Paints and Coatings - P2 InfoHouse

Paints &Coatings 

Technological innovation in the 

paint industry has moved into 

high gear, bringing with it a 

complex array of new paints and 

sophisticated methods of applying 

them. In response to spiralling 

energy and feedstock &, and 

increasingly stringent pollution 

regulations, North American 

paint manufacturers and equip- 

ment euppliers have revamped 

their tools to coat better, faster, 

with less pollution and using less 

energy. 

Not only has operating effi- 

ciency improved, but in many 

t8888 operating caste have ddp- 

ped. Yet despite the abundance of 

commercially available low- 

polluting equipment options, 

widespread implementation of 

such low-waf3te technologies lags 

eeveral &pa behind. 

There can be no question that 

modernization iil my paintirqj 

facility will cost money. However, 

because many expenditures in 

pollution prevention will result in 

increased painting efficiency, such 

expenditures can be viewed as an 

investment that yields an 

economic return, rather than as 

just a drain of money. 

In many of the smaller busi- 

nesses, the company president 

may find himself repairing 

equipment and training stafF as 

well as drumming up business and 

keeping the accounts in order. 

Given the stresses of daily life in a 

small business, it is sometimes

128 Paints & Coatings 

difficult to take the time to assess 

the eflicjenqy of .the company's 

processes. It must be recognized 

however, that if a company is not 

maximizing its processing effi- 

ciency, the resultant waste can cut 

deeply into company profits. 

A fugt step in pollution preven- 

tion taken by any company, no 

matter how small, is to amem the 

overall efficiency of the existing 

procesees. This can be determined 

by comparing raw material inputs 

with product and waste outputs. If 

the quantity of product and known 

waste outputs do not match the 

material inputs, it indica& that 

some materials are escaping un- 

noticed from the company's opera- 

tion. This is particularly trouble- 

some in coatings operations which 

use solvenbbased paints and sol- 

vent degreasing systems. Because 

solventa evaporate readily at room 

temperature, a company may un- 

wittingly lose thousands of dollars 

worth of solvents to the atmos- 

phere each year. 

Many improvements in process 

efficiency are readily affordable by 

even small businesses. For exam- 

ple, induetrial painters employing 

conventional air atomized spray 

equipment would be surprised to 

realize that as little as 30% of the 

paint sprayed actually reaches the 

target Installing elec- 

trostatic spray equipment will 

more than double the efficiency of 

paint transfer, as well as save the 

company money through reduced 

paint costa and disposal charges.' 

In other instances, the capital 

cost of new equipment is beyond 

the financing capabilities of small 

business. In such instances, small 

businesses would benefit through 

well-placed tax breaks and 

technology transfer programmes. 

Improving the rate of paint 

transfer to the target object goes a 

long way in minimizing the 

amount of paint sludge requiring 

ultimate disposal. 

Another strategy to keep paint 

overspray out of the landfill site is 

to recycle it. Some paint for- 

mulators will recycle paint for 

their clients. For large and 

medium-sized companies, the 

economic pay-back is increased by 

recycling overspray directly on the 

premise^.^ 

-1 i r .--1: ...-- .,.:*I. 

environmental and health regula- 

tions in North America has 

triggered the paint industry to 

develop several non-solvent coat- 

ing systems. Water-borne paints 

that replace solvent-borne paints 

are doing 80 at a profit in many 

instances. Coating innovations 

such as powder coating and elec- 

trodipping virtually eliminate the 

production of paint sludge. UV- 

curable paints both eliminate sol- 

vents and significantly reduce 

energy mts. 

In the future, the paint industry 

may well have to grapple with two 

major challenges. One is to con- 

tinue to identify and substitute 

lesa hazardous constituents for 

many of the coating products cur- 

rently in widespread use. The 

second challenge is to lessen the 

dependence on petrochemical 

feedstocks and shift to a manufac- 

turing system based on renewable 

resources. In the meantime, the 

paint industry must be encour- 

aged and assisted to install exist- 

ing, commercially available 

equipment to minimize environ- 

mental pollution. 

Industry Profile 

The Canadian paint industry, 

also known as the coatings indus- 

try, includea paint manufacturing 

Table 1 

Types of Products Made by the Paint and 

Coatings lndusfry 

Architectural Coatings (applied on-site) 

lnterior water-he 

Exterior water-bome 

lnterior solvent-bome 

Exterior solvent-bome 

Architectural lacquers 

Industrial Coatings (factory applied) 

Automotive finishes 

Truck and bus finishes 

Other transportation finishes, e.g. aircraft, railroad 

Marine coabhgs, including off-shore structures 

Appliance finishes 

Wood furniture and fixture finishes 

Wood and composition board flat stock finishes 

Sheet, strip and coil coatings on metals 

Metal decorating, e.g. can, container and closure 

coatings 

Machinery and equipment finishes 

Metal furniture and fixture coatings 

Paper and paperboard coatings 

Insulating varnishes 

Magnet wire coatings 

Special Purpose Coatings 

lndustrial maintenance paints - interior, exterior 

Metallic paints, e .g. aluminum, zinc, bronze 

Traffic paints 

Automobile refinish coatings 

Machinery refinish coatings 

Marine refinish coatings 

Aerosol paints 

Roof coatings 

Multicolor paints 

- ___

,. 

and paint application. The terms 

pints and coatings are used inter- 

changeably in many cases. In the 

past, when paints were applied 

predominantly by brush or with a 

spray gun, the term paint was 

preferred. More recently, with the 

development of new coating 

methods such as electrodeposition 

and powder coating, the term 

coating is gaining wider usage. 

Statistics Canada identifies 150 

Canadian companies involved in 

the manufacture of paint in 1978; 

over half of which are located in 

Ontario.5 The industry is charac- 

terized by relatively small com- 

panies. Almost half the Canadian 

plants have fewer than 50 

employees, while 7% have more 

than 100 employee^.^ There is a 

tendency for paint formulating 

plants to be located in urban 

centres, close to consumers. 

The number of companies in- 

volved in the application of paint 

is more difficult to identify be- 

cause many paint operations are 

embedded in a larger manufactur- 

ing operation. Paint application 

operations are distinguished as 

architectural or industrial. The 

architectural category includes 

on-site painting of homes, offices 

and other buildings (see Table 1). 

Industrial amlication includes 

other vehicii, appliances, furni- 

ture, pre-coated building mate- 

rials, metals, packaging and 

machinery. By 1978, industrial 

consumption of paint had surpas- 

sed domestic uses.' 

Sources of Waste 

Paint Manufacture 

The manufacture of paints and 

coatings consists of mixing vari- 

ous raw materials in batch opera- 

tions. Raw materials include 

pigments, pigment extenders, 

solvents, resins or vehicles, and 

miscellaneous additives. The 

manufacture of pigments, solvents 

and other paint components is 

carried out by the chemical man- 

ufacturing industry, which is 

characterized by complex and 

large scale chemical synthesis 

processes. 

Because the formulation of 

paints is essentially a mixing and 

I 

~ 

Paints & Coatings 129 

Figure 1 

Total Wastes Generated by US. Paint 

Manufacturing Industry @on-aqueous 

metric tonnes per year) 

American researchers estimate that on/y 25% of the total wastes 

produced by paint formulators contain potential& hazardous compo- 

nents. furthermore, the hazardous constituents within the hazardous 

wastestream comprise only 0.2% of the total wastes produced by the 

industry. 

Source Assessment of lndustflal Hazardous Waste Practfcas, Paint and Allied Products Industry, Contract 

Solvent Reclaiming operatons. and Factory Apphcahon olCmhngs. U S Enwronmental Protection 

Agency, September 1978 

r 

~ ~ ~ 

Dry Weight 

68,000 

Total Solid and Hazardous Hazardous Total Toxic 

Semi-Solid Waste Waste Stream Solvents Chemical 

3 8 9 9 0 96,,ooo 74,250 Compounds 

840 

blending process, the major source 

of liquid waste resulb from 

equipment clean-out. Other major 

sources of waste include raw 

materials packaging, solids from 

air pollution control equipment 

and spoiled batches of finished 

product. Based on 1974 data, 

American researchers estimate 

that only 35% Gf ?he bb! Tasks 

produd by paint formulators 

contain potentially hazardous 

components? Furthermore, the 

potentially hazardous con- 

stituents within the wastestream 

comprise only 0.2% of the total 

wastes produced by the industry 

(see Figure 1). It becomes appa- 

rent that the most cost-effective 

way to manage the hazardous 

waste component is by keeping 

the potentially hazardous waste- 

stream as concentrated and sepa- 

rate as possible from other more 

innocuous wastestreams. 

Paints can be either solvent- 

-- 

based or water-based, and quip- 

ment clean-out procedures will 

vary accordingly. Paint plants 

clean solvent-based formulation 

tanks and equipment with solvent 

or with a hot caustic solution. 

Contaminated solvent is handled 

in different ways. It may be col- 

lected in drums for disposal or 

incineration. Some paint for- 

mulators reclaim the solvent on- 

site or send it to a professional 

solvent reclaimer for cleaning. In 

some establishments, a for- 

mulator will recycle used cleaning 

solvent as part of the formulation 

of the next paint batch. 

Water-based paint tanks are 

cleaned by washing with water or 

a caustic solution. The wastewater 

is collected in holding tanks and 

treated before discharge, dis- 

charged directly into a sewer or 

receiving stream, collected in 

drums and landfilled, re-used in 

the next paint batch or re-used in


the washing operation. 

It is estimated that 90% of the 

solid wastes produced by paint 

manufacturers consists of raw 

materials packaging, including 

paper bags, plastic containers and 

metal Although the con- 

tainers are innocuous in them- 

selves, they may contain an ounce 

or more of potentially hazardous 

pigments or other toxic substances 

that cling to the packaging. 

Paint formulators typically use 

pigments in powder form. Pigment 

dud trapped by fdter bags in plant 

ventilation system is a source of 

small amounts of potentially 

hazardow waste. Where such 

equipment was installed, 6 pounds 

of duetwere collected for every 

1000 gallons of paint produced.e 

The quantity of waste derived 

from spoiled batches, spills, out- 

of-date stock and other discarded 

products will vary from plant to 

plant. The quantity disposed is not 

usually related to production, but 

rather to housekeeping, produc- 

tion scheduling and the degree of 

axre wed by the ~perators.~ 

Paint Application 

One of the major sources of 

pollution during paint application 

is from solvent-borne paints, 

which typically contain 60 to 80% 

solvent by volume. As the paint 

dries, all of the solvent evaporates 

and becomes a potential air pollu- 

tion and health problem. The 

United States Environmental 

Protection Agency estimated in a 

recent study that 60.7 billion 

kilograms of volatile organic com- 

pounds are emitted annually from 

stationary source8 in the United 

States. The paint application in- 

dustry accounts for 10 to 16% of 

this total output.‘ only 1 to 296 of 

the solvent emistiions produd by 

the paint industry result from the 

paint manufacturing eector. The 

remaining 98 to99% is emitted at 

the point of application? 

