TAGS: Powder Coatings Sustainability / Natural Coatings
In most businesses, including those in the paint and coating industry, sustainability has become an essential part of a company’s marketing strategy. Sustainable certifications allow manufacturers to differentiate themselves by proving that their products meet key environmental standards. Contractors often select a paint system based on the extent that a product meets these standards. Recently, a new term has crept into this equation – circularity.
The idea of circularity or a circular economy is to make better use of resources, recovering materials instead of wasting them, and preventing energy use and waste by better design of products that keeps them in use longer.
Whereas, “eco-friendly” refers to products that are not harmful for the environment, “sustainability” is a higher standard because it includes manufacturing and all related activities. Circularity is even a step ahead in that it requires a more advanced mindset. Circularity also captures the discovery and use of alternative raw materials and processes, as well as extending the functionality of materials after their use.
This article will attempt to clarify the relationship between eco-friendly, sustainable, and circularity and describe how they occur on a path to ultimately environmentally friendly products. It will also show by example how powder coatings formulated with a sustainable carbonaceous material (SCM) can not only reach sustainability targets but also deliver additional qualities that help transition the product toward circularity.
Eco-Friendly vs. Sustainable vs. Circular
The term
“eco-friendly” has a broad meaning to describe something that benefits and is not harmful for the environment. Most scholars believe that the development of eco-friendly products will not be sufficient to protect future generations from damaging environmental consequences. As a result, the term
“sustainability” was introduced.
Sustainability represents a higher standard. A sustainable product or practice is not just green or eco-friendly, but it is also considerate of the future. Sustainability presumes that resources are finite and should be used conservatively and wisely with a view to long-term priorities and consequences. In addition to being eco-friendly, sustainable products use less energy, do not reduce our natural resources, and reduce costs by improving productivity. With sustainability as a goal, raw material producers, formulators, distributors, and end-users are all able to provide for future generations.
Sustainability efforts often make good business sense, promising to deliver revenue gains, cost savings, and other benefits that lift enterprise value
1. For most paint suppliers,
sustainability has become an essential part of their product development and marketing strategy. For example, sustainable certifications allow suppliers to differentiate themselves by proving that their products meet key environmental factors.
Circularity is an even more comprehensive approach. Circularity or the circular economy has been defined as a regenerative system in which resource input and waste, emission, and energy leakage are minimized by slowing, closing, and narrowing material and energy loops. This can be achieved through long-lasting design, maintenance, repair, reuse, remanufacturing, refurbishing, and recycling
2. The three principles required for the transformation to a circular economy are: eliminating waste and pollution, circulating products and materials, and the regeneration of nature.
The terms “circularity” and “sustainability” are often incorrectly used together and somewhat interchangeably, which is unfortunately confusing and dilutes the importance and value of the actions related to either term. By making visible how these subjects are differentiated will foster a greater appreciation and understanding of how to tackle global environmental challenges.
In the more familiar
linear economy, resources are turned into products which are ultimately destined to become waste because of the way they have been designed and manufactured. This linear process is often summarized by
"take, make, waste.” In a circular economy, the emphasis is on reusing, repairing, upgrading, recycling, and having products last as long as possible.
Product Manufacturing Path in Linear and Circular Economies
Another difficulty is that one often attempts to strictly classify and isolate products as being eco-friendly, sustainable, or circular. In reality, products can have features related to each philosophy, and this is especially common as manufacturers develop products toward the goal of a circular economy. There is no strict demarcation between eco-friendly, sustainable, and circular. Instead, there is overlap. It is not the classification that is important but the pathway being followed. Moving to a completely closed-loop system may not be realistic. However, one can develop innovative ways to
increase circularity throughout the value chain.
For example, a sustainable product can have some circular features without having all of the features. This is common in product development, and the manufacturer’s emphasis on advancement should be rewarded. The application of a
powder coating containing a sustainable pigment is one example of a product that is transitioning to the circular economy.
A Case Study: Powder Coatings with Continua™ 8510P Sustainable Carbonaceous Material
Powder coatings are eco-friendly because they contain no solvents and
release little or no volatile organic compounds (VOC) into the atmosphere. Powder coatings have also been considered as sustainable materials for reasons that will be described below. However, powder coatings can progress even further along the road to circularity with the help of a pigment such as sustainable carbonaceous material (SCM).
Conventional pigments are sometimes considered to be an environmental problem due to their origin, processing, or health concerns. Other pigments such as SCM have entered the circular economy through multidisciplinary research that reduces the raw material’s environmental impact. Suppliers are investing in the latest technologies to produce grades that align with sustainable supply and circular economy models.
The following sections of this article describe in greater detail how a sustainable carbonaceous pigment
Continua™ 8510P SCM from Birla Carbon can help propel eco-friendly and sustainable powder coatings toward the eventual goal of a circular economy.
