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DECORATIVE SURFACES CONFERENCE
OCTOBER 17-19, 2012
LOEWS PORTOFINO BAY HOTEL
ORLANDO, FL
MICHAEL KNOBLAUCH
DVUV LLC
Advant...
Decorative Surfaces Conference
Global Market & Industry Overview
About UV-Curable Powder Coating
Performance Characteristi...
GLOBAL MARKET &
INDUSTRY OVERVIEW
UV-Curable Powder Coating
3
Decorative Surfaces Conference
 Global population 2012 6 Billion - 2030 7.4 billion1
 3 Billion more middle class consum...
Decorative Surfaces Conference
 Global policies to reduce carbon emissions
 By 2030 of a 42% reduction of carbon as a % ...
Decorative Surfaces Conference
 Paints and coatings market*
 Global coatings market to reach 8.7 billion gallons and US$...
Decorative Surfaces Conference
UV-Curable coating technology is increasingly being seen as the future
technology in the ar...
ABOUT UV-CURABLE
POWDER COATING
UV-Curable Powder Coating
8
Decorative Surfaces Conference
 Thermoset or thermally cured powder coatings were
developed in the 1960s as functional co...
Decorative Surfaces Conference
 1998 – 2000s: 1st commercial applications in U.S.
 Automotive radiator
 Industrial moto...
Decorative Surfaces Conference
 The differentiating characteristic of UV-curable powder
coating is the separation of melt...
Decorative Surfaces Conference
Reduced Manufacturing Footprint
Typical thermal powder plant size
>15,000 sq ft
Typical UV
...
Decorative Surfaces Conference
 A UV powder application
system
Parts are loaded and
prepared
Pretreatment
Electrostatic p...
Decorative Surfaces Conference
Resin – Unsaturated 60 – 95 wt %
Photo Initiator 0.5 – 3.0 wt %
Surface and Depth
Flow Cont...
Decorative Surfaces Conference
 Intensity - Power or density of UV energy
 Typical 1000 - 3000 mW/cm2 UV V
 Ideal condi...
Decorative Surfaces Conference
 MDF or Medium Density Fiberboard
 Made from wood fibers, resins & additives which are bo...
Decorative Surfaces Conference
 Heating the board draws moisture to the surface, making it
conductive for electrostatic p...
Decorative Surfaces Conference
 Powder Coating Advantages
 Easier to blend, process and control during
application
 Eas...
Decorative Surfaces Conference
Finishing at the Speed of LightFinishing at the Speed of Light
Finishes and Color Matching
...
Decorative Surfaces Conference
Finished Products
Interactive Retail Display
Healthcare Component
POP Display
Educational L...
PERFORMANCE
CHARACTERISTICS
UV-Curable Powder Coating
21
Decorative Surfaces Conference
Test Standard Category Test Description UV-W06-SS2 UV-W06A-SS2
ASTM D4138
Method A
Film Thi...
Decorative Surfaces Conference
 Test Duration – 24 hours
 Reagents uncovered for
duration of test
 Verification of visu...
Decorative Surfaces Conference
Technical Information and Testing
24
Color Analysis
X Rite SP 62 Spectrophotometer
 Integr...
OPERATIONAL
EFFICIENCIES
&
COST ANALYSIS
UV-Curable Powder Coating
25
Decorative Surfaces Conference
Operational Efficiencies
0 10 20 30 40 50 60
Finish Time (min)
Liquid Coatings
Thermoset Po...
Decorative Surfaces Conference
 Fast
 Instant cure
 Completed parts in 20 minutes or less
 One coat
 Clean
 No harmf...
Decorative Surfaces Conference
 Higher Quality Finished Products
 Reduces substrate thermal exposure
 Cross linked UV c...
Decorative Surfaces Conference
Material Cost & Productivity
29
Material cost comparison
$/sqare foot - Liquid and UV
cured...
Decorative Surfaces Conference
Revenue and Operating Margin
30
Operating margin data from www.nyu.stern.edu
Annual
revenue...