Another signifkant murca of 

waste is from paint overspray, 

cleansut equipment and paint 

packaging which may yield waste 

solvents, pigments and other con- 

stituents. Paint formulatiom may 

include potentially hazardous 

constituenta such as xylene, to- 

luene, methylene chloride, cad- 

mium, lead, zinc, chromium and 

cobalt.8 

Health and Environmental 

Concerns 

The variety in paint colours and 

formulations seems endless. With 

more than 1500 pigments to 

choose &om? and an even greater 

number of solvents, resins, firn- 

gicides, and other additives to mix 

in, scientists are just scratching 

the surface in understanding the 

health effects of many of these 

compounds. The John Hopkins 

University School of Public 

Health (Baltimore, Maryland) and 

the International Brotherhood of 

Painters and Allied Trades 

(Washington, New York) are cur- 

rently investigating potential 

health hazards associated with 

coatings and solvents.9 

Because of the lag time between 

commercialization of a new paint 

formulation and verification of its 

health effects on paint applicators, 

potentially hazardous coatings 

may be in current use. Aa the 

hazard is identified and verified, 

the paint manufacturing industry 

responds by replacing a hazardous 

ingredient with a less hazardous 

chemical. Usually, however, many 

years elapae bebeen the entry of a 

new formulation to the market 

place and verification of ita nega- 

tive impact on people exposed to it. 

Many industrial paint facilities 

still use manually operated spray 

guns which atomize the paint into 

a veqy fine spray. By inhaling the 

fjne paint mist, the worker is 

doubly at risk because of inhala- 

tion of both solvent vapours and 

potentially toxic constituents in 

the paint itself. Painters exposed 

to solvent-based paints for long 

periods of time show symptoms of 

toxicity such as dizziness, 

headache, blurred vision slurred 

speech and impaired mem- 

OIy.10,11.12 

Solvents are of environmental 

concern because many of them are 

photochemically reactive, result- 

ing in smog formation. Regulatory 

pressure tn reduce solvent content 

in paint coupled with increasing 

solvent costs has accelerated the 

development and implementation 

of non-solvent coating systems.

Paint Manufacturing 

Two mqjor strategies to abate 

pollution in the formulation of 

paint are more exacting blending 

operations, and more efficient 

equipment clean-out procedures. 

The computer is emerging as a 

viable and cost-effective tool in 

assisting even smaller companies 

to blend new formulations with a 

minimum number of spoiled 

batches. 

1. 

Computer Assistance 

Unlike many other small 

businesses, the paint formulator 

keeps on hand hundreds of diffe- 

rent raw materials and inter- 

mediates required to mix custom- 

specified batches of paint. And, 

unlike other small businesses, 

finished product wastes due to, 

spoiled batches and colour mis- 

matches are much higher than for 

other manufacturing sectors 

wherequality control can be snore 

predictable. 

To assist in making a complex 

job simpler, incmwing numbers of 

Canadian paint manufacturers, 

from small to large, are installing 

computer capacity to enhance 

everything fi" colour matching, 

to controlling raw materials in- 

ventory. By taking the guesswork 

out of colour matching, a company 

not only reduces the quantity of 

spoiled batches that needs to be 

disposed, but also saves company 

time, money and raw materials. 

A computer can determine pig- 

ment volumes required in a new 

formulation, or can colour match 

to an existing shade. And, for 

those pigments identified to be 

potentially toxic and threatened 

by regulation, a computer can 

select a suitable pigment replace- 

ment. By programming in pig- 

ment mat, the computer can come 

up with the cheapest pigment 

combination while maintaining 

product quality. 

A computer can optimize 

scheduling of production sequ- 

ences so aa to minimize equipment 

clean-out needs. A computer can 

also assist in reworking a spoiled 

batch into something marketable 

by recording its composition and 

indicating what ingredients need 

to be added to make it saleable. 

Because the computer can be pro- 

grammed to keep track of the raw 

materials and finished goods in- 

ventory, it can reduce the fre- 

quency of having to dispose of 

oubof-date warehouse stock. The 

increased efficiency in formulat- 

ing pain@ means that a company 

can reduce its stock of raw mate- 

riais and finished goods, a proposi- 

tion welcomed particularly by 

smaller operations. 

Some medium-sized fume such 

as Kelcoatings (London, Ontario) 

have been using computers for 

formulation and batch costing for 

some time. others, including XYZ 

Paints (Cambridge, Ontario) are 

planning major investments in 

computer ~apability.'~ 

For large companies such as 

C-I-L Paints (Toronto, Ontario) 

and Sico Inc. (Montreal, Quebec), 

computers are invaluable in both 

the lab and accounting 0fi~e.l~ 

Keeping track of raw materials 

and price data on a daily basis, as 

well as optimizing production 

scheduling, is just one more way to 

survive in a competitive market 

while minimizing pollution. 

2. 

Equipment Clean-Out 

Many of the smaller paint 

plants still clean portable mixing 

tanks and paint drums by hand 

with strong sol~ents.'~ Use of 

solvents is not only potentially 

hazardous to worker health, but is 

costly a~ well. 

From both an economic and 

safety perspective, it is more de- 

sirable to use a high pm-essure 

alkali cleaning system than sol- 

vents. Although a number of 

commercial systems are available, 

an adequate system can be instal- 

led by plant maintenance person- 

nel without too much expense, 

according to Alun Morris of the 

L. V. Lomas Chemical Company 

(Toronto, Ontario)." Before 

cleaning the mixing tank, as much 

wet paint should be removed as 

possible to minimize contamina- 

tion of the washing solution. Wet 

paint clinging to the container 

wallsduringpainttranefercanbe 

wiped free using a rubber 

squeegee. 

Caustic cleaning sblution is 

&red and heated ina special tank 

(see Figure 2). The hot caustic 

solution is pumped under lnwsure 

to the tank to be cleaned. A 

rotating jet or spray nozzle syatem 

shoots cleaning solution against 

the walls, top and bottom of the 

mixing tank. When the cleaning 

operation is complete, the dirty 

caustic solution is fdtered through 

n 8t;raining *dt d returned to 

the storage tank for re-uae.14 The 

paint mixing tank is then rinsed 

with hot water. 

The system can be modifred to 

wash 5-gallon pails and 45-gallon 

drum by inverting them over a 

spray nozzle. By installing an air 

micro-switch that would open an 

air-operated valve only once the 

container is inverted over the 

spray nozzle, operator safety is 

enhanced. A drain pan located 

beneath the cleaning area collects 

waste cleaning solution for re- 

u6e.14 

Although alkali cleaning solu- 

tions do not Dre.qPnt the gama


chronic and cumulative threats to 

health as solvents, their caustic 

nature dictates use of proper 

safety equipment mch as goggles, 

face masks and protective cloth- 

ing. 

Industry spokesmen suggest 

that caustic cleaning solution is 

recycled among many of those 

plants that use this cleaning 

method. Waste rinsewater, on the 

other hand, is typically sewered. 

Some paint formulators success- 

fully muse waste rinsewater in 

the production of water-based 

paints without impairing paint 

quality.! Such water recycling 

applications are rare. 

H Accordrng to a study of the 

United States paint mandactur- 

ing industry by Burns and Roe 

Industrial Services Corp. 

(Paramus, New Jersey), if the 

s00,OOO gallons of wastewater 

produced daily by the entire paint 

mandacturing industry in the 

United Stah were treated by 

conventional chemical precipita- 

tion and settling, it would yield a 

sludge volume of 120,OOO gallons 

per day.I5 

On the other hand, if8096 of the 

wastewater generated is recycled 

industry-wide, this would shrink 

the total wastestream to 160,000 

gallons per day.15 This assumes 

that 20% of the total wastewater 

volume would be incompatible for 

reuse because of colour and for- 

mulation restrictions. 

Recycling wastewater is antici- 

pated to be the cheapest treatment 

option because it greatly reduces 

the volume of wastewater requir- 

ing costly chemical precipitation 

and sludge disposing procedures. 

Flgure 2 

Caustic Recycling During Equipment 

Clean-Out 

Hot caustic cleaning solutlon Is pumped under pressure to the tank to be 

cleaned, where a spray system shoots the cleaning solution against the 

walls of the mixlng tank. When the cleaning operation is complete, the 

dirty caustic solutlon Is flitamd and mtumed to the storage tank for 

"e. 

Sou~:"ATankCleanlngSystemforthe Small Pain!Piant,"Joumddcodnga Tecdmibgy, September 1979. 

II fr \\ 

II II 

Paint Application 

It has been decades since in- 

dustrial painters foresook the 

paint brush for more modern 

methods such as spray painting. 

Although the development of the 

spray gun did much to escalate 

productivity and enhance the 

quality of painted finishes, it also 

unleashed a Pandora's box of prob- 

lems. In addition to potential 

health hazards posed by inhala- 

tion of atomized paint, the ques- 

tion of what to do with the millions 

of gallons of paint siudge gener- 

ated annually continues to plague 

the paint industry. 

By spraying paint onto an ob 

ject, as little as 30% of the spray 

reaches the target object. The rest, 

known as overspray, commonly 

ends up in a barrel at a landfill 

site. This dilemma has the indus- 

try pursuing several strategies to 

minimize the quantity of waste 

paint requiring disposal. The 

major thrust is in improving the 

efficiency of paint application. 

Another strategy is to maximize 

the re-use of paint overspray and 

wastewater. 

, 

A third direction is to substitute 

less hazardous materials, namely 

to reduce or eliminate the solvent 

component of paints. It must be 

recognwd, however, that some of 

the non-solvent coating systems 

contain potentially hazardous 

components such as isocyanates 

which are considered to be of even 

greater hazard than conventional 

solvent-borne systems.16.17 Re- 

search into substitution of less 

hazardous pigments and other 

cuiiyiitilents is atill in its infancy, 

but can be expected to accelerate 

as health hazards associated with 

existing components are iden- 

tified. 

Although technological innova- 

tion in the paint industry has come 

a long way, it still has some way to 

go. In the meantime, however, 

pollution reduction and company 

profits can be maximized by im- 

plementing some of the proven 

technologies now commercially 

available. 

