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<strong>Omya</strong><br />
White Mineral Filler for High Opacity in Decorative<br />
Coatings despite Low Binder Absorption<br />
Research & Technology Services, ATS-PCA<br />
<strong>Omya</strong> International AG, CH-4665 Oftringen<br />
June 2010
Asia Pacific Coating Show 2010<br />
Pigments and fillers<br />
Classification and definition according to ISO 3262-1<br />
Pigment<br />
Dye<br />
Filler<br />
A pigment is a substance consisting of particles which is<br />
practically insoluble in the application medium and is<br />
used as a colorant or by virtue of its corrosion-inhibiting<br />
or magnetic properties.<br />
A dye is a colorant that is soluble in the application<br />
medium.<br />
A filler is a substance consisting of particles which is<br />
practically insoluble in the application medium and is<br />
used to increase volume or to improve technical<br />
properties and/or to influence optical properties.<br />
2<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Influence of particle morphology<br />
Mineralogy<br />
(composition of filler)<br />
Particle size (distribution)<br />
→ Specific surface area<br />
→ Oil absorption<br />
→ Binder absorption<br />
→ Rheology<br />
→ Hiding power / Opacity<br />
→ Reflectivity<br />
→ Wet scrub resistance<br />
→ Oil absorption<br />
→ Binder absorption<br />
→ Reflectivity<br />
→ Hiding power / Opacity<br />
→ Mud cracking<br />
→ Paint stability (sedimentation)<br />
3<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Dispersibility<br />
Primary particles<br />
Primary particle<br />
Aggregate<br />
Primary particles<br />
Aggregate<br />
Primary<br />
particles<br />
Compacted<br />
aggregates<br />
Agglomerates<br />
4<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Emulsion Test Paint<br />
Product kg kg/1000l Litre<br />
Styrene-acrylic emulsion 159.4 226.7 218.0<br />
FILLER (density = 2.7 g/cm³) 465.1 661.5 245.0<br />
Additives 34.3 48.8 51.8<br />
Water 341.2 485.3 485.3<br />
Total 1000.0 1422.3 1000.1<br />
PVC: 70.0 %<br />
5<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Example for contrast ratio with different GCC fillers<br />
OMYACOAT ® OMYACARB ®<br />
855 2 5 15<br />
Formulation<br />
pigment free<br />
emulsion paint<br />
PVC 70%<br />
6<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Influence of filler size on contrast ratio for CaCO 3<br />
90<br />
Contrast ratio /%<br />
80<br />
70<br />
60<br />
50<br />
network structure<br />
40<br />
30<br />
2 4 6 8 10 12 14 16 18<br />
Mean particle size /µm<br />
7<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Contrast ratio with 2µm GCC filler<br />
PVC ladder<br />
Formulation<br />
pigment free<br />
emulsion paint at<br />
different PVC with<br />
OMYACARB 2<br />
(D50% = 2,9 µm)<br />
8<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Hiding power with GCC fillers<br />
100<br />
Formulation<br />
pigment free<br />
emulsion paint<br />
Contrast ratio [%]<br />
90<br />
80<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
OMYACOAT 855<br />
OMYALITE 90<br />
VIOLET LABEL<br />
OMYACARB 2<br />
OMYACARB 5<br />
OMYACARB 10<br />
OMYACARB 15<br />
1 2 3 4<br />
0<br />
35 40 45 50 55 60 65 70 75<br />
PVC [%]<br />
9<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Influence of filler size on sheen for CaCO 3<br />
35<br />
30<br />
Sheen /%<br />
25<br />
20<br />
15<br />
network structure<br />
10<br />
5<br />
10 20 30 40 50 60 70 80 90<br />
Top cut /µm<br />
10<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Opportunities for specialties<br />
Ultra fine ground calcium carbonate offers:<br />
1. Titanium dioxide spacing effect<br />
TiO 2 Spacer*<br />
2. Outstanding opacity of ultra fine products<br />