SUSTAINABILITY
UV-Curable Powder Coating
31
Decorative Surfaces Conference
Assumptions for this Life Cycle Assessment
Substrate MDF, 19 mm
Average Surface Area 0.5 m2...
Decorative Surfaces Conference
Sustainability
33
Decorative Surfaces Conference
 Coatings Life Cycle Assessment
Sustainability
Solid
Content
100% all powders
50% for all ...
Decorative Surfaces Conference
 Solvent-based coatings have the highest environmental
footprint
 High CFP to produce and...
FUTURE OF
UV POWDER
UV-Curable Powder Coating
36
Decorative Surfaces Conference
 Convergence of the macro market forces creates greater
opportunity for UV-curable powder ...
Decorative Surfaces Conference
 The coatings market will grow at or above aggregate global GDP.
o The market offers bette...
THANK YOU
&
QUESTIONS
UV-Curable Powder Coating
39
M I C H A E L K N O B L A U C H
P R E S I D E N T
4 6 4 1 H I N C K L E Y I N D U S T R I A L P K Y
C L E V E L A N D , O ...
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Advantages & Cost Analysis of UV-Cured Powder Coating

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A presentation by Mr. Michael Knoblauch, President of DVUV in Cleveland, OH describing the advantages & cost benefits of UV-Curable powder coatings.

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Transcript of "Advantages & Cost Analysis of UV-Cured Powder Coating"

  1. 1. DECORATIVE SURFACES CONFERENCE OCTOBER 17-19, 2012 LOEWS PORTOFINO BAY HOTEL ORLANDO, FL MICHAEL KNOBLAUCH DVUV LLC Advantages and Cost Analysis of UV-Curable Powder Coatings
  2. 2. Decorative Surfaces Conference Global Market & Industry Overview About UV-Curable Powder Coating Performance Characteristics Operational Efficiencies & Cost Analysis Sustainability Future of UV Powder Conclusion & Questions Presentation 2
  3. 3. GLOBAL MARKET & INDUSTRY OVERVIEW UV-Curable Powder Coating 3
  4. 4. Decorative Surfaces Conference  Global population 2012 6 Billion - 2030 7.4 billion1  3 Billion more middle class consumers by 20301  2012 global motor vehicle production – 51.7 million units2  2030 estimated global motor vehicle production – 80.6 million units3  Energy demand to increase by 420 quadrillion BTUs 2010 - 20301  Convergence of sources and diversity of energy mix fossil – biofuel – renewables – nuclear4 Global Market Perspective 4
  5. 5. Decorative Surfaces Conference  Global policies to reduce carbon emissions  By 2030 of a 42% reduction of carbon as a % of GDP  By 2030 stabilizing carbon at 450ppm4  Global growth 2012 – 2016 advanced economies – 1.1% to 3.0%5  Global growth 2017 – 2025 advanced economies – 1.3% to 2.6%5  Global growth 2012 – 2016 developing economies – 3.6% to 6.5%5  Global growth 2017 – 2025 developing economies – 2.8% to 4.3%5 1. McKinsey Global Institute : Resource Revolution: Meeting the world’s energy, materials, food and water needs. 2011 2. Robert W. Baird & Co.: Global Auto & Truck Markets – March 2012 3. Autelligence: Megatrends in the global auto industry to 2030: 2010 4. BP Energy Outlook 2030: 2011 5. www.conference –board.org/data/globaloutlook.cfm Global Market Perspective 5
  6. 6. Decorative Surfaces Conference  Paints and coatings market*  Global coatings market to reach 8.7 billion gallons and US$107 billion by 2017  Solventborne liquid coatings 75 – 80% of market  Global powder coating market US$5.4 billion  UV-curable coating market*  Consumption of UV- curable coatings from 2009-2017 will grow at CAGR of 6.65%  Producing by 2017 - 1210.46 metric tons of product. * Global Industry Analysts, Inc. • Coating Industry Today 6
