What inspired the creation of this new tinting technology?

In Europe, we observed that customers using traditional tinting machines faced persistent challenges such as mold, thickening and drying, primarily due to lower colorant consumption. At the same time, increasingly stringent regulations for liquid colorants added complexity to the industry.

To address these issues, our team developed an innovative solid tinting system called Pearls. The goal was to create a solution that not only resolved these problems but was also user-friendly — similar to a coffee machine. The colorant dissolves quickly and is dosed volumetrically, offering a practical and efficient alternative to traditional liquid tinting systems.

Can you provide a simplified explanation of the production process?

The process begins similarly to producing a typical liquid colorant — we create a water-based pigment dispersion, known as the liquid feed. However, unlike conventional liquid colorants, our process uses fewer raw materials, excluding biocides, humectants and most additives.

Next, this liquid feed is drip-cast into a tall tower cooled with liquid nitrogen. As the droplets fall, they freeze and are collected at the bottom on a sieve, where we separate the usable product from particles that are too large or small. The frozen particles are then placed in a freeze dryer, where the ice (water) is removed through sublimation, leaving behind dry, porous Pearls. Finally, they are packaged in 2-liter recycled PET bottles, ready for use.

How is this new tinting technology a sustainable alternative to traditional tinting systems?

The overall environmental impact is significantly lower compared to traditional tinting systems. Although we are still finalizing our extensive lifecycle analysis, we know that from cradle to grave, our solid colorants achieve a significant reduction in CO₂ emissions compared to liquid colorants.

This is due to factors such as reduced waste, a longer shelf life, fewer raw materials in the formulation and a higher pigment load, making the new solid tinting system a more sustainable solution in the long run.

How is this new tinting technology a sustainable alternative to traditional tinting systems?

The overall environmental impact is significantly lower compared to traditional tinting systems. Although we are still finalizing our extensive lifecycle analysis, we know that from cradle to grave, our solid colorants achieve a significant reduction in CO₂ emissions compared to liquid colorants.

This is due to factors such as reduced waste, a longer shelf life, fewer raw materials in the formulation and a higher pigment load, making the new solid tinting system a more sustainable solution in the long run.

Why did you choose volumetric dosing over gravimetric dosing technology?

There are several reasons we opted for volumetric dosing:
 
Faster operation: Volumetric dosing allows for simultaneous dispensing of multiple colors, while gravimetric dosing can only handle one color at a time, as it requires a scale. This makes volumetric dosing much faster.
 
Cost efficiency: An accurate scale for gravimetric dosing is expensive and slow, which would increase the cost of the tinting machine compared to current liquid dispensers.
 
Lower maintenance: Our volumetric dispensers rely on gravity, eliminating the need for costly pumps or scales. This reduces the cost of dispensers and makes them more robust, requiring much less maintenance.

How did customer needs or market trends influence the development of this new tinting technology?

Several market trends played a key role in shaping the development of this technology.

In Germany, a growing demand for biocide-free paints created the perfect opportunity, as our solid tinting system is naturally biocide-free. Additionally, in Europe, stricter regulations aimed at reducing the use of biocides and limiting certain types of chemicals further accelerated the adoption of Pearls.

Finally, the ease of use and low maintenance of the new dispenser, compared to traditional dispensers, made it an even more attractive solution, driving the popularity of this new concept.

What are the technical benefits of this novel technology compared to traditional liquid tinting systems?

Pearls contain fewer additives and no humectants compared to liquid tinting systems, resulting in minimal impact on the final paint properties.

In traditional liquid tinting systems, we sometimes observe a reduction in the hardness of the tinted paint. However, when using this new tinting technology, there is no significant impact on hardness. Similarly, scrub resistance can deteriorate when paint is tinted with a liquid system, whereas paint tinted with Pearls maintains its original scrub resistance with no notable decline.

What do you envision for the future of R&D efforts with this new tinting technology?

I see the next few years as a period of expanding our colorant offerings, building on the current technology. However, I believe we are only beginning to unlock the full potential of the dry tinting concept.

There are certainly many more applications beyond architectural waterborne coatings where Pearls can be used. Ultimately, our goal is to develop a universal technology that works across both water- and solvent-based coatings, making it suitable for a wide range of architectural and industrial applications.
 

Learn more about this novel technology.