PUTTING ENERGY INTO INNOVATION - Rembrandtin
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2020
PUTTING ENERGY
INTO INNOVATION
YOUR
True
True Colours
WORLD
November 2020
Publisher: HELIOS
Editor in chief:
Stories
Maša Bantan Marot
Editorial board:
OUR NEW
Hitoshi Nishibayashi,
Yasuo Horibe, Dietmar Jost,
Hubert Culik
SHADES
Photos: HELIOS archives,
Shutterstock or as written
I
Design and layout:
n the past, stories commonly began with the phrase
PM, poslovni mediji,
»once upon a time«, but the year 2020 gave a new
Tjaša Kastelic
meaning to all the narratives. Amid the global
CHOOSE YOUR OWN AMONG
coronavirus pandemic, the line »in challenging
Circulation: 800 pieces
times like this« has been the most used opening,
1200 NEW SHADES Contact:
HELIOS Corporate
written too many times.
As well at HELIOS, health and safety of employees
and other stakeholders became our primary concern,
communications department
and responsible behaviour was even more reflected
Maša Bantan Marot
in all our activities. Even though we have to stand
Phone: +386 1 722 4075
physically apart, we have stepped together and built
masa.bantan@helios.si
even stronger connections. Corona story itself has no
silver lining, however it encouraged us to think beyond
the health crisis and further strengthen our societal and
environmental commitments.
Although HELIOS is a coatings and chemicals
producer our aim has never been just to make things
green. We would like to turn them green with tangible
actions reducing the impact on the environment along
our entire value chain. With improved environmental
performance we are accelerating our transformation
to a carbon-neutral business. In this year's issue of
True Colours we are proudly presenting our efforts we
have put into development of innovative products and
processes that present the future of our industry.
We are picturing true people, true energy and true
stories in the background.
Take care, be safe and stay healthy!
Hitoshi Nishibayashi
CEO of HELIOS
WWW.HELIOS-DECO.COM
1
TIME IS NOW
CO
NTE 06 24 38 62
NT Designing green
coating solutions
UV/EB curing coatings
at a glance
“Energy should be
aimed in the right
direction”
A lean and green
approach for a
better performance
10 34 52 58
Raw materials supply Reusing CO2 to ADHESIVES AND SEALANTS: Building relationships
and coatings produce green the perfect match for based on trust
formulations products systems
50
Water-borne
42
HELIOS REFINISH:
22 32
Rembrandtin innovation A smart thermal
44 69
Wind energy enhanced ECOPOLIFIX:
78
Donating disinfectant
84
Thinking beyond
makeover first impressions powering the electric insulation system with Helios Resins industrial future designed during the coronavirus the immediate
of the Sofia Metro from Africa vehicles market on powder traces outbreak crisis
2 3
TIME IS NOW
PROGRESS
“Without continual growth and progress, such words as
improvement, achievement, and success have no meaning.”
Benjamin Franklin
Scientist and statesman
4 5
PROGRESS
Designing green
coating solutions
Karla Rončević
Green coating solutions and systems are designed from the ground up to reduce their environ-
mental impact and save resources. Their use will play the main role in the selection of process-
es and products, and the need for them generates continuous innovations.
I
n recent decades, the chemical indus- industry, including coatings, are based on
try has made a major step towards the fossil feedstock. That is why alterna- NEWLY DEVELOPED SOLUTIONS
environmental footprint reduction.
Initially, trends in the paint and coat-
tive feedstock, such as biomass, recycled
chemicals and carbon dioxide have lately
SAVE ENERGY, WHILE REDUCING
ings industry were strongly connected with
environmental protection. The main goal
been gaining importance. Polymers made CARBON DIOXIDE EMISSIONS.
from renewables help save fossil resources
was pollution prevention or the reduc- and reduce the carbon footprint. Bio-based
tion of VOC levels together with the shift solvents, additives and pigments are already
towards waterborne coatings, powder, and available as well. In addition to the ecolog-
UV curing coatings. Nowadays, besides the ical features, the products based on these
environment, the producers would like to raw materials need to excel in performance.
take into account the total effect of products
on the society and the economy. Solutions protecting things that matter
When designing new products, the de- While paint and coatings are commonly
velopment of all stages is closely intertwined known for providing aesthetic appeal to the
with the circular economy principles and materials they coat, their most important
the commitment towards nature and cli- function is to protect and prolong the life of
mate. This means that producers reconsider those materials. Coatings provide protec-
every stage of the coating’s life cycle from tion from degradation, such as corrosion,
raw materials formulation, application and abrasion, high temperatures, chemical
curing to disposal at the end. impact, moisture, or UV rays. In order to
contribute to sustainability, researches are
Renewable raw materials and sourcing developing coatings that are more durable,
To ensure sustainable products and formu- thus minimizing the need for maintenance.
lations, producers need to develop solutions Newly developed solutions also protect the
that will be most appropriate at the end of environment in a more direct way: they save
the material's life cycle. That is why the first energy by keeping buildings cooler and they
things to be reconsidered are raw materials are an essential part of renewable energy ROOF EXPERT AC, THE NEW ROOF COATING SYSTEM FROM
from biological and other renewable sourc- systems, while also helping reduce carbon HELIOS, PROTECTS THE SURFACE AND IS HIGHLY SUNLIGHT
es. Most chemicals used in the polymer dioxide emissions. REFLECTIVE.
6 7
PROGRESS
Functional coatings of the future provide better heat dispersion in electric THE NEW GENERATION OF ONE-LAYER COATINGS FROM
Many efforts have been devoted to the motors and transformers, thus enabling HELIOS SUCCESSFULLY REPLACED THE TRADITIONAL
development of new functional coatings higher efficiency, and enhancing the life- MULTILAYER PAINT SYSTEMS.
that represent the future of the coatings time of the components.
industry. Besides the protection and ap- The fast-growing segment of renew-
pearance, coatings provide additional de- able energy solutions needs coatings with
sired functions and, in many cases, directly additional functionalities as well. Protec-
contribute to sustainability. tive coatings used on wind turbines enable
For example, the so-called IR reflective blades to rotate under challenging con-
roof coatings offer environmental and ditions, by providing UV and weathering
cost-saving benefits for both residential protection together with the protection
and commercial roofs. Roofs protected against rain erosion or ice accumulation.
