Hazardous Waste Research and Information Center One East Hazelwood Drive Champaign, Illinois 61820
HWRIC TN94-040
Spray Painting: Improvements and Alternatives
June 8, 1994
Teleconference Materials
Presented by
The Cleveland Advanced Manufacturing Program's NIST Great Lakes Manufacturing Technology Center
Co-sponsored by
Hazardous Waste Research and Information Center, Illinois Environmental Protection Agency and Department of Commerce and Community Affairs
Printed on. recycled/recyclable paper ......
HHnola... Department... , of Energy and Natural RBsources Spray Painting:
Improvements and Alternatives
June 8, 1994
Participants Manual
Presented by:
The Cleveland Advanced Manufacturing Program's NIST Great Lakes Manufacturing Technology Center 4600 Prospect Avenue Cleveland, Ohio 44103-4314 216-432-5300 Call
800-240-87 42
with questions for
Case Study Representatives
and
Presenters
(This number is only active during the Teleconference) SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
TELECONFERENCE AGENDA
DATE: June 8, 1994 PRESENTATION TIME: 2:00 PM to 4:30 PM EDT
1:00 PM Begin Satellite Transmission Testing (see technical information) Before 2:00 PM Local Presentations
2:00 to 4:30 PM Teleconference Broadcast
Scene Setter; Welcome; Teleconference Objectives.
Presentation. How do the VOC provisions of the Clean Air Act Amendments effect Spray Painting Operations.
Mr. David R. Patrick Vice President, ICF-Kaiser Engineers Fairfax, VA
Case Study. Company that has switched from HP spray to an alternative spraying system.
Replogle Globes, Broadview, IL Mr. Harry Bhandari, Vice President of Manufacturing
Presentation. Alternative Spray Painting Systems. Focus on the characteristics of the systems, transfer efficiency, coating thickness, application techniques.
Mr. Thomas Burke Manager, Coatings Technologies FMC Corporation - Corporate Technology Center Santa Clara, CA
Case Study. Company that has implemented process changes to reduce the amount of hazardous waste generated.
Automatic Welding & Manufacturing Company, Ashland, Ohio Mr. Wayne Wilfong, General Manager
Interactive Question and Answer Session. Have your questions on the above topics answered . live over our 800 number phone lines
Panel - Mr. David R. Patrick Mr. Thomas Burke Mr. Harry Bhandari Mr. Wayne Wilfong Mr. L. C. Boyd, Jr., CAMP
15 minute Break - Video introducing and announcing the upcoming NTU Teleconference Series SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
TELECONFERENCE AGENDA con't
Case Study - Alternative Painting Formulation - Company that has switched to water based painting.
Cleveland Wood Products, Cleveland, Ohio Mr. Thomas Anderson, Production Supervisor, CWP
Presentation - Alternative Paint Formulations for lower VOC emissions. Focus on paint formulations other than standard solvent-based systems - High Solids, Water-based, UV cured, Powder Coating, etc.
Mr. Ron Joseph, Principal Ron Joseph & Associates, Inc. Saratoga, CA
Case Study - Alternative Painting Formulations - Company that has switched from Spray Painting to Powder Coating.
Newco, Inc., Janesville, WS Mr. David Mysembourg, Operations Manager
Interactive Question and Answer Session. Have your questions on any information presented during the teleconference answered live over our 800 number phone lines.
Panel - Mr. Ron Joseph, Principal, Ron Joseph & Associates, Inc. Mr. Thomas Anderson, Production Supervisor, CWP Mr. David Mysembourg, Operations Manager, Newco Mr. L. C. Boyd, Jr., Manager, CAMP
Closing Remarks and Credits
4:30 to 5:00 PM
Fill out post-conference questionnaire.
Local follow-up on how and where to access Local Technical Assistance. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
TABLE OF CONTENTS
1. Participant's Biographies
2. Pertinent Environmental LegislationUpdates
3. Overview of Coatings Technologies
4. Guide to Clean Technology, Organic Coating Replacements
5. Paint and Equipment Suppliers
6. Bibliography
7. Great Lakes Technical Assistance Programs
8. Acknowledgements SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
SECTION 1
PARTICIPANT'S
BIOGRAPHIES SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
BIOGRAPHIES
TOM ANDERSON
Tom Anderson is currently the Manager of Manufacturing and Industrial
Engineering for Cleveland Wood Products, a division of Scott Fetzer in Cleveland, Ohio. Along with providing technical and engineering assistance in the manufacturing processes, Tom is currently responsible for all product and system quality functions necessary to produce the Cleveland Wood Products line of vacuum cleaner brushes and attachments.
In 1992 the company changed the layout of their existing paint line in order to increase the transfer efficiency and make the conversion from solvent based coatings to water based coatings cost effective. In the third quarter of 1992 all water based paint testing was completed and water based paint was approved for use.
·Since joining the company in 1972 Tom has held several management positions and has been involved in project management, waste reduction, equipment justification and procurement.
HARRY K. BHANDARI
Harry K. Bhandari is the Vice President of Manufacturing at Replogle Globes Inc., in Broadview, illinois. Replogle manufactures Geographical World Globes and is the worlds largest globe producer. It uses water based coatings for the Globe surface protection. Solvent base materials are used for its wood finishing operations.
The spray coating process at Replogle was changed from conventional spray guns to HVLP guns in 1991. This has been instrumental in Replogle's reduction of VOM emitted, as well as the total coating consumption. The process is unique in that the transfer efficiency of the HVLP gun is 65-85% as compared to 30-45% for a conventional air spray gun.
Mr. Bhandari holds a Masters Degree in Mechanical Engineering fromthe University of Birmingham, England. He has over 20 years of engineering and manufacturing experience, and has been involved in VOM reducing methods, conservation, and process changes to improve work conditions and environment. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
BIOGRAPHIES con't
LAWRENCE C. BOYD JR.
Lawrence C. Boyd Jr. is the Manager of the Environmental Services Program (ESP) within the NIST Great Lakes Manufacturing Technology Center (GLMTC).
The GLMTC is a joint effort between the Cleveland Advanced Manufacturing Program (CAMP) and the National Institutes of Standards and Technology with the mission to assist small and medium sized companies in adopting technologies to improve their operations and increase their competitiveness in the marketplace.
Among the activities of the ESP are seminars related to pollution prevention and waste reduction, in-plant waste reduction assessments perfo rmed by a cadre of trained CAMP engineers, .an internship program with local universities and a hotline service. Support for this program is provided through grants from the Gund, Joyce and Cleveland Foundations; The Great Lakes Protection Fund; the Ohio Environmental Education Fund; and the Ohio Department of Development through the Edison Technology Center Program.
Prior to joining CAMP, Mr. Boyd had over sixteen years of experience in the chemical industry as a process engineer, production superintendent, process engineering manager, and technical superintendent in specialty chemical manufacturing operations. Mr. Boyd received B.S. and M. Engr. degrees from Cornell University in 1971 and 1972, respectively, and an MBA from Cleveland State University in 1984.
THOMAS J. BURKE, CMfgE
Tom Burke is the Manager of Paints and Coatings for FMC Corporation in Santa Clara, California. He has more than 12 years with FMC in this position. Previously, he was with Chemcoat Inc. for 5 years as Laboratory Manager. Tom also spent 5 years with Lilly Chemical Products in Technical Service and Sales and also served 21 years with C.W. Haynes Laboratories in several positions from Laboratory Quality Control Technician to Manager of the Machine Tool Division. He has presented seminars and papers on coatings. He has studied chemistry, math and business at the American International College and Penn State University. Tom has been a member of SME since 1988 and is with the SME Santa Clara Valley Chapter No. 98. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
BIOGRAPHIES con't
RON JOSEPH, M.S.
Ron Joseph is Principal at Ron Joseph & Associates, Inc. a coating and environmental consulting firm in Saratoga, California. A Certified Manufacturing Engineer, AFP/SME, Mr. Joseph has devoted his career to the coatings industry. For several years he has worked with air quality management districts in California compile environmental rules for industrial coatings, and he to frequently represents industry's problems before regulatory agencies.
Working closely with both commercial and military organizations, he has helped numerous companies to get into compliance by filing variances, establishing equivalency plans, and selecting and implementing compliant coating systems. He has developed and presented several training programs on voe compliance for corporations, government agencies, local air quality management districts, and the EPA.
Mr. Joseph's experience includes several years as a technical consultant for a large paint-manufacturing company, and subsequently as Manager of Coatings Technologies for the FMC Corporation. In 1984, he established his own consulting firm which consults to coating manufacturers, user of coatings, government agencies, equipment suppliers and similar organizations. He has conducted numerous application trials using compliant coatings from suppliers throughout the US. He is an expert on the measuring of transfer efficiency on production lines, and coatings facilities.
He holds a B.S. degree in Chemical Engineering from the University of
Witwatersrand, South Africa, and an M.S. degree in Corrosion Science from the University of Manchester, Institute of Science and Technology, England. He is a member of the executive committee of the Air and Waste Management Association, Golden West Section, and is a frequent speaker at international finishing conferences. He has written more than 20 papers for publication, and has recently been appointed Consulting Editor for Metal Finishing Journal. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
BIOGRAPHIES con't
DAVID R. PATRICK, P.E.
David R. Patrick is a Vice President with ICF Kaiser Engineers, an environmental and engineering consulting firm headquartered in Fairfax, VA. He is a Registered Professional Engineer, with over 30 years of professional experience, who specializes in providing air pollution engineering, health assessment and permitting services, and in developing strategies for compliance with air pollution regulations. Beforejoining ICF Kaiser in 1986, Mr. Patrick worked for 15 years for the U.S. Environmental Protection Agency where he managed programs and directed studies involving all aspects of the evaluation, measurement, regulation, and control of air pollution. He is a nationally known expert in air pollution. For example, he was Managing Editor for the Toxic Air Pollution Handbook, published in 1993 by Van Nostrand Reinhold Publishing Company; he wrote A Faclllty Manager1s Gulde to Clean Air Act Compliance, to be published in late 1994 by the BNA Books Division, Bureau of National Affairs; he is a contributing author and serves as a technical advisor for Clean Air Permits: A Manager, Gulde to the 1990 Clean Air Act, published by the Thompson Publishing Group; and he frequently gives seminars on the Clean Air Act and is a guest lecturer on air pollution regulations for Government Institutes, Inc. and Executive Enterprises.
WAYNE WILFONG
Wayne Wilfong is the General Manager for Automatic Welding & Manufacturing Company in Ashland, Ohio. Automatic Welding & Mfg. is a manufacturer of custom fabricated products including environmental, acoustical, material transportation and equipment housing and welders of carbon steel, aluminum and stainless components.
Mr. Wilfong joined Automatic Welding as a welder in the shop and since then has held increasingly responsible positions as Supervisor, Supervisor of crew installing replacement parts on Alaska Pipeline, Plant Manager and General Manager. He set up programs for Quality Assurance, record keeping and various other areas.
Automatic Welding has received Ohio EPA Certificate of Appreciation for Acknowledging Corporation Commitment to Administrator's 33/50 Program, also Chrysler Corporation's Quality Excellent Award in 1992. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
BIOGRAPHIES con't
Mr. Wilfong is a member of Society of Manufacturing Engineers and American Welding Society. Mr. Wilfong has attended seminars at Akron University. He has over 30 years of experience in fabrication of various metals. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
SECTION 2
PERTINENT
ENVIRONMENTAL
LEGISLATION
UPDATES NVIRONMENTAL WATCH
Your Source for Environmental Compliance Information
Volume 1, hsue 1 August 1992 ENVIRONMENTAL REGULATION OVERVIEW
The 1984 Amendments to the which thesegoals are accomplished. Never Resogrce tobe Conservation and Recom:yAct, andthe Jiu: in thehistory of cleanair legislation hasa law had ardousand SoUdW1steA1Dendment1
aresupplemental goals that call forthe reduction major somce is defined as one emitting 10 tons
of emissions and establish a time frame within per yearof anylisted air toxic or 25 tons per year
Produced by the Environmental Serv/cea Group • • • Man-Giii Chemical Company 23000 St. Clair Avenue Cleveland, OH 44117 1-800-627-6422 Page2of2
of any combina in thehope of reducing national pollution releases tion of listed air and off-site transfers of 17 toxic chemicals33% toxics. Reductions by the endof 1992 and 50% by the end of 1995. will be achieved utiliz use TheEPA is trying to encouragec ompanies to ing Mt1jmgmAchievable pollutionprevention practices ratherthan end-of Control Tecbnoloay pipe treatmentto achieve reductions. Pollution (MA.CD. The requirement for prevention is often cost effectivebecause it may the MACT Standards, although in reduce raw material losses, reduce reliance on in new so view for the '' cipient urce re expensive end-of-pipe'' treatment technologies recentyears , now hasbecome a mandatefor and disposal practices, conserve energy, water, assessing compliance with sources. Prior to chemicalsand otherinputs , andis environmen reaso EPA' s issuanceof a particularMACT standard, tallydesirable for these very same ns: pol sourcescan undertak e voluntaryreduction mea lution itself is reduced at the source while re suresmaking them eligible to apply fora 6 year sourcesco are nserved.Some of the 17 chemicals extension in their date for compliance withthe thatare covered in thisvoluntary program are as MACT. Anysource makinga 90% reduction in follows: CarbonTetrachloride , MethyleneChlo its toxic volatile organic compound emissions ride,Tetrachlorocthyl ene,l, 1,1-Trichloroetbane, anda 95% reduction in its toxic particulateemis and Trichloroethylene. The EPA will use the sions comparedto 1987 baselinelevels would be Toxics Release Inventory (TRI) to track these eligible forthe extension. It is obvious thatthe reductions using 1988 data as a baseline, as new CleanAir Act Amendmentsof 1990 require requiredbythe Pollution Prevention Act ofl 990. much greater sourceemission reductionnow and TheTRI industrial reporting requi rements willbe in the future. expanded beginning in calendar year 1991 to The EPA has been working on national include informationon pollution prevention. emission standardsfor eight major hazardousair ltis imperativethat facilities evaluate their pollutantsources, andmay proposethem in the need for compliance to these regulations. One ommen next two years. Issuanceof these ruleswould set rec dationis to conduct a'' comprehensive MACTstandards for a largemajority of the pollut emissionand waste inventory''. Once thepollu ants on the list. One of these rules would set tionsources/emissions are categorized, an overall standards for emissions from organic solvent airquality and pollution pre vention/wasteman degreasing operations. Another proposed rule agementprogram should be createdand include: involves hazardousorganic compound emissions ssmen fromsynthetic organic manufacturing plants, in I .Initialasse t of emissions/ cluding emissions from storage tanks, process pollutionsources; ideaof what to expectout of the vents, equipment leaks and waste water treat 2.An ment. The hu.ardousorganics rule alone could regulatoryprocess; and emission standardsfor about 400 sourc e cat 3.Systematic wayof meeting the set · egories and 140 of the 189 substances on the regulations. toxics list. To issue this rule, the agency must identifyevery chemical process or product of a M1111-GUIClle111 ical, throughit's M1111- chemical process that uses or produces a sub age1nentSewicaAgree mentProgrt1111,can help stance on the list. many industrialconcerns perfonn these assess Additionally,the EPA has established a ments 1111d implementprograms to helpbring m o vohmtarypollutionpreventioninitiati vealsocalled any ofthem int compliance. the 33/50 Prog;ram. This programw as initiated
• • • Man-Giii Chemical Company 23000 St. Clair Avenue Cleveland, OH 44117 1-800-827-8422 NVIRONMENTAL WATCH
Your Source for Environmental Compliance Information
Volume2, &me 1 Februry 1993
CLEAN.AIR ACT AMENDMENTS OF 1990
Twentyyears ago, a lawpuaedthat's mod On November lS, 1990, Congress passed est size,approximately SO pagesin all, became a theCleanAirActAmendmentsof1990. Neverin revolutionaryproinisebyConaresa toinsure clean thehistory o f clean airlegislation has lawa had The1970CleanAir airtoallAmericans. Actwu more potentialimpact on thisnation's business a legislativelandmark i n many ways,marking a andthe quality of airw e breathe. Thelaw gives highpoint in ul Congressionalconcern for the envi EPA 10 years to prom gate hundreds of new ronmentup to that time. It incorporatedwhat were regulationsand twice that l ong forfull i mplemen then in thenation's approach Congress'intent majordepartures to tation. fortheAmendments was regulation,including national, adoptan as opposedto re to innovative,market-based approach to gio al , airquality and qualityregulation emphasizingeconomic in n standards statutorydead air , lines forcompliance. centivesf or compliancerather than the traditional command-and-controltechniques. However, whilethis c leanair law accom plisheda greatdeal -substantilllyredncing emis Theregulatory of agenda theAmendments sions of suchpollutants u sulfuroxida, v olatile rangesattea1,tting from tocontrolglobal tempaa organiccompounds (VOCs),Cllbon monoxide, ture andatmospheric cblllges to rulescovering parti • culates, and especially lead the United umealedvalvesand airqualityinsideofticebuild Statesdid not achievethe Clean Air Act's goals. ings. The Amendmentsare divided into 11 parts, Ninety-six cities hid not attained the national ortitles, or repllcing addingrequiranents to those sta: ozone, �ard for the primuy inarecfient in containedthe in previous Clean Air Act. smog. �orty-onecitiesclidnotmeetthestandard caroon monoxide not of for and 72 did meet the Thefollowing overview highlights some standardfor particulate matter. Inlddition,since the new law's imJor provisions and is not in 1970, the e EPA has been ab l to regulate only tendedto be comprehensive. pollutants, sevenbuardous air outof a potential listof severalhundred. Thisis a of Title deals for rault contro I withprovisions attainment andlegal chall engesover versy provisionsof the andmaintenanceofNationalAmbientAirQuality 1970 law. by the Group Produced Environmental Services • St. Clair Avenue • Cleveland, • Man-Giii Chemical Company 23000 OH 44117 1-800-627-6422 Page2o/3
establish non emissions standards forco2, hydrocarbons and attainment areas carbonmonoxide will app ly bcgimingwith 1994 for ozone,carbon di model-year vehicles. The Agency also will de oxide, particulate mat velop standardsfor carbon monoxide (CO) emis - ter,lead, sulfur dioxide and sions undercold weatherconditions. nitrogen oxides. Under NAAQS, statesmust submit state Perhapsth e mostacross the board change in impl tationplans(SIPs) emm for each theC leanAir ActAmendments ofl 990i s withair pollutantto bring non -attainmentareas toxics or Title m. Essentially scrapping any compliance. into semblance of a risk-based approach totoxic air contaminants control in favor of a hardware Specifiedreasonably available control tech buedsystem, the new amendments specify a list utants. The EPA must nology (RACT) mustbe usedto achieve attain of 189 "toxic" air poll mentat emissions so urcessubject co to ntrol tech identifyall the source categori es(industri es) that nology guidelines (CTGs), as well as nitrogen encompassmajor emitting sourcesof thesepol oxides (NOx) andVOC sourcespotentially emi t lutants. Major sourcesarc anystationary source ting po al tons of more than50 tons peryear. Non-attainment that hasthe tenti to emit 10 peryear areas for carbon dioxide and ozone pollutant or tons peryear of a (C02) must any one listed 25 establishvehicle inspection and maintenance pro combinationof listedpollutants . grams. The Amendments also specify stricter boundariesfor d esignation of non-attainmentar Major sourcesemitting these pollutants will eas . have to complywith Maximum Achievable con trolTechnology(MACT), astandard based on the Title II of the Amendments covers mobile best-demonstrated control technology or prac emissions sources, essentially motor vehicles. ticesby used theregulatory industry. TheEPA is Motor vehicles arc still the largest source of requiredto establish emission standards for all the carbon monoxide and ozone pollution in the listed industries on a schedule outlined in the ..
United States. Emissions from cars, trucks and legislationthat results in theregulati on of alllisted buses can be decreased by using fuel and fuel sourcecategories within 10 yearsof enactment. deli verysy stemsthat are less pronepo to lluteand by changing the vehicles themselves to make Newand more complexpermitting proce them run cleaner. The Clean Air Act Amend dureswill fullybe impl ementedby 1995as part of mentsof 1990use both methods to reduce emis TitleVoftheAmendments. Additionalinforma sions relatedto motorvehicles. tion will be required, and further specificity in termsof operatingrequirements will be imposed EPA will promulgate more stringent rules by the agenciesissuing the permits. Permitsmust fortailpipeemissionsandreformulated gasoline, include enforceable emission limits and stan asw ell asinitiate oxygenated fuels programs for dards,a complianceschedule, andrequirements CO 2 non-attainmentareas. Californiawill initiate forthe source to submit semiannual reports on the a ''clean-car ilo program and a clean fuels of requiredmonitoring. p t results forvehicle in worstairpollu program'' fleets the tionareas. aeanfuel refers to compreued natural Title VI of theClean Air Act Amendments gas, ethanol, methanol,li quefiedpetroleum gas, coversStratosph ericOzone Prot ection. Theregu electricity, reformulatedgasolin e and other po lations define two classes of substances which tentialenergy sourc es. Thefirst phase of tailpipe affectozone levels, andestablish phase-out con-
• • • Man-Giii Chemical Company 23000 St. Clalr Avenue Cleveland, OH 44117 1-800-827-6422 Page.30/.3
trotsand schedules The 1990 amendments tothe Clean Air Act for each class. The established anambitious schedule for drafting regu lations implementnew emission con Amendments also re necessaryto quireregulationsrestricting trols, permit requirementsand enforcement provi the use of controlled ozone sions, and the next 10 years promise to provide manyc l depleting substances, banning hal engesto businessesin theirattempts to nonessential products, mandating complywiththesenewrequirements. Estimatesare warning labels, andestab lishing a safe thatthecostoftbislegislation will ex ceed$20 billion alternativesprogram. annuallywhen fully impl emented.
