{"id":7546,"date":"2017-12-29T08:00:13","date_gmt":"2017-12-29T14:00:13","guid":{"rendered":"https:\/\/www.ulprospector.com\/knowledge\/?p=7546"},"modified":"2024-06-26T09:00:17","modified_gmt":"2024-06-26T15:00:17","slug":"pc-reformulate-premium-ultra-matt-coating","status":"publish","type":"post","link":"https:\/\/ulprospector.ul.com\/7546\/pc-reformulate-premium-ultra-matt-coating\/","title":{"rendered":"Head Scratcher: How to Reformulate a Premium Ultra Matt Coating"},"content":{"rendered":"<figure id=\"attachment_7555\" class=\"thumbnail wp-caption alignright\" style=\"width: 300px\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/ulprospector.ul.com\/media\/2017\/12\/pc-formulation-head-scratcher-OG-300x157.jpg\" alt=\"Paint tools and expertise come in handy when trying to solve a coatings formulation challenge - how would you respond to these issues? Challenge yourself in the Prospector Knowledge Center.\" width=\"300\" height=\"157\" \/><figcaption class=\"caption wp-caption-text\">Copyright: <a href=\"https:\/\/www.123rf.com\/profile_mrtwister\" target=\"_blank\" rel=\"noopener\">mrtwister \/ 123RF Stock Photo<\/a><\/figcaption><\/figure>\n<p><em><strong>EDITOR&#8217;S NOTE: We are introducing a series of posts called &#8220;Head Scratchers,&#8221; featuring real-life coatings formulation challenges and how our coatings expert Philip Green and his team handled them. Welcome to the first installment! We will first present the challenge, with the solution hidden, so you can first consider how you might handle the situation. Then you can click the drop-down to see Philip&#8217;s resolution. After reading through, we welcome your comments on the resolutions, and any similar challenges you currently have, or how you have handled them in the past.<\/strong><\/em><\/p>\n<p>BACKGROUND<\/p>\n<p>A Southern African coastal-based medium-to-large regional paint company has been making a premium, mostly interior paint for five years with a steady increase in sales. They therefore commission you as an independent consultant to \u201cblind\u201d evaluate samples of their product, plus their main market competitors, considering the issues below.<\/p>\n<p><b>Compare<\/b> opacity contrast ratio side-by-side<\/p>\n<ul>\n<li><strong>Finding:<\/strong> similar to competition<\/li>\n<\/ul>\n<p><b>Problem:<\/b> The competition\u2019s practical opacity is better<\/p>\n<ul>\n<li><strong>Findings:<\/strong> at the same wet film build, the opacity is ok. The rheology and application properties are wrong. It is not restrictive enough and\/or the paint does not flow out enough<\/li>\n<\/ul>\n<p><b>Problem:<\/b> Brush and roller application properties are worse than the competition\u2019s (Overspreads, too many roller\/brush marks, too much foam)<\/p>\n<ul>\n<li><strong>Solution:<\/strong> The current rheology has too much pseudoplasticity so when shear forces are applied by brush or roller, it breaks down and overspreads. But when the force is removed, it does not flow; it sets up. The product needs to be made to spread less and flow more. The manufacturer needs to reduce the hydroxyethyl cellulose (HEC) level and probably the viscosity grade from 50-60000 CPS to 15000 or 4-6000 CPS.<\/li>\n<li>Also, the manufacturer needs to include end stage thickeners, probably a mixture of mid-shear and high-shear, to give both restriction flow and also spatter resistance. Now whether the end stage thickener is acrylic (hydrophobically modified alkali-soluble emulsion, or HASE) or associative (hydrophobically modified ethoxylated urethane resins, or HEUR) will depend on the market cost and product requirements. If water resistance, adhesion and dirt pick-up resistance (DPUR) all need improvement, then fully associative thickeners may be the best long-term option.