One thing is clear. Unlike the 

1940s and 1950s when solvent- 

borne alkyd resins ruled supreme,

1 . 

no single coating type will capture 

the entire coatings market. In an 

age of cost cutting and greater 

environmental awareness, in- 

dustrial finishers will have to 

make their selections in terms of 

end-use requirements and condi- 

tions specific to their own opera- 

tions.*8 

1. 

New Coating Types 

Paintmakers are tackling the 

solvent problem by formulating 

coatings with substantially leas or 

no volatile organic solvents. Low 

solvent and solventrfree paint systems 

include high-solids emulsion 

paints, twepart catalyzed systems 

that convert fully to film, 

and solution types made of 

pre-polymers, co-solvents and 

water l9V2O (see 

Figure 3). 

Conventional paints are com- 

posed of three basic components: a 

film-forming binder consisting of 

resins or drying oils; a volatile 

organic solvent or water to main- 

tain fluidity; and a pigment sys- 

tem containing colouring, opacify- 

ing materials and various exten- 

ders. Conventional solvent-borne 

paints contain 60 to 80% volatile 

organic so1vents.Xl 

Water-Borne Coatings 

Water-borne paints contain 

substantial amounts of water, 

with up to 80% of the volatiles 

being water.22 The polymers used 

can be dissolved, dispersed or 

emulsified. 

By 1977, Canadian sales of 

water-based paints exceeded those 

of oil-based paints (see Figure 4). 

Prior to 1977, solvent-borne paints 

were the predominant coating 

type- 

Water-borne industrial coatings 

consist of alkyd, polyester, vinyl 

acetate, acrylic and epoxy vehi- 

cles. Water-borne coatings are 

supplied as baking finishes as well 

as air-dry formulations. No major 

equipment changes are necessary 

to apply water-borne rather than 

solventcborne coatings for most 

paint application methods. Elec- 

trostatic spray equipment, how- 

ever, must be modified to handle 

water-based paints.16 

Figure 3 

Organic Solvent Emissions from Various Coating Types 


Some car manufacturers are 

particularly advanced in their use 

of water-borne coatings for engine 

application and prime coating 

where traditionally a solvent- 

borne coating was used. One of 

General Motor's California plants 

has a water-borne coating system 

in full operation.16 Similarly, the 

General Motor's plant in Oshawa 

(Ontario) uses electrodeposition to 

apply a water-borne coating. 

N Unlike conventional solvent 

systems in which overspray is 

difficult to collect for recycling, 

water-borne coatings can be rem 

vered and re-used. Overspray from 

a water-borne coating goes into 

solution in the water wash curtain 

in the spray booth. The solution 

can then be concentrated to the 

point where it is a paint again, and 

can be reused. Although not in 

commercial use yet, one major 

auto manuhcturer is designing a 

spray booth to recover water- 

borne paint overspray and re-use 

it.16 

N The Caterpillar Tractor Com- 

pany's new enginepainting facil- 

ity (Mossville, Illinois) minimizes 

air pollution and conserves ener- 

gy.= The use of water-borne coat- 

In recent years, regulatory pressure has been placed on the coatings manufacturer to reduce the organic solvent 

content in new paint formulations. This has resulted in coatings which are much higher in solids content. 

Sources: Coatings Industry IntroducHOn lo Air Ouality, Canadian Paint and Coatings Assodation. 1981. 

Contrdling Pdlutibn hvm the Manulecturing and Coathg of Metal Products, US. Environmental Protection Agency, 1977. 

"How to Figure Potential EmisMon Reductions for HighSolids Coatings."lndustriel Finishing, November 1979. 

85% 

15% 

70X 

30% 

45% 40% 

Acrylic 

Lacquers 

Baking 

Enamels 

High 

Solids 

Water- 

Borne 

Water- 

Borne 

Eiectro - 

Deposition 

Powder 

Coatings 

Enamels spray 


1 1 

10% 

50% 

5% 

95% 

100%

134 Paints & Coafings 

~~ ~ 

Figure 4 

Shift in Canadian Paint Production 

(in millions of gallons) 

Prior to 1977, sotvent-borne paints were the predominant coating type. 

8y 1977, S8kS Of W8fer-b8sed paints exceeded tho- Of oil-besed 

- 

p8infS. 

Source: "lndwby Statistics: Real Growth Lags But Paint Dollar Value Continues to Rise,"Coebngs Magazine. 

MarchIApril 1961. 

1975 1978 

Water-Based Coatlngs 

inga holds down air pollution 

i while a low-temperature drying 

? oven saves energy. Unlike 

. eolvent-based systems, the hot air 

! 

i 

in the drying oven used to cure 

water-borne paints can be recircu- 

lated, keeping heating costs down. 

Other advantages of the water- 

borne painting operation are re- 

ducedfuehazards24andinsurance 

costs. 

High Solids Coatings 

High solids coatings can actu- 

ally deliver more than double the 

usual amount of paint compared to 

conventional low solids or water- 

borne paints.= 

The resins used in many coab 

ings are not suitable for one 

component high solids coatings 

because as the resin solids are 

increased, the finish becomes very 

viscous, making application dif- 

ficult. To achieve the required 

viscosity, the resin is kept dis- 

persed as discrete particles. 

Known as non-aqueous disper- 

sions, these coatings achieve a 30 

to 60% solids content.2O 

14.5 

million 

gallons 

1975 

r 

12 

million 

gallons 

1978 

Solvent-Borne Coatings 

Two Component Catalyzed 


Catalyzed polyurethane coat- 

ings contain 80% or more solids by 

volume. They are two component 

systems produced by the reaction 

of isocyanates and hydroxyl com- 

pounds, and as such need no 

organic solvent; The automotive 

indmtry has been exploring the 

use of polyurethane to replace 

solvenbborne acrylic lacquers and 

enamels used for topcoating. But 

isocyanates represent highly toxic 

materials which would require the 

industry to install costly and com- 

plex robots to spray aut~s.8 

Radiation-Curable Coatings 

Radiation-curable coatings con- 

tain no organic solvents and are 

10096 solids! Reactive monomers 

are applied to a surface which is 

then subjected to high-energy 

radiation such as ultraviolet (W) 

light. Radiation-curable coatings 

now command about 12 to 15% of 

the curable coatings market, and 

are expected to capture 20% by 

1985 as equipment and formula- 

tions improve.8 

H In the W curingprocess, special 

phohinitiators such as thioxanthones, 

acetophenone derivatives 

and benzoin ethers are activated 

by photons to provide free radicals 

for the polymerization reactions. 

In the electron beam (EB) process, 

a thin coating is applied to a 

substrate and heated by a stream 

of electrons which polymerizes the 

coating instantly. 

The infrared (IR) system is 

based on a thermal cure process, 

unlike the W and EB systems in 

which the curing is based on a 

photochemical reaction. Electrical 

consumption for IR is high, 20 to 

50 times higher than for EB, and 

10 to 20 times higher than used for 

UV system^.^ The advantage of 

using the IR process is its ability to 

cure thermally-sensitive coatings 

and difficult shapes. 

H Degussa Ltd. (Burlington, Ontario) 

has developed a painting 

system that eliminates the need 

for an organic solvent. The new 

technology involves a liquid prepolymer 

and mixture of reactive 

thinners (acrylates) that are 

cross-linked by radiating with W 

lightT5 Unlike conventional solvent 

systems, the "solvent" in the 

Degussa system does not evaporate 

but rather becomes part of the 

surface coating. This solventless 

coating technology is well-suited 

for painting steel, chipboard, 

laminates, mdboard and polystyrene.% 

Powder Coatings 

Powder coatings are 100% sol- 

ids, frequently composed of hybrid 

polyester epoxy or polyurethane 

powderTO The powder is sprayed 

on to the target object and baked at 

high temperatures to fuse the 

individual particles to form a 

continuous film. Resultant coat- 

ings can be very hard and resis- 

tant to corrosion. Because the 

powder does not set until it is 

baked, it is possible to recycle 

virtually all the overspray. 

2. 

Increasing Paint 

Transfer Efficiency 

Paint transfer efficiency refers 

to the percentage of paint applied

that actuaily reaches the target 

object.*'' Paint transfer efficiencies 

for different application methods 

are listed in Table 2. 

Spray Painting 

Conventional Air-Atomized Spray 

Painting 

At present, a ir-atod spray 

painting is still the most wide- 

spread coating technique. A jet of 

compressed air impinges on the 

paint stream which subsequently 

atomizes the paint and propels it 

forward (see Figure 5). In its 

simplest form, an operator manu- 

ally directs a hand-held gun. Au- 

tomatic units are available in 

which the fxed gun is turned on 

and off as an object moves au- 

tomatically in front of the paint 

spray. 

Conventional spray painting 

using the air-atomized method has 

the lowest transfer efficiency of 

any of the coating methods cur- 

rently available. Typically only 30 

to 50% of the paint reaches the 

target.27 The other 60 to 70% of the 

spray is collected as overspray and 

incinerated or lanNilled. 

PressuwAtomkd Spray Painting 

In airless spray painting, paint 

is forced through the nozzle at a 

high enough pressure to propel the 

paint spray forward (see Figure 6). 

Such a system is an improvement 

over air-atomized painting because 

65 to 70% of the spray 

reaches the 

Electrostatic Spray Painting 

In electrostatic spray painting, 

the object to be painted is 

grounded. "he gun nozzle is given 

the opposite charge, thereby 

charging the atomized paht as it 

leaves the gun. Because the 

charged paint particles are at- 

tracted to the opposite charge on 

the object being painted, over- 

spray is greatly reduced (see Fi- 

gure 7). In air-atomized electro- 

static coating, 70 to 85% of the 

paint reaches the target. For 

pressure-atomized electrostatic 

coating, 85 to 90% of the paint 

coats the object.*' 

Users of electrostatic equipment 

point to the high quality and 

uniform coverage of this painting 

method. Where paint is deposited 

on the surface of the object, the 

charge in that area is reduced and 

ultimately changed to the charge 

of the gun. This repels additional 

paint which instead is attracted to 

areas not adequately covered. 

The W.C. Walberg Company 

(Downers Grove, Illinois) provide 

manual and hand-held electrosta- 

tic spray paint equipment that 

cuts paint consumption by at least 

50% over conventional systems. 

