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Welcome to the October 2004 edition of the IPC e-newsletter. The IPC e newsletter is distributed free to more than 2500 people around the world.

This edition of the newsletter contains:

News features.

The Powder Coating Manual (Part 33)

Exhibitions and Conferences in October and November 2004

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. While we have used our best efforts in collecting and preparing the information on this newsletter, we do not assume, any liability for any loss or damage caused by errors or omissions, whether such errors or omissions resulted from negligence, accident or other causes. The user may use their own discretion while using the information.


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Price Rise Continues!

The raw material prices for powder manufacturing continue to rise even while powder manufacturers calculate the  and estimate its implications. A couple of months ago the question was "Who will bell the cat?". Now it is,  "How big will the bell be?"

 When asked about the  company's strategy to tackle the situation,   M Rawat of Asian Paints Industrial Coatings Ltd, said in his email,

"As you have rightly observed, the crude oil prices have catapulted more than 40 % in the last four months and the feed stocks for both Polyester and Epoxy resins being petroleum based have impacted the prices of these materials to the extent of 30 to 50 % in this period. Undoubtedly all the market segments have been hit hard by such unprecedented rise in crude oil and feed stocks. Further, the short supply of Polyester and Epoxy resins have added to the woes of powder manufacturers. Given this situation the price rise of powder coatings is imminent. While most powder manufacturers are indicating a price rise but delaying the price rise will only worsen the situation. Internationally powder prices have already increased by 15 - 20 %. We are also negotiating with our customers for a price rise of 8 - 10 %. However this process will be hindered if other powder manufacturers do not support the efforts on price rise."

Mr MV Ravi from Akzo Nobel in his email to also mentioned that the rise was inevitable. He said,

"The RM prices have been increasing the past few months and trend is likely to continue. Indications are that on account of Raw Material shortages the increase could be drastic and more frequent. The current increase being attempted (though not enough to compensate the complete impact) may not be the end to this, based on indications available for the next 3 months. Markets are watching the situation and a reaction could be gauged in the coming weeks."

A press statement on Interpon's website reads

"Hikes in chemical raw material prices force up selling prices of powder coatings in Europe; Akzo Nobel Powder Coatings announces price rise"

24 May, 2004, Felling, UK; Against a backdrop of the continuing rise in prices of the main chemical raw materials used in the manufacture of polymers and other essential raw materials used in paint manufacture, Akzo Nobel has announced a general across the board rise in the prices of all its European powder coating products.

Mr Leon Ouziel, General Manager of Akzo Nobel’s European powder coatings business unit said; “due to price pressures on all sectors of the chemical industry, the raw material suppliers to our industry have imposed across the board cost increases”.

“Akzo Nobel Powder Coatings has therefore no option other than to increase powder prices with effect from 1stJuly 2004. The increases will vary between 6% to 8% depending on the specific products involved”. “If raw material prices continue to rise in line with current forecasts, then further price increases may follow in the coming months”.

In its letter addressed to its dealers, a Nasik based manufacturer mentions a  price rise of 15 %. There are similar indications from most of the other manufacturers.

One should closely watch the movements in the coming months months. How will the market react? Will there be some re-shuffling of customers and manufacturers? Will some more manufacturers pop up or shut down? Keep you informed, we will. Meanwhile we invite you to vote in our opinion poll.

  IPC Opinion Poll I
The powder prices are on the rise.  How will the market react?
The powder demand will increase.
The powder demand will decrease.
No change.
IPC Opinion Poll II
The Customer will try to find new powder suppliers and there would be a lot of reshuffling of the customers and manufacturers.

Rising crude prices — Paint industry's burden may fall on consumers
ANY further rise in crude oil prices may prompt Indian paint companies to consider a price hike, especially in the decorative segment of the business. Almost all of the raw materials used by the paints industry have a direct co-relation to crude oil.

"The way the crude oil prices have been rising, our costs have risen tremendously," said Mr H.M. Bharuka, Managing Director, Goodlass Nerolac Paints Ltd. "To whatever extent we have been able to absorb the increase in raw material costs, we have done so. Now, the time has come when we may have to pass on some increases to consumers," Mr Bharuka said. <more>

India: Shalimar Paints will set up unit in the south shortly
Coating Flash
Shalimar Paints Ltd has firmed up plans to set up a fourth paint manufacturing unit in the country and its first in the south. According to officials in the company, it has decided to either acquire a manufacturing unit for the purpose or set up one. Shalimar, which started operations in 1902, is the oldest paint company in the country. Referring to the company's plan, managing director SL Agarwal said, "This will help us establish our reach across the country." Shalimar has factories in Howrah (West Bengal), Sikandrabad (Western UP) and Nasik (Maharashtra).

