EMPEROR 1600 AND EMPEROR 1200 SPECIALTY CARBON …/media/files/guides/specialty... · 2017. 3. 22. · Our EMPEROR 1200 and 1600 carbon blacks can enable enhanced color performance,

EMPEROR® 1600 AND EMPEROR 1200SPECIALTY CARBON BLACKS FOR SOLVENT-BASED COATINGSProcessing and formulation guide

SPECIALTY CARBON BLACKS

Our EMPEROR 1200 and 1600 carbon blacks can enable enhanced

color performance, reduced dispersant loading and increased carbon

black loading during the millbase step of manufacturing. Both products

feature our proprietary Softbead™ technology. Products with Softbead

technology disperse as easily as powder carbon blacks, but with better

handling characteristics.

This guide provides an overview of the manufacturing steps that should be

taken in order to realize the benefits of these state-of-the-art pigments.

Surface modification of the EMPEROR products can:◆◆ Reduce cohesion of carbon black, resulting in easy dispersibility◆◆ Improve carbon black wetting which leads to lower millbase viscosity◆◆ Reduce required dispersant loading which can result in lower total

formulation cost and improved color performance

To achieve full performance potential for EMPEROR products, millbase

formulations may need to be modified as follows:◆◆ Increase carbon black loading◆◆ Reduce dispersant loading◆◆ Adjust pigment/binder ratio◆◆ Add rheology control additive to adjust milling viscosity◆◆ Increase millbase solids

EMPEROR® 1600 and EMPEROR 1200 specialty carbon blacks

2

Manufacturing steps overview

Pre-mix EMPEROR 1200 and 1600 carbon blacks enable reduced milling time and reduced dispersant loading, both of which reduce overall cost. The following steps are suggested in the pre-mix step to help realize this benefit.

◆◆ Soak pigments before pre-mix to facilitate mixing

◆◆ Pre-mix at high speed (>1000 RPM) until homogeneous

GRINDING RESIN

SOLVENT

CARBON BLACK

DISPERSANT

TO LETDOWN AND APPLICATIONFINISHMILLBASE

MILL

PRE-MIX

Millbase formulationEMPEROR 1200 and 1600 carbon blacks enable reduced dispersant loading and increased carbon black loading in the millbase. Excess dispersing aid in the final formulation can result in higher total formulation cost and poor color performance. Low millbase viscosity may result in poor carbon black dispersion quality.

◆◆ Reduce dispersant loading. Typical dispersant loading for other carbon blacks is 20% - 50% by weight of carbon black. EMPEROR 1600 and 1200 carbon blacks can reduce dispersant loading by up to 50%.

◆◆ Increase carbon black loading by at least 10% to achieve millbase viscosity of 65-75 KU

Finish formulation◆◆ Pre-mix the masterbatch letdown under

good agitation

◆◆ Post add the millbase to the masterbatch letdown under good agitation

◆◆ Mix under good agitation until homogeneous solution is achieved

Milling When compared to competitive products, EMPEROR 1200 and 1600 carbon blacks typically require half the milling time.

◆◆ Pre-mix and then continue to mix while pumping into the mill

EMPEROR 1200 and EMPEROR 1600 carbon blacks for masstone applications

Excellent color performance

EMPEROR 1600 and EMPEROR 1200 carbon blacks deliver exceptional jetness and blue undertone.

Coating color performance with select carbon blacks

Formulation details: Polyester/CAB resin blend. ◆◆ Mc is the color dependent black value and was developed by K.Lippok-Lohmer which is strongly correlated with the human perception of increased jetness◆◆ Mc = 100[log(Xn/X)-log(Zn/Z)+log(Yn/y)]

L-valueindicates: darkness

(lower is darker)

b-valueindicates:

blue undertone (lower is bluer)

Mc valuesummarizes:

jetness (L-value)

and undertone(b-value)

