POWDER COATINGS FOR MDF

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2 POWDER COATINGS FOR MDF CONTENT : ABOUT POWDER COATINGS POWDER COATINGS FOR MDF WOODCOTE TECHNOLOGIES DESIGN FLEXIBILTY ENVIRONMENTAL IMPACT PERFORMANCE TECHNICAL & PROCESS CONTACT DETAILS P3 P4 P6 P7 P9 P11 P12 P15 2

3 ABOUT POWDER COATINGS 1.0 POWDER COATINGS : 1.1 History First appeared in the early 1960 s in the USA and quickly became popular,especially in Europe. 1.2 Formulation Powder coatings are made from 100% solid raw materials (ie mixture of resins, pigments, fillers and additives) which means 100% of the product can be utilized 1.3Application & Process Application of the powder coatings are done by electrostatic spray application onto the substrate surface. The charged particles adhere to the substrate until heated and cured into a smooth or textured coating. Powder coatings are generally cured by a thermal convection system, however a combination with IR or induction is also possible. In recent years UV cured powders have been developed and commericalized. Powder coatings are available in a wide range of colours, textures,gloss, satin or matt finishes. The 100% solids means that powder coating have a low impact on the environment ie free of VOC materials. Recovery and reuse of the over spray powder means that the usage efficiency is very high compared to the liquid paint systems. 1.4 End Uses Powder coatings have found uses in many applications,eg * Architecture : external facades,window/door frames and fencing. * Automotive: vehicles and components * Shop fittings * Furniture : office furniture, commercial and exterior furniture. * Domestic Appliances * Air conditioning, electrical components, lighting * Industrial products plastic and heavy duty metal components. In recent years powder coating technologies, application and curing methods have made powder coatings possible on engineered wood products,such as MDF. Contrary to natural woods, MDF panels have a homogeneous surfaces and sufficient moisture content to provide conductivity of the powder coatings. 3

4 POWDER COATINGS FOR MDF 2.0 POWDER COATING FOR MDF : 2.1 Global Technology Interpon Woodcote powder coating provides a MDF decorating solution which is efficient,practical and environmentally complaint. Interpon is the global powder brand of Akzo Nobel which is the largest global manufactuer of powder coatings and the number one supplier in Australia. Interpon Woodcote is a global technology engineered by Akzo Nobel exclusively for composite wood products. 2.2 Service & Support Akzo Nobel are fully committed to the composite wood market in Australia.We have developed the Woodcote MDF decorating solution based on the outstanding physical and chemical properties of Interpon Woodcote powders and suitable moisture resistant MDF board in the market. The Interpon Powder Team in Australiasia is fully committed in supporting the technical and service requirements of this MDF market. The Interpon Woodcote colours provide a range of fashion colours to suit the needs of Architects and Designers. The excellent coating finish will be available in fine texture and smooth matt. 4

5 POWDER VS TRADITIONAL MDF FINISHING The most widely used finishing techniques for MDF boards are liquid paint, High Pressure Laminates (HPL), PVC Vinyl Wrap, and Melamine Low Pressure Laminate (LPL) So how do powder coatings compare with these other common MDF finishes? See below the comparison for various properties. scoring: 1 = very bad 5 = very good Product Powder Coatings Liquid paint HPL PVC Vinyl Wrap Melamine(LPL) Colour & Gloss A very wide range of colours, gloss, fine and coarse finishes High gloss finish is difficult to achieve. 3/5 A very wide range of colours and bright metallic effects Textured finish are not achievable Smooth, textured or patterned finish are achievable. Overall colour range is generally confined to manufacturers stock hold or large made to specials Customized colour and surface effects are possible but both expensive and limited Predominantly white. Appears similar to HPL with limited scope in colours or finish 2/5 Design Can be applied to a vast array of shapes and sizes 3-D design are achievable 5/5 Can coat a wide array of shapes and sizes. 3-D design are achievable 5/5 Restricted to straight or slightly rounded edges, surface contours nor openings. Only suitable for large volume and 2-D application 2/5 Only suitable for large volume and 2-D application Fast colour change are not achievable 2/5 Lack of flexibility Little design freedom 2/5 Chemical Resistance High chemical resistance if complete curing or UV polymerisation Bad to High chemical resistance, with regard to the nature of the liquid paint 3/5 Very high chemical resistance 5/5 Medium chemical resistance 2/5 Similar to HPL but with lower performance properties 3/5 Heat Resistance Medium to high heat resistance, depends if it a dry or a wet heat resistance test Low to high heat resistance, with regard to the nature of the liquid paint Very good heat resistance 5/5 Low heat stability properties (so it is used on cupboard doors or vertical surface) 2/5 Similar to HPL but with lower performance Light Resistance Interior Use Environment Score Very Good. 3/5 Solvent free process No VOC emissions and low formaldehyde. 5/5 Excellent Solvent based paint. High VOC s emission 1/5 Excellent Rely on solvent based glue. High VOCs 1/5 UV limitation: as direct Sun light can affect the colour of the film 1/5 Rely on solvent based glue and have high VOC s 1/5 Very Good 3/5 Similar to HPL 1/

