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

This edition of the newsletter contains:

News features.
The Powder Coating Manual (Part 10)
Exhibitions and Conferences in December and January 2002

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    News Features  
Akzo Nobel third quarter net income 3 percent down
(European Coatings Flash - November 04, 2002)
Akzo Nobel, the international pharmaceutical, coatings and chemicals company, announced a third quarter net income of EUR 232 million, 3% below last year. The outlook for 2002 was confirmed. Fritz Fröhlich, Akzo Nobel's CFO, said: "On the one hand, the Company had to absorb the impact of currencies and pension costs. On the other hand, we were able to grow the sales volume of all three business groups."  Coatings continued its strong performance with autonomous sales growth of 4% and an operating income increase of 5%.
In the third quarter, Coatings achieved autonomous growth of 4%. Sales decreased 4% due to weaker currencies. Fröhlich said: "Results of almost all businesses were up due to cost savings. The implementation of the restructuring programs is on schedule. So far the workforce has been reduced by 700 employees. Earnings of Decorative Coatings were significantly up. The industrial activities also improved, although the business climate remains weak. Car Refinishes achieved a stable performance in the face of deteriorating market conditions. Marine & Protective Coatings turned in an excellent performance, particularly in Asia, mainly benefiting from cost savings."

DuPont reduces about 650 positions
(European Coatings Flash - November 04, 2002)
As part of its strategy for sustainable growth, DuPont announced actions that will enhance its position "as a leader in the highly competitive global coatings industry". DuPont Coatings & Color Technologies will improve the productivity of its global business units by consolidating some of its assets and optimizing processes. The DuPont Coatings & Color Technologies platform includes the Performance Coatings and the Titanium Technologies businesses. These actions will result in the reduction of about 650 positions.
"These difficult but necessary actions will enable our businesses to improve customer focus while strengthening our business performance, and thus contribute more strongly to the company's goals of sustainable growth," said Edward J. Donnelly, group vice president - DuPont Coatings & Color Technologies.
DuPont estimates it will realize annual pretax savings of about $60 million as a result of these actions. About one-third of this benefit will be realized in 2003, with substantially all realized in 2004.

Fire damages Reichhold plant
(The Business Journal / www.e-epoxy.com)

Durham-based Reichhold Inc. says that the Spolchemie plant in Usti nad Labem in the Czech Republic, where Reichhold's products are produced, experienced a fire on Nov. 21 at about 9 p.m. Czech time.

The Spolchemie resin plant is a five-story building in the center of Spolchemie that is used for manufacturing epoxy resins, unsaturated polyesters, coating resins and specialty resins. The plant suffered extensive damage. No injuries were reported and the appropriate authorities are accessing the damage and investigating the cause of the fire. At this time, there are no reports of any negative environmental impact to the city of Usti.

Production at the Usti nad Labem site has been halted. The company says it will continue to serve its customers by utilizing other Reichhold global facilities, including its nine sites in Europe.

Founded in 1927, Reichhold is a subsidiary of Dainippon Ink & Chemicals, which produces printing inks and polyester resins.

Henkel Group opens technology center in Japan
(European Coatings Flash - November 25,, 2002)
The Henkel Group is investing in the Asian market: at the end of September 2002, the new "Henkel Loctite Technology Center Asia Pacific" was officially opened in Yokohama, Japan. Over 130 employees are working to ensure that industrial customers of Henkel Technologies throughout Asia will be provided with individual, tailor-made products and systems solutions in the future. The company not only aims to offer customer and engineering services in Yokohama, but also to establish the product development efforts of Henkel Loctite for the Asian market there.
Henkel Loctite can exploit the advantages of four technology centers located in the USA, Germany, Ireland and Japan. Each has defined priorities in accordance with specific regional requirements. "It is particularly important for Henkel Loctite as a specialist in engineering adhesives to individually advise and consult its customers throughout the world. Henkel Loctite was responsible for the implementation of the project in Japan," states Heinrich Grün, Corporate Vice President Loctite Engineering Adhesives of the Henkel Group. Henkel has invested a total of 23 million euros in the new location.

