Technology

March 21, 2018

Valspar non BPA Can Coatings Strategy

Valspar: How we engaged stakeholders to solve the BPA dilemma

Teresa McGrath and Bob Israel

Businessman holding a tin phone can to his ear
ShutterstockMinerva Studios
We found a silver lining in the process of replacing Bisphenol-A.

Bisphenol A (BPA)-based epoxy coatings are the most commonly used protective lining for metal food and beverage packaging. BPA-free campaigns from organizations such as the Breast Cancer Protection Partners, Clean Production Action and the Natural Resources Defense Council have raised awareness of and consumer demand for BPA-free products.

Consumer-facing food processors, can manufacturers and others who have relied on epoxy-lined cans for decades need to respond, but face the challenge of finding safe substitutes for BPA-based coatings that provide all the same functional benefits at reasonable cost.

Responding to this market opportunity, our company, Valspar, a major provider of linings to can manufacturers, undertook a novel approach to finding a safe, functional alternative that provides a promising model for how other companies might approach such challenges and opportunities.

BPA has been the subject of intense scrutiny with respect to its hormonal, estrogenic impacts, including reproductive and developmental effects. Unfortunately, common alternatives such as Bisphenol S and Bisphenol F also have been reported to show some of these effects.When formulating a food or beverage can coating, non-epoxy-based alternatives would seem to be a logical approach. Acrylic, vinyl, oleo, polyethylene solutions were considered, but none have the versatility to meet the diverse and critical performance demands of a can manufacturing plant that cranks out 6 million cans per day.

Valspar needed to find a solution that provides the performance properties of BPA-epoxy coatings without the perceived drawbacks in human and environmental health. Using an approach much like the pharmaceutical industry uses to find new drug molecules, Valspar developed a BPA-free solution with a basic building-block molecule that is not estrogenic, does not induce genetic damage (genotoxicity), meets all food safety requirements, has excellent performance and will not migrate into food.

To develop this innovative technical solution, Valspar engaged in a holistic strategy, partnering with a range of NGOs, academics, toxicologists and brand owners, following this with extensive testing and an unconventional communication strategy.

Metal is the most versatile and lightweight food and beverage packaging material. Both aluminum and steel are easily recycled with no loss in quality. Coatings on metal cans are essential to preserving food and protect against corrosion, micro-organisms and off-putting taste.In North America alone, nearly 115 billion cans were consumed in 2014. In some major can segments, an estimated 40 percent of cans use non-BPA coatings now, and the market is expected to grow to over 60 percent within the next several years. With this rapid switch to non-BPA coatings, Valspar recognized the opportunity to bring effective, safe, thoroughly tested solutions to market.

Drug discovery, in reverse

We approached this challenge using Valspar’s Safety by Design process and by partnering with endocrine activity experts. Our goal was to design a molecule with the appropriate functionality of a bisphenol epoxy resin minus the undesirable biological activity associated with BPA.

With their expertise, we identified the key structural elements of bisphenols that enable the molecules to link to sites (estrogen receptors) in the body that are influenced by estrogen and estrogen-like chemicals. Knowing this, Valspar screened hundreds of theoretical structures to find a small set that wouldn’t be able to fit into the sites.

We then took this pool of chemicals and tested them for estrogenic activity and other hazards and further for regulatory agency clearances, manufacturability, sustainable supply chain availability, infrastructure compatibility and performance.

One monomer floated to the top: tetramethyl bisphenol F (TMBPF). TMBPF lacked estrogenicity, lacked genotoxicity and, due to the synthesis pathway of the final coating system, TMBPF will not migrate into food or beverages as BPA has been shown to do. Compared to BPA and BPA-based epoxy coatings the TMBPF monomer and TMBPF-based epoxy coatings have lower hazards and lower exposure. Win, win.

Inviting skeptics to prove us wrong

Valspar recognized the level of scrutiny from stakeholders that TMBPF, as a bisphenol, would invite. In addition to the partners who advised us in the first stages of this project, Valspar invited academics, independent research laboratories, brand owners and regulatory agencies and NGOs (some of whom were behind the BPA-free campaigns), to look at TMBPF and the resulting coating, the hazard and migration data we had generated, and asked them what additional data they would need to feel that this solution, if not perfect, was an improvement over the technology they opposed.

