The Waterborne Symposium 2025

Abstract
"Microbial contamination of paint and coating products can have adverse effects on the product, such as offensive odors, discoloration, or viscosity changes. Although preservatives (biocides) are available as additives to prevent the proliferation of microbial growth, manufacturing controls should be implemented to prevent the contamination in the final product. Robust cleaning processes and other manufacturing controls can be designed to provide microbial control for equipment product-contact surfaces, preventing microbial contamination of the product. A thorough understanding of the raw materials, formulation, manufacturing process, and other manufacturing characteristics will help identify potential sources of contamination and guide the development of the contamination controls needed in manufacturing. Designing processes that can address both cross-contamination and microbial contamination on equipment surfaces would be beneficial for production efficiencies while producing quality products with a longer shelf life.

This presentation proposes a holistic approach for controlling microbial contamination through the implementation of effective cleaning processes and other cleaning-associated activities. Current regulatory trends limit manufacturers to the use of certain preservatives, which may not be as effective as some of the legacy additives used in the past. This promotes a need for the implementation of preventive controls for microbial contamination introduced during the process and less reliance on the use of preservatives in the product. A cleaning process can be designed through a formal risk assessment process where critical process controls are implemented to mitigate microbial contamination risks identified that may impact a product’s critical quality attributes. There are multiple factors that play into the design of an effective and efficient cleaning process: control of water and raw material quality, selection of adequate cleaning agents, equipment storage conditions, equipment preventative maintenance procedures, and the critical controls of the cleaning process itself. When adequate controls are implemented, the cleaning process and other preventive measures discussed in this presentation can control microbial contamination on equipment and, subsequently, the final product."

Abstract
"When considering flexible coatings, polyurethane often comes to mind. Polyurethane's flexibility is derived from its unique structure, featuring a combination of hard and soft segments, as well as hydrogen bonding within the hard segment. While polyurethane possesses diverse chemical structures and finds applications in various coatings, 2K polyurethane commonly grapples with several limitations, including the handling of often toxic isocyanates, sensitivity to moisture, yielding soft coatings, moderate curing speed, and constraints on coating thickness. Additionally, 2K polyurethane often necessitates the use of solvents to reduce viscosity for ease of application, resulting in high volatile organic compounds (VOC) emissions.

Epoxy systems are not typically associated with flexibility, as they are primarily recognized for their excellent mechanical properties, chemical resistance, and adhesion to substrates. Epoxy coatings have found widespread use in applications aimed at protecting substrates, enhancing resistance to various chemicals, and extending the service life of materials and assets. Compared to 2K polyurethane, epoxy presents advantages in terms of ease of handling, lack of moisture sensitivity, and the ability to formulate low VOC and low emission solutions. Furthermore, epoxy can be rendered flexible by incorporating a substantial amount of long-chain not environmentally and not user-friendly phenolic plasticizers. The need for fast return to service is a driving force in the coatings industry, often leading to the use of accelerators that, while speeding up curing, can compromise flexibility.

This paper introduces a novel EHS friendly flexible epoxy technology designed to bridge the performance gaps in current flexible epoxy systems using sustainable bio-based raw material. It yields coatings with rapid curing capabilities while maintaining high flexibility, even at low temperatures. These coatings exhibit high hardness, excellent substrate adhesion, substantial tensile and tear strength, all while maintaining an environmentally and user-friendly product profile. Catering to the demand for rapid return to service with minimal emissions and extended working time. The paper will also delve into key performance attributes and provide comparisons with 2K polyurethane and conventional epoxy systems.
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Abstract

Agricultural biomass raw materials are plentiful and a sustainable source of raw materials. Importantly, the physical and chemical conversion of agricultural residues to useful organic building blocks is often limited in utility by lower than preferred physical and chemical conversion efficiency. We chemically modified high purity cellulose with additional natural products to explore the utility of organic-solvent soluble cellulose based polymers in a single reaction step. The resulting biobased materials were formulated into practical surface coatings and were evaluated for material characteristics, formulation variables, solubility, film formation, and film performance. Each solvent based, waterborne, and powder coatings were produced and evaluated using the novel sustainable materials. Key parameters: solvent content versus time after application, optical clarity, film formation, solids content, rheological characteristics, and cursory thermoset testing for crosslink density were each compared with high performance petroleum based systems. The solvent based modified cellulosic formulations were further evaluated comparing rheology, film formation, wetting, adhesion, and optical clarity when formulated with conventional solvents (MEK and Toluene) with biomass derived VOC-exempt solvents with and without isocyanate crosslinkers. The formulation details and variables, the coatings characteristics, and the performance were each evaluated and compared to several commercial petroleum based coatings as we begin to understand the modified cellulosic-materials utility.