Nerolac to set up R&D centres
Goodlass Nerolac Paints is looking at setting up research and development (R&D) centres at two of its plants. The company will set up these centres at its plants in Lote, Maharashtra, and in Bawal, Haryana, to cater to customer-specific and product-specific research. They are looking at extending our R&D capabilities near our plants. This is being done so that product-specific and customer-related research can be done at the plants itself.

Nerolac recently set up an R&D centre in Mumbai at its Parel plant, which was shutdown some time back. We have a strategy to invest around 1.5 per cent of our turnover in research, to adapt to the constantly changing technology and upgrade our existing systems, Bharuka said.

The company is looking at enhancing its product portfolio for catering to the automobile segment. Nerolac is also considering to tap the foreign market in the auto segment. The company currently supplies material to some of its parent company - Kansai Paints' global customers.

Currently, they export very little material, however, we are waiting for the WTO regulations to come into place as the existing system involves a lot of duties. There will be a thrust on exporting products to global auto majors once the WTO regime comes into effect.

Nerolac currently commands a 65 per cent market share in the domestic automobile paints sector. The company is expecting to clock a volume growth of around 12 per cent in the current financial year, against an industry growth of around 10 per cent. They expect the automobile segment to continue driving the growth in the industrial paints sector this year.

Reichhold Announces Price Increase On All Acrylic Powder Coating Resins Sold in North America

RESEARCH TRIANGLE PARK, N.C. -- Aug. 2, 2004 -- Reichhold announced today a price increase of $0.10 per pound on all FINE-CLAD® acrylic powder coating resins sold in North America. The increase is for both list and off-list prices and will be applied to all orders shipped on or after September 1, 2004.

"This price adjustment is in direct response to significant cost increases Reichhold has incurred on principal raw materials used in the production of these high-performance powder resins," explained Bruce Fawcett, Reichhold senior vice president, commercial. "We've experienced price hikes across a number of key acrylic monomers including glycidyl methacrylate (GMA) monomer, for which tightness in availability has sharply driven up prices for this primary component," continued Fawcett.

"As always, we thank our customers for their business and encourage them to contact their Reichhold sales representative if they have any questions regarding this pricing adjustment," Fawcett concluded.

Reichhold's FINE-CLAD® acrylic powder resins are used as primary film-formers, crosslinkers and additives in the production of high performance powder coatings.

The Dow Chemical Company to Exhibit at ICE 2004
MIDLAND, Mich. – (September 21, 2004) – At this year’s International Coatings Expo (ICE) in Chicago, October 27 – 29, The Dow Chemical Company will showcase a wide variety of products for the paint and coatings market at Booth #718. With approximately $1 billion in sales into the coatings industry, Dow produces raw materials for virtually every application. Whether for architectural, industrial or specialty uses, Dow’s broad product portfolio meets the performance needs of paint and coating formulators.

Berger board approves amalgamation

KOLKATA: Berger Paints has approved the amalgamation of its loss-making subsidiary Berger Auto & Industrial Coatings (BAICL) with itself. The decision was taken at a meeting of Berger's board of directors on Thursday, the company said in a notice to the Stock Exchange, Mumbai (BSE). BAICL is a 100 per cent subsidiary of Berger Paints. The former posted a loss of Rs 1.5 crore on sales of Rs 25.7 crore in 2003-04, which it attributed partly to the high initial costs of customer development. In July, Berger vice-chairman G S Dhingra said that BAICL was taking steps to increase production of decorative products and curtail costs to improve its financial health. Turning around BAICL was identified as the one of the primary goals of Berger Paints to improve its bottomline in 2004-05.

Berger Paints has set aside Rs 30 crore for capital expenditure, which includes Rs 20 crore on setting up solvent-based and powder coating facilities at Jammu, in the current fiscal in order to achieve a double-digit sales growth in 2004-05. The firm, which claims to have a 17 per cent share of the Indian paints industry, had said in the past it would also eye possible acquisitions of niche players in south and south-east Asia to grow faster. Berger Paints earned a profit after tax of Rs 8.95 crore in April-June 2004 compared to Rs 5.84 crore in the corresponding period in 2003-04. <more>