Federal enforcement authority has been in Ma-Gill'sf111lliuo/C0111plillllup11ints1111d creased substantially for both civil and criminal NpOr�,,,_,.lltiNSCtlll asi&tin•uting violationsin T itle VIIof theAmen dments. Substan �replatiouwla&k«pingcostscon tialincreases in monetarypenalties and new criminal trolW. penaltieshighlight the enfo rcement provisions. In dividuals can face fines of up to a quarter-of-a milliondollars and jail sentences of up tofive years forknown violationsand up to 15 years forknown endangerment. Civil penaltiesare substantially in creased,including an administrative penalty of upto $25,000perdayperviolation. Inaddition,abounty provision authorizespayment of upto $10,000 for informationleading to a civilor criminalpenalty.
• • · • Man-Giii Chemical Company 23000 St. Clalr Avenue Cleveland, OH44117 1-800-827-8422 NVIRONMENTAL WATCH
Your Source for Environmental Compliance Information
Volume No. 3, Issue No. 2 March 1994
WASTE MINIMIZATION PROGRAMS
(GUIDANCE TO HAZARDOUSWASTE GENERATORS)
r U.S the efforts undertaken In 1984, Congress passed theHazardous and eport to . . EPA: (1) Solid Waste Amendments (HSWA)amending the during the year to reduce the volume and toxicity of waste generated, and the changes 1976 Resource Conservation and Recovery Act the (2) in (RCRA). This was the beginning of a new policy volume and toxicity actually achieved in compari son to previous concerning hazardous waste. It declared that the years. reduction or elimination of hazardous waste gen eration at the source should take priority overthe In May of 1993, the U.S. EPA published a management of hazardous wastes after they are notice, "Interim Final Guidance: Guidance to generated. Haz.ardous Waste Generators on the Elements of a Waste Minimiution Program" (Federal Regis There are several speci&c requirements con ter, Volume 58). The notice is intended to assist op tained in the HSWA that promote implementa buardous waste generators and owners and tion of waste minimizatimi. Generators of erators of hazardous waste treatment, storage with the waste hazardous waste who transpOrtwaste off-site are and disposal facilities to comply required to certify on each hazardous waste minimiz.ationon certificati requirements under manifest thattheyhave a program in place to re HSWA duce the volume andtoxicity of such waste to the c �gree determined by the generator to be eco EPA states in the guidance that waste mini nomically practicable. Owners and operators of mi7.ation programs should incorporate the follow permitted hazardous waste treatment, storage ing basic elements common to most good waste and disposal facilities are also required to provide minimization programs: . ( 1) Top management the same certification annually. Hazardous waste support; (2) Characterization of waste genera generators and owners/operators of treatment, tion and waste management costs; (3) Periodic storage and disposal facilities that manage their waste minimization assessments; (4) Appropriate own waste on-site, must also identify in a biennial cost allocation; ( 5) Encouragement of
Produced by the Environmental Services Group • • • Man-Giii Chemical Company 23000 St. Clair Avenue Cleveland, OH 44117 1-800-627-6422 Page2
technology trans parts of the organization or process where the fer; and, ( 6) Pro- greatest opportunities for waste minimization gram implementation exists. and evaluation. Exchanging information for waste minimiza Top management support in tion options and technologies is extremely benefi
cludes making waste minimization a cial. Ideas that may not be useful to you, may part of the organizations charter - in assist other departments in another area, and vice corporating it into the strategic plan. Put versa. This can also be accomplished outside of a policy in writing and adopt it in day to day the facility through trade associations, govern operations. Explicit goals needto be established ment technical assistance programs, professional for the reduction of the volume and toxicity of consultants, universities, etc. waste streams in a gi ven time frame. Manage ment needs to commit to implementing recom Finally, implement the recommendations that mendations. Most importantly, a waste are identified by the assessment process, evalua minimization coordinator should be designated tions, waste minimization teams, etc. Periodic who is responsible for facilitating effective imple reviews should be conducted of the program's ef d mentation, monitoring, and evaluation of the fectiveness to provi e feedback and identify po program. tential areas of improvement.
Characterization of waste generation and The EPA is putting great emphasis on the waste management costs is the next step in the wl$te minimization program. In November of program. A waste accounting system should be 1993, Chief Executive Officers of facilities that implemented to track the types, amounts and cost are large quantity generators received a letter of waste generated at the facility. Then "true from EPA Administrator Carol Browner. This lett er requested assistance minimizing the na costs" associated with waste management and in clean-up need to be calculated including costs of tion's hazardous waste. Ms. Browner stated that paperwork and reporting requirements; loss of because President Clinton indicated in his Earth production potential; transportation, treatment Day Message in April of 1993 that preventing and disposal costs; regulatory oversight compli pollutionis one of his top priorities, she will seek ance; and, any future RCRA/Superfundliability. every opportunity to reduce the amount of waste generated in the United States and prevent pollu tio source. Included Periodic waste minimization assessments n at the with the letter was a of guidance for a waste minimization should be performed to identify opportunities at copy the all points in a process where materials can be pre program and a reminder to these facilities that vented from becoming a waste. After theassess they are required to havethis program in place. ments, waste minimization opportunities need analyzed based on the true costs associated with In the spring of 1994, the EPA will make waste management and clean-up. available to the public the names and locations of organizations and their facilities that were subject
Allocate true costs of waste management to to this requirement in 1989 or 1991. As a result, the activities responsible for generating the waste people located near the facilities may ask to see in the first place. This can properly highlight the the details of these waste minimizationprograms.
• • • Man-Giii Chemical Company 23000 St. Clair Avenue Cleveland, OH 44117 1-800-827-6422 PageJ
Although the guidance document on waste The EPA be minimi7.ation programs describes approaches that that waste lieves mini may be used to minimize the hazardous waste c mization will provide reated, they are also important steps in the de additional environmental im sign of multi-media source reduction and recy provements over "end of pipe" cling programs for all forms of pollution. control practices, most times with a cost savings to the generator and re Mu-GIB Chlllkal Management . Pro duced levels of treatment, storage and dis- grtlllLI amt colltptlllia with teclaniqNa that posal. The benefits that accrue to facilities c1111 g1'tlfllly1ua:anlotu 1't!tlllce MUie. This is ae- that choose to pursue waste minimization some co"'l'IUWtluoagla vtll'itJu''°"" ""that c1111 times include: ( 1) Minimizing quantities of haz "'*""""1cO'lllbl elbnilu8 toxic chemicals by ardous waste generated, thereby reducing waste rqlad111 them wit/a safer a1terrudiYa. Addi management, and compliance costs and improv tiollillly, a vtllWty ofllllll reqclillg point SOllrce ing the protection of human health and the envi re4Mctio11 optiolU Cllll H doiglletl into" ,,. .. ronment; (2) Reducing or eliminating inventories that effectiNly Ngellel'Ylla process chadcals and possible releases of "hazardous chemicals"; llllll selectiwly Nlfl011G tuUl COllCentrata t/ae (3) Possible decrease in future Superfund and wast& RCRA liabilities; (4) Improving a facility's mass/energy efficiency and product yields; (5) Reducing worker exposure; and (6) Enhancing organizations reputation and image.
• • · • Men-Giii Chemlcel Compa� 23000 St. Clelr Avenue a.v.tencl, OH 44117 1-800-827-8422 SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
SECTION 3
OVERVIEW
OF
COATINGS
TECHNOLOGIES
'------�------_) .POLLVTIOJV .P.B,EVEIVTIOJV Tl.PS
• Overview of Coating Technologies
prior to 1966, before the first environmentalU.S. regulation was aClopted, almost every item that was painted was finished with low-solids solvent-borne coatings. Since that time, however, environmental concerns and the increasing cost of solvents have created demand for chemical formulationsand coating application techniques that will reduce air emissions and save raw materials. This demand increased dramatically with the passage of the 1990 Clean Air Act Amendments.
Typical solvent-based paints contain 60 to 80 percent volatile organic compounds (VOCs), �any of which are also a ard air listed as h z ous pollutants (HAPs) or toxic air pollutants. A number of new resins are being introduced into the coatings market designed to improve performance, especially in high-solids and waterborne formulations. In addition to new coat g formulations,tech nologies are changing in rapidly to improve efficiency incoating applications.
To encourage pollution prevention incoating operations, the Pollution Prevention Program (PPP) provides this on the adv ges and . TIP anta disadvantages of various coating fo rmulations and application technologies. Since many variables are involved int he selection of the most efficient technology, or combination of technologies, the PPP hopes that this information will serve as a guide making those in decisions.
Pc::>II-..iti<>:rll. P:r�"""V"�:rll.ti<>:rll. P:r<:»g:ra.m N.C. Department 0£ Eaav-lroa.me-t. Health,and Na""'--1 R- Coating Formulations lt®f1''f' coatings are solvent-based and have a igh resin concentration. Solids content High solids h the to percent range, alt ug some formulations are higher. typically falls in SO 70 ho h
• Advantages • Disadvantages and HAP emissions - Generally require high cure temperatures - Reduced VOC - Reduced solvent usage - Sensitive to inadequate cleaning of - Reduced inventory substrate - Reduced fire hazards - Extremely sensitive to temperature and humidity - Reduced number of spray applications to achieve a given film thickness - Difficult to control mm thickness - Improved abrasion and mar resistance - Tacky overspray difficult to clean - May require paint heater insystem / - Difficult to control sagging - Narrow "time-temperature-cure" window - Cannotuse dip or now coating - Difficult repair to
Waterborne Coatings
In waterborne coatings, water, alone or in conjunction with an organic solvent, acts asthe carrying medium. Most waterborne coatings contain an organic co-solvent (usually to 2 30 percent) that is added to dissolve the resin.
• Advantages • Disadvantages - Reduced VOC an emissions - May cause grain raising wood d HAP in -Conventional application processes can be - Tendency to foam used - Rubbing requires etTort - Reduced toxicity and odor, resulting in - Surface be free of oilan d dust improved worker safety and comfort must - Longer drying times or increased oven - Good storage life temperatures required . - Easy clean-up - High gloss fmish difficult to obtain - Reduced fire hazard - CleaD-up difficult oncecoating is cured - Disposal of hazardous waste minimized or - Great susceptibility to dirt pick-up even eliminated -·Most of thesecoatings cost more per gallon on an equivalent solids basis - Not many resins available for waterborne formulations - Converting solvent-home coating line may be complex, i.e.,stainless steel or plastic lines, valves, etc., are needed - Problems with atomization,i.e., reduced paint transfer efficiencies - Increased runs and sags - Needs good temperature/humidity control - Storage area requires enclosure and heating - Refinishing is difficult
June 1993 - 3 - TIP: CoatingTechnologies ..
Powder coatings con�in 100-percent resin in drypowdered form and a built-in curing agent.
• Advantages • Disadvantages - Heat requirement powder to metal - Cost savings due to: restricts -No solvent flash required finishing -No coatings mix room needed - Powder manufacturing limitations - Minimal oven length required - Difficult to make small amounts ventilation requirement - Control of texture size and distribution - Low limited - Floor space economy, i.e., system requires two-thirds to three-quarters of - Metallic powder coatings not as a e wet metallic wet paint systems ttractiv as finishes - VOC and HAP compliance, i.e., no - Recirculating system creates negative solvents pressure inbooth - Need gentle airstream to a p y powder - Quality finish p l - Durable finish - Enhanced Faraday cage effect - Good corrosion resistance - Difficult to achievethin r.Ims below 1.0 to 1.Smils - Coating utilization efficiencies can reach 95 to 99 percent - Powder clumping - Difficult to change colors - Energy savings · - Needs cool, dry area - Little operator expertise required storage - Powder coatings difficult to matchfor - Quick n packagebility" repairwith liquidpaint and hard to strip - Variety of resins available - Pretreatment of sub rate is critical - No hazardous overspray, waste sludge, or st contaminated water - Reduced worker exposure to solvent vapors
UNICARBTM S ra Svstem
In the UNICARB system, super-critical carbon dioxide rep ces a substantial amount of the TM la conventional solvents used to spray-apply industrial coatings.
• Disadvantages Advantages • - High quality finish - Limited experience - Lower uid delivery ra es than a ess or - Fewer coating applications needed O t irl spray - Reduced VOCs and HAPs air guns - Gun and supply tubing is bulky - Reduced operating costs · - Easy to retrofit - Royalty costs - High transfer efficiency - May reduce sanding requirements for wood furniture - Reduced worker exposure to solvent vapors
1JP: Coating Technologies -4- June1993 I ;tffi@±jt.l.!QllJij.G,ffhli@i
For radiation-cured co ings (ultraviolet (UV), lectron beam(EB), and infrared _3t e (IR)), electromagnetic radiation is used to alter the physical and chemical properties of a coating such that the organic substrate develops cross-linked or solvent-insoluble network structures.
• Advantages • Disadvantages and technologi use coatings with - UV EB es - Interference of photocure by pigments lower VOC and HAP content than -Higher capitalinvestment th an conventional coatings conventional ovens ovens oxidize various VOC's, thus - IR - Higher costs forEB and UV coatings reducing potential emissions - Potential problems with acrylate toxicity - Increased production rates because of short - Shrinkage and a esion problems with curing periods dh acrylate - Low energy costs - Not applicable to all finish typesb ecause it - Consistent performance produces a specific "look" - Small ovens required · - Dermatitis - Low airmovement reduces dust and dirt - Curingsensitive to shape of part contamination - Easily installed/retrofitted - Reduced fire and explosion hazard
Two-Component Reactive Liquid Coatinj?;s
a two-component reactive liquid coating system,two low-viscosity liquids are mixed justbefore In they enter into the application system. One liquid contains reactive resins, and the other contains an activator or catalyst that promotes polymerization of the resins.
• Disadvantages Advantages • - Low-temperature processing - Limited experience - Uncured resin may be harmful - Highly complex process - High level of operator skill required - High capital cost - Limited pot life
. . . . Qj11m W ki:Jfl!Cit?J!Ul! JDI mu.uflm1s!J111:i1l!ltn!!!!tJ1r.W
ter reactive resin is applie a liquid, curing induced by exposing the liquidto a vapor Af a d as is containing a compound that initiates polymerization. One example is polyol-isocycanate coatings cured by tertiary amine vapor injection.
antages Disadvantages • Adv • - Eliminates or reduces solvent - Limited experience - Lowt emperature processing -Highly complex process Unreacted overspray can be collected for - High level of operator skill required - · reuse - High capitalcost - Can be used on heat sensitive substrates
June 1993 -5- TIP: Coating Technologies Application Technologies
s r guns operate with compressed fr om an air compressor to the paint. L VHP p ay air atomize Pressures range from pounds per square typically 40 to 70 inch (psi).
• Advantages • Disadvantages - Excellent atomization permits high quality - Extensive overspray finish - Booth clean-up cost - High production rates - Filter replacement cost - Waterwash reservoirtreatment costs - High VOC and HAP emissions
HVLP spray guns operate with a high volume of air delivered at 10 psi or less to atomize the paint.
• a ta es • a v nta es Adv n g Dis d a g - Reduced overspray - Atomizationmay not sufficient for fine be - Increased transfer efficiency finishes ... High production rates may not be possible - Reduced paint waste - Lower booth clean-up costs - Reduced filterreplacement costs - Decreased waterwash reservoir treatment costs - Reduced VOC and HAP emissions
an airless spray gun,the paint is atomized pa t' s Duid pressure (ranges In by increasing. the in from 500 to 6,500 psi) without introducing a pressurized air Dow.
Ad anta es • v g • Disadvantages - High rates of paint Dow - Relatively poor atomization - Relatively high transfer efficiency - Expensive nozzles - Gun handling versatility (no air hose) - Reduced fan pattern control - Ability to apply highly viscous fluids - Coatings limitation - Tendency for tip plugging - Skininjection danger - Increased operatortraining required - Increased maintenance requirement
- - TIP: Coating Technologies 6 June 1993 About 150 to 800 psi of fluid pressure and 5 to 30 psiof air pressure are used inan air-as-sisted airless gun to atomize the paint.
• Advantages • Disadvantages
- Good atomization, but not as good as air - Skin injection danger - Varied fluid delivery - Increased maintenance required - Low bounceback - Increased operatortraining required - High paint transfer efficiency -Capital cost
With an electrostatic spray gun, the atomized paint droplets are charged at thet ip of the gun by a charged electrode. The to be pa ted el trically neutral,and the charg d paint droplets part in is ec e are attracted to the part.
• Advantages • Disadvantages -High transfer efficiency - Guns tend to be bulky and delicate - Good edge cover - Extra cleanliness essential - Good wraparound - Faraday cage effect - Uniform thickness Safe film - ty /fire hazard mustbe conductive - Parts - High equipment and maintenance cost -l:tBMQZJM.hfJJtl Insteadof airor fluidpressure, rotary atomizers use centrifugal force to atomize the paint and electrostaticcharging to attract the paint to thepart.
• Advantages Disadvantages • - Excellent atomization - Extra cleanliness essential - High solids, waterborne versatility - Faraday cage effect - Viscosity flexibility - afe ard S ty/firehaz - High transfer efficiency - Parts must be conductive l§b!IQ.fihiitS
With oll coating, thep a t is ap li d by one or more auxiliary onto an application roll, r in p e rolls which then rolls across the conveyed flat part.
• Advantages Disadva es • ntag - High transfer efficiency - Cannot painthard-to-reach areas - High production rates - Limitedto flat work
June 1993 -7- TIP: Coating Technologies •
Parts are painted by dipping them (usually by conveyor) into a tank of the paint.
• Advantages • Disadvantages - High production rates - Extremely dependent on viscosity of the - Low labor requirements paint - High transfer efficiency - Not suitable for items with hollows or cavities - Color change slow - Fire hazard -Poor to fair appearance i&t.itii.ijiii.•
a flow coat system, 10 to 80 separate paint are directedto coat allsurfaces of the In streams of parts as they are carriedthrough the flow coater on a conveyor.
• Advantages • Disadvantages - High transfer efficiency - Poor to fair appearance - Low installation cost - Principal control of d.ry-fllmthickness is - Requires little maintenance viscosity of paint - High production rates - Low labor requirement
c in coating, a waterfall flow of paint coats a part conveyed horizontally. The paint Dows at In urta a controlled rate from a reservoir through a wide variable slot.
va tag Disadvantages • Ad n es • - High transfer efficiency - Suitable only for Oat work - Uniformcoating thickness possible - Highly dependent on viscosity
Autodeposition
· Autodeposition is an oxidation-reduction precipitation processused to deposit organicpaint films onto iron, steel,zinc , and zinc alloy-plated substrates.
• Advantages • Disadvantages - Excellent anticorrosion properties (no - Dull or low-gloss appearance phosphate coating required) - Few colors available - 100-percent coverage of surfaces wetted (no Faraday cage areas) - Uses waterbornematerial - No external source of electricity
- - TIP: Coating Technologies 8 June 1993 IQMh.I§.ij(ll.fS
electrocoating, a paint from a waterborne organic sol tion is electrically deposed onto a In film u part.
• Advantages • Disadvantages - Over 90 percent utilization of coating - Substrate limitation material - Separate lines needed for each color - Very thin,uniform coating on allsurfaces -High cost to install that can be reached by electricity pro lems - High production rates - Masking b - Sophisticated maintenance requiremen - Corrosion-resistant coating ts - Air-entrapment pockets - Low VOC and HAP emissions - Bulks mall-partcoating difficult - Process can be fu lly automated - Corrosion-resistant equipment required - Can apply second coat uncured on, electrocoat - De-ionizedwater required - Sanding/stripping difficult - High energy demands - Restrictedto large volume fmis hing - Coating thickness limitation - High level of training needed foremployees
References
oobol, Norman R. Industrial Painting Principles and Practices. Carol Stream, IL: Hitchcock 1. R Publishing Co. 1991.
U. S. EnvironmentalProtection g ncy. Technical Reference Manual on Techniques for 2. A e Reducing or Eliminating Releases of Toxic Chemicals inMetal Painting. By: Battelle Laboratories. Draft.
En iro en l Protection Agency. Guide to Cl Technology, Organic Coating 3. U.S. v nm ta ean Replacements. May 15, 1992.
Roberto, Oscar E., a , and Thomas Jones. Metal Autodeposition 4. Robert G. H rt C. Finishingby of Organic Coatings. MadisonHeights , MI: Parker-+AmchemHenkel Corporation.
S. "Gunning for the Future: Nordson Sharpens its AimWith UNICARB System." UNICARB Update. Spring 1991.
For additionalinf onnation,contact
Pollution Prevention Program Office of Waste Reduction 3825 Barrett Drive, Raleigh,NC 27609 Telephone: (919) 571-4100
June 1993 - 9 - TIP: CoatingTechnologies SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
SECTION 4
GUIDE
TO
CLEAN
TECHNOLOGY
ORGANIC
COATING
REPLACEMENTS NOTICE
to This Guide Clean Technology: OrganicCoating Replacements summarizes information collected from U.S. Environmental Protection Agency programs, peer reviewed journals, industry experts,vendor data, and other sources. The original Quality Assurance/Quality Control (QA/QC) procedures for the reports and projects summarized in this guide range from detailed, reviewed Quality Assur ance Project Plans to standard industrial practice. Publication of the guide does not signify that the contents necessarily reflect the views and policies of the U.S. Environmental Protection Agency, nor does mention of trade names or commer cial products constitute endorsement or recommendation for use.