Continua™ 8510P SCM from Birla Carbon for Sustainable Powder Coatings
Powder Coatings: An Eco-Friendly and Sustainable Product
The powder used for the powder coating process is a mixture of finely ground particles of pigment and polymeric resin. Unlike conventional liquid paint, which is delivered via an evaporating solvent, powder coating is applied as a free flowing, dry powder and then cured with heat or ultraviolet light. The dry powder attaches to surfaces through electrostatic spray or immersion in a fluidized bed. Prior to coating, the part may be preheated, or it may be heated after powder application to melt the coating so it will flow and adhere properly. Parts are then cured to form an extremely hard, long lasting, protective coating.
Powder coatings are eco-friendly because they contain no solvents and release little or no amount of volatile organic compounds (VOC) into the atmosphere. Powder coatings are also considered to be sustainable because of their cost savings, finish quality, and productivity improvements. Powder coatings are now also becoming recognized for their circular traits because they
limit or eliminate over-spray waste, they reduce CO2 emission due to energy saved during processing, and they provide greater durability (life-time extension) in comparison to liquid coatings. The table describes the advantages of powder coatings as characterized by their environmental benefits.
|
Benefit
|
Eco-Friendly Characteristics
|
|
Low VOCs
|
There are no solvents and therefore no or extremely low VOCs in powder coatings. There is no solvent waste.
|
|
Low CO2 and greenhouse gas emissions
|
In a life cycle analysis3, powder coatings have 25-60% lower carbon dioxide emissions than conventional solvent borne coatings. This is primarily due to more solvent borne paint being required to produce equivalent coverage, and more energy usage for solvent evaporation and air heating.
|
|
No hazardous waste
|
There is no toxic waste generated during the powder application process. There is no need to remove hazardous solvents, and there is no sludge or waste to remove. Powder coatings have no effluent disposal problems as do waterborne coatings which sometimes are put directly into a drain or allowed to settle out in sludge tanks.
|
|
No hazardous surface treatment
|
Powder coatings do not require chrome-based primers or surface treatment to ensure adequate adhesion or durability. In fact, no primer is needed at all over properly pretreated aluminum.
|
|
Benefit
|
Sustainable Characteristics
|
|
EPA approval
|
The US Environmental Protection Agency (EPA) recommends powder coatings as a sustainable coating option.
|
|
Low cure temperature and energy costs
|
Powder coatings often cure at lower temperatures than liquid architectural coatings, which means reduced energy costs. There is also less heating of air, and the air turnover rate is significantly reduced as there is no buildup of potentially explosive solvent. Lower cure temperatures enable coating of heat sensitive parts.
|
|
Less processing time
|
Powder processing times are generally shorter than those used for liquid paints. There is no solvent so no flash off period is required. Instead, the powder coated articles can pass directly into the oven. This gives substantial saving in space and time. Total processing time can be reduced from hours to minutes.
|
|
Low-cost facility
|
A powder application plant, either manual or automatic, is extremely simple to operate and less costly than a multicoat liquid system.
|
|
Benefit
|
Circularity Characteristics
|
|
Single coat for most applications
|
Powder coatings achieve the same or better levels of chemical, mechanical and weathering performance than liquid coatings, but in a single coat. This means savings on product, time, and energy.
|
|
Greater film thickness
|
Powder coatings can achieve a controlled more uniform and, if necessary, a higher film thickness in one application with powder than with conventional liquid paint system.
|
|
Recycling and reuse
|
Any powder over spray can be reclaimed and recycled. No powder can escape into the atmosphere. Recovered powder can be blended with virgin powder to provide up to 95% utilization.
|
|
LEED points
|
Using powder coatings helps gain LEED points. When compared to liquid coatings, powder coatings can maintain or increase durability and performance. LEED certification is a globally recognized symbol of sustainability achievement and leadership.
|
|
Reclaiming damaged parts
|
Damaged or poorly coated areas can be easily rectified before baking by simply blowing off the powder and recoating.
|
|
Durability
|
Powder coating provides greater resistance to weather, corrosion, impact, abrasion, and moisture than equivalent liquid coatings.
|
Environmental Benefits of Powder Coatings as Characterized by their Eco-Friendliness, Sustainability, and Circularity
Powder coatings are considered sustainable since they reduce harm to the environment throughout the product’s entire lifecycle without sacrificing cost or performance. This includes the use of eco-friendly raw materials and processes. However, the concept of sustainability has expanded well beyond just reducing volatile organic compounds (VOCs) and other harmful components. The definition of sustainability now also encompasses downstream aspects of the product (e.g., formulation, processing, application). Sustainability efforts often make good business sense, promising to deliver revenue gains, cost savings, and other benefits that lift enterprise value
4.
Powder coatings also have several features related to circularity. These primarily consist of their long service life (corrosion resistance), minimal waste (recycling of powder over spray), and reduced energy costs (lower cure temperatures and shorter cure time). However, powder coatings can be made even more circular with sustainable starting materials.
Sustainable Carbonaceous Material (SCM) from Birla Carbon is now available as a powder coating pigment. In the future, other refinements such as the use of biobased resins and innovative curing processes will further propel powder coatings even further down the path to circularity.