with coatings that reflect the IR energy Additionally, the solar energy market
from the sun, absorb much less heat than needs efficient coatings for solar panels. By
traditional coatings. This process helps to providing special coatings that reduce the
reduce the “urban heat island” effect and reflection of sunlight, the energy output of
at the same time helps to lower the indoor photovoltaics is increased.
temperature. The health and well-being of people are
THE ANTIBACTERIAL POWDER COATING FROM Electrical insulation coatings play an also some of the main drivers of sustain-
HELIOS IS TESTED ACCORDING TO ISO 22196, important role in lowering the energy able commitments. With low-emitting
AND OFFERS ADVANTAGES WHEN USED IN losses during transmission from the gen- interior coatings, the industry is contrib-
SPACES LIKE MEDICAL FACILITIES OR SCHOOLS. eration site to distribution centres. They uting to the health and comfort of the
PRODUCERS RECONSIDER EVERY STAGE OF THE COATING’S LIFE CYCLE
FROM RAW MATERIALS FORMULATION, APPLICATION AND CURING TO
DISPOSAL AT THE END.
sensitive population, like children, elderly the same or better protection, while
people and patients. Specially formulated simplifying the application process and
coatings go even further and purify the improving efficiency.
air by transforming harmful chemical into
unharmful ones. Closing the green circle
Surfaces around us presents an ideal Through commitment to sustainability,
environment for microorganisms to devel- the coating industry recognized the con-
op their colonies and endanger our health cept of Life Cycle thinking. Our attention
and well-being. Additionally, microbial is devoted to the recent downstream in-
growth can affect the functionality of dustry developments, with efforts focused
the product, which leads to degradation, on coatings reformulation, raw materials
staining, bad odour and other unwanted or packaging used. Paints with higher life
properties. expectancy are developed to protect and
One of the most energy consuming prolong the lifetime of environmentally
parts of the coating application process costly substrates, such as metal and wood,
HELIOS’S HIGHLY DURABLE PE POWDER COATING N194, WITH LOW is oven curing. That is why development or to reduce the demand for energy. Along
TEMPERATURE CURING PROPERTIES, SIGNIFICANTLY LOWERS WITH THE REMBRANTIN PROTECTIVE APP CUSTOMERS is focused on coatings that cure on lower with sustainable packaging and recycling,
ENERGY CONSUMPTION, WHILE STILL PROVIDING DURABILITY AND CAN SEARCH FOR PROTECTIVE COATING SYSTEMS temperatures or even tries to eliminate the the paint and coatings industry contrib-
MECHANICAL PROPERTIES REQUIRED BY ACE PRODUCERS. SUITABLE FOR A VERY LONG DURABILITY PERIOD OF need for oven curing completely. Modern utes to the reduction of waste and product
CORROSION PROTECTION. coating systems need less layers to provide loss in general. •
8 9
PROGRESS
CORONAVIRUS LESSONS
Raw materials
supply and coatings R
aw materials and logistics
are crucial
formulations
The current globalized raw mate-
rials supply and logistics system
currently works in a way that production
sites in Asia ensure that a wide range of
critical products are available in Europe as
Hubert Culik cheaply as possible. This system works well
if production sites can keep up production
and transport flows remain unhampered.
2020 is a year that will go down in history as a year of drastic developments. The rapid spread of the However, the coronavirus pandemic tempo-
coronavirus from China all the way across Europe has brought unprecedented challenges to our societies rarily closed borders worldwide and across
Europe, posed export restrictions, shut
and economies. Within the coatings industry, two factors form its backbone and are crucial for its down factories in China and India which
success: the availability of raw materials and the art of coatings formulation. Both were confirmed during significantly affected supply chains and lo-
the coronavirus crisis once again. gistics – vital parts of the chemical industry.
in-time production around the world.
New conditions require new adjust-
THE CRISIS REVEALED
The crisis revealed the existing system’s
vulnerabilities and demonstrated great risk
ments. For the coatings industry, this THE EXISTING SYSTEM’S
means bringing back development and
of overdependence on global supply chains,
which was particularly unsettling for the
production to Europe. Our own know-how VULNERABILITIES AND
and experience in raw materials production
pharmaceuticals industry.
should be the basis to shift from globalisa- DEMONSTRATED GREAT RISK OF
At HELIOS, we mastered raw materials
supply during the critical months. Thanks
tion to “glocalisation”. For instance, yellow
pigments, high quality solvents, or additives
OVERDEPENDENCE ON GLOBAL
to our well-organised purchasing depart-
ment, there were hardly any raw material
currently made in China could easily be SUPPLY CHAINS.
produced in Europe.
shortages during the crisis and production
mostly proceeded as usual. An occasional
shortage of a raw material is common in Advantages of local production
normal times as well, so we are prepared for Local product development and production among local suppliers stimulates research
such cases. have many advantages. The biggest is avoid- and development, while direct communica-
ing long transport routes. Compliant with tion along a local supply chain makes it easi-
“Glocalisation” is the future the framework of the Green Deal of the er to react quickly to a change in demand.
To be prepared for a similar crisis in the European Commission, transport efficiency
future, we should consider whether is it is also a major step towards reducing CO2 R&D and formulation after the
a valuable advantage to import certain emissions. Additionally, locating production coronavirus pandemic
chemicals solely from China or India due sites in Europe reduces the risk of interrupt- Research and development as well formu-
to a slightly lower cost. Considering the ed operations as the capacities can easily be lation know-how have always been one of
time, effort and costs required to organise shifted to another site if needed. the key elements in the coatings business.
the necessary logistics, the benefit may not Locally, it is much easier to monitor and The coronavirus pandemic has pointed out
always be worth the risk. The pandemic has ensure adherence to quality, environmental, a new direction for innovation which could
shown that we have to question global just- and labour standards. Close cooperation significantly contribute to a safer life.
10 11
PROGRESS
THE CORONAVIRUS PANDEMIC HAS POINTED OUT A NEW
DIRECTION FOR INNOVATION WHICH COULD SIGNIFICANTLY
CONTRIBUTE TO A SAFER LIFE. HELIOS RESINS
01 The secret to
sustainable raw
We need to ensure that we are not com-
pletely dependent on overseas suppliers
and hence bring some of the raw materials
production back to Europe.
