Better = Sustainable
Faster = Lower energy consumption
Cheaper = More value for less cost
Market overview
Sales of UV-cured powder coatings are expected grow at least
three percent per year for the next three years, according to
Radtech’s February 2011, “Update UV/EB Market Estimates
Based on Market Survey.” UV-cured powder coatings contain no
volatile organic compounds. This environmental benefit is a significant reason for this expected growth rate.
Consumers are becoming ever more conscious of the health of
the environment. The cost of energy is influencing buying decisions, which are now based upon a calculus that includes sustainability, energy and total product life cycle costs. These buying
decisions have ramifications up and down supply chains and
channels and across industries and markets. Architects, designers,
material specifiers, purchasing agents and corporate managers
are actively seeking out products and materials that meet specific environmental requirements, whether they are mandated,
such as CARB (California Air Resources Board), or voluntary,
such as SFI (Sustainable Forest Initiative) or FSC (Forest Stewardship Council).
are not degraded or damaged because of UV-cured powder
coatings exceptionally low process temperature and fast processing speed.
UV powder coating technology
A typical UV-cured powder coating system requires about
2,050 square feet of plant floor. A solventborne finishing system of an equal line speed and density has a footprint in excess
of 16,000 square feet. Assuming an average lease cost of $6.50
per square foot per year, the estimated UV-cure system annual
lease cost is $13,300 and $104,000 for a solventborne finishing system. The annual savings is $90,700. The illustration in
Figure 1 is a graphic representation of the scale difference between the footprints of a UV-cured powder system and sol-vent-borne finishing system.
UV powder coating applications
Today, the desire for sustainable and innovative products is
greater than ever. This has driven many powder coating manufacturers to develop coatings for substrates never previously
powder coated. New product applications for low temperature
coatings and UV-cured powder are being developed. These finishing materials are being used on heat sensitive substrates such
as medium density fiberboard (MDF), plastics, composites and
preassembled parts.
UV-cured powder coating is a very durable coating, enabling
innovative design and finishing possibilities and can be used on
a vast array of substrates. One substrate commonly used with
UV-cured powder coating is MDF. MDF is a readily available bi-product of the wood industry. It is easy to machine, is durable
and used in a variety of furniture products at retail including
point of purchase displays and fixtures, work surfaces, healthcare and office furniture. UV-cured powder coating finish performance can exceed that of plastic and vinyl laminates, liquid
coatings and thermal powder coatings.
Many plastics can be finished with UV-cured powder coatings.
However, UV powder coating plastic does require a pretreatment
step to make an electrostatic conductive surface on plastic. To assure adhesion surface activation may also be required.
Pre-assembled components containing heat sensitive materials are being finished with UV-cured powder coatings. These
products contain a number of different parts and materials including plastic, rubber seals, electronic components, gaskets
and lubricating oils. These internal components and materials
Figure 1: Illustration for Typical Manufacturing Space for UV-Cured
Powder Coating vs. Solventborne Coating System
Parameters for Figure 1
• Part size– 9 square feet finished all sides ¾” thick stock
• Comparable line density and speed
• 3D part single pass finishing
• Finish film build
- UV powder – 2.0 to 3.0 mils dependent on substrate
- Solventborne paint – 1.0 mil dry film thickness
• Oven/Cure conditions
- UV powder – 1 minute melt, seconds UV cure
- Solventborne – 30 minutes at 264°F
• Illustration does not include substrate
www.coatingsworld.com
May 2011
