Waterborne Coatings

Although waterborne coatings have been used in the autobody industry in Europe and Canada for years, these coatings have been slow to become available in the United States.  Over the last decade, waterborne coatings have become more readily available, and autobody shops have started using these coatings for one of two reasons; because of regulatory requirements (such as in CA) or because of the economic and environmental benefits from using these less toxic coatings.

Water-based coatings follow the same basic steps in preparing and painting the object.  Some changes are:

• how the object is painted (usually takes less coats),
• how it is dried (air flow, rather than heat or UV),
• the cleaning of equipment and
• the storing of coatings. 

Please note that it is very important for the painter to wear protective gear when painting.  Also, the waste from water-based coatings needs to be separated from the waste of solvent-based coatings, because they usually have different waste designations, controlled waste vs. hazardous waste.  For more information on waste, call the WA State Department of Ecology, 329-3400.

The Pollution Prevention Resources Council has developed a free Webinar on waterborne coatings.  The 90-minute video is broken down into three 30 minute sections, overiew of waterborne coatings, testimonials from autobody shops and a technical college, and Q & A. The video also provide shop owner contact information of businesses that are willing to share their wisdom to assist others in the change over from solvent-based, to water-based coatings. 

Pros of Waterborne Coatings (as compaired to solvent based)

• Increase productivity due to:
     - quicker mixing process,
     - better coverge and 
     - faster drying times.
• Better color match.
• Reduced energy usage (don't need heat to dry paint).
• Reduced hazardous waste.
• Reduced VOC emissions.
• Less regulatory burden.
• Healthier work environment.
• More environmentally friendly product.

Cons of Waterborne Coatings (as compaired to solvent based)

• Need to retrain painters.  The painting skill set with waterborne coatings is different than with solvent based coatings.
• Waterborne coatings show defects in parts.  
• Paint is affected by temperatures - it cannot freeze or be overheated.  You can buy paint that hasn't been pre-mixed, and it's not as succeptable to temperatures.

Equipment

Most of the equipment used in solvent-based paint shops can be used with water-based coatings.  Keep in mind that water-based means that "water soluble" products will fail and some equipment can rust.  Guns and associated parts need to be made of rust free materials, such as stainless steel.

Consumables for waterborne coatings are different, for example, you must use plastic or metal mix instead of wood.  You will need bigger screen size for paint strainers and make sure they aren't made with water soluble products.  Tape and paper need to be water proof. Many shops time the change over to when their solvent consumables inventory is low.

One large capital expense some shops need in the changeout is to upgrade their compressed air deivery system that is now used to deliver paint and to dry paint.  Also, turbulent fans may need to be installed to aid in drying. 

Waterborne Paint Manufacturers Available (as of July 2010) 
AkzoNobel Dyna Coat – www.akzonobel.com
BASF Glasurit 90 – www.glasurit.com
DuPont Cramax Pro – www.pc.dupont.com
Henkelna – www.henkelna.com
Martin Senour from NAPA – www.martinsenour-autopaint.com
Matrix Aqualution – www.matrixsystem.com
PPG – www.ppg.com
Sherwin Williams AWX Premium Waterborne – www.sherwin-automotive.com
Standox – www.standox.com

If you are interested in switching from solvent coatings to waterborne, it's is recommended that you contact a variety of paint manufacturer's.  Have the manufacturuer's reps take a look at the equipment in your shop, and then provide a summary of costs for the switch over from solvent to waterborne coatings.  Depending on existing equipment, some shops will have minimal capital outlay for the change over.  Others shops made need to make quite a few equipment changes.  For more information on waterborne coatings, please contact the paint manufactuers listed above.