Study about the powder coatings market in Central and Eastern Europe
In 2003, the powder coatings market in the Central & East European countries is over 50,000 t valued at more than EUR 160 million. About 50% is locally manufactured and the balance imported, approaching 30 powder coatings manufacturers in the countries analysed. The powder coatings market in the Middle East & Africa is at the same level of well over 50,000 t. Penetration of powder coatings differs by country from 4% up to 10%. Irfab Chemical Consultants from Belgium  reports there is still plenty of room for increased penetration of powder coatings in the entire Region. With growth rates that vary by country and region from 7% and more per year, by the year 2013, the Powder Coatings market in Central & Eastern Europe, Middle East & Africa will pierce the two hundred thousand (200,000) Tonnes mark. These are some of the striking conclusions from the strategic market and technology assessment study conducted by Irfab with the title "Powder Coatings Markets In Central & Eastern Europe, Middle East & Africa 2003-2013'', covering more than 25 countries. The study reports imports/exports by individual country, shares of market participants, both local producers and importers, sourcing of selected raw materials, trends in novel powder coating technologies: MDF, UV, thin-film technology, listing of traders/importers. Issues like shift of powder coatings manufacturing from West Europe to Eastern Europe and joint ventures and/or commercial agreements are examined in the study.

Akzo Nobel CEO Hans Wijers:“We will double sales in China in less than five years”
Arnhem (the Netherlands), Shanghai (China), September 10, 2004 – Hans Wijers, CEO of Dutch multinational Akzo Nobel, today announced the setting up of a new regional head office in Shanghai. The decision to establish a new base in the city marks another milestone in the Company’s ongoing efforts to consolidate its activities in one of the world’s most important emerging markets. “We more than doubled our sales in China in less than five years and our ambition is to repeat that,” said Wijers. “We are strongly committed to further expansion in China, which has a key role in the Company’s growth strategy.

Dow Chemical to establish Chinese production site
The leading American chemicals Group Dow Chemical is resurrecting its expansion plans in China: At a cost of several billion US$, it plans to build an integrated chemicals plant in the People's Republic. "Whatever we do, it should be on a world market scale. And that means producing over one million tonnes", said McIlvenny. For Dow, the turnover share for all of China (including Hong Kong and Taiwan) was US$1.8 billion or 5.5 per cent of the Group turnover last year.

Mr Ratnakar Gokhale from Akzo Noble, while on a tour to Indore, visited our office. Ratnakar appreciated our website contribution in the field of powder coating. Among other things he shared his views on the general powder coating market, and the recent changes in the price structure of powder paints.

A minor explosion and fire did "very little" damage at one of two Crest Bending plants Tuesday afternoon.

Owner Bob Studer said the explosion occurred at 1:46 p.m. when a powder coating gun ignited at the plant at 602 S. Center St. That plant and one on John Street fabricate metal parts for various industries.

Studer said four people were in the building at the time with the only injury coming to one worker who got the hair on his arm singed but was back on the job Wednesday.

The factory is in a brick building with a wooden interior. Studer noted that the real damage was to the filtering system.

New Washington Police Chief Scott Robertson said the explosion is still under investigation. New Washington Fire Department responded and received mutual aid from Tiro Fire Department. Robertson said his department was also on the scene for traffic control along with the Crawford County Sheriff's Office and Ohio State Highway Patrol. <more>

'Coatings 100' Report examines changing face of global industry

Coating Flash September 20
An increasingly complex global industry structure has resulted in the concentration of coatings manufacturing in the hands of various industrial companies and private-investment firms as well as the giant chemical and "brand-management" concerns, a new industry study concludes. "The Coatings 100," from Information Research Ltd., London, says the structure of the global coatings industry has been markedly reshaped by mergers and acquisitions that have seen private equity firms holding majority stakes in coatings businesses; hardware retailers operating their own coatings-production facilities; and chemical companies holding relatively small coatings positions. These coatings businesses "compete alongside diversified chemical giants and brand- management companies for a slice of the world paint market," the publishers say.
The report says that as a result of these changes in the industry, approximately 25 of the top 100 companies active in paint and coatings production boast annual sales of $1 billion or more. The study includes a directory-style section covering the world's top 100 coatings companies, including details on sales, key executives, products, market sectors, news, and other information. A section on global coatings statistics offers figures on coatings imports, exports and demand.

New! I.D. Fluorescent Paints Provide Extreme Visibility
Krylon® Industrial Tough Coat® I.D. Fluorescent paints provide the ultimate in visibility for the labeling, coding, and marking of all steel substrates. The paints dry to touch in 15 minutes (77°F, 50 relative humidity), allowing for "production speed" marking. They are ideal for the fast identification of inventoried parts, materials, and work-in-progress...