Opacifying Filler*<br />
3. Increased pigment volume concentration<br />
Filler*<br />
11<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Spacing of pigments<br />
Filler can provide a significant impact onto pigment performance. With<br />
qualified particle size, most ideal if similar to particle size of pigment, fillers<br />
act as pigment spacer.<br />
Optimum:<br />
Particle size of pigment = particle size of filler<br />
Thus, fillers prevent the formation of pigment agglomerates, which are<br />
optical less efficient like primary particles of the pigment.<br />
12<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Spacing of pigments<br />
TiO 2 -particle<br />
6 μm filler<br />
particle<br />
TiO 2 -particle<br />
2 μm filler<br />
particle<br />
TiO 2 -particle<br />
< 0.5 μm filler<br />
particle<br />
Smaller particle size<br />
Improved spacing effect<br />
13<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Physical filler properties<br />
Tests OMYACOAT ®<br />
855 – KU<br />
OMYACARB ®<br />
2<br />
Mean particle size (d50%) 0.6 µm 2.8 µm<br />
Top cut (d98%) 3 µm 14 µm<br />
Brightness Ry 93 % 95 %<br />
Whiteness L* 97 % 98 %<br />
Oil absorption 24 g/100g 16 g/100g<br />
Specific surface area (BET) 13.4 m²/g 3.4 m²/g<br />
14<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Partial replacement of TiO 2 at similar PVC<br />
Formulation Start R10 R20 R30 R40<br />
Styrene-acrylic emulsion 170.0 170.0 170.0 170.0 170.0<br />
Tiona 595 150.0 135.0 120.0 105.0 90.0<br />
OMYACOAT ® 855 – KU 15.0 30.0 45.0 60.0<br />
OMYACARB ® 2 – HB 300.0 300.0 300.0 300.0 300.0<br />
Iceberg 50.0 50.0 50.0 50.0 50.0<br />
Alusil ET 30.0 30.0 30.0 30.0 30.0<br />
Total 1000.0 1000.0 1000.0 1000.0 1000.0<br />
PVC: 71.0 %<br />
15<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Dry opacity of reformulations at similar PVC<br />
Dry opacity<br />
%<br />
Start 98.0<br />
R10 97.7<br />
R20 97.7<br />
R30 97.6<br />
R40 97.4<br />
TiO 2 content<br />
%<br />
15.0<br />
13.5<br />
12.0<br />
10.5<br />
9.0<br />
95 96 97 98 99 100<br />
Formulation characteristics: PVC 71%<br />
16<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Wet opacity of reformulations at similar PVC<br />
Wet opacity<br />
%<br />
Start 95.3<br />
R10 95.0<br />
R20 94.6<br />
R30 94.4<br />
R40 93.8<br />
TiO 2 content<br />
%<br />
15.0<br />
13.5<br />
12.0<br />
10.5<br />
9.0<br />
90 92 94 96 98 100<br />
Formulation characteristics: PVC 71%<br />
17<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Brightness Ry of reformulations at similar PVC<br />
Brightness Ry<br />
%<br />
Start 93.4<br />
R10 93.3<br />
R20 93.1<br />
R30 92.9<br />
R40 92.6<br />
TiO 2 content<br />
%<br />
15.0<br />
13.5<br />
12.0<br />
10.5<br />
9.0<br />
90 91 92 93 94 95<br />
Formulation characteristics: PVC 71%<br />
18<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Sheen of reformulations at similar PVC<br />
Sheen<br />
%<br />
Start 6.0<br />
R10 6.2<br />
R20 6.3<br />
R30 6.4<br />
R40 6.6<br />
TiO 2 content<br />
%<br />
15.0<br />
13.5<br />
12.0<br />
10.5<br />
9.0<br />
0 2 4 6 8 10<br />
Formulation characteristics: PVC 71%<br />
19<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
ASTM Wet Scrub Resistance<br />
Wet scrub resistance ASTM<br />
cycles<br />
Start 175<br />
R10 178<br />
R20 181<br />
R30 173<br />
R40 164<br />
TiO 2 content<br />
%<br />
15.0<br />
13.5<br />
12.0<br />
10.5<br />
9.0<br />
0 50 100 150 200 250<br />
Formulation characteristics: PVC 71%<br />
20<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Viscosity Behaviour at similar PVC<br />
Formulation Start R10 R20 R30 R40<br />
Paar Physica viscometer<br />
Low shear 10s -1 /mPas 21‘500 20‘600 24‘100 24‘700 25‘600<br />
Low shear 40s -1 /mPas 9‘220 8‘940 10‘700 10‘700 11‘200<br />
