2. Presentation of powder paint on wood.
2.1 Definition :
This new technology enables us to commercialize a new coating compound powder paint – applied by an industrial process.
It is oriented to replace traditional liquid paint, applied either on a large or small scale or by individual utilizers for domestic purposes.
This technology –thermo lacquering- has existed and has been used on metal for a long time.
The innovative particularity of this coating, which contains no solvent, lies in the fact that it can now be applied to a non-conductor surface such as wood.
On solid wood (forty or so different species have been coated up to now)
On various panels (fiberboard, medium, multiplis...) distributed by the manufacturers but also available in D.I.Y stores and also from wholesalers.
2.2 Advantages compared with liquid paint.
2.2.1 Aspect.
Variety of plain shades : it is possible to obtain 150 different shades at extremely competitive costs whilst remaining within the limits of small scale production. This also applies to the variety of aspects : matt, satiny or glossy.
Variety of surface effects : such effects called hammered, frosty, granulated, metallic, are practically impossible to achieve with liquid paint except at high costs but can easily be achieved with powder paint.
Harmonization between different surfaces : The same shade used on metal, solid wood, fiberboard or medium panels will have the same aspect and the same luster.
2.2.2 Quality of the coating.
Extremely resistant to shocks and to wear : the resistance of the coating ( not to be confused with the resistance of the surface itself) makes it possible to use products coated in this way for :
Decorative vertical panels (rarely exposed to shocks) or for horizontal working surfaces ( more liable to be scratched)
Coating taking the exact shape of the surface : there is no risk, therefore of running or of insufficient or too much paint in the corners or in the groves, which happens with liquid paint. The surface is, therefore, evenly covered.
Respect of the environment : the powders are 95% biodegradable and 5% burnable. They contain less than 2% volatile organic compounds, which is far less than with liquid paint.
Coating miscible with liquid paint : this enables anyone to retouch the coating with liquid paint (in case of shock or the recutting of certain products) by following the given indications.
Compliance with standard specifications that are indispensable in certain cases : many powder paints exist that comply with the required standard specifications regarding toys or food.
2.3 Advantages compared with veneered panels.
Veneer includes melamine on fiberboard and natural veneer, particularly laminated wood. Here again, there are a number of competitive advantages :
1 A rich variety of colors compared with 5 or 6 available shades of veneer (in particular black, blue and brown).
2 Much higher resistance to U.V.’s ( the color does not change or fade after a few years)
3 The possibility of coating both sides and the four edges.
2.4 Limits :
40 out of 400 species of wood can, up to now, be coated with powder paint, which represents a good percentage of products used today on the French and European wood and carpentry market.
The lacquered finish attains almost the same level of perfection as that achieved with liquid paint : the powders formulated for metal that are used at the present moment are being developed still further thanks to research in collaboration with fellow powder manufacturers. The results are conclusive.
3 A new process of applying coating on wood.
3.1 definition
Thanks to this technology, powder paint can now be applied on dielectric surfaces and the product then fired in a kiln at 165° (even 180°) so that the powder polymerizes permanently.
This process has been operational on metal for a long time.
It is now possible to use this technology on wood and its various derivatives, which is arousing the interest of wood and paint manufacturers.
The 3 successive technological stages in this field are the following :
Treatment of surfaces : for the powder paint to be applied with an optimal result, an initial preparation of the surface is necessary. This is particularly important in the case of wood surfaces : a special preparation should facilitate the evaporation of humidity inside, the evacuation of gas in the case of certain noble varieties of wood and , lastly, enable the wood to respire once treated.
Application of powder paint : one coat only is needed, applied vertically by hand or automatically by means of a spray gun, thanks to the creation of an electrostatic field; this enables the completely even coating of the surface ( particularly in the corners, moulding, cavities and grooves). But it can also be applied horizontally.
Firing : ( at high or low temperatures ) a successful, durable and resistant polymerization with one coat only depends , essentially, on the firing. No particular equipment is necessary but rather an adaptation of a convection gas kiln. It is also important to respect the rise of temperature according to well defined stages, knowing that the different temperatures and stages vary according to the products to be thermo lacquered.
3.2 Advantages compared with the application of liquid paint
The time needed to manufacture powder paint is much reduced : It takes several days to manufacture liquid paint whereas it takes less than 2 hours to manufacture powder paint. Thus it is possible to reduce delays, to have greatly reduced storage areas (intermediary and final) and to valorize the stocks of manufactured products.
Improvement in working conditions : the absence of solvents and , therefore, of toxic emanations, implies a minimum of protection equipment for the personnel and, above all, it is easy to handle, which is an important factor.
Economy with regard to antipollution equipment : a production unit using powder does not pollute the environment, whereas the utilization of solvate paint entails considerable investment in reprocessing.
Simplified storage : powders can be stored for a much greater length of time than liquid paint without deteriorating. Moreover , as they are inflammable , (there is no flash point for the powders) this simplifies storage conditions.
Gain in raw material : powder , already more economical than liquid paint although weighing the same, can cover about twice as much surface , namely from 5 to 2 m² compared with 3 to 6 m².
Gain in productivity : one single application of powder corresponds to the equivalent of 3 to 4 coats of liquid paint (namely about 90 to 120 microns).
3.3 Conclusion
More numerous and varied products than with liquid paint.
Far greater resistance
2 to 3 times lower cost of manufacturing
Both the finished product and its manufacturing unit respect the environment.
A 2 to 3 times higher production rate than with liquid paint
Saving on the cost of industrial implementation.
4 Market
.
Immediately accessible markets, that is to say , markets where the technology can be set up at once.
The principal markets concerned are those regarding house decoration.
Products used for the outside of houses and building are subject to specific standards with which we are unable to comply at present : as the company holding the patent was only created recently, it is impossible to test aging for which 5 to 10 years are needed.
However, the accelerated tests than have already been carried out uphold our quest for quality.
Our company is already oriented towards products corresponding to the required standards for such outside surfaces as French windows and shutters.
The great number of potential markets is a further advantage in favor of this process in terms of the repartition of risks and the multiplication of opportunities
At present, seven important industrial markets are thus identified (mass production) each having.
Very different dimensions.
Contrasted progression rates.
Intermediate companies, large and small : small companies or international groups.
Very different levels of industrial concentrations.
Another industrial market : services furnished by one manufacturer for another manufacturer (medium scale production)./
There are fifty or so large companies in France carrying out thermo lacquering on metal as a service for other firms. They are therefore specialists in the application of powder on metal as medium/ mass producers for building public works and cars .
Thanks to this process, some of these companies will become experts in thermo lacquering on wood.
Another developing market : D.I.Y or smaller D.I.Y’s .
Consumers as well as certain building professionals go to Leroy Merlin, Castorama, Lapeyre to buy finished or semi-finished products in order to renovate or carry out interior decorating.
In conclusion, one can see that decoration and color are important on all these markets. The new coating that this technology proposes will become a competitive advantage.
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