<\/li>\n<li>The defoamer level and type needs also to be optimized, probably by increasing the level but also the type to more powerful but general-purpose silicone defoamers. Also, the manufacturer needs to increase the wet edge solvent level to reduce the chance of lap marks.<\/li>\n<\/ul>\n<p><b>Problem:<\/b> The current paint has sheen at 85\u00b0, which is slightly higher than the competition\u2019s (Client wants it to be less than 3\/85)<\/p>\n<ul>\n<li><strong>Solution: <\/strong>There are many ways to slightly drop the sheen but we also want to try to improve water, stain and polish resistance. Raising the PVC and\/or lowering the amount of latex would not be the right way to go. One option is to partially replace the 10-micron calcium carbonate with talc and\/or diatomaceous earth; both will make the product very matt. Talc will help with stain resistance as it will be hydrophobic and plate-like and including diatomaceous earth could help with polish resistance and make the paint less likely to overspread on brush\/roller application.<\/li>\n<\/ul>\n<p><b>Problem:<\/b> Water resistance and wet adhesion suspect<\/p>\n<ul>\n<li><strong>Solution:<\/strong> This is all down to polymer type and level. Probably an adhesion promoted pure acrylic is the best choice, especially if cost is not an issue.<\/li>\n<\/ul>\n<p><b>Problem:<\/b> Fungus (mildew) problems when the product is used in kitchens\/bathrooms<\/p>\n<ul>\n<li><strong>Solution:<\/strong> Although this issue has not been picked up in tests, the company has had reports. You need to add 0.25 or 0.5% of a less water-leachable dry film biocide. Which one you use will depend on your local dry film biocide rules.<\/li>\n<\/ul>\n<p><b>Problem:<\/b> The competition has much better hot DPUR. This has also been seen in the field, which is partially why the product is not often used for exteriors.<\/p>\n<ul>\n<li><strong>Solution:<\/strong> The manufacturer may need to think of adding TiO<sub>2<\/sub> and polymer with a microvoid opacifier. It could help improve costs, water resistance and hot DPUR, but can lead to polishing resistance issues if not formulated properly.<\/li>\n<\/ul>\n<p><b>Problem:<\/b> The competition has much better stain and polishing resistance<\/p>\n<ul>\n<li><strong>Solution:<\/strong> This issue is mostly polymer type and level related but getting the defoamer type and level correct will help stain resistance a lot. Also, using a low level of a wax dispersant will help both polishing resistance and possibly water resistance.<\/li>\n<\/ul>\n<p><b>Problem:<\/b> Slight to medium yellowing on UV exposure<\/p>\n<ul>\n<li><strong>Solution:<\/strong> Remove the styrene acrylic to reduce the chance of yellowing.<\/li>\n<\/ul>\n<p>See my modified version of the formulation, taking all the above points into account.<\/p>\n<h3>EXTERIOR ACRYLIC ULTRA MATT INTERIOR PASTEL BASE<\/h3>\n<h4>PG MODIFIED VERSION<\/h4>\n<table width=\"455\">\n<tbody>\n<tr>\n<td width=\"156\"><strong>RAW MATERIAL<\/strong><\/td>\n<td width=\"135\"><strong>KG\/APPROX 1000 L<\/strong><\/td>\n<td width=\"165\"><strong>ACTION<\/strong><\/td>\n<\/tr>\n<tr>\n<td width=\"156\">WATER<\/td>\n<td width=\"135\">275-0<\/td>\n<td rowspan=\"2\" width=\"165\">PREMIX FOR 5 MINS IN CLEAN POT<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">HEC 4-6000 CPS GRADE<\/td>\n<td width=\"135\">5-0<\/td>\n<\/tr>\n<tr>\n<td width=\"156\"><\/td>\n<td width=\"135\"><\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\">SHMP<\/td>\n<td width=\"135\">1-2<\/td>\n<td rowspan=\"3\" width=\"165\">ADD SEPERATELY IN ORDER SHOWN &#8211; MIX 2 MINS<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">45% Solids