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Osurance Roll Stock. Paper Roll Stock. SealScience Water-Based Adhesives. Performance is approaching or exceeding other oil-derived materials, the economics are now more reasonable, there are increased environmental concerns and regulatory pressures, and customers have become savvier.
Nanomaterials are of interest because they offer increased performance, but price, environmental impact, and poor incorporation into the base material have suppressed their mainstream use. Several organizations have solved the scaling issues associated with these materials, reducing their cost, while new methods for dispersing these materials into different resin chemistry formats have increased their usefulness and performance.
The strong desire for antimicrobial performance is attributed to the emergence of the COVID pandemic and the increasing prevalence of drug-resistant microbes, while rising demand for improved haptics, scratch resistance, and self-healing is due to rising expectations for aesthetics by end users, particularly in the automotive sector.
The desire for real advances in corrosion protection is driven by the enormous costs associated with failure of large capital assets. Detwiler, Eastman: The key drivers are consumers and regulatory authorities who are seeking better health and wellness solutions that will also deliver lower materials of concern, lower odor, and lower volatile organic emissions.
The market is looking for opportunities that will provide better durability to enhance product service life as well as those that offer lower material and energy demand during the manufacturing process.
Driven by upcoming regulatory changes, we are also seeing early emerging needs in some geographical regions looking for options that have better end-of-life sustainable solutions. Meier, Evonik: The reduction or elimination of VOCs in architectural and do-it-yourself wood coatings has driven the industry to use waterborne coatings and new polymer binders capable of film forming with minimal or no coalescing solvents.
These polymers generally have lower glass transition temperatures and can result in softer coatings that are susceptible to damage unless the coating can be formulated to counter this tendency. However, environmental, health, and safety drivers are not the only factors that prompt our coatings customers to seek new solutions.
Fashion trends and prevailing consumer preferences play a heavy role in the surface appearance and haptics sought in wood coatings, flooring, and architectural coatings. Listening to the voice of the customer is the top priority.
We also closely follow market trends, looking for unmet needs and opportunities where our technologies can be leveraged. Brown, Chemours: The Chemours company is committed to the sustainable and responsible development of products. This drives the way we consider new product opportunities and provides the path as to how we develop them.
Making responsible choices throughout product development is a current trend and is anticipated to become the norm in the future—but we believe it is necessary now. Safe and more sustainable product development is essential for the future for the paints and coating industry. This involves exploring new functionalities offered through engineered pigments that benefit downstream users in new ways, as well as paying close attention to regulatory and societal signposts. To do this effectively requires bridging several gaps in the fundamental science involving complex matrices, which in turn involves nurturing, recruiting, and collaborating with world class experts across disciplines.
It is very important to systematically work on a better understanding of the paint systems in formulation and at application. Digitalization creates the basis; artificial intelligence can help gain more knowledge. Kelly, DST: DST conducts research in areas where no or limited indigenous capability exists either in academia or industry and where the classified nature of the research is such that it cannot be done outside of DST.
The research into signature management coatings, such as low-emissivity coatings, is driven by the need for reducing the detectability of platforms and increasing their survivability against a range of threats. Defence desires to reduce or eliminate chromate containing primers and conversion coatings used to prevent corrosion on Australian Defense Force ADF aircraft, sincr they create waste health and safety issues during application, maintenance, and removal. The adoption of waterborne coatings is being driven by local and international regulations to reduce VOC limits, pollution, and hazards during use and storage.
Machine learning offers improved time management by accelerating the selection and discovery of new materials for tailored coatings.
There is also a strong driver for the development of polyisocyanate-free coatings. While it has been possible to move away from solvent-based two-pack polyurethane to polysiloxane topcoats on Australian Navy platforms, elimination of polyisocyanates has not been possible yet on Army or Air Force equipment due to certain performance limitations. Xu, Cardolite: New technologies can bring unique and higher performance to coating systems.
However, it is common that new technologies have some features that do not fit well with current application techniques or formulation schemes. Many archaic methods are used, primarily because the technological understanding of customers is very low and methods are considered proven.
Brown, Chemours: Adapting proven processes to produce more complex materials can be a challenge and requires innovation on the product side and the analytical and process sides. Another challenge in the coatings industry is the interface of science, art, and history.
The coatings industry has a rich history of testing and assessment methods. Some are founded on science while others are grounded more in historical practice. There is a diversity of methods, and each has its own value. However, sometimes they lead to confusion, especially when they are confounded and not fit-for-purpose. Breaking down testing barriers to help separate art from science remains a challenge.
There are several instances where a re-look at fundamentals and driving mechanisms to identify the appropriate suite of test methods could help with the adoption of the best solutions.
Rosano, BASF: Discovering environmentally friendly, cost-effective solutions that deliver the desired end-use performance is a key challenge. Carson, Alberdingk Boley: Finding sustainable raw materials that are readily available to produce water-based products is a challenge. Also, new building blocks must meet environmental regulations and produce materials that have excellent performance without a significant increase in cost.
