Wood compositesconference

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International Coating Wood & Wood Composites Conference September 13-14, 2011 Charlotte, NC UV-Curable Powder Coatings for MDF Substrates Michael Knoblauch DVUV Holdings, LLC

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Transcript of Wood compositesconference

Page 1: Wood compositesconference

International Coating Wood & Wood Composites Conference

September 13-14, 2011Charlotte, NC

UV-Curable Powder Coatings for MDF Substrates

Michael KnoblauchDVUV Holdings, LLC

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Discussion Overview

Market & Applications Why UV Powder? UV Curing Process Advantages Value of Powder Coating Environmental Benefits Questions

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Coatings Market

Paints and coatings marketNorth America paints and coatings market is valued at $21.2 billion.

In 2008, powder coating was a $6.5 billion industry.

Powder manufacturing is a $5 billion industry worldwide.

UV-cured coating marketUV-curable coatings will grow at a 7.5% rate to $2.41 billion by 2014.

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Industrial Coatings Market

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Powder Coating MDF MDF or Medium Density Fiberboard

Hardboard made from wood fibers which are glued under heat and pressure.

Excellent substrate for UV powder coatingDense & flat

Low porosity

Homogenous

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Powder Coating MDF Heating the board draws moisture to the surface, making it conductive for

electrostatic powder application. 2 Types of Application

Corona SprayPowder passes through highly charged & ionized corona field, powder picks up negative chargeHigh transfer efficiency and applies quickly

Tribo ChargingPowder develops a static charge due to frictionProvides better penetration into recesses Slower application and lower transfer efficiency

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UV Powder Applications for MDF Markets

Retail displays, fixtures and P-O-P

Healthcare and medical equipment

Storage and cabinetry

Specialty furniture

Excellent Finish and ProcessSuperior wear characteristics

Visual appeal and design innovation

Fast, efficient manufacturing

Environmentally safe production and end-products

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Why Powder Coat MDF? Increased design flexibility

No edge banding

Seamless 360° coverage Demand for environmentally

friendly products and processes.No VOCs, HAPs, or solvents

Superior wear characteristicsStrong cross-linked finish

Withstands high traffic environments

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Why Powder Coat MDF? Fast and efficient production

20 minute process

1 coat finish Ease of material handling

No messy liquids

Ability to reclaim waste powder Fast color changes

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Productivity & Innovation

Melamine

- 1 0 +1

+1

0

- 1

Productivity

Waterborne

UV

High

Pressure

HPLSolvent

Based

Vinyl

(membrane

press.)

Vinyl

Flat

PaperThermoset

UV Powder

Liquid

Lamination

Powder coating

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UV CuringUltraviolet curing (commonly known as UV curing) is a photochemical process in which high-intensity ultraviolet light is used to instantly cure or “dry” inks, coatings or adhesives.

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Cross-Linked UV Curing

Separates gel/flow stage from cure

Ensures complete cure for extended finish life

Expands potential gloss range

Enables smoother textures

Eliminates cracking

Creates cross-linked and bonded molecular finish

Produces superior surface that resists damage and maintains ideal appearance

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UV-Cured Powder Coating Process

Melt & Flow1 min

UV Cureseconds

Powder Deposition

Finished Product

Substrate Pretreatment

Raw Component to Finished Product: 20 Minutes

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14 Windy City Coatings ConferenceApril 27 & 28th, 2011

UV Powder Application System

• A UV powder application system

Parts are loaded and prepared

Pretreatment

Electrostatic powder application

Flow/Melt oven

UV Cure oven

Powder Coating Application

Environmental Room

UnloadArea

LoadArea

Pretreatment

MeltOven

UV CureOven

Prep

200 feet line – cycle 20 minutes

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UV Powder System Video

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UV Finishing Advantages Increases production speed & productivity

Liquid finishing requires flash off

Thermal curing requires 30 minutes or more

Thermoset higher temperatures require extra cooling time

Requires less energy and plant footprint

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Reduced Manufacturing Footprint

Typical thermal powder plant size >15,000 sqft

Typical UV powder plant

size2,050 sqft

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UV Finishing Advantages Reduces reject rates

Shorter line –– faster response time to fix issues

Reduced number of parts on line

Improved product performanceLess thermal exposure

Reduces outgassing

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Speed Wins!

0 10 20 30 40 50 60

Finish Time (min)

Liquid Coatings

Thermoset Powder

UV Powder

Part Cycle Time Anaylsis Thermal Cure Coating Systems (Powder & Liquid)

vs. UV Powder CoatingsCoating Application

Melt & Flow

UV cure

Solvent Flash

Thermal Cure

Cooling

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The Value of Powder Coating Applied material cost advantage

No solvents or liquids

Up to a 95% material utilization Shorter process time

Increased finishing capacity, faster ROI

Lower energy consumption

Shorter set-up times, less down time Efficient

Requires less energy and plant space

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The Value of Powder Coating Energy Productivity

Requires 1/4 to 1/8 less oven capacity than a solvent borne system

Utilizes gas to power ovens and electricity to power the UV lamp system

Solvent - FreeSavings associated to solvent incineration

Reduced waste disposal cost Less energy per part

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ROI Example

System Productive Capacity 3,000,000 Sq/ft/shift

Selling Price $4.00 Per/sq ft

Total Revenue $12,000,000 1 shift

Operating Margin 10%

Net Operating Margin $1,200,000

Net Investment $1,000,000

ROI Year 1 20%

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Environmental Benefits

Green Finish Formulation:

No VOCs (volatile organic compounds)

No HAPs (hazardous air pollutants)

No PVC (polyvinyl chloride)

No Solvents

Powder overspray can be reclaimed up to 95% MDF components can be recycled into mulch

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Environmental Benefits

Environmentally Sustainable Process:UV curing is extremely energy efficient

Fast, single-step process

20 minutes from raw MDF to finished parts Smaller manufacturing footprint

¼ - ⅓ the size required for other finishing processes Reduced energy consumption

40-60% energy savings compared to other finishes

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MDF and CARB ComplianceCARB(California Air Resources Board)

In 2007, the California Environmental Protection Agency implemented limits on the formaldehyde emitted from composite wood panels.

UV powder coating for MDF meets all CARB phase I and II compliances.

Phase I limits emitted urea-formaldehyde to <.21 ppm and <.11 for phase II.

UV-cured powder coating seals in remaining formaldehyde.

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Breadth of Pallet - Color & Effect

Metallic

Multi- Component

Full Color Pallet

Opaque

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Custom Color Matching Excellent scratch resistance hardness and chemical resistanceare all possible; together with a wide range of colors.

UV powder can be matched to meet any color standardRAL

Pantone Matching System (PMS)

Laminate Finishes

Liquid Paints

Any Supplied Sample

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Examples

Interactive Retail Display

Healthcare Component

POP Display

Educational Lectern

Architectural Element

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Conclusion

UV-cured powder coating for MDF provides:

High speed finishing and increased productivity Greater ROI Energy and space savings Environmentally friendly finishing option Durable and high quality product

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Thank You!

Questions?Michael KnoblauchPresidentDVUV Holdings, LLC4641 Hinckley Ind. Pkwy.Cleveland, OH [email protected]