02
We have to encourage local research, de-
velopment and innovation in cooperation
with local suppliers.
materials
Dr. Martin Ocepek, Dr. Peter Venturini
03
Research has to focus on new formulations
and products in the field of antibacterial
and antiviral coating materials. A team of 25 dedicated R&D employees
at Helios Resins is aiming to reduce
environmental impact by developing
Since bacteria and viruses are often Consequently, research should also advanced, green, and long-lasting
transmitted via surface contact, this crisis focus on exploring other possibilities of materials. We have managed to reduce
will put emphasis of research for antibac- surface modification which would not re-
terial and antiviral coatings. quire biocides but would remain its antivi- emissions of hazardous organic solvents,
Antibacterial coatings have been on ral effects. One alternative are bionics that create a potential for energy savings, and
the market for some time and they are provide many fields of application. They
known for providing lasting and efficient are very useful in a medical environment incorporate bio-renewable raw materials.
protection against bacteria, fungi, and but also public spaces, e.g. door handles, All this while maintaining high-quality
mould. There are various mechanisms of cars, public transport and furniture.
antibacterial action, e.g. preventing bac- products aligned with the requirements
terial attachment, release of antibacterial Lessons we have learned of our most demanding customers. Our
agents, or killing bacteria upon surface We have learned several lessons from the
contact. Currently, in most products the coronavirus pandemic that will shape re- The value of being able to react quickly efforts are also recognized annually with
antibacterial effect is achieved by adding sponses to future crises. Globalisation will was powerfully demonstrated in April the Responsible Care® certificate.
biocides to the coating’s formulation. not entirely be reversed but “glocalisation” when HELIOS, among several other
However, biocides are governed by the will help us to become more independent, chemical companies, switched production
Biocidal Products Directive (98/8/EC), while it will stimulate innovation and promptly from coatings to WHO approved
which means that newly developed biocid- contribute to the protection of the climate disinfectants. Such impressive flexibility
al coatings have to pass a time-consuming by reducing CO2 emissions due to shorter was possible due to our broad experience in
and costly authorisation procedure. transport routes. • the art of formulating.
12 13
PROGRESS
INNOVATIVE HELIOS RESINS REDUCE VOCS, BRING ENERGY
SAVINGS AND EXTEND COATING LIFETIME.
S
ustainable car refinish solutions performance Domacryl brand types has solvent. The major challenge is water’s
The European Union has adopted been developed to enable our customers incompatibility with traditionally used
directives limiting Volatile Organic to stay ahead of their competitors. polymers, which require a very high level
Compounds (VOC). Helios Resins, Patented technology has been of expertise. To provide commercially
a separate HELIOS unit, has responded to successfully implemented in the market feasible materials, water-based resins must
the new set of standards with a range of and has positioned us as a market leader be high quality, stable, and price-efficient.
High-solid (HS) resins, which enable final in the segment of FAST-drying acrylic We have developed and scaled more than
coatings producers to meet legislation resins for car refinish, general metal and 40 different water-based materials to the
limits with their ready-to-use products. industrial wood protective coatings. In industrial level to cover various needs,
Within the HS resins segment, we pay addition to reduced VOCs, our innovative especially in the segments of wood and
special attention to car refinish products, resins bring energy savings through lower metal coatings. VOCs have been reduced
where resins and coatings must meet high curing temperature and an extended by as much as 95%.
performance expectations introduced by coating lifetime. Importantly, up to 20%
car paint shops. of fossil-based raw materials have been
During the past few years, over 30 replaced by bio-renewables and increased R&D EFFORTS ARE FOCUSED
different novel acrylic and polyester types material performance.
of resins with 70-100% solid content have ON ALTERNATIVES SUCH AS
been developed and successfully launched
into the market. We have achieved a 30-
Alternative water-based resins
A significant part of R&D activities is
WATER-BASED RESINS, AS WATER HELIOS RESINS IS DEVELOPING ADVANCED, GREEN,
50% decrease in their VOCs compared to related to the development of alternative REPRESENTS THE “GREENEST” AND LONG-LASTING MATERIALS FOR TODAY, TOMORROW
standard Medium solid (MS) products. solutions such as water-based resins,
Additionally, a set of unique high- as water represents the “greenest” SOLVENT. AND THE DAYS TO COME.
A tradition of bio-based materials resins. They represent 7% of produced methacrylic acid was developed to replace
WITHIN THE HIGH-SOLID RESINS SEGMENT, WE PAY Recently in the paint and coatings quantities of Helios Resins. Renewable fossil-based standard. Furthermore, Helios
SPECIAL ATTENTION TO CAR REFINISH PRODUCTS. industry, many efforts have been oils which in nature derive from Resins is participating in COST Action,
devoted to the development of bio-based sunflower, linseed, soybean, castor, the European network of furan-based
materials. Bio-based products derive from tall and others, are standard within chemicals and materials for sustainable
plants and other renewable agricultural, the coating industry. Due to the VOCs development (FUR4Sustain). The main
marine and forestry materials to provide limitations, alkyd water emulsions objective is to catalyze a replacement
an alternative to conventional fossil- are gaining greater acceptance than for terephthalic acid, a widely used
derived products. The conversion of conventional solvent borne (SB) ones, building block in resins for coatings
biomass and bio-based ingredients into replacing up to 85% of fossil-based raw and packaging. Furandicarboxylic acid
useful products for paints and coatings materials. (FDCA) and derivatives are considered
provides considerable and sustainable a very promising replacement from a
growth potential. The demand from Dedicated to a green future renewable origin. Lastly, Helios Resins is
customers, as well as the Helios Resins In addition to its established bio-based a member of the Strategic Research and
team strategy, is to increase bio-based alkyd production, the Helios Resins team Innovation Partnership for the transition
content in produced materials. is constantly working on the development into a circular economy, supported by the
The basic and most important of new bio-based products. Close Slovenian Government. Priorities for the
bio-based Helios resins, continuously collaboration with the National Institute partnership are to reduce the amount of
produced for over 50 years, are alkyds of Chemistry has resulted in a patent production waste and to reuse existing
which are natural oil modified polyester pending technology where bio-based waste as raw material for new products. •
14 15
PROGRESS
MOBIHEL
Energy efficient THE NEW GENERATION OF
MOBIHEL PRODUCTS IS A
and highly
WINNING COMBINATION
FOR ENHANCED WORKSHOP
PRODUCTIVITY AND ENERGY
productive car SAVINGS.