  7. 7. Decorative Surfaces Conference UV-Curable coating technology is increasingly being seen as the future technology in the area of industrial coatings. The technology represents one of the rapidly growing segments in the coatings industry, and is arguably emerging as the answer to the rising environmental concerns and stringent regulations. Several application related advantages come to serve the technology that include absence of pot life issues, lower energy costs, fast cure speed, and reduced environmental impact. As such, one-component UV-Curable coating ranks among the fastest coating chemistries available in the present context. Curing of one-component UV- Curable coating takes few seconds to minutes, which makes it more ideal for use in applications that require faster turnaround time. Global Industry Analysts, Inc. March 2012 Coating Industry Tomorrow 7
  8. 8. ABOUT UV-CURABLE POWDER COATING UV-Curable Powder Coating 8
  9. 9. Decorative Surfaces Conference  Thermoset or thermally cured powder coatings were developed in the 1960s as functional coatings and have been adapted and developed for a variety of applications  Powder coatings give superior wear resistance, barrier properties, and cost effectiveness  Products include home appliances, industrial equipment, automotive primer, top coat  Powder coatings have no volatile organic compounds (VOC)or hazardous air particulates (HAPs).  Metal substrates are ideal for electrostatic powder application  Thermal cure cycle for powder coating ranges from 20 to 60 minutes depending on chemistry and part geometry Powder Coating 9
  10. 10. Decorative Surfaces Conference  1998 – 2000s: 1st commercial applications in U.S.  Automotive radiator  Industrial motor  2001: Decorative Veneer built the 1st UV-curable powder coating facility for MDF in Plainwell, MI USA, followed by RADEX in London, Ontario Canada  Application facilities built in Europe for MDF and PVC cushion floor  2005: Decorative Veneer system moved to Cleveland, OH and DVUV formed  Key markets: Retail – Healthcare – Education & Office furniture – specialty applications  2006: Keyland Polymer, Ltd. formed to develop, formulate, and manufacture UV-curable powder coatings for DVUV and other customers History of UV-Curable Powder Coating 10
  11. 11. Decorative Surfaces Conference  The differentiating characteristic of UV-curable powder coating is the separation of melt & flow from cure UV Powder Coating Melt & Flow 1 min UV Cure (secs) Electrostatic Powder Deposition Finished Product Substrate Pretreatment Melt, Flow & Cure 10-30 mins Low Temperature - 93C 11
  12. 12. Decorative Surfaces Conference Reduced Manufacturing Footprint Typical thermal powder plant size >15,000 sq ft Typical UV powder plant size 2,050 sq ft
  13. 13. Decorative Surfaces Conference  A UV powder application system Parts are loaded and prepared Pretreatment Electrostatic powder application Flow/Melt oven UV Cure oven UV Powder Application System Powder Coating Application Environmental Room Unload Area Load Area Pretreatment Melt Oven UV Cure Oven Prep 200 foot line – cycle 20 minutes
  14. 14. Decorative Surfaces Conference Resin – Unsaturated 60 – 95 wt % Photo Initiator 0.5 – 3.0 wt % Surface and Depth Flow Control Agent 0.5 – 2.0 wt % Degassing 0.5 – 4.0 wt % Pigments 0.1 – 20 wt % Filler/Extender 0 – 35 wt % Additives 0.25 – 1 wt % UV Powder Chemical Composition 14
  15. 15. Decorative Surfaces Conference  Intensity - Power or density of UV energy  Typical 1000 - 3000 mW/cm2 UV V  Ideal conditions - high intensity over short time  Exposure - Total energy received at coating surface  Typical 1000 - 3000 mJ/cm2 UV V  Intensity (mW/cm2 ) X time (secs) = Exposure (mJ/cm2)  UV Spectrum required for different applications  Clear/Tints -Mercury  Opaque - Iron additive and Gallium additive Mercury UV Curing Parameters 15 Long Wave Short Wave In depth cure Surface cure