After 30 years in the business, 

Walberg says, 'Most firms resist 

spending money to solve pollution 

Table 2 

Expected Transfer Efficiency of Various 

Painting Methods 

Painting Method 

Transfer 

Efficiency 

Air-atomized, conventional 30 to 60% 

Air-atomized, electrostatic 65 to 85% 

Pressure-atomized, conventional 65 to 70% 

Centrifugally-atomized, electrostatic 85 to 95% 

Rdl coating 90 to 98% 

Electrwating 90 to 99% 

Powder coating 90 to 99% 

Source: Calculellons d Painting Wasteloads Associated wlttr Metal Finishing. U.S. E.P.A.. 

June 1980. 

Figure 5 

Air-Atomized Spray Painting 

A jet of comprerwed 8if impinges on the pint stream which subsequently 

stomhes the paint and propels it fonuard. 

Source Cakulatk)ns d W ng Wastdoeds Assocleted wlttr Metd Hnishlng, US. Environmental Protection 

Agency, June 1980. 

. a 0 '. 0 

a : e . 

overspray

136 Peints & CoaUngs 

Figure 6 

Pressure Atomized Spray Painting 

In a/r/ess spray painting, paint is fotced through the nozzle at high 

enough pressure to prop/ the paint forward. 

Soume: Calculalkms of PahUng Wasteloads Asdated wilt, Metal Fldshhg, US. Environmental Rotecticm 


Figure 7 

Electrostatic Spray Painting 

. . : 

a 

.. ’.. .* ::. 

The obwt to be painted 1s grounded and the paint is given the opposite 

charge. Overspray is greatly reduced because the paint is attracted to the 

opposite charge on the object being painted. 

Source: ca/cu/at&m dPclhUnp Wasteloads Associated with Metal FmhMng, U S Enwronmental Protwbon 

Agency.Junel980. 

high 

... 9.. . 

.. - .. . . 5 

.. 

ground 

Automatlc electmstatic spray system. 

A dmph piupin connecthm brings 

high voitage to the gun for high-solids 

or other hlgh resistance paints. 

Watsrrbome paints rsquire no dlrect 

high voltage connection to the gun 

dnce it k applied directly to the fiuM 

suppry system. 

problems but do not hesitate to 

spend money if they can recover 

the investment in a short period of 

time. We don’t sell a system unless 

the pay-back period is less than two 

years.” 

According to Walberg, the pla& 

tics and wood industries are still 

spraying with conventional spray 

equipment. Non-conductive items 

such as wood and plastic can be 

sprayed electrostatically if con- 

ductive water-bome coatings me 

used. But this would necessitate a 

shift away from conventional 

solvent-borne paints, a shift the 

industry has been reluctant to 

make. 

B Flexsteel Industries (Dubuque, 

Iowa) changed from a conven- 

tional air spray to an electrostatic 

finishing system at its furniture 

plant.= In doing so, the company 

reduced overspray by 40% and 

saved itself $15,000 a year in new 

paint costs. Pay-back for the Binks 

(Chicago, Illinois) manual elec- 

trostatic equipment is estimated 

at less than two vear~.*~

M:inuf~ictirrrrs of’ cbl(~ct t-ostat ic 

s;pr;iy guns vary in thc nicthods 

ustd to ;itoniizc. ;ind direct t h ~ 

spr:iy. In oti(1 cqitipnicwt typb. t tic. 

rcwtrifiig:;il filrc(. ofii r;iptdl.v rotiit- 

ing lwli niows thc- p;iint to thct 

open rnti whc~c~ it p;issw through 

;in clcct roskit ic fi~ld and i*~tiw-g(~s 

;IS ii chiirgd, atomized spr:iy. 

(’vntrifugiil ;itomiz:itioti tias tIi(1 

t i i g ti c s t t ra n s fit r c1 f‘fi c i P n cy (1 I’ 

corilI~iercii\l spray paint cq ti i p- 

mcnt, achieving eficicwcios of up 

to 95!‘4 triinsfi.r.2”‘ 

Anothw varitition of clectrostii- 

tic spray equipment is the spin- 

ning disc typc. Spinning disc type 

~1cctrost;itic spray units ofGr sov- 

wit adviint;igcs ovw ;i i r a torn izcd 

sprily guns, particu1;irly in trans- 

forri ng dif~cult-to-disperse high 

~ol ids pili tits. Atomimtion with 

specd :is occurs in spinning disc 

units brcaks thc p;iint particlcs 

down finor than :iir-atoniixlition. 

iind iilso directs mor(’ piiint 

onto tho tarcibt objcct.’7 

, High-spwd electrostatic bclls 

md discs arc~currently the leading 

cdge of spray paint technoloky, 

especially where high solids coatings 

are involved. De Vilbiss 

(Chicago, Illinois) make an ultra 

high-speed rotary atomizer (c1lectrostatir 

hell) that can handlc 

water-borne and two-component 

coatings as well as high solidS 

coati rigs.:"' The Turbod i sklH (el ectrostat 

ic disc manufactured by 

Ransburg (Cooksville, Ontario) is 

well suited to handle high solids 

paints and wa ter-borne coatings. 

For those companies shifting from 

solvent-borne paints to high sol ids 

paints, Ransburg make a unit that 

can be retrofitted onto existing 

disc systems for improved atomization 

of the more viscous high 

solids coatings.:”’ 

Electrostatic hand gun system. 

Ultra-high-speed rotational atomizer. 

arrestors require daily changing.:” 

At a 1981 cost of $1 per 

filter, an industrial painting company 

can expect to spend $3000 

per year just to change fi Itc5r.s on a 

IO-foot-wide spray booth. At that 

riite, ;I company could p;~y 

for :I 

soph isticwtcd wator w:isti spr:iy 

I)ooth within ttirec. vwrs on tht. 

filtw savings alone.:” 

Sonitr ~(llf-winding f;it)ric filtcnrs 

tr;tp paint piirticl(>~ 

so c!fiicic!ntly 

;is to ptrrmit. rc.c*ircuIation of’H0‘d of’ 

the. uir within tht. sp~iv hooth. 13.y 

1 


Two rotary atomizers electrostatically 

apply a liquid coating to compressor 

tanks. 

recirculating plant air, costs of 

heating the plant are significantly 

reduced during winter months.’ 

Another product ava ila hle to 

collect overspr;iy involves coil ti iig 

the inner surfiiccs of the spray 

booth. When ;I layor or‘wastch paint 

tias ;iccu rnu 1;itcd on thc. co;i t.i i~g, 

the coating is poc.Icd of’f’along with 

thc. waste paint and rcplaccd with 

:I now co;iting. Paint ovcrspr.:iv 

eolloctcd in t,his iiiitniic1r is riot 

:irnon;it)lc. to rtyvcl ing, and t(*rids 

to hi disc:irdcd at ;i Iiindf’iII sit(,.

I 

I 

138 Paints & Coatlngs 

One promising paint arrestor is 

the water wash type in which a 

curtain of water cascades over a 

aeries of baffles (me Figure 8). 

Stray paint impinges on the water 

curtain and drains to a paint 

separator. The paint and water 

mixture is then separated 80 that 

the cldied water can be reused. 

Ultra6lt Inc. (Troy, Michigan) 

manufacture a waterlsludge 

separator which recirculates the 

collection water for re-w.32 According 

to Waste Technology Inc., 

designers of the UltrafW@ unit, it 

is just a question of time before the 

same range of waterlaludge 

ae&trabra becomea available to 

the small operators that is now 

available to the larger compani*.= 

At'the Oshkosh Truck Corporation 

(Oshkwh, Wisconsin) heavy 

specialty trucks are =&led 

and spray painted. Paint-laden air 

&om the giant spray booth is 

purified by water swirling 

through 14inch Venturi tubes. 

Water drainsf" eachtube to a 

hge holding tank. The water is 

then circulatkd through two electrostatic 

water treaters which 

make the overspray paint float for 

easy removal by skimming. Because 

the water is kept clean 

enough to be drained without 

additional treatment, the 

oshkosh Truck Company benefits 

financially by avoiding additional 

capital investment in a wastewater 

treatment facility.34 

Roll Coating 

Roll coating, also known as coil 

coating, is a process in which the 

coating is applied to a roller and 

transferred to the object by rolling 

contact, thereby limiting its appli- 

cation to flat or flexible surfaces 

(see Figure 9). Roll coating can 

apply paint to one side only, or 

both sides simultaneously. 

Roll coating requires the use of 

high viscosity paints, and as such 

contains few or no organic sol- 

vents. Transfer efficiencies are 

very high, ranging from 90 to 

98% 

Hunter Douglas of Canada Ltd. 

(Montreal, Quebec) manufacturea 

and finishes aluminum siding for 

homes and oEce buildings. Pollu- 

tion is kept to a minimum by using 

Paint arrestor spray booth.catchea and retains overspray In armator type filters. 

EIectrostatic spray operation using water wash spray booth to catch and retain 

overspray. 

water-borne rather than solvent- 

borne paints in 85% of its coil 

coating operations. According to 

company management, the 

water-based coatings have superior 

performance to most of the 

solvent-based types. 

In addition, Hunter Douglas has 

recently installed a new pretreat- 

ment system to eliminate emuent 

problems during pretreatment. 

The new pretreatment is a 

chrome-phosphate type which is 

dried in place in an infrared oven, 

thereby eliminating the need for 

an acidified rinse and treatment of 

associated waste rin~ewater.~~ 

Electrocoating 

Electrocoating, also known as 

electrodeposition, is a dip method 

for applying a water-borne coating 

to metal by electrically mgulat-

* . Paints & Coatings 739 

Manual “non-electrostetlc” operation using water wash spray booth and gas 

convection drying oven. 

ing paint solids onto the surface to 

be coated.lG The operation more , 

closely resembles the electroplat- 

ing of metal than it does painting, 

and is applicable to coating long 

runs of objects. 

The paint resin and pigment, 

which is dissolved or suspended in 

water, is given a charge. An 

electrical current is passed 

through the bath, causing the 

charged paint particles to migrate 

by a process known as elec- 

trophoresis towards the surface to 

be coated. The coating coagulates 

on the surface to be coated, and 

much of the water is squeezed out 

by a phenomenon known as 

electro-osmosis. 

The coated object emerges from 

the paint booth with a tightly 

adhered, slightly tacky coating. 