refinish products
Irena Tavčar M
ulti-layered modern car
refinish paint system
A modern car refinish paint
system consists of primer–filler/
in the resins segment, provide various
solutions. Among new materials are
very reactive polyacrylate binders and
polyaspartic binders. Polyacrylate binders
In 2019, we launched the first two
products of the new generation of highly
productive and energy efficient clearcoats
and fillers compliant with European
basecoat/clearcoat, offering waterborne enable faster curing or lowering the VOC legislation, MOBIHEL 2:1 HS
or solvent borne technology. The biggest curing temperatures, while polyaspartic CLEARCOAT FastDry and MOBIHEL HS
The latest R&D trends in car refinish prioritize sustainability challenge for car refinish paint producers binders eliminate the need for elevated FILLER AirDry. This year the additional
is to reduce drying time of fillers and temperature curing or shorten drying clearcoat MOBIHEL 2:1 HS CLEARCOAT
as one of the main quality criteria, underlining the importance clearcoats. Fillers must dry quickly to time at higher curing temperatures. AirDry joined the family of products.
of improved coatings durability, next to energy and process enable the process of sanding instantly Polyacrylates in normal conditions
after application and overcoating with the increase productivity by 20% and reduce Fast dry clearcoats for perfect end results
efficiency. This is also mirrored at Helios Refinish. basecoat afterwards. Clearcoat must be energy consumption by 50%, while Our clearcoats excel in drying regime
ready to polish immediately after a short polyaspartics perform even better. flexibility depending on the workshop
time drying and cooling down. equipment and conditions. Importantly,
A new generation of products we did not compromise the quality of
Efficient raw materials solutions The Helios Refinish R&D department polishing or the drying time regime. Thus,
Raw materials producers, especially successfully follows industry trends. the final appearance remains perfect.
LAYERS OF A REFINISH PAINT SYSTEM
FILLER
60–180 µm – surface, stone chip resistance
BASECOAT
15–25 µm – colour, metallic effect
CLEARCOAT
50–60 µm – transparent protection, gloss
16 17PROGRESS
DRYING TIMES UNDER DIFFERENT TEMPERATURE CONDITIONS TIME EFFICIENT MOBIHEL SYSTEM
FastDry CC AirDry CC New development
12 min.
super-fast 15 min./60° 5 min./60°C 5 min./60°C
36 min.
fast 30 min./40°C 15 min./40°C 10 min./40°C
energy efficient 120 min./20°C 60 min./20°C 40 min./20°C 30 min.
30 min.
New fillers for a four times smooth and flat surface for the excellent
faster drying process basecoat/clearcoat optical features.
MOBIHEL HS FILLER AirDry is
ready for sanding in approximately Advantages of the fast curing Substrate preparation
20–30 minutes when following the coating system
AirDry filler
room temperature criteria. The drying The new generation of filler/basecoat/
process is four times faster than with clearcoat are a winning combination for Basecoat
other conventional air-drying fillers. enhanced workshop productivity and
AirDry clearcoat
Different drying regimes can be achieved energy savings. The system also meets
by choosing individual hardeners high quality standards and long-term
and thinners depending on the size durability. A car bonnet can be repainted
of the painted car part and workshop in less than two hours, including Time for the complete repaint of a
conditions. After the drying and preparation, sanding, application, flash personal car bonnet with the super
sanding process, the filler ensures a very off and drying. • productive MOBIHEL System.
Remsolar:
coatings for
a greener future
Mag. Petra Gomez Alfaro-Kalteis
Today, photovoltaics continue to be a hot topic on the world stage. Extensive information, literature
and research is available in the media and online, while many roofs are already fitted with solar
panels. However, applying coatings to solar panels, specifically to the backsheets, is pioneering work.
18 19PROGRESS
REMSOLAR PROVIDES A COST-EFFECTIVE AND SUSTAINABLE
SOLUTION FOR RELIABLE SOLAR ENERGY. NEW BACKSHEET COATINGS OFFER THE FUNCTIONALITY OF CURRENTLY USED MULTILAYER FILM TECHNOLOGY, WHILE PROVIDING CAR WITH SOLAR PANELS ON THE ROOF
THE SAME LEVEL OF PERFORMANCE AND REVOLUTIONIZING THE PROCESS EFFICIENCY OF BACKSHEET PRODUCERS.
global one. With many backsheet and structures to be integrated into
Remsolar coatings ensure: module producers based in China, Asia buildings during the construction phase
• Long term protection from humidity is clearly a focus. However, Europe (e.g. facades, balconies etc.) as well into
• Long term protection from UV shows significant growth rates in this cars. This will lead to new requirements
radiation field as well. The European Union of coatings’ color availability, and
• Good adhesion to the encapsulant Market Outlook for Solar Power 2019 warranty period.
• Thermal and dimensional stability – 2023 estimates + 26% growth in At HELIOS and Rembrandtin, we
PHOTOVOLTAIC INTEGRATION IN BUILDINGS • Optical aspects (color) 2020. The biggest growth is expected believe that the right policies will give
from Spain, followed by Germany, a push to renewable and green energy.
Since this field represents a Netherlands, France, and Poland. The same applies to the growth of the
A
new market for coatings, a lot of Additionally, emerging markets such photovoltaic sector, where attributes
t Rembrandtin Coatings, a sustainable solution for reliable solar
time has been invested in defining as India, Saudi Arabia, and Egypt have such as sustainability and low costs
company part of the HELIOS, energy. New backsheet coatings offer
appropriate test procedures to ensure set very ambitious renewables targets will be the main drivers of the solar
a dedicated team together with functionality of currently used multilayer
the performance and quality of the which leads to increased demand for energy market. As of now, our aim is
external partners and experts film technology, while providing the same
backsheet and the photovoltaic module photovoltaic installations. to dive further into this market, visit
have taken on the challenge to formulate level of performance for a considerably
throughout their entire lifetime of 25+ industry events, connect with potential
and develop Remsolar, a new series of lower price. This revolutionizes the process
years. The “bright” future of photovoltaic customers, expand our knowledge, and
coatings designed to protect backsheets. efficiency of backsheet producers and
coatings increase our brand recognition. We are
Remsolar provides a cost-effective and significantly reduces the CO2 footprint.