  16. 16. Decorative Surfaces Conference  MDF or Medium Density Fiberboard  Made from wood fibers, resins & additives which are bonded under heat and pressure.  Excellent substrate for UV powder coating  Dense & flat  Low porosity  Homogenous Powder Coating MDF 16
  17. 17. Decorative Surfaces Conference  Heating the board draws moisture to the surface, making it conductive for electrostatic powder application.  2 Types of Application Powder Coating MDF 17 Corona Spray  Powder passes through highly charged & ionized corona field, powder picks up negative charge  High transfer efficiency and applies quickly Tribo Charging  Powder develops a static charge due to friction  Provides better penetration into recesses  Slower application and lower transfer efficiency
  18. 18. Decorative Surfaces Conference  Powder Coating Advantages  Easier to blend, process and control during application  Easily to clean up with an industrial vacuum  Powder coatings can be reclaimed and re-sprayed yielding up to 98% material utilization or sprayed to waste  Color changes do not require any purging materials or solvents and can be accomplished in minutes Application Process Advantages 18
  19. 19. Decorative Surfaces Conference Finishing at the Speed of LightFinishing at the Speed of Light Finishes and Color Matching Metallic Multi- Component OpaqueRAL – Pantone – PMS systems 19
  20. 20. Decorative Surfaces Conference Finished Products Interactive Retail Display Healthcare Component POP Display Educational Lectern Architectural Element
  21. 21. PERFORMANCE CHARACTERISTICS UV-Curable Powder Coating 21
  22. 22. Decorative Surfaces Conference Test Standard Category Test Description UV-W06-SS2 UV-W06A-SS2 ASTM D4138 Method A Film Thickness Tooke Gauge - Destructive 3-4 mils 3-5 mils ASTM D4060 Abrasion Resistance Taber Abrasion Test - CS-17 Wheel 500gm, 500 cycles 32.4 mg loss 29.1 mg loss ASTM D3363-05 Scratch Resistance – Pencil Hardness Hardness – Wolff-Wilborn 300 gm load, 45° / no scratch 2H 3H ASTM D523 Gloss Measurement 60° NOVO-GLOSS meter 22-25 units 16-20 units NEMA LD3-1995 Impact Resistance 224 g steel ball (1/2 lb) 1 ½” dia. No cracking at 55” No cracking at 35” NEMA LD3 - 2005 3.4 Cleanability / Stain Resistance Reagents: 10% citric acid, vegetable oil, coffee, milk, catsup, mustard, vinegar, red lipstick, grape juice, black permanent marker, water washable black marker, and # 2 pencil No permanent effect on sample surface No permanent effect on sample surface Cure MEK swap - 50 double rubs No softening or color loss No softening or color loss NEMA LD3 - 2005 3.4 Hot water Pool of boiling water placed on surface, pot placed in water for 20 minutes No blistering No blistering ASTM D3359 Method B Adhesion Cross Hatch Adhesion – MDF must be present on piece of coating removed No loss of adhesion No loss of adhesion UV-Curable Powder for MDF Substrates 22
  23. 23. Decorative Surfaces Conference  Test Duration – 24 hours  Reagents uncovered for duration of test  Verification of visual inspection of the treated surface with each reagent shows no damage or impaired surface results after 24 hour exposure Chemical Resistance Reagent Effect Engine oil no effect Gearbox oil no effect Hydraulic oil no effect Brake fluid Slight gloss loss Antifreeze no effect Cold cleaner no effect Inert cleaner no effect E95 no effect Unleaded gas Slight/moderate gloss loss (a ring) Diesel fuel no effect Battery fluid no effect 23
