Jul. 01, 2024
By Cynthia Challener, CoatingsTech Contributing Writer
The global powder coatings market is thriving, with growth closely tied to several key economic indicators such as industrial output, fixed investment, and consumer spending. This trend is backed by insights from Robert Watson, global markets and business development manager at allnex. Additionally, as Eddie Wang, regional commercial director for Powder Coatings North America at AkzoNobel, points out, the expanding acceptance of powder coatings as a viable alternative to liquid coatings amplifies the trend of growth. This acceptance is primarily driven by rapid technological advancements in powder coatings that provide superior properties comparable to liquid coatings, which encompass efficient application, outstanding durability, weather resistance, corrosion resistance, an expansive special color offering, and exceptional chipping and abrasion resistance.
While acceptance of powder coatings is on the rise, its current rate is slightly lower than the levels noted 5-10 years prior, with a significant number of liquid coating users having made the switch to powder coatings, as stated by Mark Vogel, vice president of Business Development at Diamond Vogel. The most rapid growth within the powder coatings market is being observed in China and other developing nations that are eager to adopt more eco-friendly solutions, according to Robert Cregg, North America business director for DSM Powder Can & Coil Resins. Notably in China, fresh opportunities are emerging in new sectors such as MDF and solid wood furniture as the nation attracts attention with its Blue Sky initiatives. A few of the elements contributing to this gradual yet steady expansion include positive expectations across various market segments like automotive, agricultural/construction, and general industrial furniture, along with increased consumer spending and advancements in powder coating technology aimed at bolstering durability and efficiency, explains Tabitha McLeish, global marketing director for Powder Coatings in the General Industrial Division of The Sherwin-Williams Company.
According to The ChemQuest Group, the total global market for powder coatings is estimated to be 4.9 billion pounds, equating to approximately $10 billion in global sales, growing at a compound annual growth rate of roughly 3.6% to 4.3% over subsequent years. However, estimates from Kusumgar, Nerlfi, and Growney (KNG) are slightly more optimistic, positioning the global powder coatings market volume at about 5.46 billion pounds with a value around $11.25 billion, while also suggesting a more aggressive annual growth rate of 5%. The primary manufacturers of powder coatings, accounting for 9% to 10% of the overall global coatings market in dollar value, include prominent players like AkzoNobel, Axalta Coating Systems, The Sherwin-Williams Company, Nippon Paint, PPG, Tigerwerke, Jotun, Kanai, and Pulver Kimya.
Currently, epoxy polyester hybrid coatings represent the most substantial segment in terms of global sales by both volume (2.6 billion pounds) and value ($5 billion), with a yearly growth rate of 6%, according to Steven Nerlfi from KNG. High-durability, standard polyester powder coatings make up 1.4 billion pounds and almost $3 billion, also growing at a rate of 6% annually. Straight epoxy powder coatings hold a significant market share at approximately 1 billion pounds and nearly $2 billion, growing at a rate of 5% each year. Urethanes, however, have the smallest presence in the market at 210 million pounds and $650 million, with a modest growth rate of 4% per year, according to KNG. Other powdered coatings types, including thermoplastics, account for a volume of around 240-250 million pounds, valued at $575-$500 million, with an overall growth rate of 5%. According to Aggie Lotz from The ChemQuest Group, a similar distribution of resin chemistries occurs in the United States, which also includes acrylics.
Because of the intrinsic characteristics of powder coatings, their application typically occurs in a manufacturing setting. They are predominantly utilized on metal furniture and fixtures, electrical insulation, appliances, piping, machinery and equipment, automotive componentry (by tier suppliers), and various transportation equipment (including heavy-duty trucks, buses, and recreational vehicles), as well as metal building products and protective coatings. Additionally, smaller quantities of powder coatings find usage as conformal coatings for wooden furniture, within certain metal container applications, and for some magnetic wire and cable products.