EMPEROR1600

310305300295290285280

MONARCH1300

EMPEROR1200

EMPEROR1600

MONARCH1300

EMPEROR1200

309305

292

1.81.30.80.3

0-0.3

.92

-.37

L-va

lue

b-va

lue

-.26

L-va

lue

b-va

lue

-.45

L-va

lue

b-va

lue

1.60.94

EMPEROR1600

310305300295290285280

MONARCH1300

EMPEROR1200

EMPEROR1600

MONARCH1300

EMPEROR1200

309305

292

1.81.30.80.3

0-0.3

.92

-.37

L-va

lue

b-va

lue

-.26

L-va

lue

b-va

lue

-.45

L-va

lue

b-va

lue

1.60.94

Mc value Darkness and undertone

In a typical polyester CAB blend coating, EMPEROR 1600 enables excellent performance, followed by MONARCH 1300 and

EMPEROR 1200 carbon blacks.

EMPEROR® 1600 AND EMPEROR 1200 SPECIALTY CARBON BLACKS PROCESSING AND FORMULATION GUIDE

3

Optimized millbase formulation guide

Millbase Constant EMPEROR 1600 carbon black

Raw material Amount (%)

Carbon black loading 21.75

Total solids 54.65

Dispersant loading (% active to carbon black) 50

Pigment/binder ratio 1.0/1.0

Millbase constant EMPEROR 1200 carbon black


Carbon black loading 18

Total solids 59.72





Carbon black loading 22.4

Total solids 70.56





Carbon black loading 11

Total solids 40.3



Acrylic system with EMPEROR 1600 carbon black

Polyester system with EMPEROR 1600 carbon black

Universal millbase formulation EMPEROR 1200 carbon black


Universal resin grind (60% active) 39

Dispersion agent (40% active) 11

Dispersant synergy 0.4

Butyl acetate 12.5

Propylene glycol monomethyl ether acetate 12.5

Xylene 12.5

Rheology control agent 1.1

Carbon black 11

Millbase procedure:1. Rheology control agent is required to achieve viscosity 65-75 KU2. Pre-mix the millbase at >1000 RPM for 30 minutes (milllbase 60 KU) and

until no settling is observed.3. After pre-mixing, charge the pre-mix into grinding mill.4. Mill until fineness <5 μ achieved.

Universal system with EMPEROR 1200 carbon black

Acrylic millbase formulation EMPEROR 1200 carbon black


Acrylic resin grind (55% active) 59.5

Dispersion agent (40% active) 22.5

Butyl acetate 0*

Propylene glycol monomethyl ether acetate 0*

Xylene 0*

Carbon black 18

* No solvent was used because of the low viscosity of EMPEROR 1200 carbon black.

Millbase procedure:1. Pre-mix the millbase at >1000 RPM for 45 minutes.2. After pre-mixing, charge the pre-mix into grinding mill as soon as possible

to minimize soft settling.3. Mill until fineness <5 μ achieved.

Acrylic system with EMPEROR 1200 carbon black

Acrylic millbase formulation EMPEROR 1600 carbon black


Acrylic resin grind (55% active) 40


Butyl acetate 3.5


Xylene 4

Carbon black 21.75

Millbase procedure:1. Pre-mix the millbase at >1000 RPM for 45 minutes.2. After pre-mixing, charge the pre-mixes into grinding mill as soon as

possible to minimize the soft settling.3. Mill until fineness <5 μ achieved.

Polyester millbase formulation EMPEROR 1600 carbon black


Polyester resin grind (70% active) 59.2


Butyl acetate 3.6


Carbon black 22.4

Millbase procedure:1. Pre-mix the millbase at >1000 RPM for 30 minutes and until no settling is

observed. Viscosity 140 KU2. Pre-mix and grind at same vertical ball mill.3. Mill until fineness <5 μ achieved.