ICI viscometer<br />
High shear 10‘000s -1<br />
/mPas<br />
160 150 150 140 150<br />
21<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Pigment and filler costs<br />
100 %<br />
Savings<br />
- 25 %<br />
75 %<br />
Formulation Start<br />
Formulation R40<br />
with OMYACOAT ® 855 – KU<br />
22<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Summary<br />
Results of OMYACOAT ® 855 - KU at a glance<br />
• Spacing of titanium dioxide<br />
• High opacity<br />
• Excellent dispersibility in water based coatings<br />
• High brightness and low yellowness<br />
• Outstanding wet scrub resistance<br />
• No negative impact on rheology<br />
• Savings in formulation costs<br />
• Environmental friendly<br />
• No health risks<br />
23<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Application Guide for Calcigloss ® -GU<br />
Application: Decorative (low PVC) and Industrial Coatings<br />
• Excellent dispersibility<br />
• Suitable for glossy coatings<br />
• Good gloss retention<br />
• Sold as a „filler“ to „increase“ the pigment volume concentration<br />
reduces formulation costs Filler<br />
Suitable for water- and solvent based formulations<br />
• TiO 2 Spacer<br />
Source: Glossy prospects with CALCIGLOSS – GU<br />
24<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Calcigloss ® -GU<br />
TiO 2 Spacer<br />
• Reduction of TiO 2<br />
content possible<br />
• Reduced<br />
formulation costs!<br />
Titanium Dioxide 30 % 25 % 20 %<br />
Calcigloss ® -GU 0 % 5 % 10 %<br />
Source: Glossy prospects with CALCIGLOSS – GU<br />
25<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Impact of Particle Size on Gloss of Powder Coatings<br />
Source: Technical Bulleting 169_E<br />
26<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Processes with Natural Calcium Carbonate<br />
Natural CaCO 3<br />
Grinding Precipitation Modification<br />
GCC PCC MCC<br />
27<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Particle Structure<br />
GCC PCC MCC<br />
Chalk<br />
Aragonitic<br />
Brain<br />
Calcite<br />
Marble<br />
Calcite<br />
Limestone<br />
Scalenoedral<br />
Rhomboedral<br />
Caviar<br />
Roses<br />
Golfballs<br />
28<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Particle structures of modifief calcium carbonates (MCC)<br />
Brain<br />
Roses<br />
Caviar<br />
Golfballs<br />
29<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
STEM Images of Nano-Dimensional Surface Structures<br />
Nano Edges<br />
30<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
A new Generation of Calcium Carbonate Filler<br />
OMYABRITE 1300 X - OM<br />
Fineness:<br />
Top Cut (d98%) 9 µm<br />
Mean Particle Size (d50%) 2,4 µm<br />
*measured by Sedigraph 5100<br />
Optical Properties:<br />
Brightness (Ry, C/2°, DIN 53163) 95%<br />
Yellowness Index (DIN 6167) 1.8<br />
Specific Properties:<br />
BET surface (ISO 9277) 27 m 2 /g<br />
Oil Absorption<br />
50 g/100g<br />
Pore volume<br />
1.8 cm³/g<br />
31<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Emulsion Test Formulation A 150<br />
Raw material<br />
kg<br />
Physical data<br />
Water<br />
465.0<br />
PVC<br />
50.0 %<br />
Tylose MH 30’000 YG8<br />
6.3<br />
Density (solids)<br />
1.87 g/cm³<br />
Sodium hydroxide, 10%<br />
2.8<br />
Density (liquids)<br />
1.21 g/cm³<br />
Mowiplus XW 330<br />
4.0<br />
Volume solids per litre<br />
244 ml<br />
Calgon N new<br />
2.2<br />
Volume solids per kg<br />
201 ml<br />
Mergal 723 K<br />
1.5<br />
Solids content<br />
39.0 %<br />
Byk 032<br />
2.7<br />
Binder/pigment-ratio<br />
1 : 2.5<br />
Butyl digycol acetate<br />
4.6<br />
W hite spirit, low aromatics<br />
22.5<br />
Filler / Pigment (density 2.7 g/cm³)<br />
271.2<br />
Mowilith LDM 6119<br />
217.2<br />
Total<br />
