{"id":5981,"date":"2017-02-24T08:15:29","date_gmt":"2017-02-24T14:15:29","guid":{"rendered":"https:\/\/www.ulprospector.com\/knowledge\/?p=5981"},"modified":"2017-08-30T11:28:51","modified_gmt":"2017-08-30T17:28:51","slug":"pc-formulating-waterborne-coatings-adding-colors","status":"publish","type":"post","link":"https:\/\/ulprospector.ul.com\/5981\/pc-formulating-waterborne-coatings-adding-colors\/","title":{"rendered":"Formulating Waterborne Coatings, Part 3: Making Colors for Your Application"},"content":{"rendered":"

\"\"In Part 1<\/a> of this series, we looked at a checklist for beginning a waterborne coating project. In Part 2<\/a>, I detailed how additives can help achieve desired formulation results. Now we\u2019ll discuss the different stages of formulation, pigment selection, and specific types of ingredients.<\/p>\n

Let\u2019s start with what I would call a \u201ccanned direct-to-metal (DTM) formula,\u201d found under Grace\u2019s Formulation #EPS\u00ae<\/sup> 2535 SP-3 <\/strong><\/a>on ULProspector.com:<\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n
POUNDS<\/strong><\/td>\nGALLONS<\/strong><\/td>\nRAW MATERIAL<\/strong><\/td>\nSUPPLIERS<\/strong><\/td>\nINSTRUCTIONS<\/strong><\/td>\n<\/tr>\n
80.0<\/td>\n9.60<\/td>\nwater<\/td>\n<\/td>\nadd in order with good agitation<\/td>\n<\/tr>\n
18.0<\/td>\n2.05<\/td>\nDisperse-ayd\u00ae<\/sup> W-22<\/td>\nElementis<\/td>\n<\/td>\n<\/tr>\n
3.0<\/td>\n0.41<\/td>\nSurfynol\u00ae<\/sup> 104A<\/td>\nAir Products<\/td>\n<\/td>\n<\/tr>\n
1.0<\/td>\n0.13<\/td>\nAMP-95\u00ae<\/sup><\/td>\nAngus<\/td>\n<\/td>\n<\/tr>\n
1.5<\/td>\n0.17<\/td>\nBYK\u00ae<\/sup>-024<\/td>\nByk<\/td>\n<\/td>\n<\/tr>\n
100.00<\/td>\n2.87<\/td>\nTiona\u00ae<\/sup> RCL-535<\/td>\nMillennium<\/td>\nadd in order with good agitation<\/td>\n<\/tr>\n
200.0<\/td>\n9.06<\/td>\nAtomite\u00ae<\/sup><\/td>\nNexeo Solutions<\/td>\n<\/td>\n<\/tr>\n
15.0<\/td>\n1.00<\/td>\nShieldex\u00ae<\/sup> AC 5<\/td>\nGrace<\/td>\n<\/td>\n<\/tr>\n
25.0<\/td>\n1.00<\/td>\nHALOX\u00ae<\/sup> SZP\u2013391<\/td>\nHalox<\/td>\nDisperse to 6+Hegman grind<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

Combine the following ingredients in a separate vat from the mixture above, and mix thoroughly. This is your master vat.<\/strong><\/p>\n\n\n\n\n\n\n
POUNDS<\/strong><\/td>\nGALLONS<\/strong><\/td>\nRAW MATERIAL<\/strong><\/td>\nSUPPLIERS<\/strong><\/td>\nINSTRUCTIONS<\/strong><\/td>\n<\/tr>\n
425.0<\/td>\n48.85<\/td>\nEPS\u00ae 2535<\/td>\nEPS Materials<\/td>\nlet down in order<\/td>\n<\/tr>\n
0.5<\/td>\n0.006<\/td>\nBYK\u00ae-024<\/td>\nByk<\/td>\n<\/td>\n<\/tr>\n
1.5<\/td>\n0.16<\/td>\nNuosept\u2122 95<\/td>\nISP<\/td>\nNow add grind to this vat<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