FSCT Announces Decision to Hold ICE Every Other Year

The Federation of Societies for Coatings Technology, citing the results of a survey of coatings manufacturers and suppliers, announced that the International Coatings Expo (ICE) will be held every other year beginning in 2004. The survey, conducted earlier this year, indicated that a majority of suppliers felt that an annual exhibition was too frequent - and costly - considering the current state of the industry, the Federation said. The change in show frequency was approved by the FSCT's board of directors on Oct. 29 in New Orleans, just before the start of the 2002 ICE on Oct. 30.

The Federation also announced that Chicago will become the exclusive site for the ICE, beginning with the 2004 show. FSCT Executive Vice President Robert F. Ziegler said the National Paint & Coatings Association also has agreed to hold its Annual Meeting in conjunction with the ICE in Chicago in even-numbered years. With the new ICE schedule, the event will alternate with the European Coatings Show, which is held in odd-number years in Nuremberg, Germany.

In another announcement, the Federation said the schedule for the 2003 ICE in Philadelphia has been revised from an original Thursday- Saturday program to the "more familiar" Wednesday-Friday arrangement. The event is scheduled for Nov. 12-14, and will begin with an afternoon and early-evening schedule on Wednesday, Nov. 12, in an effort to attract local manufacturers and technical personnel. The opening day also will feature a more "informal" atmosphere and special events, the FSCT said.

Under the revised ICE schedule, the show will be held in Chicago on Oct. 27-29 in 2004, Sept. 27-29 in 2006, Oct. 29-31 in 2008, and Sept. 29-Oct. 1, 2110.

While announcing the change in ICE frequency, the Federation said it plans to launch a new event for years when the show is not scheduled, and announced the creation of an "Events Steering Committee" to direct the implementation of the revised ICE and an alternating-year event or series of events. "The FSCT firmly believes than an event needs to be held every year to provide a forum for both suppliers and manufacturers to gather, discuss, and plan for the future," said Gail Pollano, the 2001-2002 FSCT president. The steering committee is headed by chairman F. Louis Floyd, executive director of PRA Laboratories Inc., and includes representatives of manufacturer and
supplier companies.

Pollano said the decision to scale back the frequency of ICE "recognizes the concerns of the industry." She said the "challenge to the Federation is to adjust its operations to accommodate diminished income, while providing the same - or increased - benefits to the industry it serves."

Ziegler said the change in ICE frequency was approved "overwhelmingly, but not unanimously" by the Federation board. The FSCT said industry suppliers - particularly the major suppliers - have favored a switch to biennial frequency for several years. But the recent survey "for the first time established a growing trend among manufacturers for a less-frequent ICE."

KW Plastics to launch recycled and recyclable paints cotainers
Recycling can be a closed loop, as illustrated by a new recycled and recyclable paint container to be launched by KW Plastics at the ICE Show in October. The all-plastic container, which is based on old car-battery casings, shampoo or soda bottles, can itself be recycled at the end of its life. Other advantages include lack of rusting, absence of dents and lighter weight. They are, however, suitable only for latex paints. The new containers will be distributed by Deeks & Co, a regional distributor based in Ohio, and will eventually appear in a range of sizes. (Modern Paint Coatings, Jul/Aug 2002, 92 (5), 15)

Thin Film Powder Breakthrough: 14 microns or lower
(Coatings Magazine September 2002)

An Ontario powder manufacturer has developed a method of creating thin films as low as 0.5 mils with particle sizes of 14 microns or lower.

Current thin film powder technology can be applied as low as 1.5 mils for whites and 4-5 mils for yellows with particle sizes of 25 microns or more. While many companies say they have thin film powders, John Nother, president and chief operating officer of Link-Syn Technologies, London, ON, says current thin film technology cannot go below 25 microns, although some are working on particle sizes of 17 microns.

Link-Syn has filed for a patent on the process, which uses a combination of chemistry and mechanical mechanisms to achieve the thin film and low micron size.

The pure resin powders don't contain any fillers, which sometimes affect weatherability and durability in formulations. The powders offer traditional gloss properties, eliminate orange peel and allow for post-forming of steel in coil coating applications.

