Painting & Coating Industry (PCI) logo Powder coating summit logo
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • MATERIALS
  • TECHNOLOGIES
  • RESOURCES
  • EVENTS
  • DIRECTORIES
  • EMAGAZINE
  • CONTACT
  • SIGN UP!
cart
facebook twitter linkedin youtube
  • NEWS
  • Latest News
  • Market Trends & Reports
  • Price Alerts
  • Subscribe to eNewsletters
  • Global Top 10/ PCI 25
  • Weekly Featured Article
  • COATLE Word Game
  • PRODUCTS
  • Product News
  • Must See Products and Services
  • MATERIALS
  • Additives
  • Resins/Polymers
  • Pigments
  • Equipment
  • Distributors
  • TECHNOLOGIES
  • Adhesives
  • Architectural Coatings
  • FINISHING
  • Industrial Coatings
  • Nanotechnology
  • Powder Coatings
  • Solventborne
  • Special Purpose Coatings
  • Sustainability
  • UV Coatings
  • Waterborne
  • FINISHING
  • Finishing News
  • Finishing Technologies
  • Finishing Equipment
  • Finishing Today
  • RESOURCES
  • Columns
  • Blogs
  • Coatings Supplier Handbook
  • Podcasts and Videos
  • PCI Store
  • Classifieds
  • eBooks
  • Sponsor Insights
  • White Papers
  • COATLE Word Game
  • Columns
  • Ask Joe Powder
  • Did you know?
  • Distribution Dive
  • Focus on Canada
  • Formulating With Mike
  • Innovation Insights
  • Moody's Coatings Conundrums
  • Powder Coating Perspectives
  • Target the Market
  • TiO2 Insider
  • Blogs
  • Editor's Viewpoint
  • Industry Insights
  • Podcasts and Videos
  • COAT-IT! Podcast
  • Videos/PCI TV
  • EVENTS
  • Coatings Trends & Technologies Summit
  • Paint and Coatings Academy
  • Webinars
  • Calendar of Events
  • Lifetime Achievement Award
  • DIRECTORIES
  • Buyer's Guide
  • Equipment Directory
  • Materials Directory
  • EMAGAZINE
  • Current Issue
  • eMagazine Archive
  • China Issue Archive
  • Editorial Advisory Board
  • CONTACT
  • Contact Us
  • Advertise
  • Subscribe to eMagazine
  • Subscribe to eNewsletters
Painting & Coating Industry (PCI) logo Powder coating summit logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Painting & Coating Industry (PCI) logo Powder coating summit logo
  • NEWS
    • Latest News
    • Market Trends & Reports
    • Price Alerts
    • Subscribe to eNewsletters
    • Global Top 10/ PCI 25
    • Weekly Featured Article
    • COATLE Word Game
  • PRODUCTS
    • Product News
    • Must See Products and Services
  • MATERIALS
    • Additives
    • Resins/Polymers
    • Pigments
    • Equipment
    • Distributors
  • TECHNOLOGIES
    • Adhesives
    • Architectural Coatings
    • FINISHING
      • Finishing News
      • Finishing Technologies
      • Finishing Equipment
      • Finishing Today
    • Industrial Coatings
    • Nanotechnology
    • Powder Coatings
    • Solventborne
    • Special Purpose Coatings
    • Sustainability
    • UV Coatings
    • Waterborne
  • RESOURCES
    • Columns
      • Ask Joe Powder
      • Did you know?
      • Distribution Dive
      • Focus on Canada
      • Formulating With Mike
      • Innovation Insights
      • Moody's Coatings Conundrums
      • Powder Coating Perspectives
      • Target the Market
      • TiO2 Insider
    • Blogs
      • Editor's Viewpoint
      • Industry Insights
    • Coatings Supplier Handbook
    • Podcasts and Videos
      • COAT-IT! Podcast
      • Videos/PCI TV
    • PCI Store
    • Classifieds
    • eBooks
    • Sponsor Insights
    • White Papers
    • COATLE Word Game
  • EVENTS
    • Coatings Trends & Technologies Summit
    • Paint and Coatings Academy
    • Webinars
    • Calendar of Events
    • Lifetime Achievement Award
  • DIRECTORIES
    • Buyer's Guide
    • Equipment Directory
    • Materials Directory
  • EMAGAZINE
    • Current Issue
    • eMagazine Archive
    • China Issue Archive
    • Editorial Advisory Board
  • CONTACT
    • Contact Us
    • Advertise
    • Subscribe to eMagazine
    • Subscribe to eNewsletters
  • SIGN UP!