The evolution of the global The share of energy from photovoltaics confident that our Remsolar will have a
photovoltaic market will grow significantly worldwide. bright and shiny future and we will keep
THE STRUCTURE OF A PHOTOVOLTAIC MODULE
The photovoltaic market is truly a In the future we expect photovoltaic you updated on our success story. •
PARTNERS ON THE PROJECT
20 21PROGRESS
Rembrandtin
innovation powering
the electric vehicles
market
Dietmar Jost
As technological progress in the electrification of two- and three-wheelers,
buses and trucks advances and the market for them grows, electric vehicles
are expanding significantly.
E
lectric cars, which accounted for 2.6% market leader in this sector, we have been
of global car sales and about 1% of supplying well-known electrical sheet REMISOL CORE PLATE
global car stock in 2019, registered a
40% year-on-year increase. HELIOS
producers and generator manufacturers
worldwide.
VARNISHES ARE
is proud to be a frontrunner and key
innovator in this segment with its core plate
Rembrandtin also has a portfolio of ENVIRONMENTALLY FRIENDLY
bonding and C5 varnishes which are already
varnishes which increase the efficiency and in use or in the process of homologation for AND CHROMIUM-FREE WITH
power of electric engines. Together with the top car making companies, such as Audi,
our innovations in the field of wind-energy, BMW, Daimler, Tesla, Toyota, or Volkswagen. LOW EMISSIONS.
photovoltaics and hydro power plants, we The focus of current developments in
are continuously striving to contribute to a the electric and hybrid vehicles market is
sustainable and green future. on thinner steel grades and less dry film
Remisol core plate varnishes are thickness of the varnish in order to improve
environmentally friendly and chromium- the performance of the electric engine.
free with low emissions. Water-based, hot Worldwide volumes are believed to
curing varnishes were developed for the increase dramatically as new environmental
electrical insulation of electrical steel sheets. policies are being put in place and as
Their excellent insulating properties reduce series production of new models begins.
eddy current losses during the operation Thanks to our ongoing developments in
of electrical machines and thus increase the field of batteries and the rapid build-
their efficiency. They improve punchability up of infrastructure for electric vehicles in
in the further processing of the sheets and combination with smart grids, we strongly
offer other important properties, such as believe in the positive power of this
weldability or annealing resistance. As the transformation. •
22 23PROGRESS
UV/EB curing
coatings at a glance
Mateja Šlibar
Since their introduction in the seventies, radiation-cured coatings and inks have been
on the rise. They have now become a generally accepted fast-growing sustainable UV/EB CURING COATING FORMULATIONS
technology within the industry. RAW MATERIAL USER REQUIREMENTS
T
he high growth of radiation- Curing with radiation
UV/EB-CURABLE COATINGS cured coatings, known also as Radiation-cured (RC) coatings and inks are
SIMPLIFY PRODUCTION, UV/EB curing coatings, is due
to their several advantages, such
formulations of components that contain
reactive groups that react with each other
ELIMINATE SOLVENT EXTRACTION as performance, productivity and low
environmental impact. The use of radiation-
after exposure to energy-rich radiation. In
general, there is no physical drying involved
STEPS, REDUCE COSTS, AND cured coatings can simplify production, in the curing mechanism, while recent
eliminate solvent extraction steps and coating formulations tend to be free of
HAVE A LOW ENVIRONMENTAL consequently reduce the cost. Moreover, organic solvents. Even though many types
FOOTPRINT. UV/EB technology does not produce CO2
and is consequently not subject to any
of radiation would theoretically be possible,
the industrial application is mainly limited
carbon tax. Existing coating units can be to the curing by ultraviolet light (UV) and
easily retro-fitted with UV/EB technology electron beam (EB).
given the small footprint. Due to the
immediate drying mechanism, UV/EB
technology reduces lead time and increases
the coating throughput.
UV CURING VERSUS TRADITIONAL COATING TECHNOLOGY
PHYSICAL DRYING CHEMICAL CURING Difference between UV and EB curing of applications use acrylic functional and monomer types then define the final
UV LED LAMP
In UV curing technology, multifunctional resins cured with a UV photoinitiator. coating properties. UV/EB formulations
Solvent evaporation No solvent evaporation
Phisycal drying Chemical polymerisation resins are polymerized or cross-linked by In EB curing technology, the same also need 1-10% of photoinitiator in case
No crosslinking Crosslinking produces a rigid network exposure to UV light. UV light triggers a multifunctional resins can be used, but no of UV curing and 1-3% of additives to
UV photoinitiator in the formulation to photoinitiator is needed. The electrons promote flow, levelling, cratering, slip or
generate polymerization initiating species initiate the polymerization and the end other properties. Such coatings or inks
which very rapidly convert the liquid UV result is also a highly cross-linked coating. can be pigmented or can contain fillers.
resins to a fully cross-linked coating. There In pigmented coatings or inks with UV
are two main curing technologies used Formulations of UV/EB curing coatings curing, the photoinitiators and lamps may
Heat UV - light in practice. The first is a free radical cure Formulations of coatings appropriate for need to be chosen correctly, not to overlap
of mainly acrylic resins, and the second UV/EB curing are usually made up from too much with the absorption spectrum
is a cationic cure of mainly epoxide ring oligomers and monomers in a 1-1 ratio of the pigments. Many different types
opening curing reactions triggered by a UV depending on the required application of photo initiators exist, with different
cationic photoinitiator. The vast majority viscosity. A broad range of different resin absorption spectra.
24 25PROGRESS
Different treatment and application types Radiation-curable water-based, powder, DRIVERS FOR THE IMPLEMENTATION OF UV LED SYSTEMS
In most cases, conventional 100% liquid RC and additionally dual-cure formulations
Technology features Environmental benefits
systems are intended for the treatment of are treated under “Special Systems” and
flat surfaces with roller application due to while water-based and powder RC coatings Instant on and off Ready to use or no warmup time, energy savings and
some limitations in application viscosity. are already well established, the dual cure positive impact on lifetime
With the development of alternative technology is still a niche area. Low electricity consumption Energy savings
systems like radiation-curable water-borne UV/EB-curable coatings simplify Low heat output Positive impact for heat-sensitive substrates
and powder coatings, spray application production, eliminate solvent extraction
HELIORES 3D IS A LIQUID No ozone, no mercury Environmentally friendly and easier integration
and processing of profiled elements is steps, reduce costs, and have a low
PHOTOPOLYMER FOR 3D PRINTING possible as well. For complex 3D objects environmental footprint. Long lifetime, constant output Lower maintenance costs and better process control
INTENDED FOR GENERAL USE WITH where UV light hardly reaches shadow
VARIOUS TYPES OF SLA AND DLP areas, so-called dual-cure coatings are Special UV/EB curing equipment
PRINTERS. used. Radiation-curable water-borne and Standard UV lamps are mercury lamps and
powder coatings combine the flexibility of can be doped with iron or gallium to control
the higher molecular oligomers with the emission spectra. The lamps typically have
hardness and resistance resulting from the an output of 80-120W/cm² and are available
high crosslink density through the acrylate in many lengths. There are 3 main types of
groups. Meanwhile, dual cure coatings UV lamps – standard mercury lamps, iron-
have two curing mechanisms, where the doped mercury lamps and gallium-doped
radiation curing mechanism complements mercury lamps. Recently, LED lamps have
the curing of polyisocyanates with polyols. been added to the selection.
