Containing virtually zero VOC content, powder coatings are already a sustainable choice. To minimise the carbon footprint of powder coatings, the industry is pushing even further.

Since they first appeared on the market more than 60 years ago, powder coatings have been a focus for innovation. In recent years, a key aim for manufacturers has been the formulation of coatings that last even longer and reduce environmental impact. One of the most exciting developments in this area is the introduction of bio-based powder coatings using renewable raw materials. Axalta are excited to lead the way, launching the first bio-based product range in Europe in 2024.

Bio-based powder coatings

Powder coatings are typically produced by blending resins, curing agents, pigments and additives. Technologists are now formulating coatings using bio-resin, made from renewable materials such as cooking oil, fats, and sugar beet pulp. 

A key challenge for manufacturers has been to increase the proportion of bio-resin in the overall resin mix without losing quality. Our research shows that the inclusion of bio-resin in the overall resin component results in a powder coating of the same high quality that is currently achieved using 100% fossil-based resin. 

The inclusion of bio-resin makes it possible to reduce the total carbon emissions of a kilogram of powder coating by 25% on average, accounting for small variances between coating types, compared to a standard coating. 

Guaranteed performance

This significant step forwards offers architects and designers even more options in powder coatings. With the increased adoption of global green building programmes such as LEED, bio-resin powder coatings could play a strategic role in gaining green building certification.  

In order to meet sustainability standards, every part of the supply chain related to bio-resin must be certified. Look out for certification by schemes such as ISCC Plus, the global sustainability certification system. 

Axalta have recently become the first manufacturer within the powder coatings industry to be ISCC Plus certified for bio-based feedstock sourcing practices, which proves Axalta’s ability to successfully produce a selection of coating formulations using bio-based resins. 

Innovation in the curing process

Another area where we see innovation potential is in the curing process. While some industry coatings have been developed to cure at lower temperatures than the standard ~180 degrees celsius, this is not the case for architectural powder coatings. They can carry up to a 25-year warranty and are formulated for extreme durability. Despite the obstacles, it’s likely that manufacturers will continue to exploit the potential for reduced curing temperatures in the future.

The drive to be more sustainable while maintaining quality is a challenge the industry is rising to. It’s just one of the reasons why powder coatings is such an exciting area – watch this space!