  Seminar Events Exhibitions  

Paint Technology
October 4 - 7, 2004 
Training Course; Teddington/Great Britain
More Information from, Paint Research Association, 8 Waldegrave Road, Middlesex, TW11 8LD Teddington, Great Britain, Fax: +44 20 8943 4705, http://www.pra.org.uk/training 

Waterborne Coatings
October 5 - 7, 2004 
Course; Ypsilanti 
More Information from, Coatings Research Institute, 430 W. Forest, MI 48197 Ypsilanti, USA, Fax: +1 734 483 0085, http://www.emich.edu/public/coatings_research , sandy.tanner@emich.edu  

Dispersion of Pigments an Resins in Fluid Media
October 11 - 13, 2004 
Course; Ypsilanti, 
More Information from, Coatings Research Institute, 430 W. Forest Ave., Ypsilanti, MI 48197
USA, Fax: +1 734 483 0085, http://www.emich.edu/public/coatings_research , sandy.tanner@emich.edu  

Printing Ink Technology
October 11 - 13, 2004 
Training Course; Teddington/Great Britain
More Information from, Paint Research Association, 8 Waldegrave Road, Middlesex TW11 8LD Teddington, Great Britain, Fax: +44 20 8943 4705, http://www.pra.org.uk/training 

What is Paint?
October 14, 2004 
Training Course; Teddington/Great Britain 
More Information from,Paint Research Association

Radiation Curing Technology
October 18 - 20, 2004 
Training Course; Teddington/Great Britain
More Information from, Paint Research Association

4th Woodcoatings Conference
October 25 - 27, 2004 
Conference; The Hague/The Netherlands
More Information from, PRA

Improving Durability and Performance of Coatings
October 26 - 28, 2004 
Course; Ypsilanti 
More Information from, Coatings Research Institute, 430 W. Forest Ave., Ypsilanti, MI 48197, USA, Fax: +1 734 483 0085, http://www.emich.edu/public/coatings_research

International Coatings Expo
October 27 - 29, 2004 
Exhibition, Conference; Chicago/USA
More Information from:Federation of Societies for Coatings Technology, 492 Norristown Road
19422-2350 Blue Bell, PA, USA, Fax: +1 (610) 940-0292, http://www.coatingstech.orgfsct@coatingstech.org  

Business Information for the Coatings Industry
November 4, 2004 
Training Course; Teddington/Great Britain
More Information from, Paint Research Association

Applied Rheology for the Coatings Industry
November 8, 2004 
Training Course; Teddington/Great Britain
More Information from:, Paint Research Association



  Powder Coating Manual -"The Powder Booth"------ (Part - 33)  

 Powder Booths

A powder booth is an enclosure that is designed to contain the powder application process. A recovery system is attached to the powder booth shell. The recovery system uses a fan to pull air into the booth and prevent the oversprayed powder from migrating out of the enclosure. The simplest powder booths are designed for a single operator to manually apply powder to a stationary product. Other booths are designed so that parts can be conveyed through the enclosure. Conveyorized systems may be designed for manual application from two sides, automatic application, or a combination of both, depending on the system requirements. The particular style, size and number of powder booths needed is related to the product size, the available space, the amount of capital and the volume of product to be coated. Powder booth shells are occasionally made of painted steel but more often they are made of stainless steel, polypropylene, polycarbonate or other clear plastic, and a few are made of glass or polyethylene sheet. Painted steel is adequate but there is some risk that the paint will chip off and contaminate the oversprayed powder in the reclaim system. Stainless steel makes a very durable booth shell with a smooth surface for ease of cleaning. Plastic walled booths offer an easy to clean surface and the walls can allow some light to penetrate into the spray area and help illuminate the process. A nonconductive plastic walled booth will collect less charged powder on the walls. This means that they can be easier to clean. It also means that they do not attract as much powder that might otherwise be attracted to the part, so they provide a modest improvement in transfer efficiency.

The part size will influence the height and width of the booth and the required product opening. The opening size must allow the part to enter with proper clearance around the edges. In most cases, the clearance is 6” between the largest part and the edges of the opening. In a conveyorized system, the booth shell should extend at least 18” above the opening to keep the hook site well above the spray zone. The amount of opening in the booth will determine powder contain-ment air requirements. In order to contain the oversprayed powder, the collector fan is designed to provide 100-120 lineal feet per minute (lfpm) of air velocity across all openings. Properly designed, the booth will have even airflow throughout the enclosure and not interfere with the coating process. Collector fan sizing must also consider safety. Each powder is rated with a lower explosion level (LEL) measured in oz/ft 3 . The booth must be designed with enough ventilation to keep the powder concentration level below 50% of the LEL. The number of guns and nominal powder output per gun determines concentra-tion. The formula below shows the method of calculating the air require-ments for a powder booth using a design face velocity of 120 feet per minute. The face velocity must be maintained at or above 100 feet per minute to ensure powder containment. The face velocity times the square feet of opening equals the fan size in cubic feet per minute.

