www.basf.com/kaolin BASF Corporation 1 Campus Drive Florham Park, NJ 7932 USA Tel: +1 8 781-8966 Tel: +1 973 245-7444 Fax: +1 8 781-8953 Fax: +1 864 332-584 Email: kaolin@basf.com About BASF BASF Corporation, headquartered in New Jersey, is the North American affiliate of BASF SE, Ludwigshafen, Germany. BASF is the world s leading chemical company, with a portfolio that ranges from chemicals, plastics, performance products, agricultural products, catalysts and fine chemicals to crude oil and natural gas. As a reliablee partner to virtually all industries, BASF s intelligentt solutions and high-value products help customers to be more successful. BASF develops new technologies and uses them to open up additional market opportunities. We combine economic success with environmental protection and social responsibility, thus contributing to a better future. Further information on BASF is availablee on the internet at www.basf.us. BASF Corporation is fully committed to the Responsible Care C initiative. For more information on Responsiblee Care go to: www.basf.us/responsiblecare_usa or www.basf.com/responsible care canada SATINTONE Specialty Extenders for Use in Coatings ApplicaA ations Calcined kaolin products have become uniiversally used in latex and solvent-based paints because of their excellent balance of properties and cost performance. BASF offers four uniquely different SATINTONE calcined kaolin extender pigments to the coatings industry. These four products span a range of particle sizes, oil absorptions, brightness levels, and a morphologies (particle shapes) that provide various coating properties. This variety gives paint formulators added latitude to choose the extender pigment with the right combination of properties for their coating needs. This study compares the four SATINTONEE products and evaluates their relative performance in latex l flat wall paints. The study provides formulators with a guide for selecting SATINTONE grades for specific formula equirements. Physical Properties All members of the SATINTONE family of extender pigments are similar in that they are calcined water processed fractions of platy kaolin. Water processing ensures freedom from coarse particles, p and, therefore, very low screen residue levels and consistently high Hegman grinds. Calcination, a controlled heat treatment, causes dehydroxylation of f the kaolin crystal and produces a very white abrasion resistant pigment particle. Calcination, more importantly, imparts changes in the particle morphology which offer enhanced optical properties to coatings. TABLE I lists the typical physical propertiess of the SATINTONE calcined kaolins in order of their average a particle size. The areas in which they differ most, in addition to particle size, are oil absorption, brightness, and, in the case of SATINTON E OP, a lower specificc gravity. They are similar in most other respects. All SATINTONE products are highly pulverized for good dispersion in waterr or solvent-bornplots p the typical particle size distributions of the SATINTONE extender pigments. SATINTONE 5HB is the finest particle size calcined grade. It is designed for maximum m hiding. It systems and offer a minimum 5 Hegman grind and low 325 mesh residue. Figure 1 has premium brightness and the highest oil absorption. The descriptions, designs, data and information contained herein are presented in good faith, and are based on BASF s current knowledge and experience. They are provided for guidance only, and do not constitute the agreed contractual quality of the product or a part of BASF s terms and conditions of sale. Because many factors may affect processing or application/use of the product, BASF recommends that the reader carry out its own investigations and tests to determine the suitability of a product for its particular purpose prior to use. It is the responsibility of the recipient of product to ensure that any proprietary rights and existing laws and legislation are observed. No warranties of any kind, either expressed or implied, including, but not limited to, warranties of merchantability or fitness for a particular purpose, are made regarding products described or designs, data or information set forth herein, or thatt the products, descriptions, designs, data or information may be used without infringing the intellectual property rights of others. Any descriptions, designs, data and information given in this publication may change without prior information. The descriptions, designs, data and information furnished by BASF hereunder are given gratis and BASF assumes no obligation or liability for the descriptions, designs, data or information given or results obtained, all such being given and accepted at the reader s risk. 211 BASF Corporation Rev. 1/212 SATINTONE SPECIAL is a fine particle size high brightness grade with intermediate oil absorption. In coatings, it offers a combination of high hiding and highh scrub resistance. SATINTONE OP is a medium particle-size grade with a lower specific gravity and brightness than other SATINTONE grades. It also possesses a unique particle morphology which gives excellent hiding, with good sheen control andd stain resistance to coatings.