This document is intended as advisory guidance in identifying new ap roaches for pollution prevention through organic coating replacements. Final selection of a - technology will be shop- and process specific and, therefore, will be done by the individual users of organic coatings. Compliance with environmental and . occupational safety and health laws is the responsibility of each individual business and is not the focus of this document. FOREWORD
Today's rapidly developing and changing technologies and industrial products and practices frequently carry with them the increased generation of materials that, if improperly dealt with, can threaten both public health and the environ ment. The U.S. Environmental Protection Agency (EPA) is charged by Congress with protecting the Nation's land, air, and water resources. Under a mandate of national environmental laws, the agency strives to formulate and implement actions leading to a compatible balance between human activities and the ability of natural systems to support and nurture life. These laws direct the U.S. EPA to perform research to define our environmental problems, measure the impacts, and search for solutions.
Reducing the generation of hazardous solvents at the source or recycling the wastes on site will benefit industry by reducing disposal costs and lowering the liabilities associated with hazardous waste disposal.
Guides Prevention, Publications in the U.S. EPA series, to Pollution provide an overview of several industries and describe options to minimize waste in these industries. Their focus is on the full range of operations in existing facilities. Many of the pollution prevention techniques described are relatively easily implemented into current operations without major process changes.
Techrwlogy: Organic Coating Replacements This Guide to Clean summarizes new commercially available and emerging technologies that prevent and/or reduce the production of hazardous materials during coating replacement. The technologies described in this document and other documents in this series are generally "next generation" clean technologies that often, but not always, represent relatively major process changes, high levels of training, and high capital investments compared to the technologies described in the Guidesfo r Pollution Prevention. The waste minimization techniques characterized in the Guidesfo r PollutionPrevention should be considered and implemented first. Although some of the clean technologies described herein could be inserted into current operations, they should be consjdered primarily for major plant expan sions or new grass roots facilities. CONTENTS
Section 1 1
Overview
Section 2 8
Available Technologies
Powder Coatings 12
High Solids Coatings 24
Water-Based Coatings 30 .
Ultraviolet (UV) Radiation-Cured Coatings 40
Section 3 44
Emergi ng Technologies
Electron Beam (EB)-Cured Coatings 48 Radiation-Induced Thermally Cured Coatings 49 Two-Component Reactive Liquid Coatings 50 Water-Based Temporary Protective Coatings 51 Vapor Permeation- or Injection
Cured Coatings 52 Supercritical Carbon Dioxide as Solvent 53
Section 4 54
Information Sou rces
References 54 Trade Associations 55 SECTION 1
OVERVIEW
What Is Clean Technology? A clean technology is a source reduction or recycling method ap plied to eliminate or significantly reduce hazardous waste genera tion. Source reduction includes product changes and source con trol. Source control can be furthercharacterized as input material changes, technology changes, or improved operating practices.
Pollution prevention should emphasize source ·reduction technolo gies over recycling but, if source reduction technologies are not available, recycling is a good approach to reducing waste genera tion. Therefore, recycling should be used where possible to mini mize or avoid waste treatment requirements when source reduction options have been evaluated and/or implemented.
The clean technology must reduce the quantity, toxicity, or both of the waste produced. It is also essential that final product quality be reliably controlled to acceptable standards. In addition, the cost of applying the new technology relative to the cost of similar technolo gies needs to be considered.
Why Use Organic Coatings? The three major classifications of organic coatings based on end use are:
+ Architectural coatings + Industrial finish coatings + Industrial maintenance coatings.
Architectural coatings are applied on site to interior or exterior surfaces of various buildings. They are applied for protection and appearance, and they cure at ambient conditions.
Industrial finish coatings are applied to factory-made articles during manufacture. Industrial maintenance coatings are field -applied high-performance coatings formulated to resist harsh environments such as heavy abrasion, water immersion, exposure to chemicals or solvents, and/or high temperatures. Alternative clean coating materials are available for all three types of use.
Paint and other coatings are applied to surfaces to enhance corro sion resistance, i mprove appearance, or both. Examples among the many industries that apply coatings include manufacturers of: Overview
• Automobiles • Aircraft • Appliances + Wood products.
The main functions of automotive coatings are appearance, durabili ty, and corrosion protection. Typical automotive coatings use an undercoat or primerto give corrosion protection and improve dura bility. The topcoats are formulated to give the desired color and gloss. In some cases, the topcoatis of two or more different layers: a low-solids polyester coat to give the color covered by an acrylic clearcoat for a high gloss finish. Automotive coatings are normally applied on sheet steel, but body parts are increasingly being made from other materials such as plastic, composite, or stainless steel.
The main functions of aircraft coatings are to resist corrosion, fluids and fuels, erosion, temperature extremes, weathering, and impact. Coatings may also assist in providing protection for lighting strike. Coatings must also give the desired appearance. Appearance may be entirely cosmetic or, in the case of combat aircraft, serve as camouflage. Aircraft finishes may be applied over aluminum, titanium, composite, or other substrates.
Appliances are often referred to as ''white goods" due to the tradi tional color of the coating applied. However, a wide variety of colors are now applied to appeal to consumer tastes. Coatings are applied to protect the underlying metal from water, salt, detergent, and other common corrosive agents at temperatures in the range of about 0°C to 100°C. The substrate is typically steel sheet.
Wood products such as furniture, siding, and doors are coated to increase durability and improve appearance. Exterior coatings must have greater weather resistance than coatings on items intended for interior use. Color or clear coatings may be chosen depending on the type and quality of the wood substrate and the intended end use.
In addition to the specific examples discussed above, coatings are used in a wide variety of other industries and applications. The coatings may provide temporary or long-term protection of wood, metal, and plastic surfaces. This wide range of applications indi cates the cross-industry applicability of clean coating material technology.
Poll ution Problem Classical organic coating materials are dilute solutions of organic resins, organic or inorganic coloring agents, additives, and extend ers dissolved in an organic solvent. The organic solvent gives the
2 Overview
coating fluid the necessary viscosity, surface tension, and other properties to allow application of a smooth layer of liquid coating solution.
The liquid coating is brushed, rolled, sprayed, flowed, or otherwise applied to the surface. As the· organic solvent evaporates, the organic resins polymerize to form the desired dry film.
Environmental concerns and increasing costs of organic chemicals and transition metals are leading to changes in the formulation of organic coatings. Coating makers and users are seeking alternative materials to reduce or eliminate waste of h azardous solvents and paint residues, particularly coatings using pigments containing metal compounds.
Typical coating solvents include methyl ethyl ketone, methyl isobutyl ketone, toluene, and xylene. The coloring agents can be inorganic pigments containing hazardous metals such as cadmium, chro mium, and lead. Mercury chemicals have been used as a paint preservative, although this use is declining. This guide describes application of clean technologies for replacement coating materials that eliminate or reduce solvent use. In many cases, the new coating also reduces paint waste, which in turn reduces waste of hazardous metals.
Solution Coating technology relies on covering a substrate material with an organic film having the desired protective, mechanical, optical, ag ing, and adhesion properties. Conventional organic coating tech nology uses dilute solutions of alkyd, polyester, epoxy, polyure thane, acrylic, vinyl, or other resins in a volatile organic solvent. Not too many years ago coating materials relied on organic solvents . to promote desired flow characteristics so the coating could be applied. The solvent would then evaporate allowing the resins to polymerize and cure to form the drycoa ting. Recent years have seen expanded use of clean technologies.
Clean technologies based on physical methods now exist for materi als that reliably apply coatings but which contain little or no volatile organic solvent. There are four general classes of clean technology for organic coating materials:
100% + dry solids materials that completely eliminate the solvent by using a dryresin formulation 100% + reactive liquids that use a liquid coating material but do not rely on any volatile organic solvent + Water-dispersed or water-soluble polymer systems that substitute water for some or all of the volatile organic solvent
3 Overview
+ High solids polymer systems that reduce the amount of organic of react solvent needed by increasing the concentration ive resin in the solvent.
The clean technologies can also prevent pollution by increasing the efficiency of use for the coating, thus reducing pai nt waste.
What's In This application guide describes clean technologies that can re This Guide? duce waste by the use of alternative organic coating materials. o c The bje tives of this application guide are to help identify potential ly viable clean technologies to reduce waste by using alternative organic coating materials and to provide resources for obtaining more detailed engineering information about the technologies. We address the following specific questions:
+ What alternative organic coating technologies are available or emerging that reduce or eliminate pollution? + Under what circumstances might one or more of these alternative coating systems be applicable to your operations? cost + What pollution prevention, operating, and benefits could be realized by adapting the technology? Other Questions About Investment Decisions Other aspects affecting the decision include:
p o ms substitute for the + Might new pollution r ble old? + Are tighter and more complex process controls needed? + Will product quality and operating rates be affected? + Will new operating or maintenance skills be needed? + What are the overall capital and operating cost implications?
This guide covers several clean coating replacement systems that are applicable under different sets of product and operating condi tions. If one or more are sufficiently attractive for your operations, the next step would be to contact vendors or users of the technolo
gy to obtain detailed engineering data and make an in - depth evalua tion of its potential for your plant.
Who Should Use This Guide? This guide is intended for plant process and system design engi neers and for personnel responsible for process improvement and process design. Process descriptions within this guide allow engi neers to evaluate options so that alternative coating materials can be considered for existing plants and factored into the selection of
new coating materials.
4 Overview
Sufficient information is presented to select one or more candidate technologies for further analysis and in-plant testing. This guide does not recommend any technology over any other. It presents concise summaries of applications and operating information to sup portpr eliminary selection of clean technology candidates for testing in specific processes. The level of detail allows identification of possible technologies for immediate application to eliminate or reduce waste production.
A list of keywords is provided to help you quickly scan the technolo gies covered.
Keywords
Clean Technology Paint Powder Coatings
Pollution Prevention Coating High Solids Coatings
Source Reduction Powder coating Water-Based Coatings
Source Control Removal Ultraviolet (UV) Radiation- Cured Coatings Recycling Stripping Electron Beam (EB}-Cured Depainting Coatings Debonding Radiation-Induced, Thermally Cured Coatings
Two-Compo nent Reactive Liquid Coatings
Water-Based Temporary Protective Coatings
Vapor Permeation- or Injection-Cured Coatings
Supercritical C02 as Solvent
Summaryof Benefits The clean technologies described in this guide are divided into two groups based on their developmental maturity - commercially available technologies and emerging technologies in advanced pilot plant testing.
Table 1 s u mmari zes the pollution prevention, operational , and economic benefits of organic coating replacement technologies.
5 Overview
You may wish to scan this summary table to select those clean
. technologies that best fit your operations and needs. Detailed discussions of these benefits and operational aspects for each clean technology are provided in the next two sections of this document.
6 Table 1. Summary of Benefits of the Clean Technologies for Organic Coating Replacements
I Availa�a Technologleo � Emerging Tachnologlao I Ultraviolet Electron Radiation· Water-Based Vapor Water- (UV) Radia· Beam (EB)- Induced Two-Component Temporary Permeation- or Supercritical Based lion-Cured Cured Thermally Powder High Solids ReactiveLiquid Protective ln)ection-Cured 1 Carbon Dioxide Coati gs Coatings Coatings Coatings Coatings Cured Coatings Coatings Benefits n Coatings Coatings , as Solvent
Pollution Prevention:
Eliminates solvent in coating • • • • • •
Reduces solvent in coating • • • •
Reduces solvent for cleaning • • • I Operational: I
Easy color blending • • • • • • • • •
Easy color change • • • • • • • • • I
Can apply thick coat • • • • • • • •
Can applythin coat • • • • • • • • I Economic:
Relatively low or medium capital cost • • •
Relatively low or • medium skill to operate • • • •
...._, SECTION 2
AVAILABLE TECHNOLOGIES
How to Use the SummaryTa bles Four available organic coating replacement technologies are evalu ated in this section :
+ Powder coatings + High solids coatings + Water-based coatings + Ultraviolet (UV) radiation-cured coatings.
Tables 2 and 3 summarize descriptive and operational aspects of these technologies . They contain evaluations or annotations de scribing each available clean technology and give users a compact indication of the range of technologies covered to allow preliminary identification of those technologies that may be applicable to specif ic situations. Readers are invited to refer to the summary tables throughout this discussion to compar� and contrast technologies .
Descri ptive Aspects Table 2 describes each available clean technology. It lists the Pollution Prevention Benefits, Reported Applications, Opera ef s , tional and Product Ben it and Hazards and Limitations of each available clean technology.
Operational Aspects Table 3 shows key operating characteristics for the available tech nologies . These characteristics serve to qualitatively rank the clean technologies relative to each other. The rankings are estimated from descriptions and data in the technical literature.
Process Complexity is qualitatively ranked as "high," "medium," or "low" based on such factors as the number of process steps in volved and the number of material transfers needed. Process Complexity is an indication of how easily the new technology can be integrated into existing plant operations. A large number of process steps or input chemicals, or multiple operations with com plex sequencing, are examples of characteristics that would lead to a high complexity rating.
The Required Skill Level of equipment operators also is ranked as "high , " "medium," or "low." Required Skill Level is an indication of the relative level of sophistication and training required by staff to ech o . t c o o operate the new t nol gy A e hn l gy that requires the opera tor to adjust critical parameters would be rated as having a high skill
8 Available Technologies
requirement. In some cases, the operator may be insulated from the process by complex control equipment. In such cases, the operator skill level is low but the maintenance skill level is high.
Table 3 also lists the Waste Products and Emissions from the available clean technologies to indicate tradeoffs in potential pollut ants, the waste reduction potential of each, and compatibility with existingwaste recycling or treatment operations at the plant.
The Capital Cost column provides a preliminary measure of pro cess economics. It is a qualitative estimate of the initial cost impact of the engineering, procurement, and installation of the process and supportequ ipment. Due to the diversity of data and the wide variation in plant needs and conditions, it is not possible to give specific cost comparisons. Cost analyses must be plant-specific to adequately address factors such as the type and age of existing equipment, space availability, throughput, product type, customer specifications, and cost of capital. Where possible, sources of cost data are referenced in the discussions of each clean technology.
The Energy Use column provides data on energy conversion equipment required for a specific process. In addition, some gener al information on energy requirements is provided.
Table 3 also lists References to publications that will provide further information for each available technology. These references are given in full in Section 4.
The text furtherdescribes pollution prevention benefits, reported applications, operational and product benefits, and hazards and limitations for each available technology. Technologies in earlier stages of development are summarized to the extent possible in Section 3, Emerging Technologies.
9 Table Available Clean Technologies for Organic Coating Replacements: Descriptive Aspects 0 2.
Available Pollution Prevention Reported Technology enefi s B t Applications Operational and Product Benefits Hazards and Umitatlons
• 100% • Powder reactive solid Applied to general apptiances, • Can apply thickcoatings in one application • Requires handling of heated parts
Coatings • Eliminates solvent use automotive, and general industrial • Lack of volatile solvent means littleair flow needed • For electrostatic application systems, and exposure of work- finishing such as: • Reduced energy use for heating makeup air - the partm ust be electrically conductive or be covered with ers to solvents -steel • No mixing or stirring needed an electrically conductive primer • Reduces need for dis- -aluminum • Cleanup requires no solvent - parts with complex shapes are dilficull to coat
- zinc and brass sii s • • posal ol solid paint ca ng Allows coating with polymers that are not amenable Some difficuttyIn applying thin coatings waste to solution coating techniques • Difficuh to incorporate metal llake pigment�
• Reduces fire and ex- • Efficient material use (near 100% transler efficiency) • Requires specialized equpmenl or extra effort to make color plosion hazards changes
• • in • • High Solids Solvent-based with Same as conventional coat gs; Reduced solvent concentrations in the coating, thus Solvent use not completely e&minated Coatings high resin concentra- resins avalable in formulations in- reducing the environmental, odor, and safety prob- • Shorter pot lffe than conventional coatings lion elude: lems caused by solvents • Reduces solvent in the - saturated polyesters • Compatible whh conventional and electrostatic ap- coaling, but solvent - alkyds plication equipment andtechniques still needed for clean- - acrylics • lower solvent loadings aHow reduced air flow In up - polyurethane curing ovens and work spaces, thus decreasing -epoxy energy needed for heating
• Used on zinc-coated steel doors, miscellaneous metal parts
Water-Based • Waler-based with low • Wide range of application • Low odor levels • Coating flow properties and drying rates can change with hu· Coatings solvent concentration • Coaling formulations include acry- • Easy to clean (uncured coating can be cleaned up midhy affecting coating application • Eliminates or reduces lies; colloids; amine-solubifized, whh water) • Senshive to humidhy, and thus require humidity control in solvent use carboxyl-lerminated alkyds; and • Reduce solvent concentrations application and curing areas • • • H i coating flow Water used lor polyesters Existing application equipment (nonelectroslalic) can igh surface tens on of water can cause poor cleanup • Used lor architectural trade finish- be used with most waler-based coatings characteristics es, wood furnhure, and damp con- • Reduced air flow in curing ovens and work spaces • Special equipment needed to allow electrostatic application crete surfaces decreases energy needed for heating • Water in the formulation can cause corrosion of coating stor·
age tanks and transfer pping , and " Hash rusting" of metal substrates under the coating
• Most require careful deaning of the substrate to ensure oil and grease are removed • Resins in contact whh water degrade , reducing shelf life • Susceptible to foaming due to surfactants
• Ultraviolet • 100% reactive liquid • Wood • Efficient material use (near 100% transfer efficiency) Styrene volatiltty • or reduces • Some metal applications • of volatile solvent means little airflow needed • Yellow color (UV) Eliminates Lack • • Low-temperature processing (reduced erg • High capital cost of equipment Radiation· solvent in the coating, FHler for chipboard en y use Cured but solvent still need· • Used for 'Wet look' finishes for heating makeup air) • Limited to thin coatings, particularly with pigments present Coatings ed for cleanup • Rapid curing • Typically best applied to flat materials Table 3. Available Clean Technologies for Organic Coating Replacements: Operational Aspects
Available Required Technology Process Skill Waste Products and Capital Energy Type Complexity Level Emissions Cost Use References
• cur o r col- o 1989 Powder Coati.ngs Medium Medium Un ed p wde can be High L w Bowden, lected lor reuse Crump, 1991 I Fish, 1982 Hester and Nicholson, 1989 lngleston, 1991 Maguire, 1988 Muhlenkamp, 1988 Robison, 1989
High Solids Coatings Low Medium • Overspray loss similar to that Low Medium Dick, 1991 of conventional coatings MP&C , 1988 Nelson, 1988 Paul, 1986 Pilcher, 1988 Smith, 1990
i 1991 Water-Based Coatings Medium Medium • Overspray loss similar to that Medium Medium D ck, 1988 of conventional coatings MP&C, 1986 • Amenable to electrocoating, Paul, which gives very high resin Pilcher, 1988 use Product Finishing, 1986 Richardson, 1988 Schartenberger, 1989 Swanberg, 1990
1988 Ultraviolet (UV) Radiation- High High • Unreacted overspray can be High Low Danneman, 1991 Cured Coatings collected for reuse Dick, Keiper!, 1990 Paul, 1986 Sun Chemical, 1991 POWDER COATINGS
Pollution Prevention Benefits Powder coating uses 100% reactive resin in dry powdered form, thus eliminating the use of a volatile organic solvent and reducing solvent exposure to workers and fire and explosion hazards. High transfer efficiency and low coating waste reduce the amount of solid
paint waste requiring treatment or disposal .
Powder coating has two attractive features from both a cost and pollution prevention standpoint:
+ The total lack of solvent in the coating formulation + The ability to apply essentially all of the coating to the substrate.
Material is applied to the su rface as a dry powder and is then melted or reacted to form the coating. There is no need for a vola tile solvent to provide a fluid medium. The powder is fluidized either by air flow up through a bed or by an electrostatic airspray gun. Because no solvent is needed to carry the coating, solvent evapora tion is eliminated. Further, the coating equipment can be cleaned without the use of solvents.
2 For example, a conventional plant painting 12,000,000 ft /yr with a voe 1.2-mil-thick coat will produce about 38 tons per year of emis sions after a treatment system with a capture efficiency of 70% . . A powder coating system using electrostatic application of polyester urethane material will emit about 0.6 tons per year with no voe control equipment in use (Hester and Nicholson, 1989).
How Does It Work? In powder coating, a coating film is formed by applying a layer of dry powdered resin on the surface to be covered and then melting the powder. Either thermoplastic powders such as cellulose acetate butyrate, polyesters, polyamides, and polyolefins or thermosetting powders such as epoxy resins, acrylics, and polyesters can be applied. Thermoplastic powders are usually applied with a fluidized bed, whereas thermosetting powders are mainly applied by elec trostatic spray.
A thermoplastic powder coating is one that melts and flows when heat is applied, but continues to have the same chemical composi tion once it cools and solidifies. Thermoplastic powders are based on high-molecular-weight polymers that exhibit excellent chemical
t , . resistance, oughness and flexibility These resins tend to be difficult to grind to the co nsistent fine particles needed for spray application, and they have a high melt viscosity . Consequently,
Available Technolog ies 12 Powder Coatings
they are used mostly in thicker film applications and are applied mainly by the fluidized bed application technique. Typical thermo plastic powder coatings incl ude :
• Polyethylene powders + Polypropylene powders + Nylon powders + Polyvinyl chloride powders l l + Thermop astic po yester powders.
