SURFACE COATINGS INDUSTRY

A Written Report for Chemical Process Industries

Nalo, Ma. Julia Camille G.
1. Introduction
A surface coating refers to substances that when applied to a surface and dried, form a thin,
functional film. Their primary purpose is to alter surface properties, like color, gloss, wear
resistance, and permeability, without changing the bulk characteristics. Different surface coatings
are produced to provide specific properties such as corrosion resistance, UV protection, abrasion
resistance, non-stick properties, conductivity, or insulation.
The surface coating industry is a crucial and multifaceted sector within materials science and
manufacturing. It has the capacity to transform and improve the properties of surfaces, playing a
significant role in applications across sectors like automotive, aerospace, construction, and
electronics. These coatings serve both aesthetic and protective purposes, safeguarding against
issues like corrosion, wear, and environmental factors, thereby contributing to the durability and
functionality of various products and structures.
Surface coatings encompass a wide range of materials and techniques, each tailored to specific
applications. They are available in forms such as paints, varnishes, enamels, and powder coatings,
each designed to meet specific needs.
Among these, paint is the most common type of surface coating. Paint is a liquid or semi-liquid
substance consisting of pigments, binders, solvents, and additives that, when applied to a surface,
dries or cures to form a thin, protective, and often decorative film. They can enhance an object's
aesthetic appeal by highlighting or concealing its surface features. For the purposes of this paper,
our focus will be on paint manufacturing, its raw materials, processes, and environmental impacts.
2. Raw Materials
Liquid paints are a combination of finely dispersed pigment in a liquid mixture made up of
a resin or binder and a volatile solvent. As a result, paints are created using three primary
components: pigments, binders, and solvents, along with various additives that impart
specific properties for particular purposes or uses.

2.1 Pigments
Pigments are a key part of paint. They need to be opaque for good coverage and chemically
stable for durability. Pigments are solid particles that give color, opacity, gloss, and control
to the paint. They can also serve functions like preventing corrosion or creating magnetic
properties.

Titanium dioxide is the most used pigment in the paint industry. When used in paints, it
provides maximum whiteness and opacity. It gives paint high hiding power, meaning the
ability to mask or hide the substrate underneath.

2.2 Binders
The most important component of a paint formulation is the binder. Binders are responsible
for forming a matrix that holds the pigment in place and enables adhesion to the coated
 surface. They also determine the drying and hardening behavior, mechanical properties,
chemical resistance, and weather resistance. They are the primary components that remain
after the paint has cured. Alkyd, acrylic, and vinyl resins are three of the most used resins.

2.3 Solvents
They dissolve thick binder components and help the paint flow smoothly for easy
application. They help in the homogeneity between different paint components, improve
pigment wetting and dispersion, control paint viscosity, and storage stability. Solvents help
release air bubbles from the paint, influence how it dries, and enhance its smoothness and
shine. They can either be organic solvents or water.

2.4 Additives
Additives are substances that are added to a coating in very small amounts to impart certain
properties to the paint. They can improve properties such as wetting and dispersing, flow
and leveling, defoaming and some can act as matting agents, and many more. Additives
include driers, thickeners, fillers, biocides, surfactants, dispersing agents, and catalysts.

3. Paint Formulation
Creating the right paint involves carefully choosing materials and calculating their quantities.
Typically, paint consists of suspended pigments and fillers in a liquid. The specific formulation of
paint depends on its intended use, which includes concealing the surface, providing color,
withstanding weather, being washable, adding gloss, and preventing corrosion. To make the right
paint, it's essential to select pigments, fillers, and carrier liquids (vehicles). To predict paint
properties like ease of application, gloss, and washability for a given formula, we use the pigment
volume concentration (PVC) as an indicator.

𝑣𝑜𝑢𝑙𝑚𝑒 𝑜𝑓 𝑝𝑖𝑔𝑚𝑒𝑛𝑡 𝑖𝑛 𝑝𝑎𝑖𝑛𝑡

𝑃𝑖𝑔𝑚𝑒𝑛𝑡 𝑣𝑜𝑙𝑢𝑚𝑒 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛 (𝑃𝑉𝐶) = 𝑥100%
𝑣𝑜𝑎𝑢𝑙𝑚𝑒 𝑜𝑓 𝑝𝑖𝑔𝑚𝑒𝑛𝑡 𝑖𝑛 𝑝𝑎𝑖𝑛𝑡
+
𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑏𝑖𝑛𝑑𝑒𝑟

The PVC represents the volume fraction of pigments in a paint compared to the total volume of
non-volatile constituents in the paint. Thus, as PVC increases, density and hiding power also
increase. However, performance properties such as durability, washability, stain resistance, and
corrosion resistance typically decrease. A low PVC also indicates a higher gloss paint and better
performance properties. The usual range of PCV of a given paint is shown in table 1.