Those raw materials also need to be listed in various chemical inventories, which is one of the biggest challenges for us. Kelly, DST: Chromate replacement has proved to be one of the most difficult challenges as there are no chromate-free primers to date that perform the same as, or better than, chromated primers.
The coatings industry, academia, and DST researchers have directed considerable effort in formulating and testing various chromate-free pre-treatments and primers for the aerospace industry and are keen to have effective replacements.
It is extremely important for DST to ensure corrosion on Defence assets is minimized, particularly in the maritime and aerospace domains where anticorrosive performance is critical for both sea and air-worthiness. Seubert, Ford: For many new paint and coating technologies, the biggest hurdle is outdoor durability and performance. Automotive durability requirements are some of the toughest requirements in any industry, and typically require 10 years of performance without major failures such as fading, cracking, delamination, or gloss loss.
Any new paint or coatings materials, whether it is low-temperature cure, radiation cure, hydrophobic coatings, or tutone paint systems, need to meet these requirements before they are considered for implementation. Pilcher, The ChemQuest Group: The greatest technological hurdles vary with regard to individual technology areas and end-use requirements. In general, however, the greatest hurdle is to develop technology that performs equal to, or better than, currently available technology, while maintaining or improving the cost-in-use to the customer.
Corrigan, ChemQuest Technology Institute: Technologies need to be scalable and compatible with existing chemistries. They also need to provide significant improvement from the current baseline, not incremental improvement. Pilcher, The ChemQuest Group: Varying needs result in different barriers that require specialized solutions.
Kelly, DST: Raw material costs are an important input factor to achieve commercially competitive products. For example, the Australian dollar has not always demonstrated strong performance, limiting the types of materials imported from overseas and therefore limiting coatings development. A frustrating conundrum lies in the cost-competitive nature of the coatings industry at times working against end-user interests. The efforts to shave off a few cents per liter on the cost of a coating can, at times, detrimentally affect long term performance of that coating applied on a Defence platform.
Carson, Alberdingk Boley: Changing the mindset of customers using traditional technologies such as solventborne can be challenging, especially when lines are running well and cost is acceptable. New technology will only be adopted when there is a clear performance differentiation at a price the market can bear, environmental legislation is passed that bans the use of certain products, or efficiencies are gained that help the bottom line.
Using a combined approach to solve a problem along with using the expertise of two or more raw material suppliers is a viable route forward as this may be the better tool to get bigger improvements in product performance compared to a standalone approach.
Corrigan, ChemQuest Technology Institute: A major barrier to adoption of new technologies is the risk of exposure due to the unknowns presented by a new material or process. To reduce this risk, extensive long-term testing is needed that simulates real-world conditions and converging stressors. Substantial beta-testing programs are also needed before transitioning to full commercial deployment.
Another major barrier is the testing standards required for any given industry, especially automotive and aerospace. Brown, Chemours: The challenge for achieving broad adoption of a technology that may alter how one formulates is a bit more complex and treads on issues related to tradition and perception. This means what we offer must be either transformative or help make a new coatings application successful.
Collaborations in the coatings technology space between raw material suppliers and coating manufacturers will be necessary to bring forward the next generation of coatings technologies. We need to show our potential customers that we are knowledgeable in their field and can respond to their needs with viable solutions, not only on the pigment side but though a wide range of consultancy.
Detwiler, Eastman: The key barrier we see for development and adaptation of new innovation is a lack of understanding of critical needs, processes and matrices used by key stakeholders at each node in the value chain. This often causes the industry to be sub-optimal in its innovation efficacy.
We see cross-value-chain collaboration in developing technologies that ultimately bring solutions to the strongest needs of the end consumers. This collaboration creates value for each node in the value chain and is the key to success.
Developing such win-win, trusting, innovative relationships across the value chain breaks down barriers and allows each partner to bring unique, complementary skills-sets and comprehensive solution development to the adoption process.
Seubert, Ford: Cost is still a major driver in any industry, and the automotive industry is no different. However, OEMs typically look at the cost-value proposition of the complete system, meaning even if a new material costs more than what is currently used, that cost increase can be offset somewhere else in the overall system, such as a reduction in oven temperatures for low-temperature cure paints, then such cost barriers can be overcome.
Some new technologies, such as targeted tutone application, have technological barriers to overcome, especially around the facilities and equipment. These barriers can be overcome through simple research and engineering discipline and innovation.
Rosano, BASF: Sometimes changes in application techniques needed to realize labor savings and speed of application require a long educational process before adoption. The industry is still very conservative and reluctant with new forms of cooperation such as open innovation. We need greater willingness to invest in longer-term research and development to develop smart coatings and apply new technologies such artificial intelligence to paint formulation and manufacturing.
Seubert, Ford: Success depends on continued funding for such activities, as well as teams of OEMs, suppliers, and technology developers working openly and together to address challenges as they arise during the development process.
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