A New Concept for Powder Coatings to Reduce Manufacturing Costs and Increase Throughput

July 24, 2000
In the traditional method of manufacturing powder coatings, dry ingredients are thoroughly blended and added to an extruder or heated batch-type mixer for the purpose of fluxing, dispersion, and creating a material as homogeneous as possible. For ease of this discussion, extruder processing will be discussed. It is in this melt stage that the dry pigments that have been incorporated must be uniformly and thoroughly dispersed.

Although some dispersion and color development of the pigment may occur during the dry-blending and mixing stages, the majority of the two processes, dispersion and color development, generally occurs in the extrusion stage, as this is where the majority of aggregates and agglomerates are separated into primary particles. If, as so often is the case, not all of the tinctorial strength of the pigment is developed, a decision as to whether to re-extrude must be made. This decision is made based upon cost of the pigment, the ability of the resin system to withstand additional heat, the effect on film properties, the ability to demonstrate a sufficient strength increase, and the physical ease or difficulty of performing this operation in production relative to the potential gain.

When a single pigment is involved, the decision is usually easier to make and often carried out after a short time of running, by testing the production material in the laboratory. The screw speed may then either be increased or decreased, depending upon the intended outcome. It is obvious that decreasing screw speed will increase residence time and may increase color development; it also reduces throughput and may have some effect on film appearance and performance.

An extreme example would be going from 400 RPM,* a typical operating condition that was arbitrarily chosen as 100% efficiency, down to 250 RPM, where a throughput reduction of 37.5% would occur. Corresponding reductions to 300 RPM and 350 RPM give reductions of 25% and 12.5%, respectively.

When we consider the energy to run the extruder at anything less than 100% (400 rpm) the associated energy increase is relative to the added time to complete the production. Similarly, all assigned overhead costs allocated to the operation of that piece of equipment will be increased, relative to the increased time needed due to running at less than optimum RPM.

As stated earlier, monochromatic (single pigment) cases are the easiest to use. However, with the exceptions of white and black, which, if not fully dispersed, will generally have more effect on application, flow and film properties than coloristic or economic properties, most colored powder coating is a mixture of two or more pigments. In this situation, white is being treated as a pigment that must be fully dispersed, due to its relative effect on the other pigments in the mixture. In this case, development of the TiO2 pigment and the colored pigment may occur at different rates, depending upon the vehicle wetting characteristics, residence time, temperature, specific pigment and surface treatment.

In our laboratories, when predispersed colored pigment was added to a commercial white powder paint and then put through the extruder two times, the resulting color was lighter after the second extruder pass than after the first, indicating that the TiO2 continues to develop tinting strength. When powder paint was made in the same fashion but using predispersed TiO2 in combination with predispersed colored pigment there was no color shift between extruder passes one and two.

Even more difficult to control are custom colors made from blends of two or more colored pigments plus white. If any one of the pigments in the blend develops differently in the laboratory than during production, significant adjustments must be made in the laboratory, during which time production equipment is sitting idle, awaiting a revised, remixed dryblend to once again extrude.

Reviewing a recent series of formulas for RAL colors, developed by a major pigment company, the majority of the color matches required four pigments, quite a few required three or five pigments, and one required six individual pigments to be dispersed. Compound this problem by considering that both organic and inorganic pigments may be needed, not only for the match but also for opacity in thin films. It is not unusual for organic pigments to be supplied with a specification of +/- 5% for strength. Therefore, with a blend of several pigments to match a color, using a formula developed from prior lots of pigment, the variations caused by strength variation +/-5%, and differing color development rates can be significant and require numerous laboratory adjustments prior to a commercially acceptable match being achieved.

Powder coating manufacturers have lived with the difficulties of providing their coatings in an environment that is rapidly changing. The markets being served by powder are growing in number. Each market requires more and different colors to be available in both large and small quantities, and in different qualities, textures, and gloss levels. End users also require custom colors to be matched in a reasonable length of time; typically 2–4 weeks under the current way of doing things. To improve turnaround time on standard colors, many companies have taken the approach of increasing their inventories of stock colors. When combining the number of colors being sold and the chemistries being offered with the gloss levels required the number can be staggering, ranging from just under 1,000 to many thousands; a logistical nightmare and costly phenomenon.