Thermosetting powder coatings are based on lower molecular weight solid resins. These coatings melt when exposed to heat, flow into a uniform thin layer, and chemically cross-link within themselves or with other reactive components to form a higher molecular weight reaction product .
The final coating has a chemical structure different from that of the basicresi n. These newly formed materials are heat stable and, after curing, do not softenback to liquid phase when heated. Resins used in thermosetting powders can be ground into very fine particles necessaryfor spray application and for applying thin, paint like coatings. Because these systems can produce a surface coat l ing that is comparab e to, and competes with, liquid coatings, most of the technological advancements in recent years have been with
. thermosetting powders Thermosetting powders are derived from three generic types of resins, i.e., epoxy, polyester, and acrylic. From these three basic resin types, five coating systems are derived. Epoxy resin-based systems are the most commonly used thermosetting powders and are available in a wide range of formula tions (Hester and Nicholson, 1989).
Powder coating use conventional equipment available from a wide s · variety of vendors.
Why Choose Th�s Technology? Applications
t Powder coa ing is applied in thick coatings of thermoplastic materials or medium-thickness coatings of thermosetting materials to substrates in a single operation.
Operating Features
The part being coated must be heated either before immersion in a fluid bed or in an oven after the powder is applied. As a result, the part must be of a size and shape to allow immersion coating or heating in a curing oven. In all cases, the part must be heated
13 Available Technologies
above the melting temperature of the resin and thus be able to withstand temperatures of 90°C and higher.
Basic Function. Fluidized bed systems are used to apply coatings of thermoplastic powders to thicknesses in the range of 10 to 30 mils. In fluidized bed application, a preheated solid substrate is immersed in a fluidized bed of thermoplastic powder.
As indicated in thesc hematic diagram (Figure 1 ), air is introduced at the bottom of a bed of powder to fluidize the mass. The sub strate temperature is adjusted to be higher than the melting point of the resin so, as particles strike the hot surface, they melt and coalesce to form a thin, continuous film on the substrate. As the part cools, the powder solidifies to form a coating. The fluidized bed method was the original method for applying powder coatings and is still favored for heavy functional coatings.
'�:: : : . •. ; . . . . . ! - ; :; . : .... . ·• •· . ;" ! . �· : . . . . • .. Powder coating tank .• . · . . . . " ·::"; ; :· ; ·. : • :'::�·!·. ; •. u:. .. . . Part tobe ..�� _":;�. ; �--· �.:�-� :;;· .. • .. : coated : · :. ..., . ; : . · ..-
__
Source : Battelle
Figure 1. Powder Coating in a Fluidized Bed.
14 Powder Coatings
Electrostatic applications in either a fluidized bed (Figure 2) or by electrostatic spray (Figure 3) can achieve coatings thicknesses in Electrostatic the range of 1 to 3 mils with thermosetting resins. fluidized beds are limited to an effective depth of about 2 to 3 in so that they are best suited to coating two-dimensional parts (Muhlen kamp, 1988).
Part to be coated Ground
Powder coating tank
Vo ltage supply
Source: Battelle
Figure c sta ic Fluidized Bed. 2. Powder Coating in an Ele tro t
In electrostatic applications, the drypowd er is applied to the unheat ed substrate as film of powder held in place by electrostatic forces. The substrate or a primer coat must be electrically conductive. The substrate, with powder coating, is then heated in an oven to melt and cure the coating. Additional polymerization and cross-linking occurs in the t� material during curing. /\�t.M�:;tt�l"'t\
15 en
Air supply Electrostatic -....- powder gun
Control unit �·,�:·:·:·� Partt o b e .,.l'l�"i:;�· coated .-:;•t;:�.::•,.:.;;.:.r.. .\ .?;��: {i� �· ..i ·; / ' ftI :1 Charged ;i) flUldlzed ··��·;;.� Voltagesupply poWder Air
Air
1 I 1 Venturi
Air :···:·:���.'/:i .: ;�:\·;·;·� (:. :: tank PoWder feed
. • ·:·. · . :.1 Fluldlzed powder
}.-- Air distribution system '--���---
Source: Battelle
Figure Schematic for Electrostatic Spray Gun for Powder Coating. 3. Powder Coatings
With spray systems, powder is supplied to the spray gun by the powder delivery system. This system consists of a powder storage container or feed hopper, a pumping device that transports a stream of powder into hoses or fed tubes. A compressed air supply is often used as a "pump" because it aids in separating the powder into individual particles for easier transport. The powder delivery system is usually capable of supplying powder to one or several guns, often located many feet from the powder supply. Delivery systems are available in many different sizes depending on the application, number of guns to be supplied, and volume of powder to be sprayed in a given time period. Recent improvements in powder delivery systems, coupled with better powder chemistries that reduce clu mping of the powder, have made possible the deliv eryo f a very consistent flow of particles to the spray gun. Agitating or fluidizing the powder in the feed hopper also helps prevent clogging or clumping of the powder prior to its entry into the trans port lines.
Electrostatic powder guns function to shape and direct the flow of powder; control the patternsize, shape, and density of the powder as it is released from the gun; impart the electrostatic charge to the powder being sprayed; and control the deposition rate and location of powder on the target. All spray guns can be classified as either manual (hand-held} or automatic (mounted on a mechanical control arm) the basic principles of ·operation of most guns are the same; there is an almost limitless variety in the style, size, and shape of spray guns. The type of gun chosen for a given coating line can, thus, be matched to the performance characteristics needed for the products being coated.
Traditionally, the electrostatic charge was imparted to the powder particles by a charging electrode located at the front of the spray gun. These "corona charging" guns generate a high-voltage, low amperage electrostatic field between the electrode and the product being coated. The charge on the electrode is usually negative and can be controlled by the operator. Powder particles, passing through the ionized electrostatic field at the tip of the electrode become charged and are thus directed by the electrostatic field. The particles follow the field lines and air cu rrents to the target workpiece and are deposited on the grounded surface of the work piece. One drawback to the use of this type of gun is the ditticulty of coating irregularly shaped parts that have recessed areas of cavities (that may be affected by Faraday cages) into which the electrostatic field cannot reach. Because the powder particles are directed by the presence of the field, i nsufficie nt powder may be deposited on surfaces outside the reach of the field.
17 Available Technologies
A relatively recent innovation in electrostatic spray guns is the tribo electric gun. The powder particles in a triboelectric gun receive an electrostatic charge as a result of friction which occurs when powder particles contact a solid insulator or conductor inside the delivery hose and gun. The resulting charge is accomplished through the exchange of ions, or electrons, between the powder and the mate rial used for construction of the supply hose and gun barrel. Be cause there is no actual electrostatic field, the charged particles of powder migrate toward thegr ounded workpiece and are free to deposit in an even layer over the entire surface of the workplace. With the elimination of an electrostatic field, the Faraday cage effect can be prevented.
Other improvements that have been made to spray guns involve variations in the spray patterns to improve the coating transfer efficiency. Nozzles that resist clogging have been introduced. Spray guns with variable spray patterns are also available to allow the use of one gun on multiple parts of different configurations. /
Innovations in the powder delivery system allow the powder supply reservoir to be easily switched to another color when necessary. However, if the overspray collection system is not also changed, the collected powder will be is a combination of all the colors applied between filter replacements or booth cleanings. For collected oversprayed powder to be of greatest value, it should be free of cross-contamination between colors. When a pellet of the wrong color adheres to the partbeing powder coated, it will not blend in with the color being used.
Numerous systems are now available that are designed to accom plish this segregation of colors and still allow several colors to be applied in the same booth. Most of these systems make use of a moveable dry filter panel or a cartridge filter that can be dedicated to one color and can be removed easily when another color is needed. Color changes can then be accomplished by disconnect ing the powder deliverysystem and purging the lines, cleaning the booth with compressed air or a rubber squeegee, exchanging the filter used for the previous color with the filter for the next color, and connecting the powder delivery system for the new color.
Equipment manufacturers have made significant design improve ments in spray booths that allow color changes to be made with a minimal downtime and allow the recovery of a high percentage of the overspray. As with spray guns, there are a large number of spray booth and powder recovery designs from which to choose, depending on the exact requirement of a g ive n finishing system (Hester and Nicholson, 1989).
18 Powder Coatings
Material and Energy Requirements. The effectiveness of powder coating depends on obtaining a smooth , nonporous film. Formation , of a good coating free of voids, pinholes and orange peel depends on controlling the particle size distribution, glass transition tem perature, melting point, melt viscosity, and electric properties of the powder.
A well-controlled size distribution is important to achieve good pack ing of the powder on the surface. Melting and melt flow properties are important to controlling the behavior. of the powder as it melts to form the coating. The electric properties of the powder are impor tant when the coating is applied by electrostatic spraying.
During fluid bed coating, powder is added to replace material · carried out by the substrate. Because very little powder is lost or degraded during coating, material utilization is near 100%. With electrostatic spraying there is overspray of powder, much like over spray with liquid paint. However, unlike liquid paint overspray which cannot be recycled, powder coating overspray can be collected and reused. Figure 4 shows a schematic of a system for powder coat ing recycling. The high utilization of powder coating means waste paint solids disposal is reduced.
Required Skill Level
Powder coating uses equipment and techniques that are very similar to those for conventional dip coating or spray painting . The operator skill level is, therefore , similar to that for conventional electrostatic spray painting.
Cost
The capital cost for booths, electrostatic spray applicators, and
curing ovens to apply powder coatings is typically somewhat higher than similar equipment for application of conventional fluid coatings. However, the conventional solvent-based coating application system may require equipment to control voe emissions. voe control
equipment will significantly increase the capital cost for the conven ti . onal coating application system
The powder coating material is more expensive than co nventional is of volume of reactive coating material when compared on the bas resin. However, the cost of the finished coating is lower for powder coating in many cases. The hig h e r cost of the powder coating ma terial is offset by the ability to effectively put essential ly all of the
19 I'll 0
Spray booth \ � G round ; ,' /, ' ,> Elect rostatic � L 11 (� -� � Powder powder gun (( supply
Charged Vo ltage fluldlzed supply powder Fiiter 'G!f>!,,,jii;'�k'f\;;i;\';� I .J Powder collectlon
Source: Battelle
Figure 4. Powder Coating RecoverySyste m. Powder Coatings
reactive powder resin onto the substrate. Coating utilization effi ciency for conventional coatings can be as low as 40% (Hester and Nicholson, 1989). The ability of powder coating to give a thick coat ing in one pass further improves the economics for powder coating for cases where a thick coating is needed.
For coating operations with a single color, maintenance and cleanup costsare low with powder coating. Because the powder coating is a dry material, no liquid mixing is needed prior to coating and no solvent is needed so cleanup can be done quickly. No waste sol vent is generated and the waste coating material volume is low, reducing the cost of waste disposal.
For coating operations requiring frequent color changes, the oper ating costs of powder coating increase. To change colors, all of the powder in the coating system must be removed and replaced with the new color. The powder removal and handling time for color changes increases the operating cost. A cost comparison of pow der, conventional, high solids, and water-based coatings is given in Hester and Nicholson (1989).
Reported Applications Powder coating is a rapidly growing area due to both cost and pollution prevention benefits. The following five resins represent the bulk of the approximately 250,000 tonnes of powder coating material usage:
+ Epoxy + Epoxy/polyester mixture + Polyester y ha e + Pol uret n + Acrylic (lngleston , 1991 ) .
Powder coating is used commercially for a wide range of small- to medium-sized metal parts, including lighting fixtures, equipment cabinets, automobile wheels, outdoor furniture, and hand carts and wagons. Some of the materials suitable for powder coatings include:
+ Steel + Aluminum • Galvanize • Zinc and brass castings ( Robison , 1989; Bowden, 1989).
Fluidized bed or electrostatic spray systems may be used to apply chlorotrifluoroethylene fluoropolymer to metals. Electrostatic spraying is used for coating thicknesses in the range of five to
21 Available Technologies
30 mils. A fluidized bed system is used if thicker coating is required. The curing temperature is about 500°F (Maguire, 1988).
Boeing is testing a powder coating material for application to both
aluminum panels and epoxy fiberglass laminate panels. Several surface treatments and primerswe re tested. Powder is applied with an electrostatic spray gun and then oven-cured in a second step (Crump, 1991 ). Both corona discharge and tribo-friction charging systems were tested.
Operational and Coating pera ion Product Benefits O t :
coating can be applied in thick coatings in one pass, • Powder even over sharp edges. • Because there is no volatile solvent, little air flow is needed through the coating application work areas or curing ovens. Reduced air flow requirements reduces energy use for heating makeup air.
• Basic resins that are not easily soluble in organic solvents can be used.
Preparation and Cleanup:
• Powder coating comes ready to use and therefore does not require mixing or stirring. e • No solvent is r quired for cleanup.
New Coating Types: Powder coating offers coating with polymers, such as polyethylene, nylon, or fluorocarbons, that are not ame nable to solution coating techniques.·
Operating Efficiency: The high material utilization, low reject rates, generally lower energy consumption, and lack of solvent waste reduces cost.
Hazards and limitations • The application of powder coating requires handling of heated parts because the parts must be subjected to elevated temperature.
• For electrostatic application systems, the part must be electrically conductive or be covered with an electrically conductive primer.
• For electrostatic application systems, parts with complex shapes can leave portions of the surface uncoated unless special application techniques are used.
• Application of thin coatings requires special techniques and equipment.
22 Powder Coatings
+ It is difficult to incorporate the metal flake pigments that are popular for automotive finishes. + Because powder coatings rely on large, fluidized bed reservoirs, it is difficult to make color changes. + Color matching from batch to batch is difficult.
Tradeoffs Powder coating can cover substrates without needing a volatile sol
vent to carry thefilm f orming resins •. In addition, because the pow der remains dry until applied and cured on �he surface, no solvent is required for equipment cleanup. In typical applications, nearly 95% of thepow der coating material is applied to the substrate. These characteristics promote very clean operation with no loss of volatile organic compounds (VOCs) and minimal generation of coating waste.
Powder coating is good for applying a thick layer of thermosetting or thermoplastic material to a wide variety of substrates. If a medium thickness coating is needed, the part must be conductive and should have a simple geometry.
· It is not possible to achieve thin coatings with present powder coating technology. Because curing is accomplished by heating, the substrate must be able to withstand high temperatures.
Summary of Unknowns Powder coating is routinely used in industry but at the moment has a limited range of applications. The major area for expanding the use of powder coatings is development of methods to apply thinner coatings particularly to complex-shaped or nonconductive substrates.
State of Development Powder coating has a well-established niche in the coating industry. Both thermoplastic and thermosetting powdered resins and equip ment for fluidized bed, electrostatic fluidized bed, or electrostatic spraying are available from standard vendors. Detailed information can be obtained from the Powder Coating Institute (see Table 6 in Section 4).
23 HIGH SOLIDS .COATINGS
Pollution Prevention Benefits High solids coatings are an evolutionary change from current coating formulations. The coating liquid formulation is very similar, but the resin systems are modified to allow a higher concentration of solids with a lower concentration of VOCs. Lower VOC levels mean less voe loss during curing, thus lowering fugitive solvent sources. The lower solvent concentrations in the coating formula tion thus result in less solvent vapor in the air in the operating areas. Reduced solvent concentration reduces health and safety problems such as worker exposure to solvent fumes and fire and explosion hazard. However, paint overspray still results in paint waste, and solvent is still needed for equipment cleanup.
For example, a conventional plant painting 12,000,000 ft2/yr with a 1.2-mil-thick coat will release about 38 tons/yr of voe emissions after a treatment system with a 70% capture efficiency. A high solids painting plant spray applying a similar coating will emit about 31 tons/yr with no VOC control equipment(H ester and Nicholson, 1989).
Some paints have been formulated with chlorinated solvents to replace the volatile organic ozone precursors. These coatings are sometimes referred to as "low voe coatings," but they are not considered clean technologies because they use 1,1, 1- trichlor oethane or similar solvents. Low-VOC coatings formulated with chlorinated solvents, therefore, are not discussed in this guide.
How Does It Work? High solids coatings are being actively developed to reduce the quantity of volatile organic solvent in coatings. Like conventional coatings, high solids coatings consist mainly of resins, coloring agents, extenders, and additives carried in a solvent. As the name implies, high solids coating liquids rely on increasing the concentration of resins in the coating formulation.
Conventional coatings typically use high-molecular-weight resins to obtain satisfactory cured-film properties. A direct increase of solids concentration with conventional resins would, therefore, result in an unacceptable increase in the viscosity of the coating fluid.
Thus, high solids coating formulations use reduced-molecular weight resins in parallel with the increase of the solids con centration.
Available Technolog ies 24 High Solids Coatings
The resulting high solids formulation is applied in much the same way as conventional coatings using the same or similar equipment. Thus high solids coatings must:
• Have viscosity and physical properties similar to conventional coating materials + Allow use of coloring additives giving the required colors and hiding power • Have a reasonable curing rate • Remain useful for an acceptable peri_od after the coating is removed from the original container (pot life) • Provide a quality coating.
Many vendors· of conventional coating materials now have alternative high solids coatings, particularly urethanes, and they are developing new formulations. For more information, contact the trade associations described in Table 6 (Section 4).
Why Choose This Technology Applications
Currently available high solids coatings are expressly developed to behave as much as possible like conventional coatings. Generic families of resins available in high solids coating formulations include:
• Saturated polyesters + Alkyds • Acrylics • Polyurethane • Epoxy (Paul, 1986; Pilcher, 1988)
Operating Features
Lower viscosity high solids coatings can be applied with conven tional equipment such as air spray, airless spray, or electrostatic spray. The major problems with high solids coating materials occur during application when the viscosity makes it difficult to achieve acceptable curing times while maintaining an acceptable use time after preparing the paint and exposing it to the air (i.e., good pot life).
High solids coating formulations with higher viscosities can be
applied with turbine bell or rotating disk atomization spray equipment. These new application technologies allow the use of high-viscosity formulations while maintaining coating quality.
25 Available Technologies
Basic Function. High solids coatings require the formulation to contain lower molecular weight resins. Lower molecular weight resins allow high solids concentration while the viscosity remains acceptable for use in conventional application equipment. However, the lower molecular weight resins alone will give an unacceptable final dryfi lm if normal curing time limits are applied. To overcome performance limitations caused by low-molecular-weight resins, additives are often used to increase crosslinking of the resins during curing.
In many formulations, e.g., alkyds, polyesters, and polyurethanes, the crosslinking additives decrease the stability of the coating fluid and, therefore, are shipped in a separate container. The additive is mixed into the coating formulationat the start of a painting session. The additives typically contribute to a shorter pot life for high solid coatings compared with conventional coatings.
In some formulations, a somewhat higher viscosity is accepted and new types of application equipment are used. These new equip ment types, such as turbine atomizers, are able to effectively atomize the more viscous high solids coatings. Disk and bell turbine applicator systems are both used in finishing operations.
With disk or bell applicators, the coating liquid is fed into a rotating, or insulated disk bell, where it spreads to the outer edge by centrif ugal force. To keep the paint from flying off the disk or bell in coarse droplets or strings, an -100-kV electrostatic charge is applied to theinsula ted disk or bell charges the paint droplets. The charge also enables paint atomization to ensure uniformity of coat ing on all sides exposed to the painting operation. The turbine . powered bells have rotational speeds of up to 50,000 rpm; disks, up to 40,000 rpmto achieve atomization by centrifugal force. A high electrostatic charge slightly improves the atomization and signifi cantly improves the transfer efficiency of the paint droplets. The article being coated typically continues through the disk or bell system on a continuous line into a curing oven.
A somewhat more conventional approach to high-efficiency application to reduce overspray loss involves high-volume, low pressure (HVLP) application equipment. HVLP's low atomizing air pressure requirement of between 0.1 and 10.0 psig combines with turbine.,.generated high volumes of atomizing air. HVLP systems routinely accompany commercially available paint application equipment.
Airless Spray is another technique to improve transfer efficiency. It does not use compressed air to atomize the liquid coating. An air less system utilizes hydraulic pressure to atomize the liquid coating
26 High Solids Coatings and deposit it on the work piece. Coating fluid under high pressure is released through an orifice in the spray nozzle. The high pres sure separates coating fluid into small droplets, resulting in a fine atomized spray. Since air is not used to form the spray pattern, the term "airless" is used.
Air Assisted Airless is a combination of airless and conventional air spray which uses some air propellant to assist in atomizing the coating liquid to a smaller droplet.
The HVLP technology is being debated relative to other methods that also achieve high transfer efficiency, such as air-assisted airless spray. Rapid developments in these high -efficiency technologies will position some of them, such as HVLP, to dominate paint application system manufacturing (Dick, 1991 ).
Material and Energy Requirements. High solids coatings are applied in the same way as conventional coatings, so overspray losses and solvent use for equipment cleanup are similar. Paint loss with high solids coating can, however, be minimized because the high solvent coatings are compatible- with conventional elec trostatic. application methods. High solids coatings typically contain 275 to 420 g VOC/I of liquid coating (2.3 to 3.5 lb/gallon) (Pilcher, 1988). Because of the lower quantity of solvent, VOC loss during preparation, use, and curing is reduced so air flow through curing ovens and in operating areas may be reduced. Lower air flow decreases energy use.
Required Skill Level
Viscosity changes in high solids coating fluids caused by solvent addition or evaporation are not as predictable as the viscosity behavior of conventional coating formulations. Many high solids a coatings ( nd some conventional coatings) are shipped as two components. Two solutions must be mixed before the coating can be applied, requiring an additional handling and mixing step just prior to starting painting.
High solids coatings generally have a shorter pot life. Even though the application equipment is similar, the above factors lead to the need for more operator skill and attention when using high· solids coatings.