EMPEROR 1200 and EMPEROR 1600 carbon blacks for masstone applications (continued)


4

Tinting performance vs. dispersant loading

Optimized tint formulation: alkyd/melamine

Alkyd/melamine black millbase 50% dispersant* 25% dispersant*

Product name Description Amount (%) Amount (%)

Alkyd resin (60% solids) Resin 48 48

Melamine resin (70% solids) Crosslinker 17.6 17.6

DISPERBYK 163 Dispersant 7.5 3.75

Solvesso® 100 Solvent 6 7.89

Butanol Solvent 2 2.63

Xylene Solvent 3.9 5.13

Carbon black Pigment 15 15

Alkyd/melamine white millbase

Product name Description Amount (%)

Alkyd resin (60% solids) Resin 45

Melamine resin (70% solids) Crosslinker 16.5

DISPERBYK 163 Dispersant 6

Solvesso 100 Solvent 8

Butanol Solvent 2

Xylene Solvent 2.5

TiO2 (TiPure R902) Pigment 20

Tint performance at 25% and 50% dispersant loading: alkyd/melamine resin system

EMPEROR® 1200 and EMPEROR 1600 carbon blacks for tinting applications

Tinting strength - LDispersant - DISPERBYK® 163 dispersant

EMPEROR 1200carbon black


37.6337.2741.3440.95

0

10

20

30

40

50

25%

50

%

25%

50

%

Undertone - bDispersant - DISPERBYK 163 dispersant



-2.27-2.52

-2.08-2.26

-3.0

-2.5

-2.0

-1.5

-1.0

-0.5

0.0

25%

50

%

25%

50

%

Undertone - aDispersant - DISPERBYK 163 dispersant

* Dispersant level is % active relative to carbon black

◆◆ Tinting test was prepared with 10 black/90 white mix ratio◆◆ Color panel preparation: After application, the system was flashed off

for 20 minutes then cured in oven at 140 °C for 30 minutes



-1.0

-0.8

-0.6

-0.4

-0.2

0.0

-.97-.99

-.88-.89

25%

50

%

25%

50

%

5

Optimized tint formulation: acrylic PU

Acrylic PU black millbase 50% dispersant* 25% dispersant*


Acrylic binder (60% solids) Resin 65 65

DISPERBYK 163 Dispersant 7.5 3.75

Butyl acetate Solvent 6.5 8.45

Xylene Solvent 6 7.8

Carbon black Pigment 15 15

Acrylic PU white millbase

Product Name Description Amount (%)

Acrylic binder (60% solids) Resin 60

DISPERBYK 163 Crosslinker 6

Butyl acetate Dispersant 8

Xylene Solvent 6

TiO2 (TiPure R902) Pigment 20

Tint Performance at 20% and 40% dispersant loading: polyester CAB resin system

EMPEROR® 1200 AND EMPEROR 1600 carbon blacks for tinting applications (continued)

* Dispersant level is % active relative to carbon black◆◆ Tinting test was prepared with 10 black/ 90 white mix ratio

◆◆ Color panel preparation: The system was catalyzed with 16.55% isocyanate to 83.35% of millbase