Sustainability is regarded as a crucial value driver for powder coatings, states Shelley Verdun, global product manager for Powder Coatings at PPG. These coatings are near-zero in VOCs, which benefits not only the environment but also user-friendliness. “Powder coatings are convenient to apply and provide high-quality, consistent coverage over complex geometries, as the electrostatically charged powder particles uniformly magnetize to the grounded metal substrate,” comments Daniela Vlad, managing director for Powder Coatings at AkzoNobel. Moreover, Michael Withers, segment leader for Powder Coatings at Axalta Coating Systems, emphasizes that there are no hazardous substances produced in manufacturing, application, or end-use of powder coatings. “Consequently, they offer corrosion protection combined with attractive aesthetics and minimal environmental impact,” he affirms. Verdun additionally highlights the lack of special storage or transport protocols, and no hazardous waste is created in the powder coating process. The high efficiency of powder coatings contributes to low wastage and minimal water usage, according to Watson.
Furthermore, as much as 90% of the powder that fails to adhere to the part can be captured and reused, assisting finishers in their sustainability efforts without compromising the superior performance, longevity, and color retention that powder coatings provide, McLeish notes. The absence of carrier solvents also plays a significant role in reducing the carbon footprint associated with powder coatings compared to other leading coating alternatives, adds Cregg. "As global trends continue to steer towards sustainability, these advantages are likely to further position powder coatings at the forefront," he asserts. End users will also benefit from the extended durability afforded by powder coatings, as they reduce the frequency of touch-ups and repainting. The decline in baking temperatures now affirms that powder can be applied to a wider range of substrates, according to Vlad, leading to reduced energy consumption without the need for solvents, thus offering a more sustainable option compared to liquid coatings and anodizing.
From a production standpoint in a manufacturing environment, the efficiency and direct labor cost savings of powder coating processes are significant compared to wet spray systems, proclaims Chris Lucy, director of Process Engineering for CQTI in South Boston, VA. “Powder coating entails no material mixing, induction times, or pot life issues. Equipment cleaning can be done using compressed air instead of chemical solvents. Continuous automated conveyor lines can be configured with a variety of pretreatment options to enhance adhesion and corrosion resistance. When powder-coated, parts require minimal handling by technicians: they just hang the part on the conveyor, apply the powder, and remove it upon completion.” Comparatively, wet spray applications are labor-intensive, time-consuming, and necessitate multiple handling steps throughout the process. A typical linear-foot powder coating line can process significantly more medium to small parts in a single shift, which increases efficiency and provides a decisive competitive edge in the OEM sector, Lucy elucidates.
Many of these advantages are being documented in the Product Category Rule (PCR) for powder coatings, being developed by the American Coatings Association to showcase the benefits of powder coatings throughout their lifecycle, as highlighted by Verdun. “PCRs are significant within the architectural sector as they enable buildings to earn LEED points, potentially yielding tax credits and other incentives. Powder coatings are now categorized as premier sustainable products,” she notes.
Within the architectural segment, powder coatings are utilized across a diverse array of smaller applications, which range from handrails to stadium seating and metallic partitions in men's restrooms to safety bars in bathtubs and showers, as well as wrought iron and aluminum décor, fencing, and lighting fixtures, according to Nerlfi. “Powder coatings are increasingly being integrated into the building construction industry for various interior and foundational products, primarily to enhance the environmental performance of these goods,” comments Vogel. He also mentions that, in several high-performance cases, powder coatings are employed as primers beneath liquid topcoats. The mounting acceptance of powder coatings by furniture OEMs, coupled with advancements in low-temperature curing technologies, is propelling the application of powder coatings on medium density fiberboard and temperature-sensitive substrates, as well as massive metal components, as observed by Watson. Additionally, Watson indicates that the trend of urbanization is fueling the demand for aluminum window and door frameworks as well as kitchen and HVAC appliance requirements, including a growing market for outdoor cooking and entertainment areas. The design versatility offered through patterned surfaces achieved via sublimation printing enhances value against traditional finishes while allowing users to escape the costs associated with polyurethane technologies, he adds. Furthermore, Watson observes that ongoing regulatory shifts in China are accelerating a transition to solvent-free systems which will boost powder coating adoption.