Fast growing market plastic coatings, resilient flooring, metal for advanced manufacturers of flat
The whole segment of RC coatings has coatings, opto-electronics and adhesives. interior furniture, which includes wooden
shown significant growth rates in the In graphic arts, UV/EB is mostly used in doors, tables, cupboards, shelves, and
recent years. While China remains the lithographic and flexo printing, as well parquet. The systems present an optimal
leader in UV/EB technology, there is a fast as in screen printing, letterpress, and ink combination of putties, base coats, top
growth of UV/EB in coating application jet printing. In electronics, UV/EB is used lacquers and enamels, processed with
in the more mature markets of North in printed circuit boards as a photo resist modern UV curing procedures for the care
America and Europe. There, application coating, in displays both on the inside of of wood veneer, solid wood, MDF and
segments with a higher market penetration the electronics as well as on the outside different decorative foils. In the future, we
of UV/EB, such as furniture and floor as a hard coat. On plastics, the technology will continue to invest in the development
coatings, printing inks and overprint works in the form of wear-resistant of innovative products, for example, invest
varnishes, show a moderate growth coatings (Gagro, ECJ, May 2020). in UV LED technology for heat-sensitive
rate of about 2-4%. In addition to the substrates, extend UV curing coatings
industrial coatings application in wood Helios’s UV/EB portfolio and its future also to exterior joinery and try to find
and paper coatings segments, UV/EB development interesting fields of using UV coatings on
curing technology can be found also in HELIOS UVEHEL/UVEHEL AQUA UV other segments, such as car repair coatings,
other emerging areas. It is applicable with curing systems offer a complete solution coatings for metal and plastic. •
26 27PROGRESS
BIOCIDAL PRODUCTS EXERT
CONTROLLING EFFECT ON
HARMFUL OR UNDESIRED
MICRO-ORGANISMS.
Biocidal L
ately, producers of paints and
coatings have come under pressure
as regulatory trends for biocides
significantly limit options and ways of
regulation
usage. With new measures, regulators tend
to improve the functioning of the internal the European Union Biocidal Products Biocidal protection of wet water-based
market through the harmonisation of rules Regulation (BPR) and classified in 22 paint
on the production and usage of biocidal Product Types (Pts) depending on their An average water-based paint contains
as the driver
products. Furthermore, the new regulation function. Only the active substances or about 10 – 15 components, and nearly all of
also ensures a higher level of environment their mixtures, which are authorised for them can be a source of bacterial infection.
and health protection. Therefore, certain purposes, can be used in biocidal The production equipment is also an
formulators are faced with the challenge products, produced and sold by the coatings additional source of bacterial infection. To
that ever fewer biocides are available, and industry. Each biocidal product must be destroy all sorts of bacteria and to achieve
of continuous
biocide concentrations have to be reduced. registered by the responsible body in the EU long term biocidal protection of wet paint,
At the same time, the quality of final country where it is sold, while some of these it is necessary to add bactericides. This
products shall not be compromised. That is products should be authorised as well. is achieved with a process called in-can
why the industry as well as the stakeholders preservation, which serves as a precondition
development
along the value chain have to develop new Biocides in the paint and coatings industry for safe and high-quality coatings with a
sustainable solutions. In the paint and coatings industry, biocides long shelf life. An in-can preservation is a
are used in a wide variety of procedures. mixture of 2 to 3 active biocidal substances
Understanding biocidal products They can be found in wet water-based with broad pH and T stability and a broad
Biocidal products are widely used agents, paint, wood impregnations, fungal or antibacterial activity. The need for in-
with an active substance that is intended anti-microbial products, disinfectants and can protection very strongly depends on
Cirila Colnar Mikeln, Hubert Culik
to destroy, deter, render harmless, hygiene coatings, and are widely used for the components of the paint. The most
prevent the action of, or otherwise exert a plant hygiene, too. That is why at HELIOS, susceptible to bacterial infection are wall
The paint and coatings industry is closely related to the use of biocides, controlling effect on harmful or undesired we use a wide selection of biocidal products paints, which require a very carefully chosen
substances that have undergone stricter regulatory measures in the past years. micro-organisms. They are regulated by and continuously research new possibilities. in-can protection.
28 29PROGRESS
into the paint. Additionally, they are hygiene legislation. Our R&D team at
also not suitable for skin disinfection, HELIOS is currently developing the
as they are irritative for skin. products for this field too.
Disinfectants are not yet submitted
to the authorisation, but it can be Regulations – continuous
expected in the future. development driver
The obligations of paint and
Plant hygiene care coatings producers, producing and
When it comes to plant hygiene, marketing biocidal products are
each plant has its own protocol of not regulated only by the BPR, but
disinfection and cleaning, depending also by the Globally Harmonized
on the technology specifics and System of Classification and Labelling
product quality. This protocol of Chemicals (GHS) and the EU DISINFECTANTS ARE NOT SUITABLE AS AN ADDITIVE TO THE PAINT AS
defines in detail the periods and Regulation on Classification, Labelling THEY ACT DIRECTLY ON THE INFECTED SURFACE AND LOSE THEIR ACTIVITY
ways of disinfection for each part and Packaging of substances and WHEN MIXED INTO THE PAINT.