A second formula may be used to determine if the airflow is sufficient to provide enough air to keep the concentration of the powder in the air below 50% of the minimum explosive concentration (MEC) in ounces per cubic feet or grams per cubic meter. The MEC of a particular powder can usually be obtained from the manufacturer.

In the above example, the booth is sized by the containment air requirement. Since the containment air is almost always greater than the safety air requirement, booth manufacturers rely on face velocity to determine the fan size. Batch booths for manual operations are made in many standard sizes, such as a lab type booth of approximately 4’ x 4’ (1.2 m x 1.2 m). They can also be constructed to fit virtually any product size. For conveyorized systems, the product opening size is determined by the largest part to be run through the system. Six inches (15 centimeters) of clearance is allowed around all sides of the largest part through the
product opening. Another factor that influences the size of the booth is the need to keep the hanger point out of the spray zone. The hanger point is the top of the rack that attaches to the conveyor hanger. If the rack or the conveyor is in the spray zone and powder collects on the metal sur-face it will cure in the oven and insulate the hanger point from ground. The importance of maintaining a proper earth ground cannot be over-emphasized. Without a good ground, it is much more difficult to get the powder on the part in an even pattern and very difficult to penetrate Faraday areas.

The hanger length from the hang point to the top of the parts being coated should be a minimum of 27” (69 centimeters). This is long enough to provide ample clearance between the conveyor hang point and the spray zone.

The booth canopy must be wide enough to provide ample space between the gun tip(s) and the part being coated. If the gun tip is not extended far enough from the wall the electrostatically charged powder may be attracted to the wall instead of part.

It is critical to have good lighting inside the booth, especially for manual sprayers. If the operator cannot see the surface they will apply too much coating or not enough. Fluorescent fixtures should be installed horizontally in the ceiling of the booth and vertically alongside the manual stations. Lighting should be in accordance with National Fire Protection Association (NFPA 33). Electrical lamps should be installed in the booth wall with a safety glass panel separating them from the inside of the spray area. Electrical lamps within 20’ (6m) of the spray area should be Class I, Div. 2 to conform to NFPA 70, National Electric Code.

The spray booth must have negative air pressure to contain the powder inside the booth. The airflow inside the booth must not be aggressive enough to compete with the part for the powder. Many homemade booths make the mistake of pulling the air through too small of an outlet that is too close to the application area. As a result, the airflow pulls powder away from the parts. The operator compensates by increasing their delivery pressure, generating excessive overspray and applying too much powder to the part. Proper airflow requires a careful balance between the need to contain powder and the need to avoid turbulence inside the booth. The inlet to the reclaim system must be large enough and located far enough from the spray zone to avoid interference with the application process.



The new layout is very good.
Amrit Rekhi, Polycoat Powders.

My name is Francois-Xavier and I work for SpecialChem in Paris.Thank you for inviting me to join your mailing list.

You website has become very attractive and informative.
Hao, China

Dear Sir, We are pleased to introduce our self has the exclusive representatives of Helmut Fischer in India for their powder coating thickness tester from past twenty two years. We are interested in listing our self in your web page. Please let us know how to go about it.
Best Regards, Sridhar L, Manager

Moderator: We have sent the details to you. Meanwhile please visit www.ipconweb.com/listing.htm

Dear Vivek, We are engaged in the manufacturing and installation of Aluminum Doors, windows, Structural Glazing, Composite panel cladding. We have an in-house facility for Electrochemical Color Anodizing and facility for Powder Coating.
Regards, Sandeep Chowdhry

We make a number of powder coating strippers, which can be used in tanks, for emersion stripping, as  well as brush or sparay on applications.
Thank you, Rudy Starsinic Solvent Kleene,Inc.

Moderator: Welcome aboard


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India Powder Coating
Vivek Soley
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While we have used our best efforts in collecting and preparing the information on this website, we do not assume, any liability for any loss or damage caused by errors or omissions, whether such errors or omissions resulted from negligence, accident or other causes. The user may use their own discretion while using the information.