Making history with eco-efficiency and innovation
Keywords: Coatings, Ecology, Efficiency, Environment
BASF Coatings is making history with eco- efficiency and innovation: In 1992,exactly ten years ago, the company presented the world's first water-borne base-coats for automotive refinishing. Apart from a reduction of the volatile organic compound (VOC) content to as little as one tenth – a sensational achievement at the time – these refinishing paints, known as Glasurif 90 Line, also claimed the great advantage of easy handling and economical application. In 1999, the ease of handling was improved again. And with some success: Glasurit waterbome basecoats hold a prominant position on the European market. This high-speed development was preliminarily summed up in 1996 by the"Allianz Zentrum fur Technik" (AZT), as a conclusion drawn from a large-scale study, the "AZT study of water-based coatings." This study states that"refinishing with waterbome coatings is practicable, and is highly welcome in the light of ecological requirements and also makes good economic sense."
It is reported that with this eco-efficient paint system, users can easily comply with all VOC regulations currently in force in Europe. To make sure that Glasurit customers will be well- placed to meet future legal requirements just as easily, the company is currently completing its product range in this field:it plans to launch additional VOC-compliant undercoat materials such as primers and surfacers. Glasurit users need not worry about the new requirements they will have to meet by November 1, 2007 in their existing plants and by November 1, 2004 in new plants.
90 Line can be used to repair metallic, special-effect and solid-colour finishes, covering the entire range of modern-day car refinishing jobs. Paintwork based on this system is characterized by mechanical, chemical and physical resistance. Furthermore, the mixing bases claims excellent storage stability even at temperatures below zero and allow the use oftinplate cans as well as existing mixing machines. And the paint system can reportedly be applied in conventional spray booths. 90 Line is an integral part of the Glasurit RATIO-AQUA System, which comprises all components needed in vehicle refinishing. These components range from products for pretreatment, anti-corrosion protection and fillers to topcoats and clear coats.
Initiated by Californian emission control act in late 1980s
Even in the middle of the 1980s, the majority belief was that water-borne paints had no future in automotive refinishing. Yet BASF was far-sighted enough to work on waterbased and high-solids coating systems from early in the 80s. These products wore originally used almost exclusively in automotive OEM coating. In 1987, for example, the company launched waterborne basecoats for metallic finishing at the Opel plant in Bochum. Due to the very different requirements on products for automotive line coating and refinishing operations,an immediate transfer of these products was impossible. However, the experience gained benefited the development of new refinishing products. When, in the late 80s, the Californian emission control act, "Rule 1151", imposed a reduction of 30 per cent on VOC emission limits from coating operations, it was clear immediately that this law would also impact European legislation and thus the ongoin development of waterbome coatings.
It was also in the late 1980s that the development of Glasurd waterborne basecoat fo refinishing began, initially exploring two approaches, One system using a water-bom mixing base and solvent-borne tinters – 90 Line –and another one using water-based tinters and a solvent-borne mixing base, which was internally called "Diabolo". Both systems were believed to have so many advantages that in 1991 and 1992 an internal competition was staged in which the company's technicians compared the two newly developed paint systems with one another. The clear champion proved to be 90 Line. It was rated better for speed of application, superior hiding power and surface hardness, outstanding shelf life and transport safety for tinting bases at temperatures below zero. A field test that was staged without delay in the US and Germany, in 1992 and 1993,focusing on a locted number of highly innovative customers, yielded new findings which were immediately taken into account for product development and additional training.
For example, painters had to get used to mixing the new paint materials. The structure of the mixing formula was duly changed to ensure that all formulas consistently show the water-borne mixing base as the first item to be weighed. This was necessary because it ensures much greater ease in mixing the highly concentrated solvent-bome tinting bases with the water-borne components of the system. Another important finding established in the field test was that colour accuracy is highly dependent on the correct spraying method. Good results were achieved with HVLP (high volume – low pressure spray guns which had been used from the start. these guns also help to reduce product use and overspray in the booth.
Anticipating the introduction of solvent- emission limits by 1998, the company launched the paint system at an early point in time, at the 1992"automechanika", an international automotive industry trade fair held in Frankfurt. However, these emission limits are actually being implemented only now in the form of VOC laws. Reservations concerning drying times and ease of handling were dispelled by means of training seminars across Europe and through cooperation with pilot and reference customers-these included for example BMW,Mercedes and Porsche. In 1994, Porsche was actually the first car manufacturer in the world to officially approve of the use of 90 Line in its own body- shops– today car manufacturers all over the world have granted similar approvals. In the same year, this innovative coating system won BASF's internal innovation award. The company granted this award to honor the integrated,thought-through system which includes all components, from the eco- efficient paint material itself to the waste disposal concept which provides a coagulating agent that helps eliminate dirty gun wash water
Today, Glasurit 90 Line waterbome basecoats are well established in many countries. In Great Britain, the Netherlands and Austria their share has for a long time exceeded that of the solvent-based Glasurit 55 Line because these countries pioneered VOC legislation. In the Netherlands, non- VOC compliant basecoats have practically disappeared from the car segment since 2001. The Scandinavian countries also have a tradition of environmental awareness, proven by a correspondingly high share of water- based coatings.
Rather than environmental aspects, the other favourable properties claimed of Glasurit 90 Line were said to be the main reason for its launch in other countries. Examples include Croatia and Portugal, where from the very start 90 Line was set up in bodyshops to completely re-place solvent-borne systems. Having used nothing but the new system ever since, these bodyshops are happy with the consistent change-over because reportedly there are no re-pair jobs they cannot do with 90 Line.
Glasurit automotive refinish
Under the Glasurit brand, BASF markets a comprehensive range of automotive refinishing paint systems, focusing on eco- efficient waterbome basecoats and high-solids paints.
According to BASF by using these systems all legal solvent-reduction requirements can be complied with anywhere in the world, and with regard to appearance and resistance, the products meet the same quality standards as solvent-home paints. In this area too, the company offers a wide variety of services to support its customers. Glasurit Automotive Refinish is stated to be approved by most of the leading car manufacturers for after- market repairs and is said to be preferred by the world's most prestigious car companies for its colour expertise.
BASF: A major international player in coatings
BASF Coatings AG and its affiliates, along with all the coatings activities of other BASF group companies around the world, belong to the global Coatings Division of the BASF Group. With about 10,000 employees, this BASF division achieved world sates of 2.3 billion euros in 2001 BASF has a major, global presence in this sector, with significant market positions in Europe, North America, South America and the Asia/Pacific region, for example with affiliates in Australia, China, India, Japan, and the Philippines. In the coatings segment,BASF develops, produces and markets a high-quality range of innovative automotive OEM coatings, automotive refinishes and industrial coatings as well as the processes needed to apply them. In this business, eco-efficient powder coatings, water-based, high-solids and radiation- curable coatings play a special part. In Brazil, the company has been successful in the decorative paints market for years and is holding the leading position.
Details available from: Tel: +49 2501- 143160; Fax: +49 2501-143750; Website: www.basf-coatings.de