of the technology. Special care is mixtures (CLP). The latter allows
applied to the equipment used for the identification of hazardous
for the production of water-based chemicals and the communication
paints, where all equipment needs of these hazards to users through
to be cleaned properly, disinfected labelling. It also provides the basis
and additionally protected by a for safety data sheets regulated
bactericide. Plant hygiene is also under the REACH regulation and
subjected to special yearly audits that sets requirements for the packaging
prove the efficiency of our procedures. of hazardous chemicals. Under this
legislation, certain biocidal active
Hygienic coatings substances have been reclassified in
IN COOPERATION WITH OUR EXTERNAL PARTNER MICROBIUM, WE ARE Impregnations for wood causing the decay of the paint film that In hygiene-sensitive areas, such the last years in a way that they can
DEVELOPING SEVERAL FORMULATIONS WHICH DO NOT CONTAIN ANY As wood is a live substrate, influenced results in a poor aesthetic appearance. as healthcare and pharmaceutical no longer be used or that the allowed
IN-CAN PRESERVATIVES. by humidity and different mechanical Indoors, harmful micro-organisms can facilities, there is a need for effective quantity should be significantly
stress, it needs to be properly protected. also be spread into the air, causing health hygiene coatings. These paints destroy reduced. This applied especially to SPEKTRA INTERIOR WALL PAINTS CONTAINING NEW MIT-FREE IN-CAN
To avoid deterioration and extend the problems. This can be prevented by adding dangerous bacteria, viruses, and fungi, our DIY products for which we had to PROTECTION, THANKS TO WHICH NO CHANGE IN THE LABELLING WAS
life of wood, impregnations containing fungicides and algicides to the paint, which which are present in the air, walls find new biocidal ways. In addition to MADE. AT THE SAME TIME SLIGHTLY HIGHER LEVELS OF MIT-FREE IN-CAN
a well-defined mixture of fungicides, temporarily very effectively decreases the or ceilings, providing easy-to-clean all the necessary tests, the labelling of PROTECTION IN OUR FACADE PAINTS AND LEVELLING COMPOUNDS
algicides and insecticides are in use. growth of micro-organisms. Paints with surfaces that comply with the rigorous products had to be changed as well. • RESULTED IN NEW LABELLING.
When developing this type of biocidal dry-film protection are not submitted to the
formulations, producers need to follow authorisation process of biocidal protection
strict regulative requirements and the as their primary function is to protect the
formulations have to be authorised as such. substrate. They are defined in the BPR as
For this purpose, an extensive dossier has »treated articles«, which is why producers
to be prepared, comprising of physical, must label them with a description of
chemical, toxicological and efficiency data active substances and a claim that the paint
for each individual formulation. Only after contains dry-film protection.
the formulation is authorised and approved
by all the EU members, it can be produced Disinfectants
and sold on EU markets. Any change of the Disinfectants contain one or more active
authorised formulation needs be approved substances with a very broad antimicrobial
again, as according to BPR, this represents a activity. They destroy fungi, algae, lichens,
new biocidal product. bacteria and yeast. Therefore, they are very
effective for the disinfection of surfaces
Paints containing dry-film protection attacked by any microbial growth. These
TO PREVENT WOOD DETERIORATION, WOOD SURFACES NEED TO BE External and internal painted surfaces, products are not suitable as an additive to THE AUSTRIAN COATINGS INDUSTRY HAS LAUNCHED THE NEW INCANPRES PROJECT TO RESEARCH NEW APPROACHES
PROTECTED WITH IMPREGNATION THAT CONTAINS A WELL-DEFINED which are exposed to high humidity, are the paint as they act directly on the infected TO IN-CAN PRESERVATION. THE INCANPRES INNOVATION PROJECT WILL INVESTIGATE A BROAD SPECTRUM OF ALL HELIOS RENDERS AND SOME OF OUR FACADE PAINTS, WOOD STAINS,
MIXTURE OF FUNGICIDES, ALGICIDES AND INSECTICIDES. usually attacked by fungal and algal growth, surface and lose their activity when mixed POSSIBILITIES TO PREVENT IN-CAN SPOILAGE. ENAMELS AND INTERIOR WALL PAINTS CONTAIN DRY-FILM PROTECTION.
30 31PROGRESS
A smart thermal
A healthy and friendly living space eliminates the conditions for mold be sanded. For the top coat we
Mold is not only an aesthetic growth. SPEKTRA Termo Top thus recommend SPEKTRA Termo Top,
problem; it is primarily a harmful creates a human-friendly living which further helps to reduce the
phenomenon. Inhaling mold space with a positive impact on transfer of heat through the wall
insulation system
spores present in such spaces can health. SPEKTRA interior putty and retain heat. In addition, it also
cause inflammation in the lungs, Termo contains less than 1 g/l of helps regulate the room’s humidity
coughing, difficulty breathing and volatile substances, so emissions and reflects more than 90% of the
can exacerbate asthma. When during application and drying are visible spectrum of light back into
such wall surfaces are treated with minimal. Its elasticity also makes the room, creating more light.
SPEKTRA interior putty Termo up its suitable for covering small The interior wall paint SPEKTRA
Cirila Colnar Mikeln to 4 mm thick, the heat transfer cracks on wall surfaces. Termo Top is available in light
through them is significantly Before the final paint, we shades, and the system is also
For DIY users, the development of paints for the decorative protection of mineral, wood and metal surfaces has long been reduced. The walls remain warm, recommend a layer of the levelling compatible with any other interior
preventing condensation of water compound SPEKTRA Level Fine, wall paint from the SPEKTRA
focused on the use of the most people and environmentally friendly raw materials possible. vapor from the air, which in turn which is easy to apply and can family. •
D
ue to a lack of knowledge in Development is to some extent guided Top in combination with SPEKTRA interior
handling coatings, non-professional by legislation, but we also develop products putty Termo form a thermal barrier,
users are most exposed to their with added value, with properties that thanks to which the surface is warmer and
potential harmful effects. European in various ways contribute to effective, more pleasant to the touch. This is made SPEKTRA TERMO TOP CREATES A HUMAN-FRIENDLY
legislation protects non-professional users
very well with various regulations and
economical, health and nature-friendly
solutions for the decorative protection of
possible by the hollow fillers found in both
products. The system keeps rooms cool in
LIVING SPACE WITH A POSITIVE IMPACT ON HEALTH.
laws, as it prohibits the use of carcinogenic, wall, wood or metal surfaces. The toolkit of the summer and warm in the winter, which
mutagenic and reprotoxic substances in HELIOS' sustainable solutions in the field significantly decreases the cost of energy
such paints. Any substance classified as of architectural coatings includes thermal sources for heating and cooling. Using
hazardous must be properly labeled on insulation interior wall coatings, which the system of both products effectively
the packaging. In addition to H-phrases, combine the coating’s decorative and prevents the formation of condensation
which describe the hazards due to certain functional properties at the highest level. and consequently also the formation of
substances in the coating, P-phrases on the mould. At the same time, their use avoids
packaging represent instructions on how to Thermal insulation interior wall coating the frequent use of disinfectants and
protect or act to prevent any harm. The interior wall coating SPEKTRA Termo renovation.