6 WOODCOTE TECHNOLOGIES 3.0 TECHNOLOGIES : The Woodcote Powder Technologies are available in both Thermal cure and UV cure systems. See table below for details. The technologies offer excellent performance for engineered wood products. A standard colour range has been developed and custom colours can be matched for specific projects. Application Technology Recommended Bake Finishes Available End Use Thermal Low Bake Woodcote C Smooth; Matt & Fine Texture Interior Only Thermal Low Bake Woodcote TLB 10 mins.@ 140C Fine & Coarse Texture Interior Only UV Woodcote UV340 UV Cure, >2500 MJ/sq.cm. Fine and Coarse Texture Interior Only UV Woodcote UV640 UV Cure >2500 MJ/sq.cm. Smooth; Matt; Satin and Fine texture. Interior & Exterior 6

7 DESIGN FLEXIBILITY 4.0 DESIGN FLEXIBILTY : 4.1 Design Flexiblity Woodcote MDF Decorating Solution provides greater opportunity in design flexibility which other finishing methods and laminating processes cannot provide. Woodcote powder coatings are suitable for office desks, work stations, screens, panels, decorative interior cladding,kitchen doors premium furniture and shop fitouts Modern office furniture design is incorporating more rounded corners and contoured edges, with cut-outs for computer and power cables to drop through complex shapes. Current lamination techniques, which rely on edge-banding methods, cannot accommodate these challenges. Woodcote powder coating can now provide solutions to these design requirements. Furniture can now have interesting edge profiles, giving the product a sophisticated look, in a reliable, durable and attractive finish. The resultant seamless finish can be cut or drilled without damage. Design flexibility includes pre-drilled holes, routed and rolled edges and much more. 4.2 One Coat Process Woodcote powder coatings are applied in a one-step application process, needing neither successive coats nor a long drying time and contains no solvents. Powder coatings are very efficient in the application process compared to wet paints, ie 95% plus use with recycling and far less harmful constituents present. The Woodcote powder coating on MDF is an attractive, practical and environmental first choice for manufacturers and designers. 7

8 DESIGN FLEXIBILITY 4.0 DESIGN FLEXIBILTY (Cont d) : 4.3 Advantages Woodcote powder coatings offers an economic,low environmental impact alternative to existing coatings, paper foils and vinyl laminates currently used for finishing MDF board. The benefits of Woodcote powder coatings are :- - One coat process - Economical cost effective - Design flexibility - Seamless finish - Lower environmental impact - Durable & tough - Humidity & chemical resistant - Cut/drill without damage - Recoatable Woodcote powder coatings are available in a range of colours, textures and finishes. Refer to Interpon Sales for further information. 4.4 CARE AND CLEANING Generally a wipe with a clean damp cloth is only required. Conventional surface cleaners are also satisfactory for cleaning. Strong solvents and cleaners may damage the surface finish and should be tested before use. 8

9 ENVIRONMENTAL IMPACT 5.0 ENVIRONMENTAL IMPACT : 5.1 Low Emission System Woodcote MDF Decorating Solution provides significant environmental initiatives with the use of VOC free coatings, and the significant reduction in the level of emissions from the MDF by coating encapsulation. Independent laboratory testing by AWPA Test Centre to the JIS A1460 Standard has confirmed that formaldehyde emission levels from Woodcote coated MDF are below the 0.3 ppm level. This meets the Type F**** Formaldehyde emission level as specified in JIS A 5905 (SE0). Woodcote provides an ideal environmental system to achieve Green Star compliance criteria for Office Interiors. Woodcote powder coating is an excellent environmental option when compared to wet paints and laminate finishes. Woodcote powder coating has been specified and successfully used on the office work stations at the Melbourne City Council 6 Star CH2 building. 9