27 Available Technologies
Cost
co s use High solids ating conventional application equipment so the capital cost for booths, electrostatic spray applicators, and curing ovens are the same as for equipment to apply conventional high VOC coatings. In fact, many of the existing items of equipment in the coating system could be retained in a switch to high solids coat ing. High solids coatings contain up to 40% solvent, so some voe control will still be required with many high solids formulations.
The high solids coating liquid is slightly more expensive than conventional coating liquid per unit of reactive resin. Coating fluid preparation, application, cleanup, and disposal costs are similar for high solids and conventional coating. A cost comparison of high solids, conventional, powder, and water-based coatings is given in Hester and Nicholson (1989).
Reported Applications Steel door makers are using high speed turbine bell atomizers to apply high solid coating to zinc-coated steel doors. In addition to lower voe emissions, the new high solids coating formulation allows lower curing temperatures required by the heat sensitive foam insulation cores now used in steel doors. The high solid coat ings meet the highest adhesion rating in ASTM D 3359 and pass a 250-hr salt spray test per ASTM B 117 (Nelson, 1988).
A U.S. Department of Energy contractor was able to identify and qualify a low-VOC urethane material (420 g VOC/I (3.5 lb/gal)) to replace a conventional urethane material (520 g VOC/I (4.36 lb/gal) for coating miscellaneous metal parts(Smi th, 1990).
High solids polyurethane materials are available meeting MIL-C- 832858 for use on aircraft and ground support equipment. These
high solids formulations contai n .340 to 420 g VOC/I (2.8 to 3.5 lb/gal). The pot life is reported to be 6 hr. The materials are formulated for electrostatic application (MP&C, 1988).
Operational and Product Benefits High solids coatings have the following benefits:
+ They reduce solvent concentrations in the coating, thus reducing the environmental , odor, and safety problems caused by sol vents.
+ They are compatible with conventional and electrostatic applica tion equ ipment and techniques. + Lower solvent loadings allow reduced air flow in cu ring ovens and work spaces, which decreases energy needed for heating .
28 High Solids Coatings
Hazards and Lim itations There are some disadvantages to using high solids coatings:
+ Although they reduce the amount of organic solvents in the coat ing formulation, they do not completely eliminate solvent use. + High solids coatings have shorter pot life than conventional coatings.
Tradeoffs The main tradeoff involved in selecting the high solids coating option is the "comfort factor" versus less complete pollution preven tion when compared to some of the other alternatives.
High solids coatings use technology that is similar to conventional solvent-based coatings. Many users will find that the transition to high solids coatings meets less resistance because it allows use of familiar equipment to apply a solvent-based coating. Both equip ment operators and plant management tend to prefer evolutionary changes to radical departures in equipment and procedures.
Although high solids coatings are a valid clean technology offering a real reduction in voe emissions, the potential reductions are not as great as with powder coating or 100% reactive liquid coatings.
Summary of Unknowns High solids coatings are limited mainly by viscosity restrictions. The solution viscosity increases roughly linearly with the weight fraction of resin present in the coating formulation. Therefore, increasing the solids content increases coating liquid viscosity. The major unknown in high solids coating technology is what types of new formulations will provide good coating adhesion, flexibility, and impact resistance while maintaining coating flexibility. Methods to optimize pot life versus curing time are also needed.
State of De"elopment High solid content solvent-based coatings are compatible with electrostatic spraying techniques. Many of the formulations, particu larly the two-component types, are compatible with conventional air spray equipment. As a result, changing to high solids coatings is less disruptive than changing to other technologies, such as 100% reactive liquid, water-based, or powder coating.
Compatibility makes high solids coatings a�ractive as near-term replacements for conventional solvent-based coatings. Develop ment of urethane formulations is the most advanced, but pai nts based on other resin types are also becoming available.
29 WATER-BASEQ COATINGS
Pollution Prevention Benefits Water-based coatings are a diverse group of liquid coating materials in which water supplements .or replaces the organic solvent. Water, alone or in conjunction with solvent, acts as the carrying medium for film-forming resins, coloring agents, and other elements of the coating formulation.
Water-based coatings have little or no solvent in the coating formulation, and the uncured coating can be cleaned up with water. As a result there is less solvent vapor in the air in the operating areas and less bulk solvent storage. Reduced solvent use reduces health and safety problems such as worker exposure to solvent fumes or liquids and potential fire or explosion hazard.
For example, a conventional plant painting 12,000,000 ft?-tyr with a 1.2-mil thick coating will release about 38 tons of voe, even with a treatment system running at 70% capture efficiency. A water-based painting plant spraying a similar coating and running no voe control equipment will emit only about 26 tons/yr (Hester and Nicholson, 1989).
Reduced solvent concentration in the coating thus results in lower voe emissions during curing and can make a significant contribu tion to lowering fugitive solvent releases. However, paint overspray still results in paint waste. New HVLP application equipment can reduce overspray loss.
Water-based coatings are not directly compatible with current generation electrostatic application equipment. Cleanup of equipment covered with uncured water-based coatings can be done with water, which also helps reduce solvent use.
How Does It Work? Water-based coatings use solvents, resins, coloring agents, extenders, and additives either dissolved or dispersed in water. A wide range of technologies are used to achieve good coating per formance with water-based coatings. There are three main classes:
+ Water-soluble or water-reducible coatings + Colloidal or water-solubilized dispersion coatings + Emulsion coatings.
Available Technolo ies 30 g Water- Based Coatings
These three vary significantly in physical and mechanical properties.
For example the handling characteristics and performance param eters for a solubilized polyester (water-soluble) with molecular c weight of 2,500 will be different from those of an a rylic latex (emulsion) with a molecular weight of more than 1 million.
Water-soluble coatings are generally easier to apply than emulsion coatings because they exhibit better. flow, substrate wetting, and leveling; less foaming; and easier cleanup. The emulsion coatings, although more difficult to formulate and apply, tend to have greater durability and resistance to chemicals (Paul, 1986).
In addition to conventional application methods, water-based coatings are amenable to electrodeposition. Electrodeposition of coating resembles electroplating in that the substrate is submerged in an aqueous bath. The ionized organic coating material is deposited on the substrate by means of the direct current flow.
Water-based latex acrylics and epoxies are available and are routinely used. New formulations are being developed for other applications. Many of the vendors of conventional coating materials have alternative water-based coatings. For more specific informa tion, contact the trade associations listed in Table 6 (Section 4).
Why Choose This Technology? Applications
The great diversityof water-based coating technology is a potential strength but presents a challenge when first encountered. Because a wide range of characteristics are available with water-based coating technology, formulations can be prepared to fit many specific applications. However, the coating formulation will typically require more care in application and have a more limited range of potential uses than similar conventional solvent-based coatings. Thus, it is difficult to characterize or classify water-based coati ngs into a few simple groups having wide ranges of application .
Two-part acrylics; colloids; amine-solubilized, carboxyl-terminated alkyds; and polyesters are examples of some of the coating for mulations generally considered as water-based tech nologies . Each of these groups has different properties creating challenges both for users in defining their needs and for coating manufacturers in providing the optimum coating to fill user needs (Pilcher, 1988).
However , the diversity of water-based coating technology allows flexibility in tailoring the performance of the coating.
Water-soluble resins are normally prepared by one of three
methods. The most common approach is to convert the polymer
31 Available Technologies
backbone to anion or cation forms by neutralizing the carboxylic or amino groups. Other possible approaches include adding nonionic groups such as polyols or polyesters to the resin to allow water solubility, or using water-soluble zwitterion (organic ion with both a positive and negative charge) copolymers.
Water-soluble formulations can include water-soluble oils, poly butadiene adducts,a lkyds, polyesters, and acrylics. Water-soluble coatings tend to have simpler formulations and are easier to apply than emulsions but have lower durability and resistance to solvents.
Colloidal dispersions lie between water-soluble and emulsion coatings with respect to both application behavior and physical characteristics. The colloidal coatings consist of a dispersion of very fine, partially water-soluble polymer droplets in water. Colloidal dispersions are used mainly to coat porous materials such as paper or leather.
' Emulsion formulations (also called latex) are currently the most commonly used of the water-based coatings. Emulsion coatings are dispersions of polymer droplets in water. The polymer droplets are stabilized in the aqueous medium by emulsifiers and thickeners. Most emulsion coatings use acrylic or acrylic copolymer resins. Emulsion coatings have lower gloss, film buildup, and pigment loading than water-soluble coatings.
Operating Features
Water-based paints are liquid products that can be applied with either conventional nonelectrostatic atomizers or modified electro static atomizers. In many cases, two-component formulations are used. Although two-component formulations slightly increase the complexity of coating liquid preparation, many conventional coatings are also shipped as two separate components.
Emulsion formulations are thixotropic and may, therefore, not be compatible with existing pumps and piping. Uncured water-based coatings can be removed with water, so solvent use is reduced both in the formulation itself and in secondary uses associated with cleanup at the end of the coating operation.
Basic Function. Water-based coatings are one- or two-component liquids that are applied in essential the same manner as conven tional solvent coatings. The thixotropic viscosity behavior of emulsion coatings may require the use of special pumping and application equipment.
32 Water- Based Coatings
Also, the electrical conductivity of aqueous solutions means that special equipment and techniques are needed for electrostatic application of water-based coatings. Electrostatic coating appli cation is widely used to reduce overspray losses. Cutting the amount of coating that does not reach the substrate helps prevent pollution and reduce costs. ·
There is also a clean technology advantage to electrostatic appli cation because reduced overspray cuts solvent releases and coat ing waste production. However, aqueous solutions have higher electrical conductivity than organic solvent solutions, so it is more difficult to maintain voltage in an electrostatic application system using water-based coatings. Four options exist for electrostatic application with water-based coatings:
• Isolate the coating liquid storage and supply system from any electrical ground to prevent current leakage from the application atomizer to ground through the coating supply system. • Use an external charging system attached to but electrically iso lated from the application atomizer. . • Electrically isolate the coating liquid storage and supply system from the application atomizer to prevent current leakage through the coating supply system. • Place the electrostatic charge on the substrate and ground the application atomizer (Scharfenberger, 1989).
Although the electrical conductivity of water-based coating solutions presents problems for conventional electrostatic spray application, it opens up the possibility of a new application approach. Coating resins can be applied to electrically conductive substrates by electrodeposition. In electrodeposition, ionized resins are attracted to the substrate by electrical charge as shown in Figure 5.
Film-forming cations can be obtained as organic substituted ammonium macro-ions such as RNH3 + or R3NH+. When an appro priate film-forming resin, R, is used , an adherent deposit will form on the substrate held at cathodic potential. Anodic film-forming resins can be prepared from coating resins that have carboxylic groups. Resins with molecular weights in the range of 2,000 to 20,000 typically are used for electrodeposition from water-based coating solutions.
Electrodeposition is used most in applying automotive primers because of its high ability to provide protection from corrosion with very thin, evenly spread films. Electrodeposition gives remarkably uniform films no matterw hat the surface. Recesses, tapped holes, and sharp edges exhibit uniform coating. By "forcing" a dense film against the substrate during coating, electrodeposition provides
33 ..
Available Technologies
excellent adhesion and resistance to corrosion. The fully automated systems that are available give higher than 95% deposition effi ciency. Because electrocoatings use water as themain solvent, fire hazards and air pollution are minimized.
Spray rinse Resin attracted to part
/ Part to be .,,,.--..._...- _ r--�-...�.A coated
Voltage supply
Resin Electrodeposltlon solution coating tank
Source: Battelle
Figure 5. Electrodepositlon Coating.
The electrodeposition technology does, however, require special equipment and procedures resulting in high installation and other costs. Electrodeposition requires new coating tanks, extra-clean
34 Water-B ased Coatings .
application and curing areas, and infrared radiation to speed up the final setting of the coating surface. Operators must learn to formu late and precisely control the coatings. Electrodeposited coatings are highly sensitive to contaminants. To produce a high gloss finish, the first coating must include a conductive pigment. The surface of metal substrates can dissolve into the coating and cause discoloration. Thus, only very large numbers of similar parts justify the costs of installing electrodeposition equipment and providing the
required training (Dick, 1991 ) .
Material and Energy Requirements. Water-based coating for mulations contain fewer voes than conventional coatings, and uncured coating waste can be cleaned up with water. Because of the lower solvent use, the voe loss during coating preparation, use, curing, and cleanup is reduced so that the air flow through curing ovens and in operating areas may be lower. Lower air flow decreases energy use.
Required Skill Level
Special equipment and procedures are needed for electrostatic application of water-based coatings. Some water-based coatings (and some conventional coatings) are shipped as two components. Two solutions must be mixed before the coating can be applied, requiring an additional handling and mixing step just prior to starting painting.
Water-based coatings typically require more care in surface clean ing and preparation than do conventional coatings. Even though the application equipment is similar, the above factors lead to the need for more operator skill and attention for application of water based coatings.
Cost
The capital cost for electrostatic spray applicators for water-based coatings will typically be higher than similar equipment for appli cation of conventional fluid coatings because of the electrical con ductivity of water-based coatings. Water-based coatings typically contain some solvent but are less likely to require voe control equipment. If voe control is needed, the lower concentration of solvent in the coating should reduce the volume of carbon absorber needed, thus reducing capital and operating cost.
The water-based coating liquid is more expensive than conventional coating liquid per unit of reactive resin. Coating fluid preparation,
35 Available Technologies
application, cleanup, and disposal costs are similar for water-based and conventional coating. A cost comparison of conventional, powder, high solids, and water-based coatings is given in Hester and Nicholson (1989).
Reported Applications Water-based coatings are primarily used as architectural coatings and industrial finish coatings. Because water-based paints are easy to apply, adhere to damp surfaces, dry rapidly, are easy to clean with soap and water, and lack solvent odor, more than 70% of architectural coatings are water-based paints. Coatings include:
• Wall primers, sealants • Interiorflat/ semigloss wall paints • Interior and exterior trim finishes • Exterior house paints
Water-based coatings have not been so readily accepted in the industrial sector. But tightening regulations are making compliance more economical through use of these coatings, and they are gain ing a foothold in both primer and topcoat industrial finish applica tions where these attributes count:
• Can be used with existing solvent-based coatings application equipment • Can be thinned using only water • Have low flammability • Otter minimized toxicity, environmental pollutants, and odor • Application equipment can be cleaned using only water (Dick, 1991).
Resins include :
• Acrylics • Epoxy esters + Alkyds • Polyesters.
About 10% of U.S. coil lines, which have aluminum as the primary substrate use acrylic-based, waterborne coatings because of the flexible and adhesive properties of these coatings. Acrylics also offer exterior durability and resistance to yellowing. Epoxy esters also reliably adhere to the substrate and are resistant to corrosion and detergents. Polyesters, on the other hand, lack detergent resis tance but provide good exterior durability. Alkyds balance lower performance with a lower cost (Dick, 1991 ).
36 Water- Based Coatings
Water-based epoxy coatings are particularly useful for application an green or damp concrete. The water-based formulations provide excellent adhesion to the concrete substrate. Water-based epoxy coatings give low odor levels during curing, and the cured coating surface is easy to clean. These characteristics make water-based epoxy coatings suitable for areas requiring a high level of hygiene, such as hospitals or food processing plants (Richardson, 1988).
A low-VOC water-based flexible epoxy primer is available as a two component formulation. Unlike most water-based formulations, no water is present in either of the two components as shipped. The components, which are supplied in a 3 to 1 volume ratio, are mixed just before application to prepare a catalyzed resin mixture.
Water is added to the mixture to reduce the viscosity to allow application. At application, the formulation contains about 340 g VOe/I (2.8 lb/gal) (MP&e, 1988).
An aerospace company compared a series of water-reducible coatings to current aerospace topcoats. The base case coatings selected were a conventional solvent-based, two-component polyur ethane meeting Military Specification MIL-e-83286 and a high solid polyurethane meeting MIL-e-85285. The voe concentrations of the conventional and high solids coatings were 600 g/l (5 lb/gal) and I a 420 g/ (3.5 lb/g l) , respectively.
Both polyurethane and polyester resin formulations were tested with and without crosslinking agents. The crosslinke rs tested were carbodiimide, polyaziridine, di-functional amine, or tertiary amino
voe alkylylamine. The concentration in the water-based formula I to 2.9 /ga ) tions ranged from 65 g/I to 345 g/ (0.54 lb/gal lb l .
Skydrol resistance testing by ASTM D 1308 showed severe soften ing for all the water-based formulations and the high solids base case. H owever, the overall performance of the cross-linked water based coatings was found to be nearly as good as the high solids solvent-based polyurethane (Swanberg , 1990).
Application methods for water-based coatings include :
• Dip coating o coating • Fl w Air spray + Airless spray • 1991 ). + Electrostatic spray (Dick,
37 Available Technologies
Operational and Product Benefits There are several operational and environmental benefits of water based coatings:
+ Because water-based coatings reduce the solvent concentrations in the coating , they reduce the environmental, odor, and safety problems caused by solvents. • Existing application equipment (nonelectrostatic) can be used with most water-based coatings. • Reduced air flow in curing ovens and work spaces decreases energy needed for heating.
Hazards and Li mitations Water-based coatings have several drawbacks:
p • They are sensitive to humidity, so effective ap lication normally requires humidity control in the application and curing areas. The high surface tension of water can cause poor coating flow • characteristics.
+ Special equipment is needed to allow electrostatic application. • Water in the formulation can cause. corrosion of the coating · storage tanks and transfer piping.
• Water in the formulation can cause "flash rusting" of metal sub strates under the coating.
• Most waterborne coatings require careful cleaning of the sub strate to ensure oil and grease are removed. + Resins in contact with water degrade, reducing shelf life for water-based coating formulations. • Water-based emulsion coatings are susceptibl e to foaming due to surfactants used to stabilize the emulsion.
Tradeoffs Water-based coatings offer a tradeoff of "comfort factor" versus pollution prevention similar to high solids coatings. However, the factors involved are different. The "comfort factor" with water-based coatings is lower because they do not use the familiar solvent tech nology and are not compatible with existing electrostatic application equipment. However, the potential for solvent reduction is higher. At least some of the water-based coatings eliminate solvent from the formulation. Also, cleanup of uncured water-based coatings can be done with water, which eliminates solvent use in cleanup. Thus the solvent reduction potential is higher with water-based coatings compared to high solids coatings.
Summaryof Unknowns Water-based coatings have proven compatible with porous surfaces such as concrete, paper, and leather. Compatibility with metal surfaces is less well established. Unless the pH of the coating
38 Water-Based Coatings
formulation is high or a corrosion inhibitor is included in the formulation, the water can corrode the substrate. Also, water-based coatings typically require a cleaner surface than solvent-based coat ings. Future work is needed to develop low-cost cleaning methods.
State of Development Many of the water-based formulations are compatible with con ventional nonelectrostatic spray equipment but require special provisions for electrostatic application. As a result, a change to water-based coatings can be somewhat less disruptive to existing coating operations than a change to other technologies such as powder coating. Compatibility gives water-based coatings the potential to replace conventional solvent-based coatings. But the high cost of clean application areas, environmental control, and infrared flashoff may limit the use of water-based coatings in small industrial finish coating shops.
39 ULTRAVIOLET 1UV) RADIATION-CURED COATINGS
Pollution Prevention Benefits UV-cured coatings allow the use of 100% reactive liquids, eliminat ing solvent use, and near 100% transfer efficiency, reducing paint waste. UV curing provides an alternative in cases where baking has been used to remove the solvent component from convention ally processed organic coatings.
How Does It Work? UV curing uses high-intensity UV light to initiate the free radical crosslinking of acrylate oligomers and prepolymers. Of the avail able chemistries, this is the most frequently used. The UV light changes the ink or coating from wet to dry product This fast, relatively cool process enables inks and coatings to be cured on heat-sensitive substrates. The crosslinking of the inks and coatings, when property cured, yields high chemical and physical resistance
(Sun Chemical, 1991 ) .
UV-cured coatings consist of:
• An oligomer or a prepolymer containing double-bond unsaturation • A reactive solvent, e.g., monomers with varying degrees of unsaturation • A sensitizer to absorb theUV radiation - initiating polymerization + Coloring agents (Sun Chemical, 1991 ).
UV-cured coatings are available from a variety of commercial ven dors. For more specific information, contact the trade associations listed in Table 6 (Section 4).
Why Choose This Technology? Applications
UV curing is most used in these industrial finishing areas:
• Wood finishing + Metal decorative coatings • Automotive coatings + Wire coatings + Packaging coatings • Floor finishing.
Available Technologies 40 Ultraviolet (UV) Radiation-Cured Coatings
UV curing often replaces conventional thermal treatments tor coat ing flat wood surfaces because of its low cost and ease of applica tion. Because the UV radiation must reach the entire coated surface, UV curing systems are most easily used with flat material. However, curing systems are being modified to allow three dimensional coating, or coating of all surfaces, at one time. UV curing has been investigated for the U.S. metal-can industry and often replaces thermally cured coatings for aluminum and galva nized steel tubing because of its hardness and salt spray resistance lasting 200 to 500 hr. The technology offers a low-cost, high throughput alternative for finishing automotive hubcaps and wheel rims. Used on both bare and insulated wire, UV-cured coatings pro vide highly cross-linked, strong, yet flexible 10-mil-thick films.
Liquid acrylic and liquid polyurethane-acrylic UV-cured coatings surpass press varnishand water-based coatings in quality and resemble film laminations. Likewise, tough UV-cured coatings have found a market niche in high-gloss vinyl floor coverings. They surpass the conventional urethane polymers in ease of application and in abrasion, solvent, and stain resistance (Dick, 1991 ).