and applied with 150 μ film build


6

Tinting performance vs. dispersant loading

Tint performance at 25% and 50%dispersant loading: acrylic PU resin system

Tinting strength - LDispersant - DISPERBYK® 163 dispersant



37.2934.26 34.57

38.16

05

10152025303540

25%

50

%

50

%

25%

Undertone - bDispersant - DISPERBYK 163 dispersant

-3.5-3.0-2.5-2.0-1.5-1.0-0.50.0

-3.08

-2.51

-1.57-1.72

25%

50

%

50

%

25%



Undertone - aDispersant - DISPERBYK 163 dispersant

-1.0

-0.8

-0.6

-0.4

-0.2

0.0

-.97

-.84 -.81

-.93

25%

50

%

50

%

25%



59.4761.13 62.94

01020304050607080

Not

tes

ted

40

%

40

%

20%



-2.0

-1.5

-1.0

-0.5

0.0

-1.45-1.33

-1.45

Not

tes

ted

40

%

40

%

20%



-2.0

-1.5

-1.0

-0.5

0.0

40

%

40

%

20%

-1.35-1.11

-1.51

Not

tes

ted



Tinting strength - L Dispersant - Solsperse® 32500 dispersant

Undertone - b Dispersant - Solsperse 32500

Undertone - a Dispersant - Solsperse 32500

Optimized tint formulation: polyester CAB

1. Black millbase formulation:

Acrylic PU black millbase

20% Dispersant

loading

40% Dispersant

loading


Setal® 189 XX-65 Resin 30.77 30.77

Solsperse 32500 Dispersant 4.45 8.89

Butyl Acetate Solvent 25.39 25.17

Propylene glycol monomethyl ether acetate

Solvent 25.39 25.17

Carbon black Carbon black 10 10

2. Universal TiO2 white millbase formulation:Product name Description Amount (%)

Laropal® A81 (50%) Resin grind 17.45

DISPERBYK 2150 Dispersing agent 2.80

DOWANOL™ PMA Solvent 7

Solvesso 100 Solvent 2.25

BYK-410 Rheology control 0.50

TIOXIDE® TR92 TiO2 70

Millbase procedure:◆◆ Premix Laropal A81 resin grind, DisperBYK2150, DOWANOL PMA, Solvesso

100, and BYK410 rheology control additive under good agitation

◆◆ Add TIOXIDE TR92 pigment under good agitation

◆◆ Mix at 6000 RPM for 30 minutes until less than 20 μ is achieved

3. Masterbatch letdown:Component Description Amount (%)

Setal 189 XX-65 Polyester resin 48.11

CAB551-0.01 (30% BA) Cellulose acetate butyrate (CAB) 29.89

Cymel® 325 Melamine resin 2.79

BYK-346 Wetting agent 0.45

Butyl acetate/PGMEA Solvent 18.77

Masterbatch letdown procedure:◆◆ Premix CAB, Cymel 325 melamine resin, BYK346 wetting agent, solvent

together

◆◆ Post-add the premix slowly into the resins under good agitation then mix

for another 15 minutes

◆◆ Discharge, then proceed to finish formulation

4. Polyester/CAB black finish:Component Amount (%)

Black millbase 10.5

Masterbatch letdown 89.5

Polyester/CAB black finish procedure:◆◆ Post add the millbase to the masterbatch letdown under good agitation

◆◆ Mix for 20 minutes, then discharge

◆◆ Proceed to the tinting formulation

5. Polyester/CAB white finish:Component Amount (%)

Universal TiO2 base 30

Masterbatch letdown 70

Polyester/CAB white finish procedure:◆◆ Post add the universal TiO2 to the masterbatch letdown under good

agitation


◆◆ Proceed to the tinting formulation

6. Tinting formulation (80/20):Component Amount (%)

Polyester/CAB black finish 20

Polyester/CAB white finish 80

Tinting formulation procedure:◆◆ Post add the polyester/CAB black finish to the polyester/CAB white finish

under good agitation


7. Application stage:

Application procedure:◆◆ Cast out the film on cold roll steel and BYKO™ chart using .003 inch cast out bar.

◆◆ Air dry for 10 minutes at room temperature

◆◆ Check for floating. If floating is observed, increase dispersant in

the formulation

◆◆ Cure at 66 °C for 10 minutes

◆◆ Air dry for another 24 hours at room temperature

◆◆ Measure hiding and color performance

7

EMPEROR® 1200 and EMPEROR 1600 carbon blacks for tinting applications (continued)

Dispersant study formulation guide

Black millbaseformulation

Efka4310

Solsperse32500


Setal 189 XX-65 resin Resin 30.77 30.77

Solsperse 32500 Dispersant 8 8.89

Butyl acetate Solvent 25.61 25.17

Solvent 25.62 25.17

Carbon black Carbon black 10.00 10.00

Millbase procedure:◆◆ Pre-mix dispersant, Butyl acetate, and propylene glycol monomethyl

ether acetate together

◆◆ Post-add carbon black to mixture under good agitation and soak for 5 minutes

◆◆ Add Setal resin to the above under good agitation then mix for

5 minutes at 4000 RPM

◆◆ Re-circulate through Eiger mill at 10 m/s tip speed until 5 μ grind is achieved

Note: The TiO2 millbase, masterbatch letdown, black finish formulation, white finish formulation, tinting formulation and application stage are the same as the Polyester/CAB dispersant loading study on previous page.