Valspar provided samples of the monomer, the oligomers (chemical structures comprised of multiple TMBPF molecules linked together), the polymer (a chemical structure comprised of multiple chemicals linked together) and the migrants from extraction testing, and asked these stakeholders to prove us wrong.

Stakeholder response

Valspar’s valPure non-BPA technology, including the V70-series coatings using the TMBPF epoxy resin, is approved for use in over 100 countries and can be found on over 20 billion cans in circulation today. The engagement from the NGO community proved to be a positive, productive relationship. Janet Nudelman, director of program and policy at Breast Cancer Protection Partners, offered the following comment on our process representative of the feedback we received: “It’s not just the new can lining that you’ve developed that we’re excited about, it is also your new proposed approach to safety testing which has the possibility of becoming a new industry standard.”

Janet Nudelman, director of program and policy at Breast Cancer Protection Partners, offered the following comment on our process representative of the feedback we received: “It’s not just the new can lining that you’ve developed that we’re excited about, it is also your new proposed approach to safety testing which has the possibility of becoming a new industry standard.”

Embracing transparency

Last, rather than claim this new molecule and coating as trade secret, Valspar thoroughly protected the intellectual property, which includes 49 patents. This allowed us to invite the public to review the data themselves by making the V70 polymer chemical identity and hazard data publicly available on Valspar’s website.

Safety by design

It was, admittedly, only after this process was complete that Valspar looked back and deemed this alternatives assessment process “Safety by Design.” This means evidence of absence of effects, not absence of evidence of effects. In this case, it means to demonstrate this new molecule does not have the same hazard profile as other bisphenol molecules.

It means collaborating with partners who think differently from us. It means being patient and ready to think outside of the box. “Safety by Design” is not the easy path. The V70 polymer took seven years and millions of dollars to develop. “Safety by Design” represents a valuable tool in the mainstreaming of green chemistry, and it means doing whatever it takes to develop a solution that safely will serve billions of people for generations to come.

https://www.greenbiz.com/article/valspar-how-we-engaged-stakeholders-solve-bpa-dilemma

March 21, 2018

Valspar non BPA Can Coatings Strategy

Valspar: How we engaged stakeholders to solve the BPA dilemma

Teresa McGrath and Bob Israel

Businessman holding a tin phone can to his ear
ShutterstockMinerva Studios
We found a silver lining in the process of replacing Bisphenol-A.

Bisphenol A (BPA)-based epoxy coatings are the most commonly used protective lining for metal food and beverage packaging. BPA-free campaigns from organizations such as the Breast Cancer Protection Partners, Clean Production Action and the Natural Resources Defense Council have raised awareness of and consumer demand for BPA-free products.

Consumer-facing food processors, can manufacturers and others who have relied on epoxy-lined cans for decades need to respond, but face the challenge of finding safe substitutes for BPA-based coatings that provide all the same functional benefits at reasonable cost.

Responding to this market opportunity, our company, Valspar, a major provider of linings to can manufacturers, undertook a novel approach to finding a safe, functional alternative that provides a promising model for how other companies might approach such challenges and opportunities.

BPA has been the subject of intense scrutiny with respect to its hormonal, estrogenic impacts, including reproductive and developmental effects. Unfortunately, common alternatives such as Bisphenol S and Bisphenol F also have been reported to show some of these effects.When formulating a food or beverage can coating, non-epoxy-based alternatives would seem to be a logical approach. Acrylic, vinyl, oleo, polyethylene solutions were considered, but none have the versatility to meet the diverse and critical performance demands of a can manufacturing plant that cranks out 6 million cans per day.

Valspar needed to find a solution that provides the performance properties of BPA-epoxy coatings without the perceived drawbacks in human and environmental health. Using an approach much like the pharmaceutical industry uses to find new drug molecules, Valspar developed a BPA-free solution with a basic building-block molecule that is not estrogenic, does not induce genetic damage (genotoxicity), meets all food safety requirements, has excellent performance and will not migrate into food.