Operating Features
UV curing actually takes place in two instantaneous steps using first the UV light energy and then the UV thermal energy. First, the photoinitiator absorbs the UV light energy and converts it to free radicals through several chemical mechanisms. Then the UV lamps provide thermal energy to make the free radicals attack the acrylic double bonds and make the ink or coating polymerize. Because curing takes place so quickly, it is advised to allow time between application and curing to allow the ink or coating to level out and to achieve maximumgl oss.
Some radicals "live on" in the film after exposure to high-intensity UV light, causing postcuring if the crosslink conversion is weak. Postcuring cannot achieve the desired properties it the initial curing has been inadequate.
Ink color and opacity to UV light affect the curing rate of inks. Darker and more opaque inks block the light and require longer exposure time for adequate curing. Likewise, thicker films and multiple films cure more slowly than thin or single films of inks and coatings (Sun Chemical, 1991 ) .
Solvent is not needed in most UV curing uses, although some dilu tion may be needed for spray applications . Solvent is used for the cleanup of uncured coating . The coating is applied as a fluid and
41 Available Technologies
exposed to the UV light, which initiates formation of a cross-linked polymer coating (see Figure 6).
Reactive slngle Ultravlolet 100% Ilg curing 11quld paint system ht
Overspray can be collected and reused
Source: Battelle
Figure 6. 100% Solids Ultraviolet-Light-Curable Liquid Paint System.
Reported t o Applica i ns UV coating formulated from polyester resin in styrene has seen commercial application as filler for chipboard. The polyester-styrene system has not been widely applied because of styrene's volatility, the yellow color of the coating, and the high capital cost of UV coating equipment.
UV-cured coatings are being developed based on acrylate-modified resins such as polyesters, epoxides, and urethanes. UV-cured
42 Ultraviolet (UV) Radiation-Cured Coatings
coatings are typically limited to wood substrates, but application to metals has been studied (Paul, 1986). UV coating techniques are used to coat flat sheet stock and to apply "wet look' finishes to assembled furniture.
A variety of Dual Cure™ urethane/acrylate and epoxy/acrylate UV cured coating systems are being developed (Keipert, 1990).
Operational and
, Product Benefits UV-cured coatings have a number of operational cost, and environmental benefits:
+ Eliminates or reduces solvent use • High transfer efficiency . • Low-temperature processing • Rapid curing • Equipment requires less space than curing ovens.
Hazards and Limitations UV technology has several drawbacks:
• It requires new equipment with high capital cost. • The presence of pigments limits penetration of UV.
Tradeoffs UV curing offers good pollution prevention potential but requires new operating procedures and expensive new equipment.
r Unknowns and Future Developments More widespread future use depends on· the development of the following:
+ More highly developed UV equipment + New products/markets for radiation processing technologies • New 100% reactive monomers and oligomers that are nontoxic and of low viscosity • New monomers, oligomers, and polymers that adhere to metal substrates o • New electronic and optr nic resist materials + Lower costs for materials • Further study of coating service life (Dick, 1991 ).
43 SECTION 3 -
EMERGING TECHNOLOGIES
How to Use the SummaryTa bles Six emerging coating replacement materials are evaluated in this section, namely
+ Electron beam (EB)-cured coatings + Radiation-induced thermally cured coatings + Two-component reactive liquid coatings + Water-based temporary protective coatings + Vapor permeation- or injection-cured coatings + Supercritical carbon dioxide as solvent
Tables 4 and 5 summarize descriptive and operational aspects of these technologies. They contain evaluations or annotations describingeach emerging clean technology and give a compact indication of the range of technologies covered to allow preliminary identification of those that may be applicable to specific situations. Readers are invited to refer to the summaryta bles throughout this discussion to compare and contrast technologies.
Descriptive Aspects Table 4 describes each emerging technology. It lists the Pollution Prevention Benefits, Reported Applications, Operational and Product Benefits, and Hazards and Limitations of each.
Operational Aspects Table 5 shows the key operating characteristics for the emerging technologies. These characteristics serve to qualitatively rank the clean technologies relative to each other. The rankings are estimated from descriptions and data in the literature.
Process Com plexity is qualitatively ranked as "high," "medium," or "low" based on such factors as the number of process steps in volved and the number of material transfers needed. Process Complexity is an indication of how easily the new technology can be integrated into existing plant operations. A large number of process steps or input chemicals, or multiple operations with complex sequencing, are examples of characteristics that would lead to a high complexity rating.
44 Table 4. Emerging Clean Technologies for Organic Coating Replacements: Descriptive Aspects
Reported Hazards and Technology Type Pollution Prevention Benefits Applications Operationaland Product Benefits Limitations !
• reactive fiquid • Used on • Efficient material use (near 100% transfer efficiency) • T p ll best applied Electron Beam (EB)-Cured 100% y ip y Coatings • Eliminates or reduces solvent in the coating, - paper • Lack of volatile solvent means little air flow needed to flat material but solvent still needed for cleanup -wood • Low-temperature processing (reduced energy use -plastic for healing makeup air)
• Rapid curing
Radiation-Induced Thermally • 100% reactive liquid • Pilot testing for curing powder • Low-temperature processing • Best when used with Cured Coatings • Eliminates or reduces solvent in the coating or waterborne coatings robotic system • May water-reducible for application and • Typically best applied be ' cleanup depending on coating to flat material
Two-Component Reactive Liquid • 1 OOo/o reactive fiquid • Undergoing initial feasibility • Low-temperature processing • Uncured resin may be Coatings • Biminates or reduces solvent in the coating, testing harmful but solvent still needed for cleanup
' Water-Based Temporary • Water-basedformulation eliminates or reduc· • Automobiles in shipment • Producestough, transparent film • Coating is temporary Protective Coatings es solvent use • Machined metalduring ship- • Safe, quick removal • Water used for cleanup ping or between manufacturing i steps . • Metal masking during milling and etching
Vapor-Permeation or • 100% reactive liquid • Pilot testing of permeation • Low-temperature processing • Furthertesting Injection-Cured Coatings • Biminates or reduces solvent in the coating, curing by amine vapor required but solvent still needed for cleanup
Supercritical C02 as Solvent • Reduces solvent in coating formulation • Replacement forconventional • Compatible with conventional and electrostatic • Solvent use not spraying systems application equipment and techniques completely eliminated
• Lower solvent loadings allow reduced air flow in • Requires new C02 curing ovens and work spaces, thus decreasing handling equipment energy needed for heating
� .,... m
Emerging Clean Technologies for Organic Coating Replacements: Operatlonal Aspects Table 5.
I Required Technology Process Skill Waste Products and Capital Energy Type Complexity Level Emissions Cost Use References
• 1991 Electron Beam {EB)-Cured High High Unreacted overspray canbe collec· Very high Low Dick, Coatings . led for reuse Paul, 1986 Sun Chemical, 1991
gh • callee· 1986 Radiation-Induced Thermally High Hi Unreacted overspray canbe High Low Paul, Cured Coatings ted for reuse when used with Poullos, 1991 powder coatings
Two-Component High High • Overspray loss simHar to that of High Low No data available Reactive Liquid Coatings conventionalcoating
Med Medium • e s ray loss simHar to that of 1986 Water-Based Temporary ium Ov r p Medium Medium Product Finishing, Protective Coatings conventional coating Toepke , 1991
Vapor-Permeation or High High • Unreacted overspray canbe callee- High Low Pilcher, 1988 Injection-Cured Coatings led for reuse
Medium • , 1991 Supercritical C02 as Solvent Medium Overspray loss simHar to that of High Medium Nordson conventional coating
.. Emerg ing Technologies
Required S i The k l l Level of equipment operators also is ranked as R q r d Skill Level "high," "medium," or "low." e u i e is an indication of the level of sophistication and training required by staff to operate the new technology. A technology that requires the operator to adjust critical parameters would be rated as having a high skill requirement. In some cases, the operator may be insulated from the process by complex control equipment. In such cases, the operator skill level is low but the maintenance skill level is high.
Table 5 also lists the Waste Products and Emissions from the emerging clean technologies. It indicates tradeoffs in potential pollutants, the waste reduction potential of each, and compatibility with existing waste recycling or treatment operations at the plant.
The Capital Cost column provides a preliminary measure of pro cess economics. It is a qualitative estimate of the initial cost impact of the engineering, procurement, and installation of the process and supportequipment. Due to the diversity of cost data and the wide variation in plant needs and conditions, it is not possible to give specific cost comparisons. Cost analysis must be plant-specific to adequately address factors such as the type and age of existing equipment, space availability, throughput, product type, customer specifications, and cost of capital. Where possible, sources of cost data are referenced in the discussions of each clean coating material.
The Energy Use column provides data on energy conversion
, equipment required for a specific purpose. In addition some general information on energy requirements is provided.
The last column in Table 5 lists References to publications that will provide furtherin formation for each emerging coating material. These references are given in full in Section 4.
The text further describes the operating pollution prevention benefits, reported applications, operational and product benefits, and hazards and limitations. Technologies in later stages of development are discussed in Section 2, Available Technologies.
47 ELECTRON BEAM (EB) CU.RED COATINGS
In a process similar to that .of UV curing, EB curing uses the high energy of accelerated electron to directly cause the crosslinking of inks and coatings. Also as with UV curing, acrylate oligomers and prepolymers are used, although other chemistries are available for EB curing.
The high energy of EB curing gives the highest margin of safety for applications where extractables or low odors are essential. This high energy ensures adequate conversion from oligomer to polymer. Thus, unlike UV curing, very thick films and laminating adhesives can be EB-cured. Furthermore, the EB process is not sensitive to either ink color or the opacity of the film or paper.
EB curing is a cold curing process.. Thus, heat-sensitive substrates can be ·printed and cured without causing deformation.
The curing chamber must be inerted, i.e., pressurized or filled with nitrogen or carbon dioxide, during EB curing. Air, i.e., oxygen, significantly retards EB curing.
EB curing takes place instantaneously. Thus, as with UV curing for high gloss applications, time should be allotted between coating and curing to let the coating or ink flow out and level. If this is not possible, other precautions and equipment should be considered to achieve the desired gloss level (Sun Chemical, 1991 ).
EB coatings are used mainly for paper, wood, and plastic sub strates. They often replace conventional thermal treatments for · coating flat surfaces. At least one company in Japan used EB curing for metal coil stock. EB has seen limited use in high-volume printing operations. A more frequent use is to finish automotive hubcaps and wheel rims (Dick, 1991 ). The high capital cost of EB curing equipment has limited the acceptance of EB-cured coatings (Paul, 1986).
Emerg ing Technologies 48 RADIATION-INDUCED THERMALLY CURED COATINGS
Laser heating, particularly when applied by a robotic system, allows accurate heat input to rapidly cure thermoplastic or water-based coatings. The laser fusion system was originally designed to cure fluorocarbon thermoplastics such as polytetrafluoroethylene. The curing of other powder and water-based coatings is being tested.
Infrared, microwave, laser, or radio-frequency radiation can be used to heat a fluid coating to induce curing by thermal mechanisms. The curing reaction is essentially similar to conventional curing in a convection oven, except that heat is supplied by the incident
radiation (Paul, 1986; Poullos, 1991 ) .
Emerg ing Technolog ies 49 TWO-COMPON_E NT REACTIVE LIQUID COATINGS
In a two-component reactive liquid coating system, twolow -viscosity liquids are mixed just before entering the application system as shown in Figure 7. One liquid contains reactive resins, and the other contains an activator or catalyst that promotes polymerization of the resins. Conventional, airless, or electrostatic spray equipment can be modified to accommodate new coating materials such as two-component epoxies, polyurethanes, and polyesters. The two components are fed into the spray gun through separate metering devices. Flow control valves and cleaning valves are built into the spray unit to prevent the two reactive components from coming in contact with each other until just before spray release. Two-component application allows coating without the use of a volatile organic solvent in the coating formulation. Some solvent may be used to clean up any unreacted liquids.
Pan A • Epoxy resin Room temperature cure or heatwith conventional ovenor Infrared lamps Pan B • Curing agent or catalyst
Paint overspraywould haveto be collected and disposed of. These paints arepermanently reactive aftermixing andcannot be reused
Source: Battelle
Figure Solids Chemical Cure T o- Componen Liquid Paint System. 7. 100% w t
Emerg ing Technologies so ..
WATER-BASED TEMPORARY PROTECTIVE COATINGS
Consumer products, particularly automobiles, are shipped from factory to consumer through an uncontrolled and potentially harsh environment A protective coating helps to maintain the quality of the factory finish. Temporary coatings are also applied to protect machined metal surfaces from corrosion during shipping or between manufacturing steps.
The normal practice is to apply a solvent-based coating. Solvent in the coating evaporates into the atmosphere as the coating cures. Solvent may also be needed for removal of the temporary coating when the product arrives at the point of sale or use.
Temporary coating materials using a water-based acrylic copolymer system are available to produce a tough transparent film. The film can protect the paint for up to 1 year but can be removed by washing with an aqueous alkali solution.
The reported removal time for the water-based temporary protective coating is 1 O minutes for an automobile compared to 20 minutes for removal of a wax coating (Product Finishing, 1986).
Water-based coatings have also been tested as masking layers to protect areas of metal substrate during chemical milling and etching (Toepke, 1991).
Emerg ing Technologies 5 1 VAPOR PERMEATION- OR INJ ECTION-CU RED COATINGS
Solvent use is avoided in vapor cure coating formulations by applying a reactive resin as a liquid and then inducing curing by exposing the liquid to a vapor containing a compound that initiates polymerization. Some solvent may be used to clean up unreacted resin. One example is polyol-isocyanate coatings cured by tertiary amine vapor injection (Pilcher, 1988).
Emerg ing Technologies 52 "
SUPERCRITICAL CARBON DIOXIDE AS SOLVENT
Supercritical C02 fluid can be used to replace organic solvent in conventional coating formulations. This new technology can sub stitute up to 80% of the organic solvent required in many spray applications. The C02 solvent is compatible with classical high molecular-weight resins and existing painting facilities and proce dures. Thus, it enables finishers to continue to use their existing resin formulations while substantially reducing voe emissions. Application of supercritical solvent coatings requires investment in new paint mixing, handling, and spraying equipment.
Supercritical C02 proportioning and supply units are available from at least one commercial supplier. The unit mixes coating concen trates and C02 to give a coating fluid with the required viscosity. The supercritical C02 solvent is mixed with coating concentrate and supplied to a specially designed spray gun. The coating/solvent mix is applied in the same way as conventional paint. The C02 oper ating pressure ranges from 1200 to 2000 psi, and the airspray supply pressure is about 70 psi (Nordson, 1991 ) .
. Emerg ing Technologies 53 '
SECTION 4_
INFORMATION SOURCES
1989. Clear." Products Finishing. References Bowden, Champ. "The Future is 53(1 0), July.
Crump, David L. 1991 . "Powder Coating Technology at Boeing." In: Sixth Annual Aerospace Hazardous Wa ste Minimization Con ference. Boeing Company, Seattle, Washington, June 25-27.
Danneman, Jeffrey. 1988. "UV Process Provides Rapid Cure for Compliant Wood Finishes." Modem Paint and Coatings. 78(2) : 28-29. February.
Dick, Richard J. 1991 . Personal Communication. Battelle, Columbus, Ohio, December 5.
Fish, John G. 1982. "Organic Polymer Coatings." In: Rointan F. Bushah (ed.), Deposition Tech nologies fo r Films and Coatings. Noyes Publications, Park Ridge, New Jersey. pp. 490-511.
Hester, Charles I. and Rebecca L. Nicholson, 1989. "Powder Coating Technology Update." EPA-45/3-89-33. October.
lngleston, Roy. 1991 . "Powder Coatings: Current Trends, Future Developments." Product Finishing. 6-7. August.
Keipert, Steven. 1990. "Dual Cure Photocatalyst Systems." In: Firs t Annual International Workshop on Solvent Substitution, pp. 245-249, Phoenix, Arizona, December 4-7.
Maguire, George. 1988. "Fluoropolymer Powder Coati ngs on the Products F ishin . Move." in g 53(1 }, October.
MP&C (Modern Paint and Coatings). 1988. "Low-VOC Coatings Applications for Military Usage Present Major Formulation Chal lenge." Modern Paint and Coatings. 78(9) : 35. September.
Muhlenkamp, Mack. 1988. ''The Technology of Powder." Modern Paint and Coatings. 78(1 }: 52-68. November.
Nelson, Larry. 1988. "Door Market Opens to Low-VOC Coatings." Products Finishing. 53(3): 48-53. December.
54 •
Information Sources
Nordson. 1991 . UNICARBTM System Supply Units. Amherst, Ohio.
Paul, Swaraj. 1986. Surface Coatings Science and Technology. John Wiley & Sons, New York, New York. ' Pilcher, Paul. 1988. "Chemical Coatings in the Eighties: Trials, Tribulations, and Triumphs." Modern Paint and Coatings. 78(6): 34-36. June.
Poullos, Mark. 1991. "Laser Curing of Finishing Systems." Pigment and Resin n l y Tech o og . 20(3): 4-6. March.
Product Finishing. 1986. "ICI Wins Pollution Abatement Award for Low Solvent Emission PaintS." Product Finishing. 39(5): 23. May.
Richardson, Frank B. 1988. "Water-Borne Epoxy Coatings: Past, Present and Future." Modern Paint and Coatings. 78(4): 84-88. April.
Robison, G. Thomas. 1989. "Custom Coating for Over a Half Cen
tury." Products Finishing. 53(7), April.
Schartenberger, Jim. 1989. "Spraying Water-Borne Coating Electrostatically." Products Finishing. 53(4): 48-56. January.
Smith, Mark D. 1990. "Low VOC Coating Alternatives." In: First Annual International Workshop on Solvent Substitution, pp. 237-244. Phoenix, Arizona, December 4-7.
Sun Chemical. 1991. Suncure. Northlake, I llinois.
Swanberg , David. 1990. "Water-Reducible Polyurethane Enamels: Candidate Low VOC Aerospace Topcoat Formulations." In: First Annual ti l Interna ona Workshop on Solvent Substitution, pp. 229-235. Phoenix, Arizona, December 4-7.
Toepke, Sheldon. 1991. "Water Base Chemical Mill Maskant." In: Sixth Annual Aerospace Hazardo us Wa ste Minimization Confer ence. Boeing Company, Seattle, Washington, June 25-27.
Trade Associations Table 6 shows the trade associations and the technology areas they cover. Readers are invited to contact these trade associations and request their assistance in identifying one or more companies that could provide the desired technological capabilities.
55 Information Sources
Table Trade Associations and Technology Areas 6.
Trade Association Technology Areas Covered Contact
Association for Finishing Processes of the Industrial finishing operations P.O. Box 930 Society of Manufacturing Engineers One SME Dr. Dearborn, Ml 48121 tel. (313) 271-1500
Federated Societies for Coating Technology Decorativeand protective coatings 492 Norristown Road Bluebell, PA 19422 tel. (21 5) 940-0m
National Paint & Coatings Association Paints and chemical coatings, related raw ma· 1500 Rhode Island Ave. N.W. terials, and equipment Washington, DC 20005 tel. (202) 462-6272
Powder Coating Institute Powder coating materials and equipment 1800 Diagonal Rd., Suite 370 Alexandria, VA 22314 tel. (703) 684-1770
Radtech International Radiation-curable coatings 60 Revere Drive Suite 500 Northbrook, IL 60062 tel. (708) 480-9576
56 SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
SECTION 5
PAINT
AND
EQUIPMENT
SUPPLIERS
Material in this section is from the TECHINFO database of the Solid & Hazardous Waste Extension Center, Madison, Wisconsin. Questions about individual equipment should be addressed to the vendor in question. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
PAINT & EQUIPMENT SUPPLIERS
COATING - LOW voe
American Chemical Corp, 5231 Northrup Avenue, St. Louis MO 631 10, (phone) 314-664-2403, (fax) 314-772�5749, epoxy coatings.
Amity, P.O. Box 36, Waterloo WI 53594, (phone) 414-478-9633, (fax) 414-478-9762, aqueous-based finishes.
Cardinal Industrial Finishes, 1329 Potrero Avenue, South El Monte CA 91733-3088, (phone) 213-283-9335, (fax) 818-444-0382, powder, enamel, epoxy, acrylic.
EVTECH, 9103 Forsyth Park Drive, Charlotte NC 2821 7-8009, (phone) 704-588-2112, (fax) 704-588-2280, powder coating.
Farboil Company, 8200 Fischer Road, Baltimore MD 21222, (phone) 301-477�200, powder coating.
Ferro, P.O. Box 6550, Cleveland OH 441 01 , (phone) 216-641-8580, (fax) 216-641-8596, powder coating.
Guardsman Products, Inc., 1350 Steele Avenue SW, Grand Rapids Mi 49507-1599, (phone) 616-452-5181, (fax) 616-241 -3624, waterborne finishes.
H.B. Fuller Co., 3200 Labore Road, Vadnais Height MN 551 10, (phone) 612-481-9558, (fax) 612-481-9047, powder coating.
PPG Industries, Inc., 19699 Progress Drive, Strongsville OH 44136, (phone) 216-572-6800, powder coating.
COATING - LOW voe; SUBSTITUTE MATERIAL
Lilly Powder Coatings, P.O. Box 414620, Kansas City MO 64141 , (phone) 816-421-7400, (fax) 816-421-4563, powder coating.
