They will remove the rough-ness and dried-on compounds that are often present on a cast surface. It is usually a good idea to alkaline clean and phosphate parts after the vibratory polishing so that and residual cleaning compound is removed before coating.

Chemical Cleaning
The first step in the chemical pretreatment process is the removal of oils, dirt, and other soils that will interfere with the development of a good quality phosphate coating, good coating adhesion, or cause surface defects. Chemical cleaning can be accomplished by subjecting a
part to an aqueous spray or dip cleaner. The cleaner may be alkaline, acidic, neutral, solvent, or emulsion. The particular cleaner used will depend on the soils to be removed, the size and type of part, the type of coating to be applied, and the substrate material.

The mechanisms for cleaning processes are generally recognized to include solubilization, saponification, emulsification, sequestration and deflocculation. In each of these processes the action requires surface wetting of the metal by the cleaning solution. Solubilization, the dissolving of soils into solution, can occur when the soils have very similar polarity and chemical affinity for the cleaning media. Emulsification, the suspension of soils in solution, requires that the soils dispersible in the cleaning media. Saponification, turning the soils into soap, applies specifically to those soils that contain carboxylic acid and ester functionality that can react with alkaline cleaning media. Sequestration involves the deactivation of metallic ions in the soil to prevent them from interfering with the detergent action of the cleaner.

Deflocculation is a process that breaks up large particles of aggregate soils into a finely divided material that is held in suspension in the solution to prevent redeposition on the part surface. The last two processes generally operate in conjunction with the first three processes

While alkaline cleaners are the most common, there are also acid cleaners and emulsion cleaners used for industrial applications. The cleaner selected must have the ability to remove a wide variety of soils, prevent redeposition, provide cleaning even when contaminated, provide foam control, be easily rinsed and be cost effective.

Proper cleaning of some parts may require a combination of spray and immersion stages. The spray stage combines the chemical properties of the cleaner with the mechanical impingement of the solution applied under pressure. Immersion penetrates areas of the part that may be inaccessible to the spray.

Spray or immersion processes can be used in manual batch operations or in automated systems with overhead conveyor. Batch systems will use a hand-held spray wand or small dip tanks. Conveyorized systems will use an in-line spray washer that has the proper number of stages. Batch systems are suitable for smaller volumes with less stringent quality standards. The list below shows some of the types of hand held systems and how they compare. Larger volumes or products with demanding quality standards will probably require a spray washer.

Spray Wand Phosphatizing – Best suited for large bulky parts where dip tanks or conveyor systems would require more space and cost. Steam Cleaning – For small volume of heavily soiled parts. Melts grease. High Pressure Hot Water – Best for cleaning large bulky parts; should have 4-5 GPM, 1,000 PSI plus heat capacity at the nozzle of 160- 200 °F (71-93 °C).

Cleaners may be classified according to their pH, a reference to the measurement of the relative alkalinity or acidity. pH is a measure of the ratio of hydrogen ions in solution to the number of hydroxyl ions in solution. If there are more hydrogen ions the solution will be acidic, if there are more hydroxyl ions the solution will be alkaline.

On the pH scale, pure water is neutral and has a pH of 7. A pH of 0 to 7 is acidic and 7 to 14 is alkaline. Caustic soda has a pH of 13 or 14 while hydrochloric acid has a pH of less than 1.

Cleaner pH varies with different products and substrate materials.
Cleaner pH will typically range from 4.5 to 10.5.

Alkaline cleaners : mild, pH 9 - 10.5
: medium, pH 10.5 - 11.5
: high, pH >11.5
Neutral cleaners : pH 6.5 - 9
Acid cleaners : pH 1.0 - 5.5
  To be Continued.....  

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