POLYACRYLATE<\/td>\n<td width=\"135\">4-0<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">DEFOAMER<\/td>\n<td width=\"135\">4-0<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">INCAN BIOCIDE<\/td>\n<td width=\"135\">2-0<\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\">DRY FILM BIOCIDE<\/td>\n<td width=\"135\">5-0<\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\"><\/td>\n<td width=\"135\"><\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\">TIOXIDE<\/td>\n<td width=\"135\">175-0<\/td>\n<td rowspan=\"4\" width=\"165\">DISPERSE UNDER HSD FOR 20-25 MINS, UNTIL GRIND IS 50 MICRONS MAX<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">10 MICRON CACO3<\/td>\n<td width=\"135\">100-0<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">TALC<\/td>\n<td width=\"135\">65-0<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">ATTAPULGITE CLAY<\/td>\n<td width=\"135\">3-0<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">DIATOMACEOUS EARTH<\/td>\n<td width=\"135\">35-0<\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\"><\/td>\n<td width=\"135\"><\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\">WATER<\/td>\n<td width=\"135\">20-0<\/td>\n<td width=\"165\">WASH SIDES OF VESSAL<\/td>\n<\/tr>\n<tr>\n<td width=\"156\"><\/td>\n<td width=\"135\"><\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\">WATER<\/td>\n<td width=\"135\">17-0<\/td>\n<td rowspan=\"3\" width=\"165\">LETDOWN, ADD, MIX FOR 10 MINS, COOL TO 40 DEG C MAX<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">COALESCENT<\/td>\n<td width=\"135\">21-5<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">WET EDGE SOLVENT<\/td>\n<td width=\"135\">21-2<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">DEFOAMER<\/td>\n<td width=\"135\">2-0<\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\">WAX DISPERSION<\/td>\n<td width=\"135\">5-0<\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\"><\/td>\n<td width=\"135\"><\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\">ADHESION PROMOTED PA<\/td>\n<td width=\"135\">375-0<\/td>\n<td rowspan=\"2\" width=\"165\">SIEVE INTO BATCH<\/p>\n<p>SLOWLY MIX FOR 10 MIN<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">MICROVOID OPACIFIER<\/td>\n<td width=\"135\">50-0<\/td>\n<\/tr>\n<tr>\n<td width=\"156\"><\/td>\n<td width=\"135\"><\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\">WATER<\/td>\n<td width=\"135\">49-3<\/td>\n<td rowspan=\"3\" width=\"165\">PREMIX, ADD, MIX FOR 5 MINS, ADJUST PH TO 8.3-8.7 WITH DISACOAT<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">RHEOLOGY MODIFIER<\/td>\n<td width=\"135\">5-0<\/td>\n<\/tr>\n<tr>\n<td width=\"156\">COMBINATION<\/td>\n<td width=\"135\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\"><\/td>\n<td width=\"135\"><\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\">WATER<\/td>\n<td width=\"135\">15-7<\/td>\n<td width=\"165\">ADJUST VISCOSITY<\/td>\n<\/tr>\n<tr>\n<td width=\"156\"><\/td>\n<td width=\"135\"><\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<tr>\n<td width=\"156\"><strong>TOTAL<\/strong><\/td>\n<td width=\"135\"><strong>1259.8<\/strong><\/td>\n<td width=\"165\"><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h3><\/h3>\n<h3>QUALITY CONTROL TESTS<\/h3>\n<table>\n<tbody>\n<tr>\n<td width=\"154\">VISCOSITY<\/td>\n<td width=\"206\">95-105 KU @ 23 DEG C<\/td>\n<\/tr>\n<tr>\n<td width=\"154\">SG<\/td>\n<td width=\"206\">1.21-1.25<\/td>\n<\/tr>\n<tr>\n<td width=\"154\">FOG<\/td>\n<td width=\"206\">30 MICRONS MAX<\/td>\n<\/tr>\n<tr>\n<td width=\"154\">VOL SOLIDS<\/td>\n<td width=\"206\">30-32 %<\/td>\n<\/tr>\n<tr>\n<td width=\"154\">PVC<\/td>\n<td width=\"206\">38-42 %<\/td>\n<\/tr>\n<tr>\n<td