COATING - NOS
ELF ATOCHEM North America Inc., Three Parkway, Philadelphia PA 19102, (phone) 215-587-7000, corrosion resistance coating.
Sino-American Pigment Systems, Inc., 5801 Christie Avenue, Suite 575, Emeryville CA 94608-1938, (phone) 510-653-9931, (fax) 510-653-7501 , non-toxic safety pigment. SPRAY PA INTING: IMPROVEMENTS AND ALTERNATIVES
PAINT & EQUIPMENT SUPPLIERS con't
COATING - NOS; SUBSTITUTE MATERIAL
· Sanchem, Inc., 1600 South Canal Street, Chicago IL 60616, (phone) 312-733-61 11, (fax) 312-733-7432, aluminum conversion coating.
COATING APPLICATOR - ELECTROSTATIC
Binks Manufacturing Company, 9201 West Belmont Avenue, .Franklin Park IL 601 31, (phone) 708-671-3000, (fax) 708-671 -1471 .
Graco Inc., P.O. Box 1441 , Minneapolis MN 55440-1441 , (phone) 612-623-6000, (fax) 612-623-6777.
Thorid Electrostatic Systems, Inc., 11431 Williamson Road, Blue Ash OH 45241 , (phone) 513-489-9399, (fax) 513-489-4631.
COATING APPLICATOR · LOW PRESSURE
Accuspray, P.O. Box 391525, Cleveland OH 441 46, (phone) 216-439-1200, (fax) 216-439-1625, high volume low pressure spray gun.
Binks Manufacturing Company, 9201 West Belmont Avenue, Franklin Park IL 60131, (phone) 708-671-3000, (fax) 708-671 -1471 , high volume low pressure spray gun.
CAN-AM Engineered Products Inc., 30850 Industrial Road, Livonia Ml 48150, (phone) 313-427-2020, (fax) 313-427-4282, high volume low pressure spray gun.
Croix Air Products, Inc., 520 Airport Road, So. St. Paul MN 55075, (phone) 61 2-455-1213, (fax) 61 2-455-961 27, turbine spray gun.
Devilbiss Ransburg, 1724 Indian Wood Circle, Suite f, Maumee OH 43537, (phone) 419-891 -8200, (fax) 41 9-891 -8205, high volume low pressure spray gun.
Graco Inc., P.O. Box 1441 , Minneapolis MN 55440-1441 , (phone) 612-623-6000, (fax) 612-623-6777, high efficiency low pressure spray gun.
IWATA Air Compressor Mfg. Co., Ltd.; Fitz & Fitz (U.S. Distributor), 2416 E Street NE, Auburn WA 98002, (phone) 206-927-9352, (fax) 206-833-6847, low volume low pressure spray gun.
Mattson Spray Equipment, Inc., P.O. Box 132, Rice Lake WI 54868-0132, (phone) 715-234-1617, (fax) 715-234-6967, high volume low pressure spray gun. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
PAINT & EQUIPMENT SUPPLIERS con't
COATING APPLICATOR · POWDER
Binks Manufacturing Company, 9201 Belmont Avenue, Franklin Park IL 60131�2887, (phone) 708-671-3000, (fax) 708-671 -1471 , powder coating booths.
Engineered Powder Applicators, Inc.; Epa, 701 Palmetto Avenue, Ontario CA 91761 , (phone) 714-947-6315, (fax) 714-947-8386, powder coating booths.
Gema Volstatic, P.O. Box 88220, Indianapolis IN 46208, (phone) 31_7-298-5001, (fax) 317-298-5881 , complete range of systems.
Nordson, 555 Jackson Street, Amherst OH 44001, (phone) 800-626-8303, (fax) 216-985-1471, complete range of systems.
Sames Electrostatic, Inc., 11998 Merriman Road, Livonia Ml 48150, (phone) 313-261-5970, (fax) 313-261-5971, powder coating spray gun.
COATING APPLICATOR · PROPORTIONING PUMP
Graco Inc., P.O. Box 1441 , Minneapolis MN 55440-1441 , (phone) 612-623-6000, (fax) 612-623-6n7.
COATING APPLICATOR · SYSTEMS
GLA Finishing Systems, 38830 Taylor Parkway, North Ridgeville OH 44039, (phone) 216-327-3323, (fax) 216-327-4498, complete range of turnkey systems.
Inland Powder Applications, 1656 "F" S. Bon View ave., Ontario CA 91761 , (phone) 714-947-1122, (fax) 714-923-7082, spray booth powder conversionsys tem.
JBI Incorporated, 1717 Omaha; P.O. Box 38, Osseo WI 54758, (phone) 715-597-3168, (fax) 715-597-2193, overspray reclaim systems.
Paint 0 Matic, P.O. Box 1426, Willits CA 95409, (phone) 707-459-941 1, (fax) 707-459-0706, vacuum application system.
Protectaire Systems Co., 8N450-A Tameling Ct., Bartlett IL 601 03, (phone) 708-697-3400, (fax) 708-697-1065, paint booth baffles.
Ransohoff, N. 5Th St. At Ford Blvd., Hamilton OH 45011, (phone) 513-863-5813, (fax) . SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
PAINT & EQUIPMENT SUPPLIERS con't COATING APPLICATOR · THERMAL
Binks Manufacturing Company, 9201 West Belmont Avenue, Franklin Park IL 60131, (phone) 708-671-3000, (fax) 708-671 -1471 .
COATING CURE OVEN · THERMAL
olis MN 55449-7102, (phone) BGK Finishing Systems, Inc., 4131 Pheasant Ridge Drive N, Minneap 612-784-0466, (fax) 612-784-1362.
Casso-Solar Corp., P.O. Box 163, Route 202, Pomona NY 10970, (phone) 914-354-2500, (fax) 914-362-1856.
Comenco, 2550 Goldenridge Rd., Unit 64, Mississauga ON 14x 2s3, (phone) 416-615-9150, (fax) 416-615-8474, batch and conveyorized ovens.
Epcon Industrial Systems, Inc., P.O. Box 7060, The Woodlands TX 77387, (phone) 409-273-1774, (fax) 409-273-4600, batch and continuous ovens.
F Systems, Inc., 400 Industrial Drive, Lynn IN 47355-0387, (phone) 317-874-2531, (fax) 317-874-1 199, conveyorized ovens.
GLA Finishing Systems, 38830 Taylor Parkway, North Ridgeville OH 44039, (phone) 216-327-3323, (fax) 216-327-4498, conveyorized ovens. lnfratech Corp, 1770 Workman Street, Los Angeles CA 90031, (phone) 213-223-1041 ; , (fax) 213-225-4518, infrared ovens.
Milbank Systems Inc., P.O. Box 419097, Kansas City MO 641 41-0097, (phone) 816-241-9450, (fax) 816-241-91 17, conveyorized ovens.
Ransohoff, N. 5Th St. At Ford Blvd., Hamilton OH 4501 1, (phone) 513-863-5813, batch and continuous ovens.
Steelman Industries, Inc., P.O. Box 1461 , Kilgore TX 75663, (phone) 903-984-3061 , (fax) 903-984-1384, batch ovens. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
PAINT & EQUIPMENT SUPPLIERS con't
COATING CURE OVEN - UV
Aetek International, Inc., 1750 N. Van Dyke Rd., Plainfield IL 60544, (phone) 815-436-2304, (fax) 815-436-6299, uv curing systems.
COATING RECOVERY
h ne) 704-7 Hi Strand; P.O. Box 368, Lenoir NC 28645, (p o 54-4992, (fax) 704-757-0422; laquer dust recycling.
COATING THICKNESS GAUGE
CMI; Coating Measurement Instruments, 2301 Arthur Avenue, Elk Grove Village IL 60007, (phone) 708-439-4404, (fax) 708-439-4425, x-ray fluorescence, eddy current induction, beta backscatter.
Defelsko Corporation, 802 Proctor Avenue, Ogdensburg NY 13669, (phone) 613-925-5987, (fax) 613-925-3407.
Elektro-Physik, n8 W Algonquin Rd, Arlington Heights IL 60005, (phone) 708-737-6616, (fax) 708-437-0053.
Fischer Technology, Inc., 750 Marshall Phelps Road, Windsor CT 06095, (phone) 203-683-0781, (fax) 203-688-8496.
KTS Tator, Inc, 115 Technology Drive, Pittsburgh PA 15275, (phone) 412-788-1300, (fax) 412-788-1306.
MASKING
Echo Engineering & Production Supplies, 962 Hanson Court,Mi lpitas CA 95035, (phone) 408-945-0325, (fax) 408-945-0336, plugs and tape.
MEDIA BLASTING
Alpheus Cleaning Technologies, Corp., 9105 Milliken Avenue, Rancho Cucamonga CA 91730, (phone) 714-944-0055, (fax) 714-980-5696, co2 blasting.
CDS Group, 469 NorthHa rrison Street, Princeton NJ 08543-5297, (phone) 609-683-5900, (fax) 609-497-7176, sodium bicarbonate blasting. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
PAINT & EQUIPMENT SUPPLIERS con't
Cold Jet Inc., 455 Wards Corner Road Suite 100, Loveland OH 45140, (phone) 513-831-321 1, (fax) 513-831-1209, co2 blasting.
Empire Abrasive Equipment Corp, 2101 W. Cabot Blvd, Langhorne PA 19047-1893, (phone) 215-752-8800, (fax) 215-752-9373, media recovery system.
Ice Blast International Corp., 627 John St., Victoria BC V8T 1T8,(pho ne) 604-383-2155, (fax) 604-386-2512, ice blasting.
JET Wheelblast Equipment, 401 Miles Drive, Adrian Ml 49221 , (phone) 517-263-0502, (fax) 517-263-0038, centrifugal blasting.
LTC Americas, 22446 Davis Drive, Suite 142, SterlingVA 201 64, (phone) 800-822-2332, (fax) 703-406-4523, vacuum blasting system.
Maxi Blast Inc., 630 East Bronson Street, South Bend IN 46601, (phone) 219-233-1 161, (fax) 219-234-0792, plastic bead.
Pauli and Griffin, 907 Cotting Lane, Vacaville CA 95688, (phone) 707-447-7000, (fax) 707-447-7036, plastic bead.
MEDIA BLASTING; SUBSTITUTE MATERIAL
The TOH Group, Inc., 760-K Industrial Drive, Cary IL 60013, (phone) 708-639-1 113, (fax) 708-639-0499, toxicity reducing blasting additive.
PAINT CAN LINER
Mattson Spray Equipment, Inc., P.O. Box 132, Rice Lake WI 54868-0132, (phone) 715-234-1617, (fax) 715-234-6967.
PAINT FILTER
Bay State Enterprises, Inc., 64 Winthrop Street, P.O. Box 4956, Springfield MA 01101-3070, (phone) 413-781-2128, (fax) 413-734-2610, solvent soluble filter.
JBI Incorporated, 1717 Omaha P.O. Box 38, Osseo WI 54758, (phOne) 715-597-3168, (fax) 715-597-2193, reusable - thermally cleaned filter.
Protectaire Systems Co., 8N450-A Tameling Ct., Bartlett IL 60103, (phone) 708-697-3400, (fax) 708-697-1065, pre-baffle system. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
PAINT & EQUIPMENT SUPPLIERS con't
SPRAY NOZZLES
Bex, Inc., 37709 Schoolcraft Road, Livonia Ml 48150, (phone) 313-464-8282, (fax) 313-464-1988. SPRAY PA INTING: IMPROVEMENTS AND ALTERNATIVES
SECTION 6
BIBLIOGRAPHY
Information contained in this bibliography was provided by the Waste Reduction Resource Center, 3825 Barret Drive, Suite 300, Raleigh, North Carolina 26709, 919-571-4100 SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
BIBLIOGRAPHY
The following is a bibliography of written resources related to the use of less-polluting alternatives to spray painti ng. Many of the resources cited are avai lable from libraries and others are commercial product literature.
Powder Coating Offers Pollution Prevention Opportunities; The Air Pollution Consultant; November, 1991. This paper reviews advantages and disadvantages of powder coating. A case study is presented.
VOC ControlSyste ms; Products Finishing, May, 1993. This article describes voe control options including low voe coatings, oxidation, recuperative thermal oxidizers, catalytic oxidizers, regenerative thermal oxidizers, and adsorption systems.
Useful Facts and Figures; Akzo Coatings, Inc., 4th Edition Extensive information on major coating resins and their use, physical and chemical testing of organic coatings, color storing and preparing of coatings and current regulations. General information on processes and productsfo r wood and metal furniture.
Special Equipment Requirements for Spray Finishing with Compliance Coatings; Bain, R.C. and Muir, G.; Metal Finishing, March, 1988.
Powder Coating Advantages; Bocchi, Greg; The Powder Coating Industry; 1991 , This paper compares the capital, operating, and disposal cost of conventional solvents, water borne, high-solids, and powder coatings.
Compliance Coatings - An Overview; Bolek, Bernice; Metal Finishing; May, 1988.
Finishing Efficiency with LPHV; Bunnell, Michael; Metal Finishing; October, 1988.
Water-based coating challenges electrodeposition; Cassidy, Victor; Modem Metals; September, 1988.
Coatings Get A New Look, as Pace of Solvent Phaseout Quickens; Chowdhury, Jayadev; Chemical Engineering, January 19, 1987.
High-Solids Coatings, Electron Beam Curing and Ultraviolet Curing; Clark, Keith; Waste Reduction - Progress and Pollution Prevention: Prospects within North Carolina; Raleigh, N.C.: N.C. Pollution Prevention Program & UNC Water Resources Research Institute, 1988.
Painting Bells (Tips); Daignault, Cindy; Paintcon '93 - Finish World Class! - Liquid Coatings; Atomization principles of bells, system optimi zation & integration are discussed.
Waterboume Spray-System Electrostatic Charging (Tips); Paintcon '93 - Finish world Class! Liquid Coatings; A comparison of waterborne and solventbome electrostatic systems is provided. Safety, reliability to maintenance of waterborne systems is reviewed. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
BIBLIOGRAPHY con't
HVLP: High Volume , Low Pressure, The DeVilbiss Company, Toledo, Ohio, 1989. This brochure discusses why HVLP is such an important spray technology, how HVLP compares to other high transfer efficiency spray systems, & how to choose the right HVLP system for a particular operation.
Powder Coater Boosts Productivity; Douglass, David; Products Finishing, June 1990. Discusses new powder coating equipment designed for rapid color changes.
The Use of Process Modifications in Reducing Industrial Wastes from Spray Coating Operations; Duletsky, B.W. and Newton, D.L. ; 1985 Triangle Conference on Environmental Technology
Use of Electrostatic Spray Techniques for the Surface Coating of Business; Duletsky, Barbara; Midwest Research Institute, 11 July, 1984; Project File 7705-L.
Use of Air-Assisted/Airless Spray for the Surface Coating of Plastic Parts for Business Machines: Midwest Research Institute, 22 October 1984. Project File 7705-L.
Finish to Win; EVTECH; Eastman Kodak Company; , 1991. This guide to powder coating discusses benefits, operational and line design tips, cost comparison with piquid systems, and safety considerations.
A New Generation of Water-Based Coatings; Fisher, Peter; AIPE Facilities; July/August 1992. This report discusses the advantages of using water-based paints in place of solvent-based paints. New generation water-based epoxy enamels, and floor coatings performances are compared to solvent-based products.
Solvent Waste Minimization by the Coatings Industry; Frick, Neil and Gruber, Gerald; PPG Industries, Inc.
Alternative Approaches to Waste Reduction in Materials Coating Processes; Gardner, Lisa and Donald Huisingh; Mary Ann Liebert, Inc., Publishers, 1987.
Coatings for Compliance; Graves, Beverly; Products Finishing; July, 1990.
Interrelated Factors to be Considered when Developing an Optimal Solvent Emission Control Strategy; Hakkei, Adel; DOE Industrial Solvent Recycling Conference, Tarrytown, N.Y.: Chem Systems, Inc. This paper presents sources of solvent emissions and wastes along with control options. It also discusses reformulation options, improved application methods, and voe destruction/recovery options.
The Reductionof VOC Emissions from Metal and Plastic Surface Coating Operations: A Strategy for Compliance; Hess, Peter and James Guthrie; 80th APCA Annual Meeting and exhibition.paper 87-51.4, 1987. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
BIBLIOGRAPHY con't
Waste Reduction in Painting and Printing Operations; Irish, Allen; Conference for Southern States on Hazardous Waste Minimization. Pollution Prevention and Environmental Regulation This article contains several excerpts fromthe 1990 Pollution Prevention Act and lists several chemicals targeted by ITP and 33/50.
Waste Source Reduction and Recycling Measures; Jacobs Engineering Group, Inc.; Pasadena, CA; Jacobs Engineering Group, Inc. A bullet list of wasteerduction options is given for parts cleaning, equipment cleaning, materials handling and storage, and coating operations. This report gives excellent checklist and initial ideas.
Autodeposition-the Environmental Advantage; Jones, Thomas; Presented at Finishing '91 , September 23-25, 1991. Autodeposition utilizes aqueous dispersions of polymer, pigment and activators to coat metal. The process eliminates the need for a conventional conversion coating. The coating bath operates at room temperature and is chemical rather than electrically activated. Autodeposition has a high coating transfer efficiency, and eliminates volatile organic compounds.
Selecting Low VOC Waterborne Coatings in the '90s; Joseph, Ron; Metal Finishing; April, 1993. Focuses on a range of waterborne coating technologies, which include water reducible, dispersion and latex formulations.
Electrostatic Applications; Kish, Stephen; National Conference for Industrial Painting Operations. This presentation provides a thorough overlook of electrostatic basics.
High Volume Low Pressure Spray Systems; Kish, Steven; Teleconference for Industrial Painting Operations This paper discusses H.V.L.P. automation as a means of reducing overspray and improving transfer efficiency.
Transfer Efficiency: Comparing Different Delivery systems; Kish, Steven; Teleconference for Industrial Painting Operations, Graco, Inc. This paper gives a detailed look at airless & air spray basics, adjustments, spray techniques, and operator maintenance/trouble shooting.
Finishing Products and the Environment; LeBlanc, Destin; Products Finishing; September, 1993.
Powder Coating Equipment - Part Gun II Motion & System Design; Liberto, Nicholas; Metal Finishing; September, 1990. This article provides guidelines in determining equipment requirements. System design examples and gun motion devices including oscillators, reciprocators, multi-axis machines and robots are discussed.
HVLP Spray Puts You in Compliance; Marg, Ken; Metal Finishing; March, 1989.
Meeting Emission Standardsfor Paint Spray Systems; Marg, Ken; Plant Engineering, November 7, 1991. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
BIBLIOGRAPHY con't
Conventional Air-Atomized and HVLP Guns (Tips); Mattson, Ross; Paintcon '93 - Finish World Class! - Liquid Coatings. Tips given for the use of air atomized guns.
Checklists for Identifying Waste Reduction Opportunities; MISSTAP; Mississippi State University, MS. This workbook on waste reduction opportunities is provided by the State of Mississippi. Operating procedures, cleaning, machining, plating/metal finishing, coating/painting and formulating are covered.
Airless and Air-Assisted Guns (Tips); Muir, Glen; Paintcon '93 - Finish World Class - Liquid Coatings. Tips given for the use of airless guns.
Finishing Costs: A Comparative Analysis; Nordson Corporation; 1984. These worksheets for approximating finishing costs include formulations for computation. Solvent systems, waterborne systems, high-solids systems and powder systems are compared.
Alternative Technologies fo r Paint Application; Purcell, Arthur; lncinerable Hazardous Waste Minimization Workshops; California Department of Health Services and the Association of Bay Area Governments. Waste minimization is linked to delivery technologies, application techniques and recovery and recycling efforts. Sprayers and powder coating are discussed (summary only).
Metal Finishing by Autodeposition of Organic Coatings; Roberto, Oscar, Hart, Robert and Jones, Thomas, Parker+Amchem.
Evaluation of VOC Control Options; Science Applications International Corporation; December, 1991 voe reduction options - including destruction, recovery, metal-cleaning, degreasing, soil remediation, dry cleaning and spray painting technologies.
Lower Temperature Cure Powder Coatings; Sandor, Timothy, St. John, James; Metal Finishing, August, 1988.
Waste Reduction in the Paint Application Industry; Skovronek, Herbert; Proceedings Hazardous Waste Reduction Audit Workshop, 164-172; Trenton, N.J.; N.J. Department of Environmental Protection, 1987.
Guide to Clean Technology - Organic Coating Replacements; U.S. EPA; Draft; 15 May 1992. Clean technologies discussed include powder coatings, high solids coatings, water-based coatings, ultraviolet radiation cured coatings, electron beam-cured coatings, radiation induced thermally cured coating, 2 component reactive liquid coatings, water-based temporary protective coatings, vapor permeation or injection cured coatings and supercritical C02 as a solvent.
Electrostatic Spray Coating Equipment; Metal Finishing; April 1989; 47-52. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
BIBLIOGRAPHY con't
Transfer Efficiency; Paint Con '87; This paper discusses the broad definition of transfer efficiency including quality of finish, edge buildOup, uniformity of paint film, etc. It also discusses the different types of guns and the type of paint used.
How to Spray Plastic and Wooden Parts Electrostatically; Wahlberg,Arvid ; Industrial Finishing; November, 1982
The materials and publications listed below help promote the utilization of powder coating. For additional information, contact: The Powder Coating Institute, 2121 Eisenhower Avenue, Suite 401, Alexandria, Virginia, 22314, (703) 684- 1770.