Co-Authors: Franklin Leal, and Dan Weinmann

Abstract

Epoxy resins have been used for decades in applications demanding excellent adhesion and corrosion resistance, but historically have not been suitable for coatings where ultraviolet (UV) resistance is needed. A direct-to-metal coating, comprised of a novel modified cycloaliphatic epoxy resin combined with a lower yellowing amine curing agent, was designed to deliver superior performance in corrosion resistance and adhesion. Additionally, this epoxy resin system offers improved gloss retention and color stability compared to standard epoxy coatings. Both the resin and curing agent are optimized to minimize dry time while maximizing hardness development. The relationship between epoxy-amine stoichiometry and coating performance was evaluated to further improve the system. Comparative testing with a commercially available epoxy-polyamide DTM coating showed that the novel epoxy system performs well against the competitive material while significantly improving the UV resistance, as determined by gloss and color retention.
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Co-Authors: Christin Jäger and Katja von Nessen

Abstract
"In the coating industry there is increasing demand for environmentally friendly and safe products driven by regulations such as reduction of VOCs and CO2 emissions and the replacement of critical raw materials. Bio-based raw materials have been found to be appropriate substitutes as they frequently exhibit a significantly lower carbon footprint, a better toxicological profile as well as the capability of biodegradation.

In this study, the performance of bio-based citrate esters as coalescing agents for an architectural paint formulation was investigated and the results were compared to market standards. Furthermore, the useability of xanthan gum as rheology modifier was studied and the performance was compared to cellulose thickeners (HEC, Hydroxylethycellulose) for the same application. Contrary to most of the classical coalescent agents, citrate esters are non-VOC and comply with the latest toxicological and environmental safety requirements: they are characterized by highly efficient solvation, low migration and non-VOC attributes. To showcase those features 2.4 wt% coalescent agent were incorporated into an architectural paint based on an acrylic binder. The deviations in properties of the dried paint were not significant among the tested coalescent agents. The study also revealed that the same dosage of xanthan gum leads to a low shear viscosity about 60% higher compared to cellulose thickeners. This effectively improves storage stability, due to the high stabilization of pigment particles, while leading to comparable levelling and sagging. High shear viscosity on the other hand is about 50% lower, which improves applicability. The versatility of xanthan gum is not limited to pigmented systems. It is possible to adjust the viscosity of clear coats, while maintaining transparency."

Abstract

"2K coatings are being heralded as an innovative means to increase the move towards 100% solids materials and reduce the need for thermal curing, thus reducing the energy required for the coating process. While the benefits are indisputable, there are issues associated with these technologies that can make them difficult to process in the manufacturing environment. All of these must be dealt with as part of the application process and, if not properly handled, can result in production delays that reduce throughput, reduce quality, and increase costs. Obviously, this runs counter to the objectives of these advanced technologies.
In this presentation we will:
 define induction time and pot life and the relationship between them.
 discuss the implications these pose to the modern manufacturing process.
 identify novel methods to leverage these properties, turning them from adversaries to allies in the application process.
 identify opportunities to minimize waste, reduce rework, increase throughput, and improve the quality of the coating process."

Please visit our exhibitors in the exhibit hall - Grand Ballroom D.

Please join us for our 2024 Student Poster Session! Student Resume books will be available and privet interviews available upon request - Please contact the Waterborne staff to set up an interview.


Please see the attached file for the poster abstracts

Bio: Brian Vest, Linda Adamson, Celine Burel

Abstract
"Perfluoro and Polyfluorinated-Alkyl Substances (PFAS) have been extensively utilized across various industries due to their exceptional ability to resist heat, oil, grease, and water. Among these PFAS chemicals, Fluorocarbon Surfactants (FCS) have been particularly effective in waterborne coatings to enhance early ""hot block"" resistance. However, increasing regulatory pressures and risk management considerations are pushing formulators to phase out these substances. This shift necessitates a careful balance between maintaining performance and adopting more sustainable alternatives.

Our study focuses on the development and application of novel phosphate ester wetting agents that offer improved early hot block resistance without the environmental drawbacks associated with fluorocarbon chemistry. These innovative additives are APE-free and have very low or zero VOC content, contributing to better colloidal stability. This stability enhances the wetting, dispersing, and compatibility properties of the final water-based coating. Our data will demonstrate the overall performance of the paint and explore the structure/property relationships that contribute to enhanced anti-blocking performance."