Then add grind in a separate vat, with constant agitation.<\/strong><\/p>\n\n\n\n\n\n\n
POUNDS<\/strong><\/td>\nGALLONS<\/strong><\/td>\nRAW MATERIAL<\/strong><\/td>\nSUPPLIERS<\/strong><\/td>\nINSTRUCTIONS<\/strong><\/td>\n<\/tr>\n
130.9<\/td>\n15.71<\/td>\nWATER<\/td>\n<\/td>\nPremix next three items<\/td>\n<\/tr>\n
10.0<\/td>\n1.20<\/td>\n\u00a04% Sodium Nitrite<\/td>\n<\/td>\nbefore adding solvent<\/td>\n<\/tr>\n
4.0<\/td>\n0.45<\/td>\nRHEOLATE\u00ae<\/sup> 1<\/td>\nElementis Specialties<\/td>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

Then add the solvents.<\/strong><\/p>\n\n\n\n\n\n\n\n\n
POUNDS<\/strong><\/td>\nGALLONS<\/strong><\/td>\nRAW MATERIAL<\/strong><\/td>\nSUPPLIERS<\/strong><\/td>\nINSTRUCTIONS<\/strong><\/td>\n<\/tr>\n
38.3<\/td>\n5.01<\/td>\nDipropylene Glycol Normal Butyl Ether (DPnB)<\/td>\nLyondell<\/td>\nadd to above premix<\/td>\n<\/tr>\n
19.1<\/td>\n2.05<\/td>\nSanticizer 160<\/td>\nEra Polymers<\/td>\nAdd to above premix and then add total mixture to above master batch with good agitation.<\/td>\n<\/tr>\n
1.0<\/td>\n0.11<\/td>\nACRYSOL\u2122 RM-825<\/td>\nDow Coating Materials<\/td>\nPremix and add for viscosity<\/td>\n<\/tr>\n
1.0<\/td>\n0.11<\/td>\nwater<\/td>\n<\/td>\n<\/td>\n<\/tr>\n
1074.80<\/td>\n100.00<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

Let\u2019s look a little more closely at the additives in this type of formulation.<\/p>\n

The first mixture is for the color part of the formula. Starting with water, you then add an ingredient to help disperse the \u201cpowder\u201d that will go into the grind stage. In this case, that dispersant is Disperse-ayd W-22. The choice depends on the PVC (Pigment Volume Concentration) level you intend to achieve.<\/p>\n

If you have a higher PVC, ask a supplier which dispersant they recommend to try, as well as their recommendation for a lower PVC. Formulating the correct PVC is critical in optimizing your coating. As in this case, an additional disperse aid assisted in long term stability of the formulation.<\/p>\n

Defoamers are always used in color formulations. In this example, Surfynol 104A not only defoams, but has an added benefit of providing dynamic wetting. The use of multiple defoamers in not unusual as in this case, where BYK-024 was also used several times. This is a typical case where I would have chosen a different type of defoamer so as not to have these compete.<\/p>\n

Pigment selection is up to the formulator, as well as your choice of type of filler to offset the cost of the TiO2<\/sub> in your formula. In this example, we see a reduced amount of TiO2<\/sub> and an increased amount of Atomite. Check your selection, for both have different particle sizes available. Some grind down well, some do not! This formula also incorporated two anti-corrosion pigments.<\/p>\n

Resin selection is still dependent on the very first checklist we created in Part 1 of this article. This formulator chose a styrenated acrylic emulsion, as it is supposed to offer outstanding corrosion resistance, adhesion and early water resistance. Acrylics are known to promote adhesion, where urethanes bring the chemical resistance and exterior durability.<\/p>\n

We finish off the film formation with some solvent packages. The use of DPnB (25% on resin solids) is recommended to form films as low as 40\u00b0F while offering excellent corrosion resistance and open dry times for finishing large objects. Small additions of plasticizer, such as Paraplex WP-1, Santicizer 160, or KP-140 may enhance the film properties.<\/p>\n

Then finally we finish things off with a viscosity adjustment. It may be necessary at times to use a package of Rheology modifiers, to attain viscosity control as well as proper sag resistance. Among those showing particular success with this resin system were:<\/p>\n