After a water rinse to remove 

excess coating, the object under- 

goes heat curing in a conventional 

drying oven.27 

Electrocoating can be 90 to 99% 

efficient in paint usage. Although 

electrocoating paint formulations 

may cost 10 to 25% more than 

conventional coatings, elec- 

trocoating can save money be- 

cause of its excellent ability to 

cover and penetrate into 

corrosion-sensitive areas. A single 

electrocoat layer may substitute 

for a conventional two-coat sys- 

tem.16 

.The electrocoatingsystem’s high 

transfer efficiency is due in part to 

closed-loop rinsing (see Figure 10). 

a considerable amount ofenergy 

and money is saved. As solvent 

costs continue to soar, the 

economics of water-borne systems 

such as electrocoating look more 

attractive every day. 

UltrafilP Suspended Sludge Separator. The flbreglass separator tank 

is positioned on an 8 x 10 foot elevated platform. Sludge pump and 

sludge hopper are located below the platform. 

The paint sludge enters the middle section where “doctor“ blades on 

variable speed skimmer sweep sludge out of the water into the hopper 

below.

740 Palnts & Coatlngs 

Figure 8 

Water Bath Paint Arrestor in Spray Booth 

Spray palnt lmplngeti on a curtaln of water- cascades created by water falling over a serles of baffles. The paint 

and water mMum can be separated, penn/tt/ng IY)-USB of the water. 

Source: Cda1/8f/o~ ol Pslnthg Wastelosde Awockrted MUI Metal FMhg, U.S. EnviroMlental ProtecuOn Agency, June 1980. 

4 .... 

: . 

.;:*. . .e 

.'j '. . . ',. .. . .'.. 

exhaust 

alr 

waste 

-1 water 

Figure 9 

Furniture makers can both 

Roll Coating 

reduce pollution and increase productivity 

by switching to elec- 

The palnt is applied to 

. 

a roller and transferred to the object by rolling trodeposition coating techniques. 

contact. Roll coating can apply palnt to one side only, or both sides La-%Boy (Dayton, Tennessee) has 

simultaneously. 

raised ita production of metal sofa 

Source: Cakulabbns of Painffng Wasteloads Associated wfth Metd Flnrshlng. U.S. Environmental Protection bed mechanisms eight-fold since 

Agency. June 1980. 

installing an electrodeposition 

paint line. Increasing productivity 

has meant a savings in labour and 

maintenance costs.37 

Sputtercoating 

Sputtercoating is a process where 

a thin metallic deposit is 

sandwiched between two organic 

coatings to give an object a metallic 

appearance (see Figure 11). The 

sputtercoating process most 

closely resembles a spray paint 

n- \ / R 

operation, however the finished 

product resembles an object that 

has been electroplated. Metals 

pw.lbd palnt that are applied by sputtering 

include chromium, silver, gold, 

. * 

w

- 1 

Figure 10 

The Electrocoating Process 

Electrocoatlng can be 90 to 99%effklent In paint usage. The high transfer 

effklemy Is due In part to closed-loop rinsing. Loose paint particles In the 

rinsewater can be recycled back to the coating tank. 

source: cakulations d Paintina Wastebads Associated with Metal Finishing. U.S. Environmental Protection 

" 


rinse rinse rinse 

Cheln On Edge co8tlng pm 

tem producer thin (approx.- 500 duccw base or topcoat over irwular 

angstrom) mete1 film on furn/fure shapes. 

corner. 

Linear Pass reciprocating spray system 

Produces base or topcoat at 5-15 

feetlminute. 

Ultraviolet Curing Station Is capable of 

fully curing topcoat In seconds. 

Paints & CoaUngs 741 

brass, bronze, aluminum, copper, 

stainless steel and rhodium. 

According to Robert Rainey, 

operations manager at Varian's 

Advanced Industrial Coating Op- 

eration (Florence, Kentucky), 

sputtering is a physical phenome 

non that was discovered in the 

1880s as a failure mode in high- 

voltage vacuum tubes. The metal 

from the cathode of the tube would 

"sputter" away and end up as a 

build-up on the glass enclosure.38 

"It wasn't until the mid-19OOs 

that thisproblem was converted to 

a useful tool for the formation of 

thin films," says Rainey.= 

Until the 19706, sputtering 

technology application was ham- 

pered by the slow rate at which the 

metal layer could be deposited. 

Since then, the development of 

high-rate magnetron sputkring 

sourceshasincreasedmetaldepos- 

ition rates 30-fold to a level com- 

patible with rapid production 

needs.% 

The resulting metal layer is 

very thin, typically ranging from 

500 to 1000 angstroms in thick- 

ness. Because thin coatings reduce 

the quantity of metal used, pro- 

duction & are shaved accord- 

ingly. In addition, sputtering con- 

sumes only one-third of the energy 

required in conventional electro- 

plating? 

The base coat, the first layer to 

be applied, functions to level and 

seal the substrate as well as 

Figure 77 

Structure of a 

Spuff ercoat 

The sputtercoat Is composed of 

an organic base coat, a very thin 

metal /ayw and an organk fop 

coat which functions to protect 

the metal layer. 

Source: "Sputtercoating A Produdion Reakty." 

PlatlngandSurfecaFinishmg. &dl 1981 

-1 

top coat 

0.5-1.0 MIL 

metal 

500-1000 A" 

base coat 

0.51 .O MIL 

I 

substrate 

I 

I

142 Paints i3 Coatings 

improve the adhesion of the metal- 

lic layer. Frequently, the base coat 

is 100% solids UV-curable paint 

that is spray-applied. Conven- 

tional solvent-based paints are 

used only if required by the pro- 

duct specifications. UV-curable 

paints offer an advantage over the 

more conventional air-dry or 

bake-dry paints in that they sig- 

nificantly reduce energy require- 

ments. 

Depending on the product 

specifications, the top coat may 

vary from solvent-borne 

urethanes to UV-curables. Rainey 

concedes that problems still exist 

with UV-curable topcoats in view 

of their poor adhesion to the metal 

film. Improving the performance 

standards of low-polluting top 

coats is just one of the challenges 

that Varian Associates hopes to 

solve in the coming decade. 

Varian’s Florence plant, which 

opened late in 1980, will apply a 

metallic finish using the sputter- 

coating technique to appliances, 

furniture and plumbing compo- 

nents fabricated of plastic. The 

types of plastic to be coated at the 

new plant will centre mainly on 

acrylonitrile-butadiene-styrene 

(ABS) plastics and some poly- 

propylene plastics. Varian As- 

sociates has demonstrated that 

other sputterable plastics include 

polystyrene, nylon, phenylene- 

oxide-based resin, polycarbonate, 

acrylic, thermoplastic, acetal and 

p~lyurethane.~~ 

According to Rainey, sputter- 

coating economics might not be as 

good today as more conventional 

painting methods, but it is gener- 

ally competitive with electroplat- 

ing. Unlike electroplating which 

is a proven technology, sputter- 

coating is a newcomer to the 

finishing world. 

Rainey speculates that in five 

years, sputtercoating will be two 

times cheaper than electro- 

plating.39 Unlike electroplating, 

which requires complex and costly 

pretreatment steps to prepare 

the substrate for plating, the 

sputtercoating process is 

relatively simple. 

Powder Coating 

In the powder coating process, 

specially formulated fusible paint 

Small parts in the load zone, background is the spray booth and far right hand side 

background Is the oven. 

Cabinets - upside down on the conveyor at the unload zone. 

powder is applied to the object to 

be coated and fused to its surface 

by heat curing in an oven. At most 

modem installations, powder is 

applied by an electrostatic spray 

method to keep the powder on the 

surface of the target object until it 

can be fused. Because powder 

coatings are 10Wo solids, they 

,. 

present no solvent emission prob- 

lems during curing. Another sig- 

nificant low-pollution aspect of 

powder coatings is that they are 

easily recycled. Operating costs 

are lower than for conventional 

liquid paint lines because of re- 

duced material, labour and energy 

req~irements.~~

I 

I 

Moyer Diebel (Jordan, Ontario) 

has recently upgraded the small 

paint line at its vending machine 

manufacturing plant. In a spirit of 

modernization, Moyer Diebel 

chose an automated powder coat- 

ing operation. 

“We were very hesitant when 

we first considered going to pow- 

der because it represented some- 

thing of a leading edge technology. 

Being on the leading edge is not a 

very comfortable position tobe in,” 

says George Perdue, vice presi- 

dent of manufacturing. 

According to Perdue, the capital 

cost of the automated powder 

system and the automated con- 

ventional liquid system were vir- 

tually the same. At the time of the 

installation, Moyer Diebel paid 

$280,000 for its new powder line 

manufactured by Interrad Inter- 

national, about $5,000 less than 

for a liquid paint line. The real 

savings result from the reduced 

energy consumption, reduced 

material costs, and reduced 

maintenance costs. The powder 

system is costing Moyer Diebel 

about 15% less in operating costs 

than a comparable liquid sys- 

tem?’ 

At Moyer Diebel, the majority of 

parts coated are steel. Some 

aluminum and stainless steel 

parts are coated as well. Before the ‘ 

parts can be coated, they must be 

washed to permit proper adhesion 

of the paint. Steel parts usually 

have a thin protective film of oil on 

the surface which must be re- 

moved before painting. Since the 

company installed its powder line, 

the previous four-stage washing 

system has been reduced to a 

three-stage process. 

Perdue says, “We were sur- 

prised to find that the powder 

coating stuck on easier and with 

less cleaning. The upshot is that it 

is cheaper to pre-clean surfaces to 

be powder-coated because fewer 

cleaning cycles are needed.” 

For Moyer Diebel, reducing the 

total volume of wastewater gener- 

ated by reducing the number of 

cleaning cycles is a significant 

benefit. The company’s rural loca- 

tion means that no sewer is avail- 

able to accept their wastewater. 

The wastewater from the washing 

Process is recycled for re-use as 

washwater. Sludge and residual 

Manual dry powder electrostatic 

spray gun. 

Dry powder electrostatic touch-up 

booth on automatic appliance line. 

Twin air bell powder booth and 

reclaim unit. 

wastewater are hauled away by a 

disposal company. 

Once the parts have been moved 

automatically through the three- 

stage wash system and dry-off 

oven, the parts are ready to pass 

through an enclosed spray booth. 

E 

E 

m 

U 

C 

J - 

0 

c 

2 

m 

s 

s 

U 

m 

- 

B 

C 


Several spray guns automatically 

spray coat the part with a posi- 

tively charged powder, allowing 

the powder to adhere to the metal 

until baking. A manual touch-up 

using hand operated electrostatic 

guns follows immediately to coat 

inaccessible areas. 