To develop this innovative technical solution, Valspar engaged in a holistic strategy, partnering with a range of NGOs, academics, toxicologists and brand owners, following this with extensive testing and an unconventional communication strategy.

Metal is the most versatile and lightweight food and beverage packaging material. Both aluminum and steel are easily recycled with no loss in quality. Coatings on metal cans are essential to preserving food and protect against corrosion, micro-organisms and off-putting taste.In North America alone, nearly 115 billion cans were consumed in 2014. In some major can segments, an estimated 40 percent of cans use non-BPA coatings now, and the market is expected to grow to over 60 percent within the next several years. With this rapid switch to non-BPA coatings, Valspar recognized the opportunity to bring effective, safe, thoroughly tested solutions to market.

Drug discovery, in reverse

We approached this challenge using Valspar’s Safety by Design process and by partnering with endocrine activity experts. Our goal was to design a molecule with the appropriate functionality of a bisphenol epoxy resin minus the undesirable biological activity associated with BPA.

With their expertise, we identified the key structural elements of bisphenols that enable the molecules to link to sites (estrogen receptors) in the body that are influenced by estrogen and estrogen-like chemicals. Knowing this, Valspar screened hundreds of theoretical structures to find a small set that wouldn’t be able to fit into the sites.

We then took this pool of chemicals and tested them for estrogenic activity and other hazards and further for regulatory agency clearances, manufacturability, sustainable supply chain availability, infrastructure compatibility and performance.

One monomer floated to the top: tetramethyl bisphenol F (TMBPF). TMBPF lacked estrogenicity, lacked genotoxicity and, due to the synthesis pathway of the final coating system, TMBPF will not migrate into food or beverages as BPA has been shown to do. Compared to BPA and BPA-based epoxy coatings the TMBPF monomer and TMBPF-based epoxy coatings have lower hazards and lower exposure. Win, win.

Inviting skeptics to prove us wrong

Valspar recognized the level of scrutiny from stakeholders that TMBPF, as a bisphenol, would invite. In addition to the partners who advised us in the first stages of this project, Valspar invited academics, independent research laboratories, brand owners and regulatory agencies and NGOs (some of whom were behind the BPA-free campaigns), to look at TMBPF and the resulting coating, the hazard and migration data we had generated, and asked them what additional data they would need to feel that this solution, if not perfect, was an improvement over the technology they opposed.

Valspar provided samples of the monomer, the oligomers (chemical structures comprised of multiple TMBPF molecules linked together), the polymer (a chemical structure comprised of multiple chemicals linked together) and the migrants from extraction testing, and asked these stakeholders to prove us wrong.

Stakeholder response

Valspar’s valPure non-BPA technology, including the V70-series coatings using the TMBPF epoxy resin, is approved for use in over 100 countries and can be found on over 20 billion cans in circulation today. The engagement from the NGO community proved to be a positive, productive relationship. Janet Nudelman, director of program and policy at Breast Cancer Protection Partners, offered the following comment on our process representative of the feedback we received: “It’s not just the new can lining that you’ve developed that we’re excited about, it is also your new proposed approach to safety testing which has the possibility of becoming a new industry standard.”

Janet Nudelman, director of program and policy at Breast Cancer Protection Partners, offered the following comment on our process representative of the feedback we received: “It’s not just the new can lining that you’ve developed that we’re excited about, it is also your new proposed approach to safety testing which has the possibility of becoming a new industry standard.”

Embracing transparency

Last, rather than claim this new molecule and coating as trade secret, Valspar thoroughly protected the intellectual property, which includes 49 patents. This allowed us to invite the public to review the data themselves by making the V70 polymer chemical identity and hazard data publicly available on Valspar’s website.

Safety by design

It was, admittedly, only after this process was complete that Valspar looked back and deemed this alternatives assessment process “Safety by Design.” This means evidence of absence of effects, not absence of evidence of effects. In this case, it means to demonstrate this new molecule does not have the same hazard profile as other bisphenol molecules.