  24. 24. Decorative Surfaces Conference Technical Information and Testing 24 Color Analysis X Rite SP 62 Spectrophotometer  Integrating d/8° sphere geometry  4 Illuminants: daylight, cool white fluorescent, TL84 triband fluorescent and incandescent Visual Color Assessment Light Booth  5 Light sources: daylight, cool white fluorescent, TL84 triband fluorescent, incandescent and ultraviolet  NIST traceable documentation UV Lamp System  300 W/in microwave UV lamp, D, H and V bulb  600 W/in microwave UV lamp, V bulb Coating Thickness Measurement  ASTM D6132, Non Destructive, Ultrasonic Film Build  ASTM D4138, Method A, Destructive Tooke Film Build Gauge Abrasion Resistance  ASTM D4060, Taber® Abraser 5130 Adhesion  ASTM D3359 Method A & B Surface Hardness  ASTM D3363, Pencil Hardness Scratch & Gouge Impact Resistance  NEMA LD3 – 1995, 3.8 Mandrel Bend  ASTM D 522 Gloss Level  ASTM D 523, NOVO-GLOSS™ Gloss Meter Boiling Water Resistance  NEMA LD3 – 2005, 3.4 Cleanability / Stainability Test  NEMA LD3 – 2005, 3.4 Cure Analysis  PCI Test Method #8, 50 MEK Double Rub Test Texture Evaluation  Tenibac Plaque
  25. 25. OPERATIONAL EFFICIENCIES & COST ANALYSIS UV-Curable Powder Coating 25
  26. 26. Decorative Surfaces Conference Operational Efficiencies 0 10 20 30 40 50 60 Finish Time (min) Liquid Coatings Thermoset Powder UV Powder Part Cycle Time Anaylsis Thermal Cure Coating Systems (Powder & Liquid) vs. UV Powder Coatings Coating Application Melt & Flow UV cure Solvent Flash Thermal Cure Cooling 26
  27. 27. Decorative Surfaces Conference  Fast  Instant cure  Completed parts in 20 minutes or less  One coat  Clean  No harmful chemicals, monomers or additives  Safe to use – no special safety gear  Easy material handling and clean up  Green  Smallest carbon footprint of any coating material  No VOC’s  Waste recycling or repurposing  No operating permits UV Powder Finishing Advantages 27
  28. 28. Decorative Surfaces Conference  Higher Quality Finished Products  Reduces substrate thermal exposure  Cross linked UV curing  Design and formulate coatings that are product specific  Lower Cost of Quality  Higher throughput  Reduced WIP  Fewer defects  Faster and Higher ROI  Able to process more material in a shorter period of time  Lower total applied cost compared to other finishing systems UV Powder Process Benefits 28
  29. 29. Decorative Surfaces Conference Material Cost & Productivity 29 Material cost comparison $/sqare foot - Liquid and UV cured powder Liquid 2 coat low VOC $0.2712 UV powder spray to waste $0.2940 UV powder spray to reclaim $0.2054 $- $0.0500 $0.1000 $0.1500 $0.2000 $0.2500 $0.3000 $0.3500 Material Cost per Square Foot of Surface Finished Parts Produced per Day 8 hour Shift Liquid 2 coat low VOC 388 UV-cure powder spray to waste 1164 UV-cure powder spray to reclaim 1164 0 200 400 600 800 1000 1200 1400 Parts Produced per Day
  30. 30. Decorative Surfaces Conference Revenue and Operating Margin 30 Operating margin data from www.nyu.stern.edu Annual revenue Operatin g margin EBIT $ Operatin g margin EBIT % Liquid 2 coat $907,621 $77,692 8.56% UV-cure spray to waste $2,722,863 $233,077 8.56% UV-cure spray to reclaim $2,722,863 $544,302 19.99% $- $500,000 $1,000,000 $1,500,000 $2,000,000 $2,500,000 $3,000,000 Revenue & Operating Margin Liquid 2 coat UV-cure spray to waste UV-cure spray to reclaim Total revenue/day $3,630 $10,891 $10,891 Total material/day $1,210 $3,995 $2,750 Gross margin/day = R-C $2,420 $6,897 $8,142 $- $2,000 $4,000 $6,000 $8,000 $10,000 $12,000 Daily Revenue, Material and Gross Margin
  31. 31. SUSTAINABILITY UV-Curable Powder Coating 31