The excess powder that does not 

adhere to the object falls to the 

bottom of the paint booth onto a 

moving belt. The belt carries the 

excess powder to a vacuum system 

which collects and transports the 

overspray to the filter units. Once 

the overspray has been filtered to 

remove dirt, metal bits and clumps 

of paint, the powder is returned to 

the feed hopper for ~e-use.~“ 

Only 40 to 50% of the powder 

sprayed stays on the target object, 

however the highly efficient over- 

spray recycle system means that 

almost all of the 5000 pounds of 

powder used each month is actu- 

ally used in coating the parts. 

“Because the recovery rate of 

overspray is about 99 percent, we 

don’t accumulate barrels of paint 

sludge,” says Perdue. 

The powder-coated parts are 

then moved to a gas-fired oven 

which cures the paint for a durable 

finish. Although powder baking 

requires an oven temperature of 

400” to 425”F, about 20°F higher 

than for a liquid system, the 

overall energy efficiency is much 

higher.42 According to Perdue, the 

new powder line requires 35% less 

energy than a conventional sys- 

tem. 

“We used to have to exhaust hot 

air from our baking ovens because 

it was laden with solvents,” says 

Perdue. “Now we get excellent 

energy conservation because the 

hot oven air is filtered and recy- 

cled immediately instead of 

exhausted. The energy savings are 

especially tremendous in the 

winter.” 

There is no doubt in Perdue’s 

mind that the economics of powder 

are best for those applications that 

do not need many colour changes. 

Powder coating technology does 

have a relatively wide range of 

application, particularly in the 

appliance industry, the outdoor 

furniture industry, or as a base 

coat in the automotive industry. 

Colour change takes about three 

hours to accomplish. This is done

y manually weeping down the 

walls of the booths and switching 

spray gun hosee to the hopper 

containing the other colour. The 

powder that is brushed from the 

walls and air-purged from the 

spray guna is then recycled back 

into the system.42 Unlike conventional 

liquid paint systems which 

generate large volumes of wastewater 

and sludge during a colour 

change, changing colour for a 

powder system is sludge-fkee. 

M The W.C. Woods Company 

Ltd. (Guelph, Ontario) has been in 

the powder coating business for 

more than ten years. The company 

can powdewmat its free” in any 

of four colours, and it is about to 

install another powder coating 

sysknwith greater mdti-colour 

capacity.’3 According to company 

management, the real benefits of 

the powder coating system are 

often hidden. The benefits are the 

things that are not required, such 

as no solvents to worry about, no 

sludge to dispose of, and no need 

for heat or air make-up. 

Mar~hall Industries Ltd. (Rex- 

dale, Ontario) manufkctures a 

wide range of wire products h m 

patio furniture and dishwasher 

racks to grocery shopping carta. 

PVC and nylon are the predomin- 

ant powders used to coat the metal 

objects. When the company 

started using powder coatings in 

1963, it was one of the fmt in 

Canada to use this technology. 

Company management claims 

that the economics of powder coat- 

ing will only improve with time as 

the coat of competing finishes such 

as conventional wet coating and 

electroplating continue to es- 

m The US1 Agribusiness Plant 

(Atlanta, Georgia) installed a 

powder system to paint its poultry 

feeding equipment, egg collectors, 

and environmental control 

equipment. Design and installa- 

tion assistance was imported from 

Torrid Oven La. (Mississauga, 

Ontario), with spray equipment by 

Volstatic Equipment Division of 

Canadian Hanson (Toronto, On- 

tario). 

The coating applied is a hybrid 

polyester epoxy designed to re- 

place porcelain enamel used in the 

past. Advantages of the polyester 

epoxy coating include ita excellent 

corrosion and abrasion resistance. 

Company management claims 

that no solvent system would 

appmch the finish and durability 

achieved with their powder coati 

ing operation.4s 

3. 

Recycling Overspray 

With paint sludge disposal coets 

in an upward spiral, and paint and 

solvent costa following suit, some 

businesses are turning to recycling 

paint overspray as one buffer 

against high overhead. 

In the United Stab, paint 

sludge (overspray) is claseifed as 

hazardous waste, and as such is 

causing industrial painters some 

very expensive headaches. Dispod 

coets for a drum of paint 

sludge have jumped as high as 

$200 per drum in parte of the 

United States, up 100-fold since 

the $2 charge in the early 1970s.@ 

One chronic problem with recycling 

overspray is that the paint 

dries and becomes unworkable as 

a new paint. Recycling is most 

efficient if the drying or curing 

factor can be minimized. Many of 

the new paint formulations and 

innovative coating methods enhance 

paint recovery opportunities. 

For example, in radiation 

curing and powder coating 

methods, the coating that is 

applied will not cure until it is put 

through a special curing cycle. 

Hence, it becomes technically possible, 

and in many cases economically 

necesSary to recycle overspray. 

3M (St. Paul, Minnesota) redesigned 

a apray booth to eliminate 

excessive resin overspray and to 

recycle the overspray back into the 

project. In doing so, the 3M company 

avoided wasting 500,000 

pounds of resin a year as unused 

spray. With a capital investment 

of $45,000, the company turned its 

finances around to net themselves 

an annual saving of $125,000.47 

The W.C. Richards Company 

(Blue Island, Illinois) has been 

recycling overspray for more than 

30 years. According to Bill 

Richards, company president, the 

recycling of paint overspray is 

hardly a breakthrough in new 

technology. Quite the contrary. 

“It was a war-time crisis which 

forced UB to develop the technology. 

As supplies improved and 

prices dropped in the 19508 and 

19&, industry gradually driRed 

back to the use of virgin materials. 

We put recycle on the back shelf, 

but today’s battles against inflation 

and environmental deterioration 

are forcing a return to an 

already proven technology,” says 

Richards. 

The W.C. Richards Company’s 

own history of paint recycling has 

its mots in scarcity and necessity. 

Back in 1946 when the firm still 

manufactured toys, red enamel 

paint was in such short supply 

that Richards, in desperation, ab 

tempted to reclaim the sludge 

fkom spray booths. The experiment 

met with such succee8 that 

other manufacturers requested 

Richards to recycle their paint 

wastes. Seizing a business opportunity, 

the company abandoned ita 

toy line and plunged into the paint 

formulating and recycling 

business.@ 

More than 30 years later, business 

is still booming, although the 

company is once again shifting ita 

direction. In the past few years, 

the fm r cled about 1 million 

gallons of ”r s udge a year, mainly 

from the appliance and automo- 

tive industries. At present, how- 

ever, they are cutting back on the 

quantity of paint they accept for 

recovery. Instead, the company is 

assisting businesses in on-site re- 

covery. The Blue Island plant has 

about 100 employees, more than 

30 of which are technical people 

who consult other companies on 

how to recycle overspray. 

Technical director Arthur Gay 

explains, “Nowadays we are more 

interested in licensing other com- 

panies to use our recycling process 

to reclaim their own paint wastes. 

We want to teach people to do it for 

themselves.” 

The technical consultants will 

tell a company if it is economically 

feasible to recycle its paint sludge. 

In addition, the consultants will 

provide the design and specifica- 

tions for the on-site construction of 

the paint reclamation system, as 

well as train operators to use the 

new equipment.@ 

What is industry’s reaction to

paint sludge recycling? ‘They 

think it’s a great idea but they 

want someone else to do it for 

them!” exclaims Gay. 

Why not continue to recycle 

paint instead of teaching other 

companies how to do it? Both 

Richards and Gay suggest many 

reasons why paint recycling 

makes most sense when done 

on-site by the company that generates 

the sludge. 

Paint designed for a production 

line should be re-used as paint for 

that same production line because 

that paint is already tailor-made 

for those specific demands. To find 

another customer with the same 

specification is very difficult. It 

makes more sense to reclaim 

primer sludge as primer, and 

enamel sludge as enamel, than to 

reclaim mixed sludges as 

primerP6 

Another argument in favour of 

on-site recycling is that the sludge 

can be reclaimed soon after it is 

generated, while it is still fresh. 

The fresher the sludge, the greater 

the yield of reclaimed paint.- 

According to Gay, airdry paint 

systems give a much smaller yield 

of reclaimed paint than do bake 

systems. The overspray of baketype 

paints remains in the liquid 

unpolymerized form, unlike airdry 

paints which quickly’ 

polymerize and form a skin. Typically, 

80 to WO of the paint sludge 

of an air-dry system can be reclaimed. 

For a bake system, 97 to 

99% of the paint sludge can be 

recycled. 

On-site recovery offers another 

advantage over hauling the paint 

sludge to an outside reclaimer by 

eliminating freight and handling 

costs, In the United States, any 

movement of hazardous wastes off 

a company’s premises must be 

accompanied by multiple forms 

designed to track the location of 

these substances. Recycling paint 

on-site eliminates the paperwork 

necessary to comply with the manifest 

system. 

The psychological effect of having 

a company deal with its own 

wastes on-site appears to be a 

favourable one. Gay laments the 

difficulties his own company has 

had in obtaining consistently 

clean paint sludge, free of 

cigarette butts, lunch lehvers 

and other garbage. 

“There is the human element. 

People have been treating this 

stuff as garbage for so long that it 

is hard to get them to collect it and 

keep it clean when they know it 

goes off their premises. It would be 

easier to keep the overspray clean 

if it were treated every day right at 

that facility. It is a continual 

education process at the plant,” 

says Gay. 

But what are the economics of 

sludge recovery? How small a 

company can benefit? 

“If a company generates 100 

drums (5000 US. gallons) of 

sludge a month, it is worthwhile to 

recycle paint. Even with 50 drums 

it might be worthwhile,” says Gay. 

Typically, industrial paints sold 

for !$8 to $14 a gallon in the United 

States in 1981. By recovering 

paint on-site, the recycled paint 

cost only $3 to $5 per gallon. If the 

sludge is hauled off-site for re- 

claiming, the cost of the reclaimed 

product may reach $7 per gallon, 

still well below the price of virgin 

paint.- 

The economics of recovery are 

sound. Given that a company 

generates only 100 drums (5000 

US. gallons) of sludge a month, 

assume that 8Wo or 4OOO gallons 

are reclaimed at a cost of $7 per 

gallon. If the virgin product sells 

for $12 per gallon, the monthly 

savings in paint costa alone would 

be $20,000. Add to this the more 

than $3000 saved each month by 

avoiding sludge disposal costs and 

the economics become even more 

promising.@ 

The W.C. Richards Company 

suggests that most types of paints 

can be recovered, including al- 

kyds, acrylics, lacquers and epoxy 

esters. The company has been 

successful in recycling many of the 

new high solids formulations and 

some water-borne formulas. 