The current era of powder coatings can be compared to liquid paint in the mid 1950s. Tinted paints were made in the factory and called ready mixed. Your choice in the paint store was made from among the 60 or so precolored paints available in several qualities and gloss levels. Today, however, the end user is accustomed to having available an almost unlimited number of colors in any quality, gloss level, and quantity. The consumer also expects same-day service and the ability to come back later and get the same color again and again.

The approach Elementis Specialties is developing is borrowed from liquid paint technology. The approach allows us to be able to reduce manufacturing time and inventory costs and increase throughput.

The company has designed the TINT-AYD “DPC” palette of colorants, which will be controlled, as its liquid system colorants are, to +/- 2% for strength; these are controlled gravimetrically; and, using a reflectance file generated for these colorants, will enable the company to provide formulas for commercial matches to RAL colors, Federal Standard 595 colors, and other series or custom colors wherever computer color-matching capability exists.

The colorants in this system are based upon a proprietary, universal vehicle that is compatible with all currently commercial powder coating chemistries. The pigments being incorporated have been chosen for their value as either interior or exterior quality. Having both grades of pigment allows the end use of the powder coating to dictate the correct pigment dispersions for greatest efficiency and value.

This color system will provide the powder coating manufacturer with the ability to achieve the following.

  • Color all state-of-the-art powder coating resins.

  • Complete color development in one extruder pass.

  • Pre-blend only clear powder paint raw materials which eliminates lengthy and costly blender cleanups.

  • Add pre-weighed, blended pre-dispersed pigments simultaneously with clear powder paint materials.

  • Obtain commercial matches to custom colors reproducibly with predetermined formulas and minimum laboratory time.

  • Minimize the need for large inventories of standard colors and reduce working capital.

  • Minimize the response time to provide custom colors.

  • Increase throughput by maximizing the efficiency of the pigment dispersion and color matching processes and in doing so reduce energy costs, fixed processing costs, and laboratory assessments per color.

    For more information on colorants, contact Elementis Specialties, Rheox Inc., Colorants & Additives, PO Boc 700; Hightstown, NJ 08520; phone 800/866.6800 or 609/443.2500; fax 609/443.2422; visit www.elementis-specialties.com; e-mail specialinfo.usa@elementis-na.com.

    Links

    • Elementis Specialties

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • PCI-0724-Global10-Feature-1440.png

    2024 Global Top 10: Top Paint and Coatings Companies

    Who ranks on top? PCI’s annual ranking of the top 10...
    Paint and Coating Market Reports
    By: Courtney Bassett
  • PCI-0724-PCI25-Feature-1440.png

    2024 PCI 25: Top Paint and Coatings Companies

    PCI's annual ranking of the top 25 North American paint...
    Global Top 10 and PCI 25
    By: Courtney Bassett
  • pci1022-Kinaltek-Lead-1170.jpg

    A Novel Pigment Production Technology

    Following an extensive R&D program that demonstrated...
    Paint and Coating Pigments
    By: Jawad Haidar and Nitin Soni
You must login or register in order to post a comment.

saamiyaqoob@gmail.com
January 22, 2021
Your points: Pre-blend only clear powder paint raw materials which eliminates lengthy and costly blender cleanups. Add pre-weighed, blended pre-dispersed pigments simultaneously with clear powder paint materials....... This will increase cost,, first pre blend clear powder raw materials,,, later Re blend with required pigment??

Article comment

Kristin Johansson
January 22, 2021
Thanks for your comment. As the article was posted in 2000, things may have changed.

Report Abusive Comment

Manage My Account
  • eMagazine
  • eNewsletter
  • Online Registration
  • Subscription Customer Service

The Coatings Minute: Your Guide to the 2025 Coatings Supplier Handbook

The Coatings Minute: Your Guide to the 2025 Coatings Supplier Handbook

CTT Registration Now Open

CTT Registration Now Open

The Coatings Minute: Your Inside Look at PCInnovations

The Coatings Minute: Your Inside Look at PCInnovations

The Coatings Minute: Print Returns with PCI’s New Showcase Issue

The Coatings Minute: Print Returns with PCI’s New Showcase Issue

More Videos

Sponsored Content

Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the PCI audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of PCI or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

close
  • Modern arapartment complex painted in bright colors.
    Sponsored byEPS - Engineered Polymer Solutions