  32. 32. Decorative Surfaces Conference Assumptions for this Life Cycle Assessment Substrate MDF, 19 mm Average Surface Area 0.5 m2, coated both sides Coating TiO2 Pigment/Resin/Filler 20/60/20 for all (avg) Solid Contents 100% all powders 50% for all 2-k systems 40% for waterborne UV Layer Thickness 150 um (6 mils) Curing Temperature Depending on System Sanding Not factored Utilization % (Transfer Efficiency) 95% Powder 90% Waterborne UV 60% 2k solventborne and waterborne Solvent Treatment Incineration Durability, Functionality, End of Life No differentiation Sustainability – Life Cycle Assessment Collaboration with DSM Coating Resins, originally presented at 2011 Decorative Surface Conference Orlando, FL 32
  33. 33. Decorative Surfaces Conference Sustainability 33
  34. 34. Decorative Surfaces Conference  Coatings Life Cycle Assessment Sustainability Solid Content 100% all powders 50% for all 2-k systems 40% for waterborne UV Utilization % (Transfer Efficiency) 95% Powder 90% Waterborne UV 60% 2k solvent and waterborne Assumptions Substrate : MDF 0.75” Thick Coating both sides Surface area – 5.4 sq ft Pigment/Resin/Filler 20/60/20 for all (avg) TiO2 34
  35. 35. Decorative Surfaces Conference  Solvent-based coatings have the highest environmental footprint  High CFP to produce and dispose solvents  Waterborne paints (conventional and UV 100% solids) have lower environmental impact  UV-curable powder coatings have the lowest environmental impact of coating materials Sustainability – Findings Coating Technology Impact on Carbon Footprint Solventborne-2K Waterborne-UV UV Powder Carbon Dioxide, CO2 (kg/m2) 0.96 / mil of coating 0.35 / mil of coating 0.21 / mil of coating Typical Coating Thickness 5 mils 2 mils 2 mils Coating Carbon Footprint (CO2) 4.8 kg/m2 0.7 kg/m2 0.41 kg/m2 10 x More 35
  36. 36. FUTURE OF UV POWDER UV-Curable Powder Coating 36
  37. 37. Decorative Surfaces Conference  Convergence of the macro market forces creates greater opportunity for UV-curable powder coating  Population growth and migration to cities  Reduction of carbon consumption as a % of GDP & establishment of carbon targets  Continuing growth of transportation sector  Continuing growth rates in emerging economies  UV-curable powder coating opportunities  Innovative chemistries and application technologies deliver more value at lower cost  Displacing existing finishing chemistries & application technologies  Develop and penetrate new markets and material applications Future of UV-Curable Powder Coating 37
  38. 38. Decorative Surfaces Conference  The coatings market will grow at or above aggregate global GDP. o The market offers better than average GPM and ROI opportunities to firms that bring into the market innovative chemistries and coatings that meet market specific needs. o Improved coating performance o Demonstrably sustainable, economically viable and have a reduced carbon footprint o Fast application time and fast cure response  UV-Curable powder coatings are a viable but nascent finishing system. o The productive and economic capability of UV-curable application technology is clearly demonstrable and generates greater than market GPMs and higher ROIs. o More resources need to be expanded to meet the significant market opportunities. o UV-curable powder coating application technology and chemistry are poised to capture a significant and profitable market share of the Global Coatings Industry. Fast – Clean & Green™ Conclusion 38
  39. 39. THANK YOU & QUESTIONS UV-Curable Powder Coating 39
  40. 40. M I C H A E L K N O B L A U C H P R E S I D E N T 4 6 4 1 H I N C K L E Y I N D U S T R I A L P K Y C L E V E L A N D , O H 4 4 1 0 9 2 1 6 - 7 4 1 - 5 5 1 1 M F K @ D V U V . C O M W W W . D V U V . C O M DVUV, LLC
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