width=\"154\">pH<\/td>\n<td width=\"206\">8.3-8.7<\/td>\n<\/tr>\n<tr>\n<td width=\"154\">SHORTFALL FACTOR<\/td>\n<td width=\"206\">0.984<\/td>\n<\/tr>\n<tr>\n<td width=\"154\"><\/td>\n<td width=\"206\"><\/td>\n<\/tr>\n<tr>\n<td colspan=\"2\" width=\"360\">SHEEN SIMILAR TO STANDARD (LESS THAN 3\/85 DEG HEAD MAX)<\/p>\n<p>OPACITY SIMILAR TO STANDARD BRUSH, ROLLER APPLICATION, FLOW SIMILAR TO MAJORS<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n","protected":false},"excerpt":{"rendered":"<p>EDITOR&#8217;S NOTE: We are introducing a series of posts called &#8220;Head Scratchers,&#8221; featuring real-life coatings formulation challenges and how our coatings expert Philip Green and his team handled them. Welcome to the first installment! We will first present the challenge, &hellip; <a href=\"https:\/\/ulprospector.ul.com\/7546\/pc-reformulate-premium-ultra-matt-coating\/\">Continued<\/a><\/p>\n","protected":false},"author":62,"featured_media":7554,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"episode_type":"","audio_file":"","podmotor_file_id":"","podmotor_episode_id":"","cover_image":"","cover_image_id":"","duration":"","filesize":"","filesize_raw":"","date_recorded":"","explicit":"","block":"","itunes_episode_number":"","itunes_title":"","itunes_season_number":"","itunes_episode_type":"","footnotes":""},"categories":[16],"tags":[237],"ppma_author":[1274],"class_list":{"0":"post-7546","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-paint-coatings","8":"tag-formulation-challenge","9":"entry"},"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Reformulating an ultra matt coating: Formulation challenge<\/title>\n<meta name=\"description\" content=\"A manufacturer requests that you improve your coating formulation to meet certain criteria. 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Challenge yourself to figure out the answers here!\" \/>\n<meta property=\"og:url\" content=\"https:\/\/ulprospector.ul.com\/7546\/pc-reformulate-premium-ultra-matt-coating\/\" \/>\n<meta property=\"og:site_name\" content=\"Prospector Knowledge Center\" \/>\n<meta property=\"article:published_time\" content=\"2017-12-29T14:00:13+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2024-06-26T15:00:17+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2017\/12\/pc-formulation-head-scratcher-OG.jpg\" \/>\n\t<meta property=\"og:image:width\" content=\"1200\" \/>\n\t<meta property=\"og:image:height\" content=\"628\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/jpeg\" \/>\n<meta name=\"author\" content=\"Philip Green\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:image\" content=\"https:\/\/ulprospector.ul.com\/media\/2017\/12\/pc-formulation-head-scratcher-150x150.jpg\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Philip Green\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"5 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/7546\\\/pc-reformulate-premium-ultra-matt-coating\\\/#article\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/7546\\\/pc-reformulate-premium-ultra-matt-coating\\\/\"},\"author\":{\"name\":\"Philip Green\",\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/#\\\/schema\\\/person\\\/32b1d388eee0a534347bad77b56556af\"},\"headline\":\"Head Scratcher: How to Reformulate a Premium Ultra Matt Coating\",\"datePublished\":\"2017-12-29T14:00:13+00:00\",\"dateModified\":\"2024-06-26T15:00:17+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/7546\\\/pc-reformulate-premium-ultra-matt-coating\\\/\"},\"wordCount\":967,\"image\":{\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/7546\\\/pc-reformulate-premium-ultra-matt-coating\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/ulprospector.ul.com\\\/wp-content\\\/uploads\\\/2017\\\/12\\\/pc-formulation-head-scratcher-600x400.jpg\",\"keywords\":[\"formulation