If the company's claims are proven--Link-Syn has secrecy agreements with several OEM manufacturers to test the powders--it will be the first company in the world to have achieved thin films at such low microns

.John Nother, president and chief operating officer, won't divulge the secrets behind the technology, but he does say that Link-Syn has worked five years on refining the technology in collaboration with other institutions.

"Everyone has been trying to achieve thin film powders and we're the first company on the market that has been successful. Although it's thin film technology, we use the term high efficiency powders to differentiate ourselves from other thin film powders on the market that have a micron size of 25. We can go below 14 microns."

The thin films that can be achieved using the technology depend on the colour. For traditional yellows, Link-Syn can go down as low as 2 mils, compared to the average thin film yellows, which are at about 4-5 mils. For traditional blue whites, the company can achieve thin films of 1 mils compared to the average 3 mils.

Nother stresses that despite the thin film, performance properties are not compromised. Indeed, he says that because the powders are pure resins, properties such as chemical resistance are enhanced. Nother estimates that finishers can realize savings of between 30-35 per cent. "Just on material alone, finishers will see a 10 per cent reduction in cost. In addition to that, throughput goes up, shipping costs (of the powders) go down and recoatability is improved."

Nother adds that the technology can be used to formulate all types of powder coatings, including low temperature and UV cure systems.

BASF sells industrial-coatings facility
(European Coatings Flash - November 18, 2002)
BASF Corp. announced the sale of the company's general industrial coatings manufacturing plant in Chicopee, MA, to C&C Ventures L.L.C. The sale includes the site's property, buildings, production equipment and customer list for specific products for which C&C Ventures acquired the proprietary rights. BASF acquired the site as part of its 2000 purchase of the Morton industrial coatings business from Rohm and Haas Co.
BASF said the sale is part of its plan to focus on coil, extrusion and powder coatings and certain types of general industrial coatings. The company continues to manufacture industrial coatings at sites in Batavia, IL; Decatur, AL; Morganton, NC; Colton, CA; and Belvidere, NJ.

Brillux launches Non- Allergeniv SIlicate paint.
German paint manufacturer Brillux GmbH has launched a new non-allergenic interior silicate paint, aimed at Germany's 17-19M allergy sufferers. The new Elf 1806 paint is formulated without preservatives, plasticisers and VOCs, without sacrificing durability. The paint's anti-allergenic properties have been tested to standard RWTÜV. (Brillux, Press Release, Sep 2002, 1p)

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

BS ISO 15710: 2002: Paint and varnishes - corrosion testing by alternate
immersion in and removal from a buffered sodium chloride solution

For further information, please go to:

SSPC-PA 7: Issued by SSPC (The Society for Protective Coatings) this standard
concerns applying thin film coatings to concrete.

SSPC-PA Guide 5: Issued by SSPC (The Society for Protective Coatings) this is
a revised guide to maintenance coating programs for steel structures in
atmospheric service.

For further information, please go to:

Quick Links www.ipconweb.com
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    Exhibitions, Seminars, Course, Lectures  
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: http://www.piranet.com

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

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/

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

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:

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

  Powder Coater’s Manual ------- (Part - 10)  
Alkaline Cleaning

Alkaline cleaners are the most common method of soil removal for metal preparation prior to the application of powder coating. Cleaners based on sodium hydroxide (caustic) are very economical where cleaning by saponification is desirable. Caustic cleaning media are highly reactive on non-ferrous surfaces and they can cause over-etching on aluminum and zinc surfaces, possibly creating smut and adding zinc to the solution. Caustic cleaning residues are also difficult to rinse away, especially if the solution temperature is in the high range. Alkali silicates are excellent for cleaners that are used on non-ferrous surfaces. Silicates can provide good cleaning with minimal chemical attack and they do a good job of soil emulsification. They are a little more costly than alkalis and not easily rinsed.

Synthetic detergents and surfactants offer many variations in composition. In some cases they cost a little more than alkalis but they provide a longer bath life which offsets the higher raw material cost. With good performance, easier handling and disposal, and superior effectiveness
over a wider array of metals, these products are a good solution for many systems.