Continua™ 8510P SCM: A Sustainable Carbonaceous Material
As described above, circularity extends downstream to the recycling and reuse of materials, but it can also extend upstream to the manufacture and selection of raw materials. This can occur when switching from petroleum-based resins to natural biobased resins. However, this can also pertain to the use of sustainable pigments. The pigments industry has recognized such value and invested significantly in making operations sustainable and compliant.
Continua™ 8510P SCM from Birla Carbon is a highly engineered form of a sustainable carbonaceous material that can be used as a pigment in paints, coatings, and inks. It is a new material that is more than just an alternative for black pigments such as carbon black, organic dye, and iron oxides. Similar to other black pigments,
Continua™ SCM allows formulations with a color spectrum ranging from gray to deep black and achieves required properties in the final product such as
high tinting strength, improved jetness or blue undertone, and conductivity
5. However, Continua™ 8510P SCM also brings the value of a sustainable raw material into the pigment portfolio.
Continua™ 8510P SCM is also a carbon-negative pigment. A comprehensive life cycle assessment conducted according to ISO 14040 and ISO 14044 has demonstrated that each tonne of Continua™ 8510P SCM eliminates 3.1 tonnes of direct and indirect CO
2 emissions when compared to conventional furnace carbon black. Continua™ SCM significantly reduces the overall carbon footprint throughout the common value chain as illustrated in.
Carbon Footprint of Continua™ SCM (Ton of CO2 Equivalent per Ton of Continua™ SCM)
Continua™ 8510P SCM provides an option to take sustainable powder coatings a step further toward circularity. It provides full shade color and tint capability for general purpose powder coating applications. At equivalent pigment loading, Continua™ 8510P SCM produces a
level of opacity and jetness comparable to high quality carbon black pigments but with the added value of sustainability.
Polyester-TGIC Powder Coating Color Performance per ASTM D2244
Since powder coatings contain no solvents, they must rely on glass transition additives and pigment selection to influence film properties. The Continua™ SCM particle morphology enables
good flow and leveling in powder coatings, allowing for smooth surface finishes. Coatings made with
Continua™ 8510P SCM offer improved orange peel performance when compared to Birla Carbon’s high quality carbon black.
Polyester-TGIC Powder Coating Orange Peel per ASTM D3451
Gloss requirements of powder coatings can range from extremely
high gloss to matt finishes, and they are influenced by pigment selection and degree of cure. When compared to a high-quality carbon black,
Continua™ 8510P SCM shows high gloss while exhibiting minimal impact on curing properties as measured by
chemical resistance testing.
Polyester-TGIC Powder Coating Gloss Performance per ASTM D523
| Product |
MEK Rubs |
| Raven 410P |
>50 |
Continua™ 8510P SCM
|
>50 |
Chemical Resistance of Polyester-TGIC Powder Coating via MEK Rub Test per ASTM D4752
Continua™ 8510P SCM, a carbon negative raw material, provides powder coating manufacturers with a new pigment to take their circularity aspirations closer to reality. In the case of powder coatings, it propels an environmentally friendly product into one which is far more sustainable and illuminates the pathway to a circular economy.
Trends and Developments
A recent study by Grand View Research reports the global powder coatings industry is expected to expand at a CAGR of 7.2% from 2021-2028
6. The growth can be attributed to positive environmental factors that have been highlighted in this article. The powder coatings market is expected to expand due to increasing applications in industries such as automotive, construction, and furniture. Moreover, growing usage in agricultural equipment, exercise equipment, file drawers, computer cabinets, laptop computers, and electronic components will propel industry expansion. Considering substrates, there is increasing use of powder coatings for aluminum extrusion used in windows, door frames, building facades, and household fixtures.
The most significant trends in powder coatings with respect to sustainability and circularity will come from raw materials as demonstrated by the events below.
- A new generation of modified super durable polyesters for powder coatings that demonstrates improved corrosion resistance for ACE (agriculture and construction equipment) applications has been developed7.
- A supplier recently expanded its powder coatings offerings with a range of products for heat-sensitive substrates. The low-temperature curing technologies include both UV and thermally curing powders that cure at ultra-low (80° - 100 °C) temperatures and are ideally suited for use on MDF, plywood, thermoplastics, and composites8.
Conclusion
To deliver the maximum environmental benefit, it is necessary to adopt an approach that examines the entire lifespan of a product, from the raw materials and processes used to manufacture it, through the use phase, to the end-of-life processing which includes ease of disassembly and the capability to re-use or recycle materials and components. The linear consumption philosophy is reaching its limits. A circular economy has benefits that are operational as well as strategic, on both a micro- and macroeconomic level. This is a trillion-dollar opportunity, with enormous potential for innovation, job creation, and economic growth
9.
Black powder coatings formulated with
Continua™ 8510P Sustainable Carbonaceous Materia (SCM) provide an example of how an industry can transverse to a circular economy. Continua™ 8510P SCM is a solid example of Birla Carbon’s commitment to join hands with their customers toward a circular economy. The environmental, sociological, and economic benefits are available today and promise to flourish even more in the future.