Tinting performance vs. dispersant type

Impact of dispersant type: polyester CAB resin system

Tinting strength - L

Efka 4310 Solsperse 32500

63.19

65.54

59.47

62.94

55

57

59

61

63

65

67

EMPEROR 1200 carbon black EMPEROR 1600 carbon black

Undertone - b

Efka 4310 Solsperse 32500-2.0

-1.5

-1.0

-0.5

0.0

0.5

-.08

.04

-1.35-1.51


Undertone - a

-2.0

-1.5

-1.0

-0.5

0.0

-.68 -.74

-1.35-1.51

Efka 4310 Solsperse 32500


cabotcorp.com

The EMPEROR, MONARCH and Softbead names are trademarks of Cabot Corporation. The BYK and DisperBYK names are registered trademark of BYK-Chemie GmbH. The Solvesso name is a registered trademark of Exxon

Mobil Corporation. The Ti-Pure and TIOXIDE names are trademarks of E.I. DuPont de Nemours and Company. The Solsperse name is a trademark of The Lubrizol Corporation. The Setal name is a trademark of Nuplex

Industries Ltd. The Efka and Larapol names are trademarks of BASF SE. The Cymel name is a trademark of Cytec Technology Corp. The BYKO name is a trademark of BYK-Gardner USA. The DOWANOL name is a trademark of

The Dow Chemical Company.

The data and conclusions contained herein are based on work believed to be reliable, however, Cabot cannot and does not guarantee that similar results and/or conclusions will be obtained by others. This information is

provided as a convenience and for informational purposes only. No guarantee or warranty as to this information, or any product to which it relates, is given or implied. This information may contain inaccuracies, errors or

omissions and CABOT DISCLAIMS ALL WARRANTIES EXPRESS OR IMPLIED, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AS TO (i) SUCH INFORMATION, (ii) ANY PRODUCT OR (iii) INTELLECTUAL PROPERTY

INFRINGEMENT. In no event is Cabot responsible for, and Cabot does not accept and hereby disclaims liability for, any damages whatsoever in connection with the use of or reliance on this information or any product to

which it relates.

© 2017 Cabot Corporation.

R03 1/17

NORTH AMERICACabot Corporation Business

and Technology Center

157 Concord Road

P.O. Box 7001

Billerica, MA 01821 - USA

Technical service

T +1 800 462 2313

Customer service

T +1 678 297 1300

F +1 678 297 1245

SOUTH AMERICACabot Brasil Industria

e Comericio Ltda.

Rua do Paraiso 148 - 5 andar

04103-000 Sao Paolo,

Brazil

T +55 11 2144 6400

F +55 11 3253 0051

EUROPECabot Specialty Chemicals

Coordination Center

SIA Cabot Latvia

101 Mukusalas Street

Riga, LV-1004, Latvia

T +371 6705 0700

F +371 6705 0985

MIDDLE EAST & AFRICACabot Dubai

P.O. Box 17894

Jebel Ali Free Zone

LOB 15, Office 424

Dubai

United Arab Emirates

T +371 6705 0700

F +371 6705 0985

ASIA PACIFICCabot China Ltd.

558 Shuangbai Road

Shanghai 201108

China

T +86 21 5175 8800

F +86 21 6434 5532

JAPANCabot Specialty Chemicals Inc.

Sumitomo Shiba-Daimon Bldg. 3F

2-5-5 Shiba Daimon,

Minato-ku

Tokyo 105-0012

Japan

T +81 3 6820 0255

F +81 3 5425 4500

Documents

EMPEROR 1600 AND EMPEROR 1200 SPECIALTY CARBON …/media/files/guides/specialty... · 2017. 3. 22. · Our EMPEROR 1200 and 1600 carbon blacks can enable enhanced color performance,