1000.0<br />
32<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Dry opacity of different fillers and pigments<br />
– GCC<br />
– PCC<br />
Dry opacity<br />
%<br />
19<br />
46<br />
– <strong>Omya</strong>brite 1300 X - OM<br />
– TiO 2<br />
92<br />
95<br />
0 10 20 30 40 50 60 70 80 90 100<br />
• Draw down bar 150µm<br />
• Formulation A 150, PVC 50%<br />
33<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Properties <strong>Omya</strong>carb ® 2 <strong>Omya</strong>brite ® 1300 X - OM<br />
Mean Particle Size (d50%)* 2.5 µm 2.4 µm<br />
Top Cut (d95%)* 12 µm 9.0 µm<br />
Brightness Ry 94% 95 %<br />
Yellowness Index 2.5 1.8<br />
BET Surface 3.0 m 2 /g > 25 m 2 /g<br />
Oil absorption 19 g/100g 50 g/100g<br />
Pore Volume 0.1 cm 3 /g 1.8 cm 3 /g<br />
*Sedigraph 5100<br />
34<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Test Formulation with PVC = 50%<br />
Formulation Start A B<br />
Water deionised kg 433,0 440,9 440,9<br />
Tylose MH 30 000 YG8 kg 5,8 5,9 5,9<br />
Sodium hydoxide, 10% kg 2,7 2,7 2,7<br />
Mowiplus XW 330 kg 3,8 3,9 3,9<br />
Calgon N neu kg 2,0 2,1 2,1<br />
Mergal 723K kg 1,4 1,4 1,4<br />
Byk 032 kg 2,5 2,6 2,6<br />
Butyl diglycol acetate kg 4,3 4,4 4,4<br />
Kristallöl 30 kg 20,9 21,3 21,3<br />
<strong>Omya</strong>carb 2-GU kg 121,3 108,8 58,8<br />
<strong>Omya</strong>brite 1300 X - OM kg 50,0 100,0<br />
Tiona 595 kg 200,0 150,0 150,0<br />
Mowilith LDM 6119, 50% kg 202,3 206,0 206,0<br />
Total 1000,0 1000,0 1000,0<br />
35<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Optical results of draw downs at 60-70µm dry film thickness<br />
Test Results Start A B<br />
Ry white (Gap = 150µm) DIN 53 140 % 91,7 91,0 91,2<br />
Yellowness index (Gap = 150µm) % 1,6 1,9 1,7<br />
Contrast ratio (Gap = 150µm) ISO 2814 % 91,2 90,0 91,6<br />
85° Gloss (Gap = 150µm) DIN 67 530 % 15,2 4,9 3,3<br />
• Opacity is kept on same level whilst sheen is reduced!<br />
36<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Summary of Emulsion Paint Study of<br />
<strong>Omya</strong>brite 1300 X OM<br />
• Excellent dry opacity<br />
• High brightness<br />
Unique and never<br />
before obtained<br />
performance with<br />
calcium carbonate<br />
• Low sheen<br />
• Brilliant wet scrub resistance<br />
37<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Further Potentials with MCC in Paints<br />
• Improved optical paint properties<br />
• Partial substitution of TiO 2<br />
• Rheology functionality<br />
• Replace of opacifying fillers having a high oil absorption<br />
• Cost savings<br />
38<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Road map to applications with functional fillers<br />
Product<br />
<strong>Omya</strong>coat ®<br />
855 - KU<br />
Calcigloss ® -<br />
GU<br />
<strong>Omya</strong>brite ®<br />
1300X - OM<br />
Application / Purpose<br />
- Water-based decorative coating systems<br />
high PVC of 70 to 90%<br />
- Partial substitution of titanium dioxide<br />
- Substitution of other opacifying fillers<br />
Cost savings!<br />
Solvent-based and powder coating systems<br />
low PVC of 15 to 30%<br />
- Partial substitution of titanium dioxide by spacing effect<br />
Cost savings!<br />
Water-based decorative coating systems<br />
medium PVC of 30 to 70%<br />
- Partial substitution of titanium dioxide<br />
- Substitution of other opacifying fillers<br />
Cost savings!<br />
39<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
Asia Pacific Coating Show 2010<br />
Thank you for your attention!<br />
40<br />
This document contains some proprietary information which shall not be<br />
used and disclosed without <strong>Omya</strong> International AG express written authorization.<br />
<strong>Omya</strong>
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