REDUCES HEAT
TRANSFER THROUGH
THE WALLS.
REFLECTS MORE THAN
90% OF LIGHT BACK INTO
THE ROOM.
PARTIAL SAVINGS IN
HEATING, COOLING AND
LIGHTING COSTS.
SPEKTRA TERMO TOP AND
SPEKTRA INTERIOR PUTTY TERMO
32 33PROGRESS
Reusing CO2
greenhouse gas emissions, and the increase POSSIBILITIES OF USING CAPTURED CO2
Fuels Food
in the energy efficiency of facilities that • Flavours/Fragnances
• Decaffeination
have obtained a greenhouse gas emissions
• Algae
permit. Fuel price parities, especially of • Greenhouse gases
NT
TA
to produce
coal and natural gas, electricity prices and
AC
Carbonated beverages
TR
Carbonates
EX
demand for it are also important factors. BIOLOGICAL N
FO DU
IO
PR
CONVERSION AT Liquid
OD CT
O
LIZ
/ S
ERA fuels
N
MI • Methanol
Objectives and responsibilities of
CAPTURED
• EOR ENHANCED
• Oil • Urea
• EGR FUEL
• Gas CHEMICALS • CO Fertilizer
companies involved in trading
CO2
• ECBM
green products
RECOVERY
• Methane
Trends in European policy and the economy TICS REFR Secondary
PLAS IGER chemicals
ANT
look at reducing CO2 emissions as much INERTING MI
ON SC
SI AGENT
as possible. These can be a significant PRES
EL
LA
NE
Polycarbonate SU OU
cost for companies, which have to reduce polymers FI
RE S
• Refrigeration
• Blanket products
• Dry Ice
their carbon footprint while maintaining • Protection for carbon powder
• Shield gas in welding
Matija Mencinger production capacity. EU ETS trading
leaves it up to companies to assess how • Injected into metal castings
Fire extinguishers • Respiratory stimulant (added to medical O2)
many emissions they can afford based
The European Union has introduced emissions trading system years ago with the aim to on what is financially viable. At the same
• Aerosol can propellant
• Dry ice pellets used for sand blasting
• Red mud carbonation
strategically reduce carbon dioxide emissions. Belinka Perkemija is one among more than time, it equates the costs of reducing GHG
emissions across the EU by allowing cross-
11,000 companies from all over Europe taking part in the system. Next to emissions reduction, border trade. This minimizes restrictions on Carbon capture and storage technologies companies that choose to capture their
the company has identified CO2, formed as by-product in the production of hydrogen peroxide, competition between companies, operators In the coming trading period from 2021 CO2. Through various processes, emissions
of facilities that produce GHG emissions onwards, a combination of new carbon caught and stored are then deducted
as a product with wide use value. in the European single market. Last but capture and storage (CCS) technologies will from the amount of emissions produced
not least, the aim of the system is to help also be available to companies involved in a company. A smaller final amount of
reduce GHG emissions in the future and to the EU ETS. This technology captures up emissions allows savings on permits and
A
reward innovation in reducing emissions. to 90% of CO2 emissions produced from consequently on costs.
BY REUSING OR INCORPORATING s part of its climate and energy
policy, in October 2014 the
contribute to the reduction of GHG
emissions. The most cost-effective way Companies must obtain a GHG emissions the use of fossil fuels in industrial processes
THE CO2 IN NEW PRODUCTS, European Council has adopted to achieve such goal is through the EU permit before they start operating, and
must regularly monitor emissions, produce
or electricity production, and prevents
CO2 from entering the atmosphere. The
Possibilities to incorporate CO2
in green products
a binding agreement that the Emissions Trading System (EU ETS). In
BELINKA PERKEMIJA European Union will achieve a minimum Slovenia, 49 companies are included in the an annual report and hand over the EU also offers significant subsidies for the At Belinka Perkemija, carbon dioxide,
40% reduction in greenhouse gas (GHG) system. In addition to Belinka Perkemija, a appropriate number of emission allowances. installation of CCS-enabled facilities for which is formed as a by-product in the
CONTRIBUTES TO THE CARBON emissions by 2030 compared to 2005. company part of the HELIOS, there are also production of the otherwise green and
widely used chemical hydrogen peroxide,
FOOTPRINT REDUCTION. All economic sectors are expected to thermal power plants and heating plants,
producers of steel, glass, ceramics, cement, has been identified as a product with wide
lime and paper, and others. use value. Direct CO2 emissions formed
in the companies’ industrial processes can
FLUCTUATING MARKET PRICES OF EMISSIONS ALLOWANCES OVER THE TRADING PERIODS The EU Emissions Trading System be captured and processed or liquefied
The EU ETS consists of trading permits for using special processes. By reusing or
ICE EUA FUTURES REAL PRICE greenhouse gas emissions and entered into incorporating the CO2 in new products,
force with the first trading period in 2005; Belinka Perkemija is consequently
the third trading period will end in 2020. THE CO2 LIQUEFACTION PROCESS contributing to reducing the carbon
The basic trading unit in the EU ETS is the footprint. CO2 enables processing to food
emissions allowance, which represents industry purity and use instead of natural
1 tonne of carbon dioxide emitted into the sources, whose emissions are similar
GREEN
atmosphere. In the event of a deficit or METHANOL to those from synthetically produced
surplus of emissions allowances, companies (OR DERIVATIVES) products. At Belinka Perkemija, experts
participating in the EU ETS can buy or sell are actively working on the development
permits on the exchange. and possibilities of incorporating CO2 in
The price of emissions allowances is new green products in addition to further
influenced by factors such as the number RENEWABLE POWER supplementing the capacities of the existing
OR BYPRODUCT CRI CO2 liquefaction process. •
of emission allowances allocated free of HYDROGEN EMISSIONS TO LIQUIDS
Source: Wikimedia Commons. charge, the cost of measures to reduce TECHNOLOGY
34 35PROGRESS
SUCCESS
“Action is the foundational key to all success.”
Pablo Picasso
Painter
36 37You can also read