Table 1. Typical range of PVC for different types of paints

4. Classifications and Applications of Paint
Paints are majorly classified as either water-based or solvent-based paints.
Water-Based Paints Solvent-based Paints

Uses water as liquifying agent Uses organic solvents that are meant to evaporate
via a chemical reaction with oxygen.

Lower VOC levels, reduced odor, more Higher VOC levels means prominent odor,
environmentally friendly. flammables, less environmentally friendly

Thinned with water and equipment can also be Thinned with turpentine, white spirit or other
cleaned with water, reducing the need for organic thinners as required.
solvent as thinners.

Water-based paints take longer to dry in high More tolerant of weather conditions such as
humidity and lower temperatures. humidity or high temperatures.

Keeps its sheen better throughout its lifetime Has a tougher and glossier finish making it easier
to clean but become brittle with aging.

Ideal choice of paints for home interiors. Ideal choice for exteriors where dirt and
temperature changes more frequently.

Examples are latex and acrylic paints primarily used Examples are alkyd paints which are often used for
to paint homes, structures, and spaces. furniture and enamels paints which are often used
on metal, wood, and ceramic surfaces.

5. Manufacturing

Figure 1. Flowchart of Paint manufacturing

The manufacturing procedures illustrated in Fig. 1 and described here are for a mass-production
paint. The first operations are housed on the top floor so that, as manufacturing continues, the
materials can be transferred easily and economically from floor to floor by gravity. The
manufacturing of paint is typically done in batches. Batch processes allow paint manufacturers to
produce a wide variety of paint formulations with different colors, properties, and ingredients. This
flexibility is essential because the paint industry produces a vast array of products to meet customer
demands. As noted by The Environmental Protection Agency (EPA) in a document entitled Control
of VOC Emissions from Ink and Paint Manufacturing Processes, only physical processes of
weighing, mixing/dispersing, milling, tinting, thinning, and packaging take place and thus no
chemical reaction are involved.
5.1 Mixing
The first step in the manufacturing process is preassembly and premixing. In this step,
liquid raw materials such as resins, solvents, oils, alcohols, and water are mixed. Then
pigments and other solid materials are added into the liquids to create a thick mixture
known as the mill base. It's crucial to measure each raw material accurately before mixing
to ensure the proper balance of pigments, resins, and solvents, which prevents pigment
clumping during and after the mixing process.

5.2 Milling
The mill base undergoes further processing through milling, which aims to disperse and
break apart solid clusters and clumps, resulting in a uniform distribution of tiny solid
particles within the liquid mixture. The degree to which this is done determines the coating
effectiveness and permanency of the paint.

5.3 Finishing
In the final product finishing step, specifications are met by thinning, tinting, and blending.
Thinning involves diluting the milled dispersion with binders, solvents, or diluents to achieve
desired characteristics like viscosity and drying time. Additional additives can also be
introduced at this stage. Tinting, on the other hand, involves adjusting the product's color by
adding tinting bases. Both thinning and tinting are achieved by blending the necessary
ingredients with the milled dispersion.

5.4 Filtration
Before packaging, the final mixture must be purified using a bar screen. This is to further refine
the product and remove undispersed pigments and any entrained solids that could affect the
product’s final appearance and performance.

5.5 Filling/Packaging
The finished paint is transferred to containers, which can vary in size from small cans for
consumer use to large drums or bulk containers for industrial applications. Containers are
labeled with relevant information, including product details, safety information, and branding.
Specific types of paint require different raw materials to be used, thus the order in which these
materials are added can differ for each product. An example of the production line in solvent-based
paint production line is seen in figure 2 and the water-based paint production line seen in figure 3.
Where the specific raw materials/inputs needed for each process and its subsequent pollution
sources are seen.

Figure 2 Solvent-based Paints Production Line Figure 3 Water-based Paints Production Line
6. Apparatus and Equipment
6.1 Mixers
A wide variety of containers and tanks are used as mixers in the paint industry. Their
materials of construction must be appropriate to the contents being mixed. In producing
paint, a high-speed mixer and high-speed dispersion tanks are commonly used.
6.1.1 High Shear Mixer
In continuous high-speed mixers, a common system involves a rotor and a stationary
stator. This setup usually includes a rotor with four blades spinning at high speeds inside
the stator that doesn't move. When the rotor blades spin, they keep pulling materials into
the mixing area and then push them out forcefully through openings in the stator. This
process creates strong hydraulic forces that quickly mix, break down clumps, and create
emulsions.
6.1.2 High-speed disperser
High-speed dispersers are composed of a circular, toothed blade attached to a rotating
shaft agitates the mixture and blends the pigment into the solvent and break down loose
agglomerates.
6.2 Mills
Mills are commonly used in the paint manufacturing industry as a part of the process for
creating and dispersing pigments, binders, and other ingredients to formulate paint and
coatings. These mills are designed to efficiently mix and grind the raw materials to produce
a homogenous paint or coating mixture. The paint industry uses different types of mills,
but ball mills are most commonly used.
6.2.1 Ball Mills
 Ball Mill grinds material by rotating a cylinder with steel or ceramic grinding balls, causing
the balls to fall back into the cylinder and onto the material to be ground. The rotating
balls strike the material, grinding it into a finer state.
6.2.2 Sand Mills
Sand mills are vertical cylinders filled with grinding media. They use grinding media, such
as small glass beads or sand, to break down agglomerates and disperse solid particles
within a liquid medium. The grinding media moves within a cylindrical chamber and
imparts kinetic energy to the particles, causing them to break apart.
6.3 Filters
The most widely used filter in paint manufacturing is the screen filter. It simply consists of
a sheet of cross-linked steel with holes.