SATINTONE W is a medium particle-size grade with high brightness and the lowest oil absorption. SATINTONE W offers a balance of good hiding, sheen control, and scrub resistance. This combination of properties and cost-performance has made SATINTONE W a standard of the coatings industry. Formulations and Test Methods The four SATINTONE products were compared for paint performance in 5 and latex flat wall paint formulas given in Table II and III, respectively. The formula represents a high quality latex flat where good wet and dry hiding, good touch-up, excellent scrub resistance, and excellent holdout are required. The formulation is designed for low cost, high dry hiding and minimum sacrifice in other performance properties. The paint properties are summarized in Table IV and V. Several properties are graphically displayed in bar chart form in Figures 2-8. Figure 8 - % Holdout, K&N Ink % Holdout 7 6 5 4 3 2 1 Hiding was measured using both contrast ratio and Kubelka-Munk (K-M) methods. The K-M method is considered more accurate and equalizes each formulation for film thickness and reflectance. K-M opacity is expressed in coverage at complete hiding (.98 contrast ratio) per unit volume of paint. Scrubbability was measured using the shim method with silica abrasion media. Tint strength was measured using 3 oz/gallon of universal black tint. Film porosity was measured testing % ink holdout (K&N). Touch-up was compared visually by brushing a picture frame pattern over a film of the same paint applied by a roller. Relative Paint Performance In general, all of the SATINTONE products gave good hiding, scrub resistance and tint strength. These features are what make SATINTONE calcined pigments the extender pigments of choice for flat and egg-shell wall paints. However, differences between SATINTONE grades are apparent. The greatest differences between paints is generally poorer film integrity between 5 and formulations, regardless of SATINTONE grade used. The following summarizes the major differences between the SATINTONE grades for paint performance: SATINTONE 5HB SATINTONE 5HB gave the highest hiding and tint strength of all the SATINTONE grades, and the highest gloss and sheen. This is expected since it has by far the finest particle size distribution. On the other hand, it gave lower scrubbability and holdout, due to its high oil absorption. SATINTONE 5HB is ideally suited for developing extremely high hiding in both low and high PVC formulas. It is generally recommended at low levels (5%) in combination with other SATINTONE grades to enhance hiding. In formulations below the CPVC, SATINTONE 5HB gives the best TiO 2 extension, because of fine particle size spacing effects. It is used in many egg-shell and satin formulas for this reason.
Figure 6 85 Degree Sheen 85 Sheen 3 25 2 15 1 5 Figure 7 Whiteness Index Whiteness Index 9 8 7 6 5 4 3 2 1 SATINTONE SPECIAL SATINTONE Special gave an excellent overall balance of properties with very good hiding and tint strength combined with good holdout, (especially at lower PVC) and the best scrub resistance. Sheen was higher than all but SATINTONE 5HB. SATINTONE Special is recommended for egg-shell formulas and lower PVC flats where good overall cost performance is required. SATINTONE OP SATINTONE OP gave the most interesting performance of all the grades. It has unique morphology which enhances optical properties. Consequently, it gave the second highest hiding, tint strength, and relatively low sheen. Its unique morphology also results in the best touch-up properties and very good holdout. Scrub resistance and reflectance were the lowest of all the SATINTONE grades. This combination of properties makes it very well suited for low cost, high dry hiding flats where high whiteness and scrub resistance are less critical. It is also used in exterior coatings, such as interior/exterior house paints, where good crack resistance, mud crack resistance, and good hiding are required. SATINTONE W SATINTONE W is the most commonly used grade and possesses an overall balance for good hiding, scrub resistance, sheen control, color and holdout properties. It is used in the broadest range of coating applications. TiO 2 Extension An additional series of paints were prepared and tested for opacity to compare the relative cost performance of each SATINTONE grade as a TiO 2 extender. In this study, SATINTONE W was considered the control and the TiO 2 level (2 parts) was reduced to a level required to give equal contrast ratio with the other SATINTONE products. The calcium carbonate level was increased on a volume basis to maintain. The results are given in Table VI and show that SATINTONE 5HB, OP and Special give better TiO 2 extension than SATINTONE W. SATINTONE 5HB is particularly interesting because it required 2% less TiO 2 for equal hiding, thereby offering significantly lower formula costs. Conclusions The broad range of SATINTONE calcined kaolins available allows paint formulators increased latitude in optimizing cost-performance in latex or alkyd coatings. Each SATINTONE grade offers a different balance of paint properties, TiO 2 extension, and cost. The PVC level selected by the formulator dramatically affects film properties, in many cases more than the pigmentation. However, proper selection of pigment combinations helps modify and optimize cost-performance.
