Presented at the Coatings Trends and Technologies Conference September 2016.

1. Ultra Violet Light
Cured Powder Coating
Productivity + Performance = Profits

2. UV-Curable Solid Materials
Resins – Coatings - Materials

3. Productivity – 21st Century

4. UV-Cured Powder Coating
• The differentiating characteristic of UV-curable powder coating is the
separation of melt & flow from cure
Melt & Flow
1-2 minutes
UV Cure
(seconds)
Minimal
cooling
Electrostatic
Powder
Deposition
Finished
Product
Substrate
Pretreatment
Melt, Flow & Cure
5 to >60 mins
+ cooling
Thermal Powder Coating
UV Powder Coating

5. UV & Thermal Powder
Time & Temperature
Hold Temperature
End
Enter Melt/UV
Oven
Leave Melt/Cure
End
Start Enter Preheat
Leave Preheat
Enter Application
Exit Melt/UV Oven
0
20
40
60
80
100
120
140
160
0 5 10 15 20 25 30 35
Temperature
(°C)
Minutes
UV
Thermal
Enter Melt/Cure
5
System description Length Speed Preheat Melt/Cure Plant size Avg Parts/hr kWh
Feet ft/min time min time min sqft
UV 200 10 1 1 2500 550 158
Thermal 321 10 2 5 6440 520 461

6. UV-Cured Powder Coating Thermal
Profile
1 second 47 seconds 96 seconds
65°C 78°C 104°C
Total time in front of IR panel 120 seconds
Total dwell time in front of IR panel 96 seconds
Surface temperature end of cure – 85o C
Melting powder not heating part

7. Advantages of Low Heat
• Reduction in energy consumption
– Shorter & faster thermal cycles
• Less time in oven(s)
– Smaller ovens
• Finish heat sensitive substrates
– MDF/Wood
– Plastics
– Composites
– Assembled products
• Less risk to substrates
– Reduced moisture loss in MDF & Wood
– Reduced potential thermal cracking in MDF & Wood
– Reduced potential of outgassing cast metals
– Eliminate damage to heat sensitive gaskets and seals

8. Advantages of Short Line
• Smaller plant footprint
• Faster turn around
• Fewer parts on the line
• Faster part change over
• Better inventory control

9. Advantages of Low Labor Cost
• Fewer part touches
• Lower variable cost
• More effective floor management
• Higher profits per hour

10. UV-Cured Powder Coating &
Thermal Cured Powder Coating
• Disclaimer
• The following comparative examples are
based upon the model shown on slide #5 and
is for demonstration and reference purposes.
Actual results will differ.
• Additional background data is available from
the author.

11. Annual Cost of Energy & Plant
$-
$10,000
$20,000
$30,000
$40,000
$50,000
$60,000
$70,000
$80,000
$90,000
$100,000
UV Thermal
Energy
Cost
in
Dollars
Powder Systems
Annual energy cost to operate ovens and
UV lamps
UV
Oven
$-
$10,000
$20,000
$30,000
$40,000
$50,000
$60,000
$70,000
$80,000
$90,000
UV Thermal
Footprint
cost
Powder Systems
Plant footprint cost

12. Capacity Model & Profits/Hour
-
200,000
400,000
600,000
800,000
1,000,000
1,200,000
Units
SKU's a Day
Annual Total Parts Produced
UV
Thermal
0
500
1000
1500
2000
2500
3000
1 3 5 7 8
Dollars
SKU's Per Day
Profit/2000 hour year
UV
Thermal

13. UV-Cured Powder Coating & Liquid
Coating
• Disclaimer
• The following comparative examples are
based upon information gathered from market
sources and is for demonstration and
reference purposes. Actual results will differ.
• Additional background data is available from
the author.