However, the foremost growth potential exists within the domain of powder coatings employed for protecting aluminum extrusion products across residential, commercial, and monumental projects, notes Verdun. “Historically, this application has utilized liquid coatings, but powder solutions are capturing the interest of the architectural sector,” she remarks. In fact, in North America, the current market share for powder in the aluminum extrusion sector remains relatively low, representing the largest current opportunity for powder in the architectural domain, asserts Cregg. “In Europe, powder dominates the coatings used on extrusions, yet it remains below 50% in North America,” he adds. Wang agrees that the architectural segment in North America is expected to experience growth rates surpassing the overall market growth in the next five years, driven by residential and commercial building developments and an ongoing trend of transitioning from liquid to powder coatings. “The North American market demonstrates potential as architects and specifiers increasingly pivot from liquid to powder coatings, fueled by a quest for sustainable solutions and ambitions to curtail environmental impact. With process efficiencies, low wastage, and zero VOCs, powder coatings offer a sustainable alternative to liquid coatings,” he notes.
The introduction of Environmental Product Declarations (EPDs) for powder coatings is becoming instrumental in illustrating the sustainability benefits of opting for these solutions over traditional liquid coatings, according to Wang. “The international EPD system explicates the environmental performance of a product across its lifecycle. Architectural specifiers are increasingly acknowledging that powder coatings can perform comparably to conventional finishing types,” he explains. The focus on green construction is also a key motivator. “Most large commercial and monumental projects are being developed to qualify as green buildings per the Leadership in Energy and Environmental Design (LEED) certification administered by the Green Building Council, thus architects and specifiers are duly heedful of all design elements that could influence LEED credits, including the incorporation of powder coatings,” explains Verdun.
Despite the hindrances to powder's presence in the North American extrusion market, several factors are not related to performance level issues, states Cregg. Many powder resin technologies can satisfy the requisite American Architectural Manufacturers Association (AAMA) standards for coatings on aluminum extrusions. Powder also offers exceptional durability, surface strength, and scratch resistance meeting AAMA specifications. “Resin and pigment suppliers have successfully addressed the challenge of delivering superior weathering capabilities, while powder coating manufacturers have innovated formulations that marry these attributes alongside unmatched mechanical properties,” asserts Withers. Developments in super durable resins lead to powder coatings exhibiting improved flow and flexibility, alongside moisture resistance enhancements, encouraging usage on aluminum extrusions and ACE applications, according to Watson. In fact, powder coatings are supported by performance guarantees and industry certifications, as Wang points out. “Hyper-durable powder coatings are among the top weather-resistant coatings available, employing similar chemistry to liquid polyvinylidene difluoride (PVDF) coatings adhering to the most stringent standards for coatings, but presenting a more sustainable alternative,” he says. Cregg notes that new blends featuring polyester and fluoropolymer resins fulfilling AAMA weathering specifications provide a cost-effective alternative for the high-performance segment of the aluminum extrusion industry.
In terms of color offerings, McLeish reveals that trends emerging from adjacent sectors including automotive, appliances, and fashion are exerting influence on the color palette within the architectural market. For instance, the rising popularity of black as a favored color necessitates the demand for cleaner, more jet-black finishes. “Broadening the current range of color and aesthetic choices will promote market prospects. There's an uptick in metallic finishes as well as requests for lower gloss finishes with ultra-smooth surfaces that comply with AAMA standards,” she elaborates. Withers points out that new manufacturing technologies allow for striking metallic finishes in powder coatings that closely reach the aesthetics attained through multiple liquid coatings, thus broadening applicability within this sector. To illustrate, Verdun cites the encapsulation of metallic pigments that enables the application of powder coatings featuring metallic finishes without requiring an additional clearcoat. Producing weather-resistant, ultra-matte powders emulating anodized surfaces is yet another notable advancement, asserts Watson. “The ability to fabricate weather-resistant, ultra-matte powder coatings is significant, as these coatings can imitate the anodizing finishes currently trendy in commercial architecture while eschewing challenges often linked with anodizing,” adds Wang. Watson also mentions the growing area for powder concerning low-bake powders applicable to aluminum extrusions with plastic-insulated components.
Applications for powder coatings capable of resisting mold growth, thereby reducing the necessity for harsh cleaners and overall frequency of cleaning, also present promising future prospects, according to McLeish.
Additionally, advancements in powder coating application technology are creating greater opportunities for usage among extruded aluminum within the architectural sector. “Some applicators are transitioning to vertical powder coating lines rather than the traditional horizontal configurations, enabling them to coat much larger aluminum extrusion sections with increased throughput and faster processing times,” explains Verdun.
