page_banner

New Opportunities for UV-Curable Powder Coatings

The growing demand for radiation cured coating technology brings into focus the significant economic, environmental and process benefits of UV-curing. UV-cured powder coatings fully capture this trio of benefits. As energy costs continue to increase, the demand for “green” solutions will also continue unabated as consumers demand new and improved products and performance.

Markets reward firms that are innovative and adopt new technologies by incorporating these technological advantages into their products and or processes. Developing products that are better, faster and cheaper will continue to remain the norm that drives innovation. The purpose of this article is to identify and quantify the benefits of UV-cured powder coatings and demonstrate that UV-cured powder coatings meet the “Better, Faster and Cheaper” innovation challenge.

UV-curable powder coatings

Better = Sustainable

Faster = Lower energy consumption

Cheaper = More value for less cost

Market overview

Sales of UV-cured powder coatings are expected grow at least three percent per year for the next three years, according to Radtech’s February 2011, “Update UV/EB Market Estimates Based on Market Survey.” UV-cured powder coatings contain no volatile organic compounds. This environmental benefit is a significant reason for this expected growth rate.

Consumers are becoming ever more conscious of the health of the environment. The cost of energy is influencing buying decisions, which are now based upon a calculus that includes sustainability, energy and total product life cycle costs. These buying decisions have ramifications up and down supply chains and channels and across industries and markets. Architects, designers, material specifiers, purchasing agents and corporate managers are actively seeking out products and materials that meet specific environmental requirements, whether they are mandated, such as CARB (California Air Resources Board), or voluntary, such as SFI (Sustainable Forest Initiative) or FSC (Forest Stewardship Council).

UV powder coating applications

Today, the desire for sustainable and innovative products is greater than ever. This has driven many powder coating manufacturers to develop coatings for substrates never previously powder coated. New product applications for low temperature coatings and UV-cured powder are being developed. These finishing materials are being used on heat sensitive substrates such as medium density fiberboard (MDF), plastics, composites and preassembled parts.

UV-cured powder coating is a very durable coating, enabling innovative design and finishing possibilities and can be used on a vast array of substrates. One substrate commonly used with UV-cured powder coating is MDF. MDF is a readily available bi-product of the wood industry. It is easy to machine, is durable and used in a variety of furniture products at retail including point of purchase displays and fixtures, work surfaces, healthcare and office furniture. UV-cured powder coating finish performance can exceed that of plastic and vinyl laminates, liquid coatings and thermal powder coatings.

Many plastics can be finished with UV-cured powder coatings. However, UV powder coating plastic does require a pretreatment step to make an electrostatic conductive surface on plastic. To assure adhesion surface activation may also be required.

Pre-assembled components containing heat sensitive materials are being finished with UV-cured powder coatings. These products contain a number of different parts and materials including plastic, rubber seals, electronic components, gaskets and lubricating oils. These internal components and materials are not degraded or damaged because of UV-cured powder coatings exceptionally low process temperature and fast processing speed.

UV powder coating technology

A typical UV-cured powder coating system requires about 2,050 square feet of plant floor. A solventborne finishing system of an equal line speed and density has a footprint in excess of 16,000 square feet. Assuming an average lease cost of $6.50 per square foot per year, the estimated UV-cure system annual lease cost is $13,300 and $104,000 for a solventborne finishing system. The annual savings is $90,700. The illustration in Figure 1: Illustration for Typical Manufacturing Space for UV-Cured Powder Coating vs. Solventborne Coating System, is a graphic representation of the scale difference between the footprints of a UV-cured powder system and solvent-borne finishing system.

Parameters for Figure 1
• Part size—9 square feet finished all sides 3/4″ thick stock
• Comparable line density and speed
• 3D part single pass finishing
• Finish film build
     -UV powder – 2.0 to 3.0 mils dependent on substrate
     -Solventborne paint – 1.0 mil dry film thickness
• Oven/cure conditions
     -UV powder – 1 minute melt, seconds UV cure
     -Solventborne – 30 minutes at 264 degrees F
• Illustration does not include substrate

The electrostatic powder application function of a UV-cured powder coating system and a thermoset powder coating system are the same. However, the separation of the melt/flow and the cure process functions is the differentiating characteristic between the UV-cured powder coating system and the thermal powder coating system. This separation enables the processor to control the melt/flow and cure functions with precision and efficiency, and helps maximize energy efficiency, improve material utilization and most importantly increase production quality (see Figure 2: Illustration of UV-Cured Powder Coating Application Process).


Post time: Aug-27-2025