Typically, a mild alkaline cleaner (pH of 9 to 10) will provide better soil removal and longer bath life than a high caustic solution. Residues of alkali salts will kill the free acid, drop out metal salts and kill the phosphate bath. A mild alkaline cleaner, prior to the phosphate stage, will aid in the formation of a more uniform, dense phosphate coating, leading to better paint adhesion and corrosion protection. If the cleaning is not adequate, it is usually better to increase the time in the cleaner rather than the concentration. Two mild alkaline cleaner stages are better than one high caustic stage. Mild alkaline cleaners are good for multiple metals and they can be run at a wide variety of temperatures. A higher pH cleaner may be necessary on occasion for very difficult soils.

An alkaline cleaner is typically comprised of:

• alkaline base
• surfactant/detergent package
• additives for
• defoaming
• minimizing attack on substrates
• coupling agents
• water conditioners

Alkaline Cleaner Component Functions

• Silicates - (sodium metalicate, sodium orthosilicate) High alkalinity, good saponifier and dispersant, softens water by precipitation, inhibits dissolution of zinc and aluminum. May leave a whitish residue on parts in not properly rinsed.

• Phosphates - (trisodium phosphate, sodium tripolyphosphate,tetrasodium pyrophosphate, disomium phosphate) Softens water alkalinity, improves rinsing, saponifier.

• Carbonates - (sodium carbonate, sodium bicarbonate) Alkalinity,good buffering.

• Hydroxides - (sodium hydroxide, potassium hydroxide) High alkalinity, saponifier.

• Nitrites - (sodium nitrite) Minimizes oxidation of metal due to cleaner drying.

• Chelants - (versene) Softens water, changes form of precipitation.

• Surfactants - Provide water/oil solubility. Enables cleaners to work more efficiently by reducing surface tension at the metal surface. Also, prevents part from drying between stages or the spray washer.

• Defoamers - Control foam.

• Inhibitors - Minimize attack on metal.

The alkaline cleaner is added to water (typically 2 - 10%) and applied hot. Solutions of this type have low surface tension, which means they can easily penetrate beneath and between dirt particles. In addition, the soap or detergent present can often combine with dirt, oil or grease and emulsify them in water to remove them from the surface of the part. When used with pressure spray or mechanical scrubbing, hot alkaline cleaning for 1-2 minutes is a very effective cleaning method.

Surfactants used for cleaners are usually anionic or nonionic, polyaddition products of ethylene oxide and/or propylene oxide with alcohol’s, amines and phenols. Sometimes the surfactants used in dip cleaners are sulfonates.

The purpose of the surfactants is to break oil and grease from the surface of the parts and emulsify it in the solution. Oils will rise to the surface when the circulation pump is turned off and they can be removed by skimming or overflowing.

A typical spray cleaner stage in a washer is 60 to 90 seconds, while a dip stage may be anywhere from 3 - 5 minutes with temperatures ranging from 120 to 180 0F (49 to 82 0C). Times, temperatures and cleaner concentration vary depending on the cleaner used and the condition of the substrate.

The rinse stage following the cleaner is ambient tap water to remove any residual alkaline cleaner or loosened soil. Rinse stages are overflowed with fresh water as parts are processed.

Cleaning and rinsing alone prior to painting is sufficient as a stand alone pretreatment in a limited number of situations. As with mechanical cleaning, it will provide initial adhesion only and offers nolong-term protection.

When cleaning prior to conversion coating, it is important to consider how the cleaner and its effect on the substrate may interfere with the formation and deposition of the conversion coating. Will the cleaner drag-out adversely affect the conversion coating solution? Will the cleaner alter the surface (etching, smutting, etc.)? In a pretreatment process, the cleaner should not be viewed as a separate process but as an integral part of the total pretreatment process that can effect the quality of the conversion coating.

Cleaner Performance Factors

Over time, the soils that are removed from the parts will build up in the cleaner solution. Solid particles will settle to the bottom of the tank as sludge and oils, grease and some floating debris will float on the top of the solution. There is a limit to the amount of contamination that a cleaner bath can tolerate before it will cease to clean and need to be dumped and recharged. Overflowing the solution can help to reduce the accumulation of floating debris but solids can still cause a problem and overflowing the solution will create a need for more chemical. Oil skimming and sludge removal can extend the life of the cleaner. Techniques for this are explained in the discussion on washer design.

