TEGO® Powder Aid C01 – a novel technology approach for boosting corrosion protection in powder coatings

Powder coatings are becoming increasingly popular for a wide range of applications due to their numerous advantages. The market for powder coatings was valued at over $13.5 billion in 2022 and is expected to grow significantly, reaching over $20 billion by 2032, with an annual growth rate of more than 6% (Lit.1). This growth is largely driven by the increasing focus on reducing volatile organic compounds (VOCs). Powder coatings emit negligible VOCs compared to traditional liquid coatings, making them a more sustainable and environmentally friendly option.

These coatings come in a variety of finishes and colors and are known for their high  durability. This makes them ideal for architectural uses like outdoor stadium seating, window and door frames, as well as furniture applications. With technological advancements in binder and additive chemistries, their use also has expanded into high quality surface finishing, such as heavy construction machinery and even automotive parts, highlighting their versatility and excellent resistance towards harsh conditions.

In addition to environmental benefits, powder coatings also offer a lot of practical advantages. They are cost-effective, require less personal protective equipment, and do not need solvents for cleanup, further reducing their environmental impact. Even the overspray can be recycled in most cases. Powder coatings also allow for thicker application without the risk of running or sagging and do not contain any solvents, which lowers transportation and storage costs.

Commonly used powder coating additives that contain a significant amount of silica can sometimes go hand in hand with several unwanted effects. These include a slight loss of gloss, orange-peel, reduced film flexibility, or even a loss of adhesion. Such issues result in inferior coating quality, where the surface protection might not perform as effectively as intended. This can lead to a lower quality perception of the final product, as the coating may not provide the desired aesthetic or protective properties.

TEGO® Powder Aid C01 uses a novel technology, where modified polyester polymers come into action. This technology creates the desired effects in coatings without the drawbacks of silica containing additives. It may positively impact desired paint film properties, for example providing a smoother surface and improving film flexibility. 

TEGO® Powder Aid C01 consists of free-flowing granules that are simply added to the premix before the extrusion process. There is no special handling necessary, as the product is very easy to use and incorporate.

Extended laboratory trials across various binder technologies have shown a significant improvement of results after exposure to a natural salt spray (NSS) test following DIN EN ISO 9227. Fig. 1 for example shows a white glossy powder coating (PE/HAA - 95/5, DFT 85-90µm on zinc-phosphated steel panels) with both 3% and 5% TEGO® Powder Aid C01 after exposure to salt spray for approx. 860h.  

Figure 1: 860h Salt Spray test results of TEGO® Powder Aid C01 in a white glossy PE/HAA powder coating 

In addition to the optimized corrosion protection properties, less impact on the gloss level of the coating was observed. Fig.2 shows the gloss levels in 20° and 60° angle, comparing TEGO® Powder Aid C01 to a silica based market standard and a typical ion-exchanged anti-corrosion pigment. Having a look on the influence of adhesion, Fig.3 shows best results in terms of chipping and loss of adhesion, even on the cutting edges of the cross-cut test.

Figure 2: Gloss levels of TEGO® Powder Aid C01 vs. market references

Figure 3: Cross cut adhesion of TEGO® Powder Aid C01 vs. silica based product

In conclusion, the use of TEGO® Powder Aid C01 can not only increase the corrosion protection properties of your powder coatings, but also features best adhesion and surface finish properties.  

(Lit.1) Coatings World: Powder Coatings Market Expected to Reach $20.8B by 2032