In the sludge recovery process, 

the first step is to redissolve 

everything that is soluble in the 

sludge. Some of the paint sludge 

will remain in its polymerized 

form as lumps. The next step is to 

filter out or centrifuge the non- 

soluble lumps. Essentially all the 

pigment is saved. Some binders, 

resins, solvents or other ingre- 

dients are added to bring the paint 

back close to ita original condition. 


Although the W.C. Richards 

Company is not the only company 

involved in paint recycling, its 

approach is somewhat unusual. 

By putting paint recycling back in 

the hands of those who generate 

the sludge, the company hopes to 

help win today’s battle against 

inflation and environmental de- 

teriora tion. 

The Clyde Paint and Supply 

Company (Clyde, Ohio) is another 

company which recycles paint 

overspray f“ other businesses. 

The company accepts paint from 

automotive paint lines. The paint 

is reconditioned and returned to 

the automotive companies for use 

as a primer coat.= 

In Britain, Leigh Analytical 

Services Ltd. have come up with a 

new use for difficult-tdiqme-of 

paint sludges. Leigh, which 

specializes in waste treatment and 

recovery, have developed a novel 

means of converting waste paints, 

tars, oil sludges and latex into a 

homogeneous solid form. The 80- 

lidfied material, which has an 

energy content similar to brown 

coal, can be easily stored, trans- 

ported and then burned as a solid 

f~e1.4~ 

4. 

New Directions in the 

Paint Industry 

The coatings industry is not 

alone in ita heavy dependence on 

petrochemicals. The plastics, 

adhesives, pesticide, ink, organic 

dyes, solvents, automotive, 

appliance and textile industries 

all depend on a steady and afford- 

able supply of petrochemicals. 

This was not always the case. 

Prior to the 194Os, the manufac- 

turing sector had to look to the 

forests and fields for many of its 

raw materials. 

The boom of the petrochemical 

industry in the 1950s provided 

such a predictable and cheap sup- 

ply of petrochemical-based poly- 

mers as to edge other competitors 

out of the market. Polyester re- 

placed cotton, natural dyes were 

substituted by synthetic dyes, and 

plastic invaded markets preVi- 

ously held by the paper industry. 

A similar change swept the paint

146 Palnts & Coatings 

industry. 

Historically, the paint industry 

has been a large user of renewable 

resources. Prior to the 19508, 

soybean and linseed oil were the 

workhorses of alkyd resin technology. 

Alkyd resin technology 

yielded paints which were readily 

solvent in turpentine. The use of 

renewable raw materials such FM 

turpentine, soybean and linseed 

oil has declined slowly but steadily 

since the 196%. This decline can 

be attributed in large part to the 

increased availability of 

pebochemid-based acrylics and 

other polymera currently in use by 

the paint industry. 

I 

L 

Ta6ki- 3 

RENEWABLE RESOURCES FOR THE COATINGS INDUSTRY 

There are seved sources of renewable raw materials that are usable by the coatings industry. Some 

of the natura/ materials listed, such as turpentine and linseed oil, can be used relatively direcfiy with little 

additional processing. Other materials, such as forestry and agricultural wastes can undergo complex 

chemic& reactions to yield resins, polymers and binders important in the manufacture of paints. 

Source "RmwabIe Resouces for the Coathgs Industry"Jwma/ d Coafings Technology. November 1981. 

Traditional Agricultural Feedstocks Used by the Paint Industry 

soybean 

Linseed 

Castor bean Castor bean oil is an important source of hydroxy substituted fatty acids currentiy used 

in the coatings industry. 

Alternative Agricultural Feedstocks 

Crambe 

Crambe has an extremely high erucic acid oil content. Crambe can be grown in 

(Crambe the desetf. 

abyssinice) 

Jojoba 

(Simmondsia 

chinensis) 

Buffalo gourd The seed oil contains 60% linoleic acid and 22% oleic acid. When the oil is for- 

(Cucurbita mulated to a protective coating, it exhibits properties between those of linseed 

feotidissima) oil and soybean oil. 

Vemonia 

This species of plant produces seeds containing 30% of an oil which is rich in 

anthelmintica vemolic acid. 

Guayule 

Euphorbia 

If petroleum resources were 

suddenly restricted through some 

calamity, could the coatings in- 

dustry remain in business? Ac- 

cording to the Renewable Re- 

sources Committee of the Chicago 

Society of Coatings Technology, 

the answer is "yes", but the 

renewables-based technology 

would be 30 to 50 years behind the 

types of coatings the industry ie 

capable of producing today.5o 

There is a vast potential of 

renewable raw materials from 

natural sources available to the 

coatings industry (see Table 3). 

Numerous plant species exist 

which produce hydrocart>ons suit- 

able for chemical processing and 

energy uses, while others can yield 

specialized oils and chemical 

feedstocks. Cellulose and starch 

can provide new polymer types or 

they can be converted to basic 

alcohols for the synthesis of many 

of the required chemicals.= 

One major source of material 

and energy resources available to 

industry is organic waste. Con 

cobs and oat hulls are two agricul- 

tural wastes that can be used to 

produce the chemical inter- 

mediary furfural. Furfural can 

undergo further processing to 

yield a range of solvents usable by 

the coatings industry.m 

Prior to the 1950s, alkyd resin technology was based on soybean and linseed oil. 

Since the 1950s, paint production shifted to petroleum-based acrylics and other 

po/ymers. 

Jojoba seeds contain 50% oil by weight which is made up of fafty esters. This oil 

is a good substitute for sperm whale oil. 

The Guayule is a small shrub that grows in semi-arid regions of the world. The stems 

and branches yield a natural latex used in the production of rubber. The resinous 

material in the latex, and the seed oil are believed tu be suitable for the production of 

paints. 

Euphorbia is a plant native to semi-arid areas. Like guayule, the euphorbia plant 

produces a natural latex potentially usabie by the paint industry.

' C 

The Synthesis of Chemicals and Polymers from Agricultural Feedstocks 

Soybean 

Paints&CoaUngs 147 

Linseed 

Linseed and safflower acrylates and methacrylates have been synthesized and 

Safflower incorporated into emulsion polymers. 

Corn cobs 

Oat hulls 

Corn 

Sorghum 

Wheat 

Potato 

and other plants 

abundant in starch 

Wood Feedstocks 

Wood resins Trees have traditionaty fumished the coatings industry with turpentine, resin, @ne oil 

and saps and dipentine. 

Cellulose 

Wood waste 

Similarly, starches from ag- 

ricultural wastes are valuable raw 

materials for the coatings indue- 

try because of their application as 

paint thickeners, absorbents, 

sizes, adhesives and flocculants. 

The cellulose in forestry and wood 

waste can be used to produce 

celldosic film formers such as 

nitrocellulose and cellulosic thick- 

eners for latex paints.w 

There are many renewable 

materials that potentially could 

supply the chemicals and fuel of 

the paint industry. Some renew- 

able materials have been used 

widely in the past and the technol- 

ogy to use them is well known. In 

other instances, years of intensive 

research are required to produce 

high quality coatings from renew- 

able materials. Furthermore, the 

cultivation and harvesting of the 

resource base requires careful and 

h-qgt" planning to ensure a 

sustainable yield. The time to plan 

for the future is now. Creative 

chemical engineering and strong 

government support are needed to 

shift industry from its petrochem- 

ical dependench to a manufactur- 

ing system based on renewables. 

The unsaturated fatiy acids from soybean can be used in the production of pdyamides 

andpolyesters for Coatings and adhesives. Itis also applicable to urethane technology. 

These agricultural wastes can be used to produce furfural and other related 

compounds. Furfuryl alcohol, furan, tetrahydmfurfuryl alcohol and tetrahydrofuran we 

all excellent solvents. 

Starches are a valuatde renewable raw material for the coatings industry because of 

their use as paint thickeners, absorbents, sizes, adhesives and flocculants. 

Cellulose can be used to produce cellulosic film formers such as nitrocellulose and 

cellulosic thickeners for latex paints. 

Conversion of wood waste to methanol could become a souTce of many coatings resins 

such as epoxies, pdlesters, phenolics, vinyl resins and others. 

Conclusiop 

The paint industry has blos- 

somed with technological innova- 

tions in the last two decades 

despite the hurdles presented by 

tightening health and environ- 

mental regulations. No longer 

content with open-ended proc- 

esses, equipment engineers are 

designing several paint applica- 

tion systems that are virtually 

closed-loop systems. 

Those businesses well on the 

road to closed-loop processing 

through solvent re-use, waste- 

water recycling and recovery of 

paint overspray are finding that 

eliminating waste not only pro- 

teda the environment but also 

enhances company profits. 

For smaller businesses, the 

challenge to reduce pollution may 

be more formidable than for the 

larger companies. Scarce financial 

resources and technological exper- 

tise will make the small operator 

reluctant to divert any company 

time or money to control pollution 

when the same resources could be 

spent on soliciting more business 

or making more product. It must 

be recognized, however, that fail- 

ure to minimize waste can cut 

deeply into company profits. 

Furthermore, in the face of strin- 

gent anti-pollution regulations, 

failure to abate pollution'can 

threaten the future survival of a 

business. 

Many of the smaller and 

medium-sized firms do not have 

sufficient access to technical ex- 

pertise and financial resource8 

nece8B81y to reduce the amount of 

wastes requiring off-site & ~ l - 

Accemibility to expertise and 

fun- must be improved if the 

small business sector is to improve 

ita manufacturing p"3ses. 

There is a need to provide 

economic incentives that promote 

waste reduction and recovery 

above and beyond conventional 

pollution abatement. Incentives 

and regulations must be struc- 

tured to make waste recycling a 

cheaper option than waste burial. 

Failure to do so will impede rapid 

modernization and the minimiza- 

tion of pollution in the manufac- 

turing sedor.

748 Palnts & Coatlngs 

Air Pollution Control 

The Canadian Paint and Coat- 

ings Association has completed a 

pollution control guidebook for the 

coatings industry entitled Introduc- 

tion to Air Quality. The guidebook 

provides cursory information on air 

pollution, Canadian regulatmy ac- 

tivity, coatings technology and pol- 

lution control equipment and pm 

' cedures. This association also pro- 

vides information on waste man- 

agement and occupational health 

issues. 

Contact Canadian Paint and 

Coatings Assocletlon, 

Suite 825, 

515 St. Catherine St. W., 

Montreal, Quebec. 