Nevertheless, opportunities for further development remain, and with continued technological advancements, the prospects for powder coatings within the architectural segment are likely to flourish. For McLeish, the singular most significant innovation driving demand in the architectural market would be the availability of a broader spectrum of colors featuring richer, more saturated shades that comply with stringent AAMA standards. “Innovations concerning texture—including ultra-smooth finishes that mimic the look of liquid coatings, improved coating flexibility for durability, and enhanced service aspects such as rapid color matching—will cater to applicator demands,” she adds. Further enhancements in powder coatings delivering metallic finishes are also imperative. “New advancements are necessary to improve the weathering and mechanical attributes of these coatings while lowering the applied costs to streamline transitions to powder coatings,” asserts Withers. Verdun agrees that bridging the gap between the appearance provided by liquid coatings versus powder coatings with special effect pigments will spur changes. She also emphasizes the necessity of reducing powder coating thickness while maintaining high performance standards, which in turn can drive costs down and stimulate further interest.
The defining factors influencing the pace of market transformation towards powder coatings are the preferences of architects and specifiers as well as the prevalence of powder lines in the landscape of job coaters, according to Wang. “Further innovation and development of products will also help accelerate this transition; improved aesthetic appeal, enhanced mechanical, and corrosion protection properties are key considerations,” he states. Cregg adds that the continual push towards sustainability in the building arena will only serve to heighten the status of powder coatings as preferred technology. As LEED building programs in the United States begin recognizing the added value provided by factory-applied finishes—not solely those applied on-site—powder coatings are poised for accelerated growth within the architectural sector. “It is exciting to see that powder coating technology can now satisfy virtually any architect's vision while retaining the durability and performance attributes outlined by AAMA,” expresses McLeish. “Should industry trends continue down this path, powder will firmly establish itself as a valuable option for building materials.”
The demands for corrosion protection and resilience to weathering remain pivotal drivers behind the application of industrial and protective coatings, asserts Withers. “Manufacturers aim to differentiate themselves from competition, and demonstrating that their products retain attractive appearances post exposure outdoors is a considerable marketing advantage since consumers expect longevity in aesthetics after extended outdoor use,” he articulates. Concurrently, there is a persistent drive in industrial and protective coating markets to deliver elevated performance while utilizing fewer resources at reduced expenses, maintains Vogel. “Progress in powder coating technology is making it increasingly appealing for many applications because it facilitates the achievement of these objectives,” he comments. Similar to developments within architectural sectors, the ability to attain lower energy cures while ensuring high-performance qualities as well as desired aesthetics with thinner film applications remains an area of focus. “There exists a host of venues where powder could advance and become more prevalent in the coming years, provided companies are prepared to invest time and resources into development initiatives for emerging market segments,” affirms Cregg. He notes that while the market for powder on OEM metal substrates reaches relative maturity, opportunities still exist in other segments and locations requiring coatings on heat-sensitive substrates.
From a performance lens, powder coatings provide exceptional durability against UV exposure and corrosion challenges. Nevertheless, enhancements are necessary—particularly when it comes to corrosion resistance on edges found on substrates commonly utilized in exterior operations, such as heavy-duty machinery, remarks Verdun. “In addition to exhibiting good corrosion resistance, especially on edge surfaces, primer powders need to present strong adhesion and address the variances among substrates like voids in aluminum wheels and moisture found in stable MDF boards,” adds Watson. Where thicker film builds are necessary, the capability of powder coatings to produce high thickness while presenting desired levels of gloss and flow, all without sagging or dripping, proves advantageous as opposed to competitive liquid coatings. Moreover, Watson notes that functional epoxy powders primarily find their applications in corrosion protection (e.g., for pipeline coatings), while specialized powder coatings suited to problematic substrates, such as galvanized steel, can be applied direct-to-metal efficiently. In the automotive domain, Verdun points out that enhancing functions within industrial and protective coatings— such as bolstered chip and mar resistance—remains a segment ripe for advancement in powder-coated vehicle beneath applications. “Recent innovations point towards effective chip mitigation systems as a key area of development,” she explains. For appliances, there’s a growing need for heightened resilience against chemicals and heat, ranging from detergents and bleach to mustard and coffee.