14. Material Cost Comparison
Material cost per square foot
Waterbourne acrylic baking enamel $0.4186
Aklyd Air Dry Enamel Low VOC $0.2003
Zero VOC Acrylic $0.6204
UV powder spray to waste $0.2730
UV powder spray to reclaim $0.1912
$0.0000
$0.1000
$0.2000
$0.3000
$0.4000
$0.5000
$0.6000
$0.7000
Material Cost per Square Foot of Surface Finished
*Liquid systems 2-coat
UV-cured powder 1 coat

15. Production Comparison
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

16. Profitability Comparison
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

17. Project Analysis
• Replacing a liquid coating system with 2 coat UV-cured
powder coating system
• Costs as a % of sales (estimated)
– Substrate & machining 40%
– Paint/coating materials 15%
– Labor 20%
– Indirect 5%
Total cost of good 80%
Gross profit margin 20%
A 10% cost savings utilizing UV-cured powder generates $2.5
million of annual saving and a $0.15 increase in earnings per
share (EPS) a 7% EPS increase.

18. Speed Changes Everything
• More throughput
• Higher/faster ROI
• Higher productivity
• Higher customer satisfaction

19. UV LED Curing Technology
• UV LED technology is increasing market
interest and demand for UV cured materials
– Higher energy output efficiency
– Lower total cost of energy
– Targeted curing
– Cure complex shapes/geometries
– No IR

20. UV-Cured Power Coating Quality &
Application Performance
• DVUV Application process quality performance
Total Internal R&A Total 1st Pass
Quality
– 2016 99.20% <.1% 99.20%
– 2015 98.92% 0.1% 98.91%
– 2014 98.93% 0.3% 98.63%
– 2013 98.66% 0.3% 98.36%
– 2012 97.82% 0.4% 97.42%

21. UV Powder Performance
• Material Performance
– Keyland Polymer test lab
• www.keylandpolymer.com for testing results
– AIDIMA, Valencia Spain
• UNE 11022/1 and UNE 11023/1
• FIRA Standard 6250
– “For interior GENERAL use in horizontal surfaces, excluding
kitchen worktops and other surfaces (like front and side parts of
furniture, vertical wall panels …”
– Third party independent testing
• Element Materials Technology, formally Stork Materials
Technology
– Customer testing

22. Resin Platform
• Polyester – broad range of performance attributes – can achieve
ASTM 1000 hour corrosion resistance
– MDF
– Metal
– Composite
• Epoxy – Hard functional coatings – primarily for interior applications
– Metal
– Composites
• Hybrid – Polyester/Epoxy – for specialized applications
– MDF
– Metal
– Plastics
– Composites

23. Substrates for UV Powder
• Substrates
– MDF – Low heat – less moisture volatilization
more stable substrate
– Wood – Low heat - less resin volatilization
– Plastics – Low heat – less warp of certain plastics
– Composites – No degradation of substrate
– Metals – ASTM B-117 – 1000 hour corrosion
resistance
– Assembled parts – Low heat – no damage to heat
sensitive gaskets and seals

24. Markets
• Furniture
– Retail fixtures – POP displays
– Commercial & industrial – Healthcare, Office,
Education
– Kitchen & Bath
• Components
– Transportation
– Industrial
– Assembled products

25. Market Sizes
• Industrial Products ~ General global industrial
finishing materials $22 billion – internal
estimate
• Kitchen & Bath ~ $12.7 billion – Freedonia
group
• Office Furniture ~ $10 billion - BIFMA
• Retail Displays ~ $4.055 Billion –
Designretalineonline.com Fixture Leaders
Listing 2016

26. UV-Cured Powder Coating on
MDF
Fi i hi t th S d f Li ht
Fi i hi t th S d f Li ht
High Gloss Finishes
Solid Surface Finishes
Metallic Finishes
Wide Palette of Colors
Opaque Finishes

27. MDF – Assembled Parts

28. MDF – Cabinet Doors & Drawers
MDF – Hollow Core Doors

29. Finished Products
Interactive Retail Display
Healthcare Component
POP Display
Educational Lectern
Architectural Element

30. Conclusion
The Walt Disney Company/Mike Blandino. Walt Disney’s “Paul Bunyan”. Online video clip. Youtube. Mike Blandino,
July 31, 2013. www.youtube.com/watch?v=4CNtcDjywBA. September 23, 2016

31. Thank you
• Questions
Michael Knoblauch
Keyland Polymer, Ltd.
4621 Hinckley Ind Pky
Cleveland, OH 44109
216-741-7915
mfk@keylandpolymer.com
www.keylandpolymer.com