Abstract

Grinding pigments and fillers using cowles dissolver is a standard practice for breaking down agglomerates and aggregates into primary particles during the production of waterborne paints, especially architectural paints. Serrated disc introduced at the appropriate peripheral speed forces a specific flow in the vessel, which causes the agglomerated particles to rub against each other and collide with each other. The wetting and dispersing additive introduced to this process is supposed to build a double electrical layer according to the DVLO theory, but this is only a theory that has little to do with practice. Of course, the theory of wetting, significant zeta potential and other properties of dispersing additives are true, but their correct use in mill-base formulations and further influence on the parameters of the grinding process itself and the parameters of the paints depends solely on the effectively found dose and balance between mill-base concentration allowing grinding at low viscosity and maximum solids loading, without adding any rheology additives during grinding. The paper discusses examples of grinding of various pigments and fillers used in architectural paints and discusses how to properly balance the ingredients and the grinding process to achieve the lowest possible viscosity, low energy consumption and donut-shaped flow, without using rheological additives that prevent proper grinding and breaking down of pigments and fillers into primary particles. It also presents how to properly control the mill-base slurries obtained after the grinding process and how to combine them with latex polymer dispersions in the let-down process to obtain stable architectural paints.

Abstract

Dirt pick-up resistance (DPUR) is a critical property in surface coatings, particularly for outdoor applications. Additives play a crucial role in enhancing DPUR by improving both the visual appearance and durability of coated surfaces. Silicone-based compounds, hydrophobic agents, and nanoparticles have been shown to reduce surface energy, thereby minimizing the adhesion of dirt particles and dirt slurries. In addition, certain polymeric and film-forming additives can improve surface smoothness and reduce porosity, further preventing dirt accumulation. The incorporation of photocatalytic additives has also been explored, leveraging their self-cleaning properties under sunlight exposure. This paper reviews the different types of additives used to enhance DPUR, their mechanisms of action, and their effectiveness with various methods. The optimization of additive in the formulations is key to achieving a balance between surface protection, durability, and environmental considerations, making them necessary in modern surface coating technologies.

Co-Authors:
Alann O. P. Bragatto, Suzy S. Alves, Bruno S. Dario

Abstract
"The selection of wetting and dispersing agents in pigment concentrate formulations is a non-trivial task. The vast array of available products and technologies, coupled with a frequent lack of adequate technical information, makes the formulator’s job extensive, intricate, time-consuming, and inefficient due the lack of rationalization in the use of these additives. These factors created a barrier to innovative and more sustainable products since the work required to screen new additives became an art instead of a science.
The present study aims to demonstrate how the use, development, and implementation of physicochemical methodologies, combined with digital tools and high throughput screening, can generate highly useful data for formulators in the additive selection and formula optimization process, making it faster, smarter, and more efficient.
The first and most comprehensive part of the work illustrates how physicochemical techniques and parameters applied to surfactants can be utilized in the selection of wetting and dispersing agents. It is demonstrated the correlation between static surface tension, dynamic surface tension, wetting time, contact angle, and free adsorption energy with performance and process properties in pigment concentrate formulations, such as deflocculation curves, process time, tinting strength, rub-out, and stability.
The second part of the work is focused on the development of a method to create adsorption isotherms and on their use. This data is extremely valuable as it allows for comparisons between additives from different technologies even when the chemical structure is unknown. The study demonstrated how the curves and parameters obtained from this technique can help formulators understand which additive has higher affinity for a given pigment, aiding in the selection of dispersing agents with higher potential to provide good performance and longer stability. Additionally, this methodology helped understanding the versatility of the additive, clarifying whether the same molecule could be used with different types of pigments. The results from the adsorption isotherms were correlated with the stability, tinting strength, and rub-out of the pigment concentrates.
The final part of the work aims to apply Hansen solubility parameters (HSP) to evaluate the compatibility of wetting or dispersing agents with pigments. The current focus is on using high throughput screening to determine the HSP values of a variety of wetting and dispersing agents – such as surfactants and polymerics with or without charges. After the parameters of the additives and the pigments of interest are obtained, formulators could use these data to simulate the interaction between the additive and the pigment, enabling the selection of the most promising candidates for experimental evaluation. The last goal of the work is to provide initial data on the HSP parameters determination and compatibility simulations to then correlate with experimental performance data of pigment concentrates, such as tinting strength, rub-out, and stability. Once the correlation is proven, this methodology will allow a quick determination of parameters without requiring knowledge of product’s composition and will aid the development of better coating formulation."