Control Parameters
The parameters for process control of a cleaning solution are process time, chemical concentration, temperature, spray pressure, drain time,and the volume of contaminants in the solution. These are the items that must be monitored, recorded, and maintained within proper ranges in order to achieve predictable cleaning performance.

Acidic Cleaning

Acidic cleaning is based on attack of the metal surface by sulfuric, hydrochloric, nitric, phosphoric, hydrofluoric, fluorboric, or chromic acids and the various acid salts of these acids. They generally include a surfactant package, metal ion sequestrants, alcoholic solvents, and an inhibitor to prevent excess attack of the metal. They can be useful for removal of light oxides, organic residues, persistent salts and other soils that are readily dissolved in acid.

Because of the fact that acids are corrosive and therefore more difficult to pump and handle, and because in some cases they are inferior to alkaline cleaners on organic soils, they are much less commonly used. For metals that are prone to hydrogen embrittlement, such as alloy steels and high-carbon grades of steel, acid cleaning is not an option. Acids can also react with some metals to form insoluble byproducts that interfere with subsequent processes.

In a three-stage washer, the first stage combines the cleaning and iron phosphating. These solutions will typically be made up of phosphoric acid, a wetting agent, and an activator.
Acid solutions may also be used to remove scale or oxides in pickling solutions. These solutions are relatively strong mineral acid solutions, using sulfuric, hydrochloric, phosphoric and nitric acid. This type of solution can be useful for removal of stubborn inorganic contamination. One particularly good use is the removal of laser cut scale. Laser cutting of steel will form an oxide layer that is resistant to alkaline cleaning. Pickling rates increase with higher acid concentration and higher temperature. Excess concentration should be avoided because of the corrosive nature of the solution and the risk of an overly aggressive attack
on the metal.
  To be Continued.....  

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Dear Sir,
We are pleased to inform you that Services International in association with ‘Indian Paint Association’ is organizing India International Coatings Show 2003 Exhibition alongside the 21st Indian Paint Conference at Hotel JayPee Palace, Agra, India during 17th-19th January 2003.
The Coatings Show is an exhibition par excellence with focus on the need of the coating industry. It provides marketing opportunities for suppliers to the coating industry as they attract a wide variety of material and equipment buyers, specifiers and influencers from all over the world.
Thanking You
For Services International
Geetanjali Kapoor
Moderator: We invite you to inform further details of the Coating show through our website.
Dear Sir,
we are one of largest manufacturer such as LOW-GLOSS CURING AGENT MB68 and LOW TENPERATURE AND FAST CURING AGENT MB31 and TGIC as well as Epoxy Resin and polyester resin which used for powder coating in Huangshan of China
Best Regards, Jane  
Huangshan Deping Chemical Co.,Ltd , Anhui,China
Dear Mr. Vivek,
I have gone through the site and it is really a good effort and keeping a dedicated site for growing industry like powder coating. The site is quite informative and all the important details for the industry people are available as ready reference.
Ananda Kumar N.
Chemicals & Materials Practice, Frost & Sullivan
Dear Mr. Soley
Regarding EPSI we have changed our address and move to much larger complex.
N90 W14700 Commerce Drive,Menomonee Falls, Wisconsin 53051, USA
Tel  1 262-253- 3774, Fax 1 262-253 3775  Toll Free numbers (866) ASK EPSI,    (866) FAX EPSI
sales@epsi.com website : www.epsi.com
Kinds regards
Kissak Sarajian
Our new telephone & fax numbers are as follows
+ 91 22 2409 0347 + 91 22 2403 2736   and the new fax number is   + 91 22 2409 2468
Thanks & best wishes,  
Arjun. Sen Business Consultant..
Dear Mr. Soley,
This is to inform you that our telephone numbers have changed to the following numbers.
Old Telephone Number New Telephone Number
6318633 26318633
6334735 26334735
6316565* 26316565
6924151 56924151
6924152 56924152
6924153 56924153
6924154 56924154
Old Fax Number New Fax Number
6368776 26368776

Kindly make a note of the new numbers.
* Old fax number 6316565 is no longer valid as fax number.
Thanks & Regards
Mitsuba Systems

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