PROCESS ECONOMICS PROGRAM SRI INTERNATIONAL Abstract Menlo Park. California 94025 Process Economics Program Report No. 152 ULTRAVIOLET CURABLE COATINGS, PRINTING INKS, AND ADHESIVES (March 1982) Since their Introduction in the 19608, UV curable coatings, printing inks, and adhesives have shown remarkable growth by displacing conventional materials. This first PEP report on the subject presents technical information on the four commercially available types of UV curables: acrylate, unsaturated polyesterlstyrene, thlo-ene, and epoxy. Formulation components--oligomers, photolnitlators, and reactive diluents--are discussed. The three industrial types of UV curing equipment--medium pressure mercury vapor arc lamps, electrodeless lamps, pulsed xenon arc lamps--and the other components of a UV curing station are described. Economic comparisons are made between UV, thermal, and electron beam (EB) coatings. PEP'80 MS
Report No. 152 PRINTING UV CURING OF COATINGS, INKS, AND ADHESIVES by MAX SACKS March 1982 A private report by the PROCESS ECONOMICS PROGRAM Menlo Park, California 94025
For detailed marketing data and information, the reader is referred to one of the SRI programs specializing in marketing research. The CHEMICAL ECONOMICS HARDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States and Western Europe. ii
CONTENTS 1 INTRODUCTION. 1 2 SUMMARY. 3 3 INDUSTRY STATUS... 9 Major Markets in the United States... 10 Coatings for Wood... 10 Coatings for Metal... 10 Coatings for Paper and Paperboard... 11 Coatings for Plastic... 11 Coatings for Resilient Flooring... 12 Miscellaneous Coatings... 12 Printing Inks... 13 Adhesives... 14 U.S. Market Sizes and Projections... 15 Coatings... 15 Printing Inks... 16 Adhesives... 17 Market Participants in the United States... 17 Industry Status in Western Europe... 18 Industry Status in Japan... 24 Coatings... 24 Inks... 27 Adhesives... 29 4 CHEMISTRY... 31 Introduction... 31 UV Curing versus EB Curing... 32 Acrylate Coatings... 34 Acrylated Polyester Oligomers... 36 Acrylated Urethane Oligomers... 36 Acrylated Epoxy Oligomers... 37 Acrylated Polyether Qligomers... 38 Acrylated Acrylic Oligomers... 39 Photoinitiators... 40 Multifunctional Acrylates (Cross-Linkers)... 45 Unsaturated Polyester/Styrene Coatings... 50 Thiol-Ene Coatings... 51 Eooxy Coatings... 58 iii
CONTENTS 4 CHEMISTRY (Continued) Oligomers... Reactive Diluents... Wetting Agents... 60 Fillers and Pigments... 60 Cationic Initiators... 61 Hybrid Systems... 67 5 PROCESS REVIEW 73 6 ULTRAVIOLET CURING EQUIPMENT... 111 Medium Pressure Mercury Vapor Arc Lamp... 111 Lamp Start-Up and Shutdown... 112 Irradiator... 113 Shielding, Cooling, and Safety Equipment... 114 Control Station... 115 Electrodeless Lamp... 116 Pulsed Xenon Arc Lamp... 117 7 ECONOMIC COMPARISONS OF Capital Costs. Production Costs Discussion of Cost: Coating. UV Lamps Electric Power. Nitrogen Inert Gas. Incinerator Fuel Gas Capital-Related Costs UV vs EB uv, THERMAL, AND EB CURING... 121..... 122..... 123...... 124... 124... 125... 126... 126... 126... 127... 127 CITED REFERENCES 129 PATENT REFERENCES 153 iv
TABLES 2.1 3.1 3.2 3.3 3.4 3.5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 Clear Topcoat for Printed Particle Board Panels Summary of Incremental Production Costs... U.S. Suppliers of UV Curing Equipment... U.S. Suppliers of UV Curable Coatings, Printing Inks, and Adhesives... U.S. Suppliers of Monomers, Oligomers, Photoinitiators, and Photosensitizers... West European Suppliers of UV Curable Coatings, Printing Inks, and Adhesives... West European Suppliers of Monomers, Oligomers, Photoinitiators, and Photosensitizers... Summary of Patents Issued to General Electric Co... Summary of Patents Issued to SCM Corp... Summary of Patents Issued to W. R. Grace & Co,... Summary of Patents Issued to PPG Industries, Inc... Summary of Patents Issued to Sun Chemical Corp... Summary of Patents Issued to Union Carbide Corp... Summary of Patents Issued to Eastman Kodak Co... Summary of Patents Issued to Du Pont... Summary of Patents Issued to American Can. Co... Summary of Patents Issued to Ciba-Geigy Corp... Summary of Patents Issued to Mobil Oil Corp... Summary of Patents Issued to Mitsubishi Rayon Co. Ltd.. Summary of Patents Issued to Toyo Ink Mfg. Co., Ltd... Summary of Patents Issued to Nippon Oil Seal Industry Co., Ltd... Summary of Patents Issued to Kansai Paint Co., Ltd... Summary of Patents Issued to Dainippon Ink & Chemicals, Inc... Summary of Patents Issued to Nippon Synthetic Chemical Industry Co., Ltd... 6 19 20 21 25 26 74 76 78 80 82 84 86 88 89 90 91 92 94 96 98 99 100 V
TABLES 5.18 5.19 5.20 5.21 5.22 5.23 5.24 6.1 7.1 Summary of Patents Issued to Fuji Photo Film Co., Ltd. Summary of Patents Issued to Nippon Paint Co,, Ltd., Summary of Patents Issued to Teijin Ltd., Summary of Patents Issued to ICI Ltd, Summary of Patents Issued to BASF AG Summary of Patents Issued to Bayer AG Summary of Patents Issued to Hoechst AG. Comparison of UV Lamps Clear Topcoat for Printed Particle Board Panels Incremental Production Costs.. 101. 103. 104. 105. 106. 108. 109. 120. 128 Vi