10 ENVIRONMENT 5.0 ENVIRONMENTAL IMPACT (Cont d) : 5.1 Akzo Nobel EMS Akzo Nobel operates an Environmental Mgt. System (EMS) accredited to ISO Water,energy and waste management form part of the EMS improvement system. This means that we have an active environmental program with annual improvement targets. As part of our commitment to environmentally sustainable development, we have Product Stewardship management systems to provide us with a framework to manage the environmental impact of our products throughout the development process and product lifecycle. We also constantly strive to exceed international safety and environmental standards. All Interpon powder coatings manufactured locally by Akzo Nobel are free of lead and heavy metals.they are free of solvents, contain minimal VOCs and hazardous air pollutants. Akzo Nobel is a member of the Green Building Council of Australia. 5.2 Sustainability While steel and aluminium are finite resources and massive energy is needed for their creation and recycling, wood-based products are renewable and forest/plantations can be sustainably managed. Woodcote powder coatings are an excellent environmental option when compared to wet paints (solvent and water-based), vinyl wrap, laminates and polyurethane finishes. The Woodcote powder coating process totally coats all the MDF surfaces and encapsulates the formaldehyde and other volitiles that could be released into an office or home environment, unlike other MDF substrate finishes. 5.3 Other Woodcote benefits: 1. Unused powder can be reclaimed (using suitable equipment) and recycled back through the coating system. This efficiency reduces the application process waste to less than 5% of total usage. 2. Powder coated items can be re-coated a real PLUS when it comes to sustainability and refurbishments. A new look is a matter of recycling your components, even re-shaping them, and then simply applying a new Woodcote powder colour. 10

11 PERFORMANCE 6.0 PERFORMANCE : 6.1 Tough Woodcote powder coating is a low temperature, thermally cured system which provides an excellent film for physical and chemical resistance. Woodcote powder coating provides a robust coating which allows consistency in process application and reliability in performance. The coatings are developed and manufactured under quality accreditation systems that include ISO Woodcote is available in a range of colours to suit interior designs. The colour consistency and appearance are excellent. The surface appearance is available in a fine texture, smooth matt or smooth satin finish. 6.2 Furniture Standards The Woodcote powder coating provides a tough and durable coating for office and furniture. The powder meets the performance requirements of International Furniture Standards DIN68861 and FIRA Akzo Nobel can supply additional performance data, application and curing information. 11

12 TECHNICAL & PROCESS 7.0 TECHNICAL & PROCESS : 7.1 MDF SELECTION Only certain moisture resistant and high density MDF board are suitable to withstand the powder coating process. From our experience the MDF should have the following key parameters: * Density >750kg/m3 * Core density >700 kg/m3 * Moisture content 6 to 10% Akzo Nobel in Australia have successfully tested the following grades of MDF board with Woodcote : a/ CHH Customwood SPMR MDF. Thickness of 12,16 and 18mm. b/ Alpine MR MDF board. Thickness of 16,18 & 25mm. We recommend the MDF board be tested for suitability for powder coating. 7.2 MDF PREPARATION Preparation of the MDF is very important for obtaining a good and uniform coated surface. Mechanical sanding of the edges is critical to achieve a smooth appearance. The board must be cleaned of dust with air blowing prior to pre heating. 12

13 TECHNICAL & PROCESS 7.0 TECHNICAL & PROCESS : (CONT D) 7.3 PROCESS 13

14 TECHNICAL & PROCESS 7.0 TECHNICAL & PROCESS (Cont d) : PRE HEAT :- The MDF boards are preheated in either a convection oven or IR to increase surface conductivity. This preheat stage enables the application of the powder via the standard application techniques of Corona and Tribo. The panels are normally heated to achieve a board surface temperature of 60-80C at the powder application. The time and temperature for preheat is normally adjusted for different MDF thickness due to the rate of heat take up. APPLICATION :- The MDF board should be coated when the board surface has dropped to 55-70C. The powder is applied by automatic or manual electrostatic application on all surfaces. The target dry film is 100 to 120 micron. CURE :- The MDF boards are heated with IR to achieve as soon as possible the curing temperature at the board surface. This IR stage melts the powder and enhances a good film appearance. The gas convection stage achieves the final cure. An effective cure of C is required. COOLING TUNNEL :- Cooling is recommended to allow panel handling and unloading. Note: Refer to Interpon Woodcote Technical Guidelines and TDS for more details. 14

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