Co-Authors:
Tom-Seung Cheung, and Yanjun Luo

Abstract
PFAS compounds provide surface tension (ST) reduction, coefficient of friction (COF) reduction, hydrophobicity, oleophobicity and chemical stability.  These fundamental properties result in applications such as stain resistance, block resistance, oil resistance, lubricity, release, AFFF and many others.  
Siltech have presented previously on replacing PFAS components with organomodified silicones which provide similar and satisfactory performance on ST, COF and hydrophobicity. The difficult challenge is oleophobicity. We have had some success in this category and will report this here. We will emphasize some UV cured acrylate structures which are giving strong performance in this critical category.

Co-Author: James Rawlins

Abstract

The effective mitigation of corrosion through the application of protective coatings is of paramount importance, impacting both economic and safety outcomes.  Historically, the detection of coating failure and the ensuing corrosion has largely depended on visual inspection and destructive testing methods, which do not adequately predict onset or service lifetimes.  Current methods also lack correlation to specific polymer characteristics that govern corrosion resistance.  This research introduces a novel, nondestructive method that combines Electrochemical Frequency Modulation (EFM) and Confocal Laser Scanning Microscopy (CLSM).  By studying epoxy-amine coatings through a range of tailored glass transition temperatures (Tgs), ranging from high (269 °C) to sub-ambient (4 °C), these research results work contributes to the predictive modeling of coating lifetimes and advances our understanding of the relationship between polymer properties and performance in mitigating corrosion.
Previously, we have shown that the more hydrophilic a crosslinker was, the faster micro-blister formation around a predefined defect occurred.  Micro-blister with delay times varied from 47.5 to 5.5 hours for coatings with increasing hydrophilicity.¹  These results showed that a coating with a Dry Film Thickness (DFT) of 45 μm reduced micro-blistering and exhibited slower corrosion rates compared to the same materials at 5 μm DFT. These results emphasized the role of mechanical beam integrity and corrosion resistance and confirmed that coatings that limit swelling in water and delay physical state changes during immersion were dramatically better at reducing corrosion activity. Example, a coating designed with a high glass transition temperature (Tg) of 269 °C showed less than 3% swelling under all conditions and preserved mechanical properties, including a storage modulus of 2416 MPa, after exposure to corrosive environments. The results indicate that strengthening the mechanical robustness and reduced swelling and physical state changes (such as from glassy to rubbery) for a given coating during exposure are crucial for corrosion control and substrate protection.

Abstract

Stability under low shear storage and shipment conditions can be critical to the stability of waterborne coatings and dispersions against sedimentation and syneresis. Judicious selection of a fit-for-purpose low shear thickener plays a crucial role in preventing sedimentation, especially in cases where dense pigments are incorporated into waterborne formulations. During the application process, traditional thickeners enhance sag resistance and influence leveling to facilitate robust film build. More importantly for longer-term storage, low shear thickeners can prevent syneresis in colorant-tinted coating systems. This presentation introduces an innovative rheology modifier technology based on a novel zirconium complex that eliminates sedimentation and syneresis under extremely low shear conditions associated with coating storage and transport. This technology offers the user-friendly option of post-addition under moderate mixing conditions, in contrast to other rheology modifiers that require neutralization and high-speed mixing processes. This presentation shows results illustrating the valuable outcomes achievable through the utilization of this unique low shear thickener platform.

Co-Authors: Roger Mouhanna and Laurent Desfontaines

Abstract

Fluoro resins, commonly used in outdoor coatings, offer exceptional weather resistance, durability, and stain resistance. They help maintain the aesthetic appearance of coated surfaces for extended periods, reducing the need for frequent maintenance and repainting.
However, the use of fluoro resins is increasingly regulated due to concerns about PFAS substances. Regulatory bodies have implemented stricter controls on the manufacture, use, and disposal of PFAS, due to their persistence in the environment and the potential health risks. These regulations aim to minimize the release of harmful substances and encourage the development of safer alternatives.
Hybrid resins, combining inorganic polysiloxane with organic acrylic or polyurethane components, offer a compelling alternative to traditional fluoro resins for outdoor coatings. These advanced resins provide superior long-term protection and aesthetic appeal, significantly reducing maintenance costs. Available in various water-based formulations, including 1K and 2K systems, they meet diverse application needs and regulatory requirements, making them a versatile and effective choice for outdoor coatings. In the frame of this work, we will illustrate these benefits with specific examples and case studies, demonstrating the superior performance and compliance of these hybrid resins with current regulations.