challenge\"],\"articleSection\":[\"Paint &amp; Coatings\"],\"inLanguage\":\"en-US\"},{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/7546\\\/pc-reformulate-premium-ultra-matt-coating\\\/\",\"url\":\"https:\\\/\\\/ulprospector.ul.com\\\/7546\\\/pc-reformulate-premium-ultra-matt-coating\\\/\",\"name\":\"Reformulating an ultra matt coating: Formulation challenge\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/7546\\\/pc-reformulate-premium-ultra-matt-coating\\\/#primaryimage\"},\"image\":{\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/7546\\\/pc-reformulate-premium-ultra-matt-coating\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/ulprospector.ul.com\\\/wp-content\\\/uploads\\\/2017\\\/12\\\/pc-formulation-head-scratcher-600x400.jpg\",\"datePublished\":\"2017-12-29T14:00:13+00:00\",\"dateModified\":\"2024-06-26T15:00:17+00:00\",\"author\":{\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/#\\\/schema\\\/person\\\/32b1d388eee0a534347bad77b56556af\"},\"description\":\"A manufacturer requests that you improve your coating formulation to meet certain criteria. 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Challenge yourself in the Prospector Knowledge Center.\"},{\"@type\":\"BreadcrumbList\",\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/7546\\\/pc-reformulate-premium-ultra-matt-coating\\\/#breadcrumb\",\"itemListElement\":[{\"@type\":\"ListItem\",\"position\":1,\"name\":\"Home\",\"item\":\"https:\\\/\\\/ulprospector.ul.com\\\/\"},{\"@type\":\"ListItem\",\"position\":2,\"name\":\"Head Scratcher: How to Reformulate a Premium Ultra Matt Coating\"}]},{\"@type\":\"WebSite\",\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/#website\",\"url\":\"https:\\\/\\\/ulprospector.ul.com\\\/\",\"name\":\"Prospector Knowledge Center\",\"description\":\"Welcome to the blog for UL Prospector, the most comprehensive raw material search engine for product developers.\",\"potentialAction\":[{\"@type\":\"SearchAction\",\"target\":{\"@type\":\"EntryPoint\",\"urlTemplate\":\"https:\\\/\\\/ulprospector.ul.com\\\/?s={search_term_string}\"},\"query-input\":{\"@type\":\"PropertyValueSpecification\",\"valueRequired\":true,\"valueName\":\"search_term_string\"}}],\"inLanguage\":\"en-US\"},{\"@type\":\"Person\",\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/#\\\/schema\\\/person\\\/32b1d388eee0a534347bad77b56556af\",\"name\":\"Philip Green\",\"image\":{\"@type\":\"ImageObject\",\"inLanguage\":\"en-US\",\"@id\":\"https:\\\/\\\/ulprospector.ul.com\\\/media\\\/2017\\\/12\\\/Philip-Green_avatar_1512676090-96x96.jpg92d8c8841f6ee512f2b754457fe053be\",\"url\":\"https:\\\/\\\/ulprospector.ul.com\\\/media\\\/2017\\\/12\\\/Philip-Green_avatar_1512676090-96x96.jpg\",\"contentUrl\":\"https:\\\/\\\/ulprospector.ul.com\\\/media\\\/2017\\\/12\\\/Philip-Green_avatar_1512676090-96x96.jpg\",\"caption\":\"Philip Green\"},\"description\":\"Philip Green, born and educated in Manchester, UK, has an Honour Degree in Nuclear\\\/Radiation\\\/Environmental Chemistry. After working at a Research Nuclear Reactor in the UK, then as an Explosives Chemist in South Africa, he finally joined the South African paint industry in 1982. He first worked for Dulux South Africa from 1982-1996, working his way up from bench chemist to Senior Development Manager for all Decorative Products in Southern Africa. He then went to Mauritius where he was Technical\\\/Production Manager for a paint company SOFAP LTEE. He returned to South Africa in 1998 and has been an independent Paint Technology Consultant ever since. 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