Rising demands for sustainable solutions that align with customer expectations regarding performance enhancements is another motivator for the application of powder coatings across industrial and protective domains. “With the goal to lessen environmental impact, clients continually strive for improved process efficiencies,” states Vlad. She highlights recent advancements in powder coating technologies—like eliminating extra coating steps and optimizing utilization of coating materials—that further enhance appeal. The industry is also exploring recyclable and renewable raw material inclusion, such as ingredients from plant sources and incorporation of recycled plastics in resin product formulations per Verdun.
The readiness of powder-coated goods for packaging is another persuasive factor elevating preference towards powder rather than liquid coatings. “Powder coatings deliver robust durability post-curing, which boosts manufacturing plant productivity by allowing for predictable operations and schedules,” elucidates Vogel. This advantage is supplemented by powder’s comparatively simpler application requirements, correlating to shorter training durations— a crucial consideration in today’s competitive labor market.
Many technological advancements enabling greater market advantages for powder coatings in architectural environments are also influencing progress in industrial and protective applications. Developments in application equipment, resin technology, and overall formulation techniques have significantly contributed to powder’s newfound growth, notes Cregg. A standout factor includes significant advancements in powder coatings employing special effect pigments. “We are now capable of accommodating a higher volume of customer requests for varied aesthetic outcomes than we could have managed 5-10 years past,” affirms Vogel. Innovative resins allowing curing of powder coatings at temperatures lower than 250°F are opening new terrains of possibility for powder coatings, according to Verdun. Simultaneously, Withers stresses the key achievement of powder coatings is to strike an ideal balance of superior weathering alongside great mechanical properties. “It isn’t only beneficial to attain one, as consumers demand both high-quality performance at a competitive price,” he states.
Increased efficiencies paired with reduced costs will encourage immediate growth within the powder coating marketplace, according to Cregg. He emphasizes breakthroughs in one-coat applications that eliminate some primer systems and the advent of quick cure systems to improve throughput at the user level. The evolution of powder-on-powder systems in ACE applications enhances overall film traits by achieving greater layers with only two applications—this is another significant example noted by Watson. For instance, he highlights that low-bake powder coatings for MDF requiring no more than two applications present processing advantages in contrast to liquid paints, which necessitate a minimum of four individual applications coupled with sanding efforts between layers. Powder coating technologies succeed in enhancing application efficiencies while generating less waste.
CQTI vice president, Douglas Corrigan, is analyzing performance/cost levers with forensic scrutiny for powder coating clients. One relevant case study highlighted in the October issue of CoatingsTech, titled “Getting Out of the Lab—Advantage of Evaluating Coatings in a Real-World Manufacturing Environment,” illustrates how variations in part shapes and various types of curing ovens influence powder coating curing dynamics. “User ovens can substantially differ in terms of type (convection being one variant), airflow, and heating techniques (including gas, electric, or infrared); in tandem, the shapes and mass of parts heavily dictate the thermal profile experienced throughout the curing process,” he notes. Accordingly, a technical data sheet suggesting curing rates at 400°F for 10 minutes could fall short if not adhered to appropriately for optimal curing.
After spanning over two decades of commercial usage, confidence in powder coating technology as a sustainable alternative across various market sectors is substantial. Amidst resilient economic growth, capital investment within powder coating manufacturing appears to be resurging, according to Withers. “This increased activity will materialize in products of superior performance,” he asserts. Concurrently, both Watson and Withers note that segments such as powder coatings for can applications and coil coatings are newly penetrating previously unchartered territories.
Digital solutions are gaining prominence within this sector as well. Online tools now facilitate color-matching tasks and expedite online purchases, ensuring timely powder coating deliveries, pinpoints Verdun. “Customers now have the convenience to access color libraries and other important data direct from their desktops, laptops, or mobile devices, significantly enhancing powder coating accessibility— particularly beneficial for smaller enterprises,” she explains. Wang concurs, explaining that e-commerce represents a burgeoning market route, resulting from an ever-increasing pressure for efficient product access and purchasing methodologies, which is propelled by the demand from the extensive pool of trade coaters.
This digital momentum reflects an extensive commitment from resin, pigment, and additive producers alongside coating formulators who consistently channel investments into innovation efforts. “All we do revolves around market requirements as we work towards providing increasingly sustainable solutions for our global clientele. Ensuring the provision of top-tier powder coating solutions, alongside aiding customers in meeting their sustainability objectives, encompasses the core of our mission,” concludes Verdun.
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