Please visit our exhibitors in the exhibit hall - Grand Ballroom D.

Abstract

"Regulatory activity in both the EU and USA is targeting a large group of chemicals known as PFAS (per- and polyfluoroalkyl substances). As a result, formulators in many industries are working to replace additive powders based on PTFE and PTFE hybrids with alternative materials that provide the same level of performance.
This presentation will detail a unique nanocomposite approach to eliminate PTFE in surface additives by replacing PTFE with hard, inert, durable materials such as aluminum oxide and ceramics. Data will be presented to show that this portfolio of over 8 additives provides equal or (in most examples) improved surface durability (lubricity, scratch & abrasion resistance) without the use of PTFE."

Abstract

"Waterborne polyurethane dispersions (PUDs) are renowned for their exceptional film-forming ability, toughness, and flexibility. However, they are often challenged by poor water resistance and higher production costs. Polyurethane/acrylic hybrid resins offer a balanced, cost-effective solution, combining the strengths of both PUDs and acrylics. These hybrid systems provide enhanced mechanical properties alongside superior water and chemical resistance, making them an ideal choice for high-performance coatings.

This presentation highlights the development of an innovative polyurethane/acrylic hybrid waterborne resin designed to meet both environmental and high-performance requirements. Synthesized in the absence of added solvents, this resin allows for coatings to be formulated at low VOC levels while still offering a balance of hardness, flexibility, and favorable coalescence properties, making it an ideal binder for applications with stringent environmental constraints. Free from amines, the resin also addresses concerns over amine-related issues such as migration and yellowing, while enhancing overall formulation stability. The resin also exhibits good solvent resistance and excellent adhesion to a wide variety of substrates, including metals, plastics, and woods, making it suitable for diverse industrial applications."

Abstract

The increasing demand for sustainable solutions in coatings has prompted the development of innovative renewable defoamer technologies. This presentation explores the formulation of a cutting-edge defoamer derived from bio-based resources, focusing on its physical and chemical attributes that optimize defoaming effectiveness without compromise in wetting. The new defoamer achieves significant regulatory compliance and boasts a renewable bio-based content exceeding 75% while being mineral oil- and siloxane-free. This development redefines performance standards for renewable defoamers.

Abstract

The paint and coating market for kitchen cabinets, trim, and doors focuses on products designed to enhance the appearance and durability of wood and other commonly used materials. These coatings must meet stringent performance standards, including early block resistance, surfactant leaching resistance, body lotion resistance, and scrub resistance. Traditionally, per- and polyfluoroalkyl substances (PFAS) additives have been used to improve block resistance. However, due to increasing regulatory restrictions on these hazardous substances, there is a growing need for alternative solutions. This paper explores the current market landscape for kitchen cabinets, trim, and doors, and discusses our recent sustainability efforts to develop innovative waterborne acrylic latex binders specifically designed for these applications. We will also discuss general strategies to enhance key properties, including early block resistance, surfactant leaching resistance, and body lotion resistance.

Please join us for our 2024 Student Poster Session! Student Resume books will be available and privet interviews available upon request - Please contact the Waterborne staff to set up an interview.


Please see the student pages for individual abstracts.

Join us for our fourth annual lightning round style Graduate student poster competition Sponsored by Evonik. Each student will be given five minutes to present his/her poster to the judges and audience and answer questions about their work.

Moderated by Tristan Clemons

Our students will also be available during all the coffee breaks.

No early breakdowns

*Adding to your schedule on the scheduler DOES NOT register you for the event. To register for the event, please add to your registration online (free) or visit us at our registration desk. Space is limited, so no late registrations are guaranteed.

Celebrate and empower at the 2025 Waterborne Symposium's Women in Science Networking Event! Please join us for our Women in Science Networking event for some cocktails and an intimate discussion about these topics with our plenary speaker, Victoria Scarborough.

We are delighted to host this special occasion dedicated to honoring and supporting women in STEM. Join us for an extraordinary opportunity to connect with inspiring individuals, foster meaningful collaborations, and contribute to the advancement of women in science and technology. Let's come together to share experiences, build a supportive network, and pave the way for a brighter future in the world of science. Don't miss this empowering event! #2024WaterborneSymposium #WomenInScience #STEMNetworking