"Powder Coating .. Technology of the Future .. Here Today" (video)
POWDER COATING VISUAL SMOOTHNESS STANDARDS
POWDER COATING SYSTEM TROUBLESHOOTING GUIDE
TROUBLE SHOOTING SLIDE SETS
POWDER COATING TEST PROCEDURES
USER'S GUIDE TO POWDER COATING
THE POWDER COATING INSTITUTE TECHNICAL BRIEFS
THE PCI INFORMATION BROCHURE & POWDER COATINGS BROCHURE
THE PCI SLIDE GUIDE COST ESTIMATOR SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
��;���I
SECTION 7
GREAT
LAKES
REGION
TECHNICAL
ASSISTANCE
PROGRAMS SPRA Y PAINTING: IMPROVEMENTS AND ALTERNATIVES
GREAT LAKES STATE AND PROVINCIAL
POLLUTION PREVENTION PROGRAMS
AND THE GREAT LAKES
POLLUTION PREVENTION ACTION PLAN
OHIO ENVIRONMENTAL PROTECTION AGENCY POLLUTION PREVENTION SECTION DIVISION OF HAZARDOUS WASTE MANAGEMENT
SEPTEMBER 1992 SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
GREAT LAKES STATE AND PROVINCIAL POLLUTION PREVENTION PROGRAMS
(317) 232-8172 ILLI NOIS David Thomas, Director Lynn A. Corson Hazardous Waste Research and Information Pollution Prevention Program y Center Purdue Universit One East Hazelwood Drive 1291 Cumberland Ave . Suite C Champaign, IL 61820 West Lafayette, IN 47907-1385 (317) 494-5036 (217) 333-8940 MICHIGAN Michael Hayes Illinois Environmental Protection Agency Office of Pollution Prevention Nan Merrill 2200 Churchhill Road Departments of Commerce and Natural Box 19276 Resources Springfield, IL 62794-9276 Office of Waste Reduction Services (217) 785-0833 P.O. Box 30004 Lansing, Ml 48909 Diane Shockey (517) 335-1178 Industrial Material Exchange Service 2200 Churchhill Road, #24 David Fiedler Springfield, IL 62794-0276 Departments of Commerce and Natural (217) 782-0450 Resources Office of Waste Reduction Services INDIANA P.O. Box 30004 Lansing, Ml 48909 (517) 335-1 178 Thomas Neltner Indiana Department of Environmental Janet Vail Management Waste Reduction Management Program Office of Pollution Prevention and Technical Grand Valley State University Assistance Water Resources Institute 105 S. Meridian Street Allendale, Ml 49401 P.O. Box 6015 Indianapolis, IN 46206-6015 Dr. Gregory A. Keoleian (317) 232-8172 National Pollution Prevention Center for Higher Education Gabriele Hauer University of Michigan Indiana Department of Environmental Dana Bldg, 430 East University Management Ann Arbor, Ml 481 09-1 115 Office of Pollution Prevention and Technical (313) 764-1412 Assistance 105 S. Meridian Street P.O. Box 6015 Indianapolis, IN 46206-6015 SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
The International Materials and Information NEW YORK Exchange Network Waste Systems Institute John lonatti, Director 3250 Townsend NE Pollution Prevention Unit Grand Rapids, Ml 49505 New York Department of Environmental (616) 363-3262 Conservation 50 WoH Road Albany, NY 12205 (518) 457-7266 MINNESOTA William J. Welisevich Cindy Mccomas, Director Pollution Prevention Program Minnesota Technical Assistance Program Erie County Environmental Compliance Division 1313 5th Street, S.E. 95 Franklin St. Suite 207 Buffalo, NY 14202-3973 Minneapolis, MN 5541 4-4504 (716) 858-7674 (612) 627-4555 Tom Hersey Bob Lundquist Pollution Prevention Program Minnesota Technical Assistance Program Erie County Environmental Compliance Division 1313 5th Street, S.E. 95 Franklin St. Suite 207 Buffalo, NY 14202-3973 Minneapolis, MN 5541 4-4504 (716) 858-7674 (612) 627-4555 Terry Agriss, President Eric Kilberg,Coor dinator New York State Environmental Facilities Pollution Prevention Program Corporation Minnesota Pollution Control Agency Industrial Materials Recycling Program 520 Lafayette Road 50 WoH Road St. Paul, MN 55155 Albany, NY 12205-2603 (612) 296-8643 (518) 457-4133, (800) 882-9721 (NY only)
Kevin McDonald Carrie Mauhs-Pugh Minnesota Office of Waste Managment Northeast Industrial Waste Exchange 1350 Energy Lane 90 Presidential Plaza, Suite 122 St. Paul, MN 55155 Syracuse, NY 13202 (612) 649-57 44 (315) 422-6572
Metropolitan Waste ControlCommission Ralph Rumer Mears Park Center, 230 East 5th NYS Center for Hazardous Waste Management St. Paul, MN 551 01 SUNY at Buffalo (612) 222-8423 207 Jarvis Hall Buffalo, NY 14260 (71 6) 645-3446 SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
Mary Rose Glazer National Environmental Technology Larry Boyd, Manager Applications Corporation Environmental Services Program. 615 William Pitt Way Cleveland Advanced Manufacturing Program Pittsburgh,PA 15238 4600 Prospect Avenue (412) 826-5511 Cleveland, OH 441 03 (216) 432-5350 WISCONSIN Harry Stone Institute of Advanced Manufacturing Sciences David S. Liebl 1111 Edison Drive University of Wisconsin, SHWEC Cincinnati, OH 45216 529 Lowell Hall (513) 948-2000 61 O Langdon St. Madison, WI 53707 Michael Kelley, Manager (608) 262-8179 Pollution Prevention Section Ohio Environmental Protection Agency WI Department of Natural Resources 1800 WaterMark Drive P.O. Box 7921 Box 1049 Madison, WI 53707 Columbus, 43266 OH (608) 267-9700 (614) 644-3469 Kathy Bero The Greater Milwaukee Toxics PENNSYLVANIA Minimization Task Force 260 West Seeboth Street Jack Gido P.O. Box 3049 Pennsylvania Technical Assistance Program Milwaukee, WI 53201 -3049 11O Barbara Building II 81 O N. University Drive University Park, PA 16802-1013 ENVIRONMENT CANADA (814) 865-0427 Raymond Rivers Edgar Berkey, President Environment Canada Center for Hazardous Materials Research Communications Directorate University of Pittsburgh Applied Research Ontario Region Center 25 Clair Ave. East, 6th Floor 320 William Pitt Way St. Toronto, Canada Pittsburgh, PA 15238 M4T 1M2 (412) 826-5320 (41 6) 973-1098 Meredith Hill ONTARIO Department of Environmental Resources Bureau of Waste Management Division of Waste Minimization and Planning P.O. Box 2063 Harrisburg, PA 17105 (717) 787-7382 SPRAY PA INTING: IMPROVEMENTS AND ALTERNATIVES
Peter Dennis, Eric Leggatt Ontario Ministry of the Environment 135 St. Clair Ave. West Suite 100 Toronto, Ontario M4V 1 PS (416 ) 314-4140
Richard Nowina Ontario Waste Management Corporation 2 Bloor Street West, 11th Floor Toronto, Ontario M4W 3E2 (41 6) 923-2918
Stewart Forbes Great Lakes Pollution Prevention Centre 265 North Front Street Suite 112 Sarnia, Ontario N7T 7X1 (51 9) 337-3423 SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
STATE OF ILLINOIS
Program Name Office of Pollution Prevention, Illinois Environmental Protection Agency (IEPA); Hazardous Waste Research and Information Center (HWRIC), Departmentof Energy and Natural Resources
Program Established IEPA-1 989; HWRIC-1984
Program Emphasis source reduction, recycling, hazardous waste minimization
Program Activities
Information Clearinghouse IEPA, HWRIC
Research and Development HWRIC
Technical Assistance I Regulation Interpretation IEPA, HWRIC
On-site Technical Assistance IEPA, HWRIC
Financial Assistance to Industry HWRIC
Financial Assistance to LocalGovernment
Waste Exchange IEPA, HWRIC
Pollution PreventionI Waste Minimization HWRIC Assessments
Workshops/Seminars/Conferences HWRIC
Newsletter HWRIC
Review Prevention Plans IEPA
Works with Academia to Promote Pollution IEPA, HWRIC Prevention
Awards Program HWRIC ·
Regulatory/Financial Incentives IEPA - Expedite review of permit application, support of variance petitions, support of site specific rules, technical assistance
Statutory/Regulatory Requirements Illinois Toxic Pollution Prevention Act SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
STATE OF INDIANA
- .. - Program Name Indiana Pollution Prevention Program
Program Established 1990
.. Program Emphasis
Program Activities
Information Clearinghouse no
Research and Development no
Technical Assistance I Regulation Interpretation yes
On-site Technical Assistance yes
Financial Assistance to Industry no
Financial Assistance to Local Government yes (for recycling programs)
Waste Exchange yes
Pollution Prevention I Waste Minimization yes Assessments
Workshops/Seminars/Conferences yes
Newsletter no
Review Prevention Plans no
Works with Academia to Promote Pollution no Prevention
Awards Program yes (for recycling)
Regulatory/Financial Incentives Hazardous Waste Disposal Fee
Statutory/Regulatory Requirements House Bill 1106, House Bill 1240 SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
STATE OF MICHIGAN
Program Name Office of Waste Reduction Services, State of Michigan (OWRS); Waste Reduction and Management Program, Grand Valley State University (WRAMP); National Pollution Prevention Center (NPPC)
Program Established OWRS-1989; WRAMP-1990; NPPC-1991
Program Emphasis solid waste, hazardous waste, air emmission, waste water discharges, and liquid industrial wastes (OWRS); solid and hazardous waste, source reduction and recycling (WRAMP)
Program Activities
Information Clearinghouse OWRS, WRAMP
Research and Development
Technical Assistance I Regulation Interpretation OWRS
On-site Technical Assistance OWRS, WRAMP
Financial Assistance to Industry Michigan Department of Natural Resources Solid Waste Alternatives Program
Financial Assistance to Local Government
Waste Exchange
Pollution Prevention I Waste Minimization OWRS, WRAMP Assessments
Workshops/Seminars/Conferences OWRS, WRAMP, NPPC
Newsletter WRAMP, "The Water Resources Review"
Review Prevention Plans
Works with Academia to Promote Pollution Prevention
Awards Program
Regulatory/Financial Incentives Hazardous waste landfill fee and a refund system for waste reduction accomplishments (Public Act 195)
Statutory/Regulatory Requirements Public Acts 195, 245, 246, 247 (1987); Public Act 328 (1988) SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
STATE OF MINNESOTA
Program Name Minnesota Office of Waste Management (OWM), Minnesota Technical Assistance Program (MnTAP), Minnesota Pollution Control Agency (MPCA)
Program Established OWM- 1989; MnTAP-1984
Program Emphasis source reduction, recycling, hazardous waste minimization
Program Activities
Information Clearinghouse MPCA, MnTAP
Research and Development
Technical Assistance I Regulation Interpretation OWM, MPCA, MnTAP
On-site Technical Assistance MnTAP
Financial Assistance to Industry OWM
Financial Assistance to Local Government
Waste Exchange
Pollution Prevention I Waste Minimization MPCA Assessments
Workshops/Seminars/Conferences OPWM, MPCA, MnTAP
Newsletter MnTA P
Review Prevention Plans MPCA
Works with Academia to Promote Pollution OWM, MnTAP Prevention
Awards Program OWM
Regulatory/Financial Incentives OWM - Fees based on amount of toxic pollutants released; large quantity generator fee $500/year
Statutory/Regulatory Requirements Toxic Pollution Prevention Act of 1990; Comprehesive Chloroflourcarbon Reduction and Recycling Act (1990) SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
STATE OF NEW YORK
Program Name New York State Department of Environmental Conservation (NYSDEC); Erie County Department of Environmental Planning, Office of Pollution Prevention (ECOPP); New York State Environmental Facilities Corporation (EFC)
Program Established NYSDEC-1987; ECOPP-1990 ; EFC-1981 ; NYSCHWM-1987
Program Emphasis source reduction, recycling, hazardouswaste minimization
Program Activities
Information Clearinghouse NYSDEC, ECOPP, EFC, NYSCHWM
Research and Development ECOPP, NYSCHWM
Technical Assistance I Regulation Interpretation NYSDEC, ECOPP, EFC, NYSCHWM
On-site Technical Assistance NYSDEC, ECOPP
Financial Assistance to Industry EFC
Financial Assistance to Local Government
Waste Exchange NIWE
Pollution Prevention I Waste Minimization NYSDEC, ECOPP Assessments
Workshops/Seminars/Conferences NYSDEC, ECOPP, NYSCHWM
Newsletter NYSDEC, ECOPP, NYSCHWM
Review Prevention Plans NYSDEC
Works with Academia to Promote Pollution NYSDEC Prevention
Awards Program NYSD EC
Regulatory/Financial Incentives NYSDEC
Statutory/Regulatory Requirements NYSDEC; Hazardous Waste Reduction Act of 1990 SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
ST A TE OF OHIO
Program Name Pollution Prevention Section, Ohio Environmental Protection Agency (Ohio EPA); Ohio Department of Development, Edison Technology Centers (ETC) CAMP, IAMS
Program Established
Program Emphasis source reduction, recycling, hazardouswaste minimization
Program Activities
Information Clearinghouse Ohio EPA, ETC
Research and Development ETC
Technical Assistance I Regulation Interpretation Ohio EPA, ETC
On-site Technical Assistance
Financial Assistance to Industry
Financial Assistance to Local Government
Waste Exchange Ohio EPA
Pollution Prevention I Waste Minimization ETC Assessments/Surveys
Workshops/Seminars/Conferences Ohio EPA, ETC
Newsletter ETC
Review Prevention Plans Ohio EPA
Works with Academia to Promote Pollution ETC Prevention
Awards Program Ohio EPA
Regulatory/Financial Incentives
Statutory/Regulatory Requirements House Bill 147 SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
STA TE OF PENNSYLVANIA
Program Name Divison of Waste Minimization and Planning, Department of Environmental Resources (DER); Pennsylvania Technical Assistance Program (PENNTA P); Center for Hazardous Materials Research (CHMR); National Environmental Technology Applications Corporation (NETAC)
Program Established CHMR-1986; NETAC-1988
Program Emphasis source reduction, recycling, hazardous waste minimization
Program Activities
Information Clearinghouse DER, CHMR, NETAC
Research and Development CHMR, NETAC
Technical Assistance I Regulation Interpretation DER, CHMR, PENNTAP, NETAC
On-site Technical Assistance CHMR
Financial Assistance to Industry DER, NETAC
Financial Assistance to Local Government
Waste Exchange DER
Pollution Prevention I Waste Minimization PENNTAP, NETAC Assessments
Workshops/Seminars/Conferences CHMR, PENNTA P, NETAC
Newsletter CHMR
Review Prevention Plans
Works with Academia to Promote Pollution Prevention
Awards Program DER
Regulatory/Financial Incentives DER - Grants for hazardous waste recycling equipment
Statutory/Regulatory Requirements DER; Act 101 SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
PROVINCE OF ONTARIO and ENVIRONMENT CANADA
Program Name Environment Canada (EC); Ontario Ministry of the Environment (OMOE); Ontario Waste Management Corporation (OWMC); Great Lakes Pollution Prevention Centre (GLPPC)
Program Established GLPPC - 1992
Program Emphasis
Program Activities
Information clearinghouse EC, GLPPC, OMOE
Research and development EC, GLPPC, OMOE
Technical Assistance/regulation interpretation EC, GLPPC, OMOE
On-site technical assistance EC, OMOE
Financial assistance to industry EC, OMOE
Financial assistance to local government EC, OMOE
Waste exchange OMOE
Pollution Prevention/Waste minimization EC, OMOE assessments
Workshops/seminars/conferences EC, GLPPC, OMOE
Newsletter EC, GLPPC, OMOE
Reviews prevention plans EC, OMOE
Works with academia to promote pollution EC, GLPPC, OMOE prevention
Awards program EC, OMOE
Regulatory/financial incentives EC, OMOE
Regulatory requirements EC, OMOE (Proposed) SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
SECTION 8
ACKNOWLEDGMENTS SPRAY PA INTING: IMPROVEMENTS AND ALTERNATIVES
ACKNOWLEDGEMENTS
The Cleveland Advanced Manufacturing Program would like to thank the following individuals, who participated in the planning for this teleconference:
Boyd, Larry;_ Manager, Environmental Services; Cleveland Advanced Manufacturing Program; 4600 ProspectAv e; Cleveland, Ohio 441 03. Phone: (216) 432-5300; FAX: (216) 361- 2900.
Foecke, Terry; President; Waste Reduction Institute for Training and Applications Research (WRITAR); 1313 5th St. SE, Suite 325, Minneapolis, MN 55414-4502. Phone: 612- 379-5995; FAX: 612-379-5996.
Green, Danielle; Environmental Protection Specialist, Great Lakes National Program Office; US EPA; G-9J, 77 West Jackson Blvd.; Chicago, Illinois 60604-3590. Phone: (312) 886- 7594; FAX: (312) 353-2018.
Hersey, Thomas R.; Erie County Office of Pollution Prevention; 95 Franklin Street, Room 1077; Buffalo, NY 14202. Phone: (716) 858-7674; FAX: (716) 858-6257.
Horan, Marcia D.; Auto Project Coordinator; Office of Waste Reduction Services; P.O. Box 30004, Lansing Ml 48909. Phone: (517) 373-9122; FAX: (517) 335-4729.
Joyce, Joanne; Pollution Prevention/Technical Assistance; Indiana Department of Environmental Management; 105 South Meridian St. Indianapolis, IN 46206-6015. Phone: (317) 232- 8172; FAX: (317) 232-5539.
Kmit, Jordan; Waste Reduction Engineer, Cleveland Advanced Manufacturing Program; 4600 Prospect Avenue; Cleveland, Ohio 441 03-4314. Phone: (216) 432-5367; FAX (216) 361 -2900.
Liebl, David S.; Pollution Prevention Specialist, University of Wisconsin-Extension; 610 Langdon Street; Madison, WI 53703; Phone: (608) 265-2360; FAX: (608) 262-6250.
McKee, Noreen, Administrative Assistant; Cleveland Advanced Manufacturing Program; 4600 Prospect Avenue; Cleveland, Ohio 441 03-4314. Phone: (216) 432-5351 ; FAX (216) 361 -2900.
Merrill, Nan; Manager of Waste Reduction Services, Office of Waste Reduction Services; P.O. Box 30004, Lansing Ml 48909. Phone: (517) 335-1178; FAX: (517) 335-4724.
Metcalf, Cam; Training Manager, Center for Industrial Services; University of Tennessee; 226 Capitol Blvd. Bldg., Suite 606; Nashville, Tennessee 3721 9-2456. Phone: (615) 242- 2456; FAX: (615) 741 -6644.
Miller, Gary; HWRIC; Illinois Department of Energy and Natural Resources; One East Hazelwood Dr., Champaign, Illinois 61820. Phone: (217)-333-8940; FAX: (217) 333- 8944. SPRAY PAINTING: IMPROVEMENTS AND ALTERNATIVES
ACKNOWLEDGEMENTS con't
Ostheim, Steven T.; Director, Government Programs; Center for Hazardous Materials Research; University of Pittsburgh Applied Research Center, 320 William Pitt Way, Pittsburg h, PA 15838. Phone: (412) 826-5320; FAX: (412) 826-5552.
Peterson, Donna N.; Assistant Director, MnTAP; Suite #207, 1313 5th Street S.E.; Minneapolis, MN 55414. Phone: (612) 627-4555; FAX: (612) 627-4769.
Peterson, Gayle; Program Director, The Great Lakes Protection Fund; 35 East Wacker Drive, Suite 1880; Chicago, IL 60601. Phone: (312) 201-0660; FAX: (312) 201-0683.
Sasson, Anthony; Environmental Supervisor; Pollution Prevention Section, Ohio EPA; P.O. Box 1049 Columbus, OH 43266-0149. Phone: (614) 644-2970; FAX: (614) 644-2329.
Smelcer, George; Director, Hazardous Waste Extension Program; Center for Industrial Services, University of Tennessee; 226 Capitol Blvd. Bldg., Suite 606; Nashville, Tennessee 37219-2456. Phone: (615) 242-2456; FAX: (615) 741 -6644.
Tarmohamed, Yasmin; Pollution Prevention Branch.Environment Canada; 25 St. Clair Ave. East, 6th Floor; Toronto, Ontario M4T-1M2. Phone: 41 6-973-3347; FAX: (416) 973- 7438.
Waslovski, Dennis; Systems & Programming Dept., US EPA, 14th Floor, 77 W. Jackson Blvd., Chicago, IL 60604. Phone: 312-353-5907; FAX: 312-353-4342.
Wessel, Elizabeth; Toxic Use Reduction Specialist; Citizens for a Better Environment; 222 South Hamilton St., Madison, WI 53703. Phone: 608-251-2804.
Wever, Grace ; Vice President, Environmental Affairs,Council of Great Lakes Industries and Director and Liaison to the Council of Great Lakes Industries for Eastman Kodak Company; Eastman Kodak Company, 1999 Lake Ave, #3-83RL, Rochester, NY 14650- 2215. Phone: (716) 722-3348; FAX: (71 6) 722-6525.
The Cleveland Advanced Manufacturing Program would like to thank the following organizations for permission to reprint written documents found in this manual:
Man-Gill Chemical Company
United States Environmental Protection Agency
United States Powder Coating Institute
Waste Reduction Resource Center for the Southeast