    Architectural Polymers Leading the Way in Coatings Innovation

  • paint sprayer in a workshop
    Sponsored byallnex

    Enabling Performance and Compliance: allnex Introduces a New Line of VOC Exempt Solvent-Borne Resins

Popular Stories

BASF SE Logo

BASF Reportedly Eyes Exit from Coatings

No. 7 BASF Coatings

BASF Comments on Potential Sale of Coatings Business

Ancamine-2858

Ancamine® 2858 – High-performance solution for hot climates



PCI Buyers Guide

Submit a Request for Proposal (RFP) to suppliers of your choice with details on what you need with a click of a button

Start your RFP

Browse our Buyers Guide for manufacturers and distributors of all types of coatings products and much more!

Find Suppliers

Events

September 3, 2025

Coatings Trends & Technologies Summit

The Coatings Trends & Technologies (CTT) Summit is an annual conference for both liquid and powder coatings formulators and manufacturers to discuss innovations in coatings technology. This event combines high-quality technical presentations, a resource-rich exhibit hall, and dedicated networking opportunities to connect scientific minds, foster innovation, and cultivate game-changing new ideas!

January 1, 2030

Webinar Sponsorship Information

For webinar sponsorship information, visit www.bnpevents.com/webinars or email webinars@bnpmedia.com.

View All Submit An Event

Poll

Longest-running laboratory experiment

What is the longest-running laboratory experiment?
View Results Poll Archive

Products

CTT Summit Short Courses (Live 9/3/25)

Coatings Trends & Technologies Summit is expanding its offerings with four short courses. These short courses will offer an extensive day of interactive learning.

See More Products
pci  webinar april 2025

PCI CASE EBOOK

Related Articles

  • WEB EXCLUSIVE!!
    Performance Contracts Reduce Abatement Costs For Paint and Coatings

    See More
  • Color Stabilization of Wood and Durability Improvement of Wood Coatings: A New UV Light-Protection Concept for Indoor and Outdoor Applications

    See More
  • A Novel Concept for Improving Scratch and Abrasion Resistance for Automotive Coatings

    See More
×

Keep the info flowing with our eNewsletters!

Get the latest industry updates tailored your way.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Directories
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletters
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey & Sample
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • Youtube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing

Painting & Coating Industry (PCI) logo Powder coating summit logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Painting & Coating Industry (PCI) logo Powder coating summit logo
  • NEWS
    • Latest News
    • Market Trends & Reports
    • Price Alerts
    • Subscribe to eNewsletters
    • Global Top 10/ PCI 25
    • Weekly Featured Article
    • COATLE Word Game
  • PRODUCTS
    • Product News
    • Must See Products and Services
  • MATERIALS
    • Additives
    • Resins/Polymers
    • Pigments
    • Equipment
    • Distributors
  • TECHNOLOGIES
    • Adhesives
    • Architectural Coatings
    • FINISHING
      • Finishing News
      • Finishing Technologies
      • Finishing Equipment
      • Finishing Today
    • Industrial Coatings
    • Nanotechnology
    • Powder Coatings
    • Solventborne
    • Special Purpose Coatings
    • Sustainability
    • UV Coatings
    • Waterborne
  • RESOURCES
    • Columns
      • Ask Joe Powder
      • Did you know?
      • Distribution Dive
      • Focus on Canada
      • Formulating With Mike
      • Innovation Insights
      • Moody's Coatings Conundrums
      • Powder Coating Perspectives
      • Target the Market
      • TiO2 Insider
    • Blogs
      • Editor's Viewpoint
      • Industry Insights
    • Coatings Supplier Handbook
    • Podcasts and Videos
      • COAT-IT! Podcast
      • Videos/PCI TV
    • PCI Store
    • Classifieds
    • eBooks
    • Sponsor Insights
    • White Papers
    • COATLE Word Game
  • EVENTS
    • Coatings Trends & Technologies Summit
    • Paint and Coatings Academy
    • Webinars
    • Calendar of Events
    • Lifetime Achievement Award
  • DIRECTORIES
    • Buyer's Guide
    • Equipment Directory
    • Materials Directory
  • EMAGAZINE
    • Current Issue
    • eMagazine Archive
    • China Issue Archive
    • Editorial Advisory Board
  • CONTACT
    • Contact Us
    • Advertise
    • Subscribe to eMagazine
    • Subscribe to eNewsletters
  • SIGN UP!