H3B 184 

(514) 2858381 

Solvent Recycling 

The National Association of Sol- 

vent Recyclers (NASR) in the Un- 

ited States has completed a nar- 

rated slide presentation on solvent 

recycling. Solvent recycling is 

applicable to many industries in- 

cluding the paint industry. No sol- 

vent recycling association has been 

formed to date in Canada, although 

some Canadian solvent reclaimers 

belong to the American association. 

Contact National Association of Sd- 

vent Recyclers, 

1406 Third National 

Building, 

Dayton, Ohio. 

45402 

(5 13) 223-04 19 

Health Hazards Associated 

with Paint Application 

Increasing attention is being paid 

to painter health problems in the 

United States. In Canada, occupa- 

tional hazards associated with 

painting have not surfaced as an 

issue to the same degree is in the 

United states. The lntemational 

Brothemgod of Paints and Allied 

Trades is active in investigating 

potential health hazards associated 

with the application of paint. 

Contact Health and Safety 

Director, 

lntemational Brother- . 

hood of Paints and 

Allied Trades, 

1750 New York Ave., N.W., 

Washington, D.C. 

20006 

(202) 637-0700 

Safe Industrial Use of 

Radiation-Curable Coatings 

The US. National Paint and Coat- 

ings Association has produced the 

publication Safe Handling and U s 

of Ultraviolet/Electron Beam Cura- 

ble Coatings to assist operators in 

the safe use of radiation equipment. 

Chapter titles include Handling and 

Application Guidelines, Industrial 

Hygiene and Safety, Toxicology 

Testing, and Biological Safety 

Evaluation. 

Contact: National Paint and 

Coatings Association, 

1500 Rhode Island Ave. 

N. W., 


20005 

(202) 462-6272 

Associations 

Contact the following associa- 

tions for information on low-waste 

technologies and equipment. 

These trade associations can assist 

you direcdy, or point you in the right 

direction for more information on 

commercially available recycling 

equipment, technology transfer 

programs, technical expe& in the 

field, existing tax breaks and other 

economic incentives, and upcom- 

ing regulations. 

Encourage those associations 

which rank pollution control low on 

their priority list to direct more 

attention to pollution prevention. 

Preventing pollution can benefit 

both ttm business commundy and 

the environment. 

The following list identifies 

primarily national associations in 

Canada and the United States. It is 

not uncommon for Canadian com- 

panies to belong to American as- 

sociations. Contact the national 

associations and ask if a local 

chapter is in operation near your 

business. 

Canadian Paint and 

Coatings Association, 

Suite 825, 

515 St. Catherine 

st. west, 

Montreal, Quebec. 

H3B 184 

(514) 285-6381 

National Paint and Coatings 

Association, 

1500 Rhode Island Avenue, N. W., 


20005 

(202) 462-6272 

Federation of Societies for 

Coatings Technology, 

Suite 830 

1315 Walnut St., 

Philadelphia, Pennsylvania. 

19107 

(215) 545-1506 

-r 

Chemical Coatem Association, 

Box 24 1, 

Wheaton, Illinois. 

60187 

(3 12) 668-0949 

Canadian Painting Contractors 

Association, 

Suite 218, 

85 Ellesmere Road, 

Scarborough, Ontario. 

MIR 483 

(41 6) 444-7958 

lntemational Brothehood of 

Painters and Allied Trades, 

1750 New York Avenue, N.W., 

washington, D.C. 

20006 

(202) 637-0700 

National Association of 

Solvent Recyclers, 

1406 Third National Building, 

Dayton, Ohio. 

45402 

(5 13) 223-04 19 

I

Journals 

Numerous excellent publications 

are currently available in both 

Canada and the United States. The 

joumals listed below frequenf/y 

contain articles that relate to improv- 

ing paint transfer efficiency, energy 

and materials conservation, and 

waste recovery. Thesejoumds dso 

carry an assortment of advertise- 

ments by manufacturers of low- 

waste paint application and mcov- 

ery equipment. 

COATINGS MAGAZINE, 

86 Wilson St., 

Oakville, Ontario. 

L6K 3G5 

CANADIAN PAINT AND FINISHING, 

Maclean-Hunter Ud., 

481 University Avenue, 

Toronto, Ontario. 

M5W 1A7 

JOURNAL OF COATINGS 

TECHNO LOG Y, 

Federation of socletles for -e 

Coatings Techndogy, 

Suite 830, 

1315 S. Walnut St., 

Philadelphia, Pennsylvania. 

19107 

INDUSTRIAL FINISHING 

Hitchcock Publishing Co., 

Hitchcock Buildino. “I 

Wheaton, Illinois. 

60187 

AMERICAN PAINT & 

COATINGS JOURNAL, 

American Paint Journal Co., 

291 1 Washington Avenue, 

St. Louis, Missouri. 

63 103 

FINISHING INDUSTRIES, 

Wheatland Journals Ud., 

157 Hagden Lane, 

Watford, Heris, 

England. 

WD1 8LW 

THE PAINTERS AND 

ALLIED TRADES JOURNAL, 

Intemational Brotherhood of 

Painters and Allied Trades, 

1750 New York Avenue, N. W., 


20006 

References 

1. Walberg, Arvid. A.C. Walberg 8, Co., 

Downers Grove, Illinois. Personal 

communication, August 1981, 

2. Aldorfer, D.M. and Praschan, E.A. 

Preliminary Repoti on Transfer Effi- 

ciency of Water-Bome Enamel. 

General Motors Transfer Efficiency 

Task Force. April 24, 1979. 

3. Gay, Arthur. W.C. Richards Com- 

pany, Blue Island, Illinois. Personal 

communication, July 1981. 

4. “Industry Statistics: Real Growth 

Lags But Paint Dollar Value Con- 

tinues to Rise.”Coatings Magazine, 

March/April 1981. 

5. Environment Canada. Characteriza- 

tion of Industrial Wastes Generated 

in the Manufacture of Organic Coat- 

ings, Pharmaceuticals and Medici- 

nals. Solid Waste Management 

Branch Report EPS 3-EC-77-1, 

February 1977. 

6. Soofield, F. Assessment of Industrial 

Hazardous Waste Pm$ces, 

Palnt and Allied Products lnduslry, 

Contract Solvent Reclalming Operations, 

and factory Application of 

Coatings. Prepared for the U.S. 

Environmental Protection Agency, 

September 1978. 

7. “Industry Now Leads in Paint Us- 

age.“ Canadian Chemical hoces- 

sing, June6,1979. 

8. “New Mixes Meet Air-Quality 

Tests.” Canadian Chemical Pm 

ceSsing, June 6, 1978. 

9. ”Painting Health Hazard Claimed by 

U.S. Unions and Study Groups.” 

Coatings Magazine, May/June 

1981. 

10. Ebfsson, S.A. et al. “Exposure to 

Organic solvents.” Scandinavian 

Journal of Work and Envimnmental 

Health, No. 6,1980. 

11. Arlien-Soborg, P. et al. “Chronic 

Painters’ Syndrome.” Acta 

Neumlogica Scandinavica, No. 60, 

1979. 

12. Selikoff, I.J. Investigations of Health 

Hazards in the Painting Trades. 

Washington, D.C.: National Institute 

for Occupational Safety and Health, 

December 1975. 

13. “Computers are Like Having 

Another Staff in Laboratory.” Coat- 

ings Magazine, MayNune 1981. 

14. Morris, A. “A Tank Cleaning System 

for the Small Paint Plant.”Joumalof 

Coatings Technology, September 

1979. 

15. Dawson, R.A. “Sludge Management 

in the Paint and Coatings Industry.” 

Sludge, SeptemberKktober 1979. 

16. Mock, J.A. “Water-Bome Paints Cut 

Auto Costs, Help Reduce Pollution 

Problems.” Materials fngineerlng, 

May 1978. 

17. Marchetti, Alvaro. Canadian Paint 

and Coatings Assodation, Montreal, 

Quebec. Personal communication, 

February 1982. 

18. “No Single Coating Expected to 

Sweep the Market,” Coatings 

Magazine, November/December 

1980. 

19. ~arct~tti, mare. +ew wave.” 

Coatings Magazine, November/ 

December 1980. 

2O.Canadian Paint and Cbatings As- 

dation. Coatings lndusby lntm 

duction to Air Quality. Montreal, 

Quebec, 1981. 

21. U.S. Environmental Protgction 

Agency. Contrdung Pollution from 

the Manufactudng and Coating of 

Metal Products: Metal Coating Air 

Pdlution Control. Environmeqtal 

Research Information Center, US. 

E.P.A., 1977. 

22. Niemi, B. “How to Figure Potential 

Emission Reductions for High- 

Solids Coatings.” Industriel Finish- 

ing, November 1979. 

23. “Meeting Tough Mandates.” Indus- 

trial Finishing, February 1981. 

24. Newman, R.M. and Dobson, P.H. 

Evaluation of Fire Hazard of 

Water-Borne Coatings. Prepared for 

the National Paint and Coatings 

Assodation, Washington, D.C., De- 

cember 1977. 

25. “Solvent-Like Prepolymers Could 

Save Oil-Based Caatings from Ob- 

livion.” Canadian Chemical Proces- 

sing, March 21, 1979.

28. Degussa (Canada) Ltd. Radiation 

Curing. Burlington, Ontario: De- 

gossa (produd literature). 

27. Brewer, G. Calculations of Painting 

Wasteioads Associated with Metal 

Finkhing. Industrial Environmental 

Research Laboratory, U.S. En- 

vironmental Protection Agency, 

June 1980. 

28. "Compliance with OSHA Standards 

Offers Fumitwe Maker opporhrnity 

to Modernize finishing System and 

Redm Costs."/ndusW Fhishing, 

May 1979. 

29. Santilb, Sam. Flexsteel Industries, 

Dubuque, Iowa. Personal communi- 

' cation,Juty1981. 

30. "New Pah~t Techndogies Eking New 

Spray Systems." Coatings 

- Magatlne. May/June 1981. 

31:'Alter Cost Rising Fast, What's 

Alternative?" Coatings Magazlne, 

March/Aprii 1981. 

32. Water Technobgy IC. UWW' 

Suspended s(udge Separator A 

New Technology kr Pelnt Sludge 

Removal. Troy, Michigan: Uhrafiit 

Im., 1979 (produd meratwe). 

33. MOK, Allen. Water Technology Inc., 

Chicago, IIbois. Personal com- 

munication, July 1981. 

34. "Oshkosh Truck Paint Booth Saves 

Energy." Industrial Finkhing, May 

1979. 

35. "New Pretreatment System Ends 

Effluent Problems." Coatings 

Magazine, May/June 1981. 

36. Schrantz, J. "Fisher Body's New 

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