Table I BASF SATINTONE Calcined Kaolin Extenders for Coatings Applications Typical Physical Properties SATINTONE Product Designation 5HB SPECIAL OP W Physical Form Hydrous Pulverized Powder Special Modifications Dehydroxylated by Controlled Heat Treatment Average Particle Size (µm) (Equivalent Spherical Diameter).8 1.2 1.3 1.4 Hegman Grind, Min. 5+ Rubout (D-281)** 85-95 55-65 75-85 5-6 Oil Absorption Gardner-Coleman 15-12 7-8 87-97 6-7 Residue, +325 Mesh Wet Screen, % Max..15.1.2.2 Brightness (G.E.) 9-92 9-92 86-88 9-92 ph 5-6 Refractive Index 1.62 Specific Gravity (g/cc) 2.63 2.5 2.63 Free Moisture, % Max.5 lbs per gal 21.9 2.8 21.9 Bulking Value gal per lb.46.48.46 Bulk Density Loose 12 16 lb/ft 3 Tamped 18 3 2 3 Figure 4 Tint Strength (L Reflectance) Tint Strength (L Reflectance) 79 78 77 76 75 74 73 72 71 7 69 68 Figure 1 Typical Particle Size Distributions 1 9 8 Figure 5 Scrub Cycles to Failures 8 7 6 Satintone 5HB Satintone Special Satintone OP Satintone W 7 6 5 4 3 Percent Finer Than Scrub Cycles 5 4 3 2 1 2 1 2 Equivalent Spherical Diameter in Microns 2.2
Figure 2 Contrast Ratio 1.5 mil (.38 mm) Table II Interior White & Light Tint Base Materials Parts by Weight* Contrast Ratio 98 97.5 97 96.5 96 95.5 95 94.5 Water 135. KTPP 1. Dispersant 6. Wetting Agent 4. Biocide.5 Defoamer 1. Coalescing Aid 14. HEC Thickener 3. Propylene Glycol 2. Water 5. Mix Until Smooth & Add Flat Grade TiO 2 2. Calcium Carbonate, 5 µm 1. SATINTONE Calcined Kaolin 125. ATTAGEL 4 Thickener 7. Disperse at High Speed & Add Defoamer 1. Vinyl Acrylic Latex (55%) 298. 2% HEC Solution 13. Water 5. Total 1145.5 *Formulation in pounds yields 1 US gallons; kilograms yields 833 liters Figure 3 Kubelka-Munk Opacity at.98 Contrast Ratio (ft 2 /gal) Table III Interior White & Light Tint Base Opacity (ft 2 /gal) 6 5 4 3 2 1 Materials Parts by Weight* Water 223. Dispersant 2.5 Wetting Agent 3. Biocide 1. AMP -95 2. Defoamer 1.5 HEC Thickener 3. Propylene Glycol 25. Water 5. Mix Until Smooth & Add Flat Grade TiO 2 75. Calcium Carbonate, 5 µm 155. SATINTONE Calcined Kaolin 26. ATTAGEL 4 Thickener 7. Disperse at High Speed & Add Defoamer 1.5 Vinyl Acrylic Latex (55%) 24. 2% HEC Solution 151. Total 1164.5 *Formulation in pounds yields 1 US gallons; kilograms yields 833 liters
Table IV Paint Performance Properties Latex Paint Properties 5HB SPECIAL OP W Viscosity KU 81 81 8 82 Contrast Ratio 1.5 Mil (.38 mm) 97.6 96.1 97.1 95.9 3. Mil (.76 mm) 99.3 99. 99.3 98.9 Kubelka-Munk Opacity at.98 CR ft 2 /gal 474 395 423 392 m 2 /liter 11.63 9.69 1.38 9.62 Reflectance White 92.3 91.7 91.4 91.5 Whiteness 82.9 82.7 76.8 82.5 Yellowness 2.5 2.6 3.9 2.7 6 Gloss 2.7 2.6 2.5 2.5 85 Sheen 14. 7.8 4.9 6. % Holdout, K&N Ink 52.4 62.2 61.8 64. Scrub Cycles to Failure 42 676 374 682 Touch-Up Good Good Good Good Tint Strength L Reflectance 73.8 72.3 72.7 71.9 a -8.3-8.3-8.4-8.3 b -25.9-27.7-26.6-27.7 Table VI Comparison of TiO 2 Extension for SATINTONE Products Latex Paint Pigmentation (parts by weight) SATINTONE SATINTONE SATINTONE SATINTONE W (Control) OP Special 5HB TiO 2 2 185 195 16 SATINTONE Products 125 125 125 125 Calcium Carbonate 1 111 14 13 Hiding Contrast Ratio (1.5 MIL) 95.9 96.1 95.8 95.9 Contrast Ratio (3. MIL) 98.9 99. 98.8 99. Table V Paint Performance Properties Latex Paint Properties 5HB SPECIAL OP W Viscosity KU 82 79 84 79 Contrast Ratio 1.5 Mil (.38 mm) 97.8 96.6 97.6 96.3 3. Mil (.76 mm) 99.5 99.1 99.3 98.7 Kubelka-Munk Opacity at.98 CR ft 2 /gal 517 391 475 351 m 2 /liter 12.69 9.6 11.66 8.62 Reflectance White 92.2 91.6 9.7 91.3 Whiteness 79. 76.9 68.1 76.6 Yellowness 3.6 3.9 6.2 4. 6 Gloss 3.5 2.8 2.8 2.7 85 Sheen 27.4 13.6 7.4 1.4 % Holdout, K&N Ink 32.9 36.5 41.4 4. Scrub Cycles to Failure 66 1 57 85 Touch-Up Fair Fair Good Fair Tint Strength L Reflectance 78. 75.1 75.5 74. a -7.7-8.1-8.4-8.3 b -2.4-24. -21.2-24.4