7. Environmental Impact Analysis

In a study conducted by Ekang in 2018, the environmental impact analysis of the paint
manufacturing cycle was evaluated. The impacts evaluated were global warming potential (GWP),
abiotic depletion elements (ADP) abiotic depletion fossil (ADP fossil), freshwater aquatic
ecotoxicity potential (FAETP), human ecotoxicity potential (HTP), marine aquatic ecotoxicity
potential (MAETP), acidification potential (AP), eutrophication potential (EP), ozone layer
depletion (ODP), terrestrial ecotoxicity potential (TETP) and photochemical ozone creation
(POCP).
For instance, water-based paint showed a 17% lower impact in abiotic resource depletion of fossil
fuels (ADP fossil) and a substantial 73% reduction in terrestrial ecotoxicity potential (TETP).
Specifically, water-based paint had a 28% lower impact on human toxicity potential (HTP), which
assesses potential harm to humans due to the release of toxic materials into the environment, and
on photochemical ozone creation potential (POCP), which considers the formation of reactive
compounds like ozone in the troposphere through photochemical reactions. However, it had a 10%
higher impact in ozone depletion potential (ODP) due to emissions from the production of silicone
defoamers using methyl chloride.
Both types of paint had marine aquatic ecotoxicity potential (MAETP) as their most significant
environmental impact indicator, suggesting harm to marine ecosystems. The manufacturing and
packaging stages were similar for both paints, with differences primarily related to energy use and
raw materials. Both paint types consumed fossil resources during the packaging and raw material
stages, with raw materials also contributing to ODP, MAETP, and freshwater aquatic ecotoxicity
potential (FAETP) due to heat energy use from natural gas and other sources.
Figure 4 Contribution of solvent-based paint and water-based paint to the environmental impact
based on life cycle phases
Solvent-based paints, in particular, release harmful substances like paint waste and volatile organic
compounds (VOCs), which can lead to health problems, especially for those exposed to them
regularly. Regulations have been introduced to reduce the harmful effects of these chemicals, and
water-based solvents have been developed to lower VOC emissions. However, the environmental
impact of paint manufacturing continues to grow due to increasing production and usage.
The cleaning phase generates most of the waste in paint manufacturing, and the resulting effluents
can harm aquatic ecosystems, leading to pollution and disruptions in the food chain. In the paint
industry, both solvent-based and water-based paints produce wastewater with hazardous
substances, and managing these effluents is challenging. Despite the preference for water-based
paints, they generate more wastewater as their use expands, making efforts to reduce the
environmental impact more complex.
8. Insights
Reducing waste in paint manufacturing is crucial, and one of the most important actions to mitigate
this is through process optimization. To minimize waste of all types, it's essential to have efficient
equipment and facilities. Process optimization not only reduces waste but also enhances the overall
efficiency of the manufacturing cycle.
Addressing gaseous waste and atmospheric emissions is a vital component of responsible paint
manufacturing. Dust collectors are commonly used to capture emissions during various production
stages, and they play a key role in collecting dust in bag houses. The collected emission control
dust or sludge can be repurposed by incorporating captured pigments as extenders in low-grade
paints, promoting sustainability in the industry.
Organic solvents, which often become contaminated through industrial usage, provide
opportunities for reclamation and reuse. These solvents are typically generated during equipment
cleaning processes. Solvent reclamation is typically achieved through distillation or evaporation,
which condenses them into a clean storage vessel. This practice not only reduces waste but also
conserves valuable resources.
In addition to waste reduction and responsible waste management, the paint manufacturing
industry is increasingly focusing on adopting sustainable practices. This includes minimizing
hazardous emissions, refining waste management processes, and investing in the development of
low-impact paint formulations. Regulations are continually evolving to promote eco-friendly
practices and products, while ongoing research and development efforts are driving the creation of
more environmentally friendly paints. Ultimately, heightened awareness of environmental issues
within the industry is essential for mitigating the environmental impact as the paint industry
continues to expand.
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