It means collaborating with partners who think differently from us. It means being patient and ready to think outside of the box. “Safety by Design” is not the easy path. The V70 polymer took seven years and millions of dollars to develop. “Safety by Design” represents a valuable tool in the mainstreaming of green chemistry, and it means doing whatever it takes to develop a solution that safely will serve billions of people for generations to come.

https://www.greenbiz.com/article/valspar-how-we-engaged-stakeholders-solve-bpa-dilemma

March 15, 2018

Huntsman TPU Partnership

HUNTSMAN FORMS PARTNERSHIP WITH T. MICHEL FORMENBAU

Osnabrück, GERMANY – The thermoplastic polyurethanes (TPU) team at Huntsman has formed a special partnership with T. Michel Formenbau GmbH & Co. KG – a leading producer of molds and tools for the plastics processing industry.

The alliance is designed to benefit plastic product manufacturers wanting to explore the use of expanded TPU (eTPU). Together, Huntsman and T. Michel Formenbau will offer a complete end-to-end material selection and steam-mold service – providing advice on the best materials to use for specific applications plus mold design, production and testing. The two companies will also work together on research projects, exploring eTPU and steam-molding improvements that could make life easier for plastic processors wanting to use this lightweight technology in different application areas.

Under the terms of the agreement, Huntsman will also use T. Michel Formenbau’s technical center in Lautert, Germany to test and demonstrate the processing performance its own eTPU products. On site, Huntsman will assess new products to ensure their compatibility with the very latest steam-molding techniques. It will also conduct steam-molding trials and demonstrations for customers wanting to evaluate existing materials such as smartLite® PF 1560 TPU. This super lightweight, particle foam technology is widely used in sports shoes but has broader potential across a variety of industrial markets.

Huntsman chose to work with T. Michel Formenbau because of the extensive range of molding equipment available at its technical center. T. Michel Formenbau specializes in the development of EPS / EPP foam molding tools; PUR foam molding tools; injection molding tools; deep drawing tools; and injectors for particle foams. The business has also invested in the latest laser equipment, enabling it to create molds that deliver special surface textures.

Olaf Michel, Global Technology Manager at Huntsman Polyurethanes, said: “As a global company we have extensive testing equipment available in-house – but we also know it’s important to collaborate with external companies. In the case of T.Michel Formenbau, it’s invaluable to tap into their knowledge, use their equipment, and get feedback on our materials. We first made contact with the business in 2015 and quickly realized the potential for a longer-term relationship. Initially, our work together focused on testing our eTPU materials for the footwear sector. Moving forward, we’ll continue that work but we’ll also be actively exploring how eTPU can be used across a broader range of applications.”

Thorsten Michel, General Manager of T. Michel Formenbau, said: “The very best research is not undertaken in isolation. It’s collaborative and based on strong partnerships, knowledge exchange and the optimization of materials and processes. These elements are the cornerstone of all the research projects we undertake. This approach, combined with the equipment available at our Lautert technology center, means we can quickly satisfy the research objectives of our partners – whether we’re testing particulate foam materials or other plastics for light construction applications. We look forward to working with the team at Huntsman on a variety of joint research projects.”

T. Michel Formenbau GmbH & Co. KG was founded in 2000 and employs around 50 people. The business creates bespoke molds for plastic processors – offering them an end-to-end tooling service that covers product development, process development, mold manufacturing, laser texture, filling injectors, measuring probes and sampling. The company’s work spans all types of precision mold making – from the smallest, intricate tooling designs to large-scale molds for major engineering projects. With the help of two new laser-texturing machines, T. Michel Formenbau can also give its customers a wide range of options when it comes to surface design. Using this equipment means there are no limits to the creation of personalized and individual surfaces on molds. Filling injectors, tool cooling systems and numerous measuring probes (such as the patented MIC probe (2in1)) can also be provided by the T. Michel Formenbau team.

March 15, 2018

Huntsman TPU Partnership

HUNTSMAN FORMS PARTNERSHIP WITH T. MICHEL FORMENBAU

Osnabrück, GERMANY – The thermoplastic polyurethanes (TPU) team at Huntsman has formed a special partnership with T. Michel Formenbau GmbH & Co. KG – a leading producer of molds and tools for the plastics processing industry.

The alliance is designed to benefit plastic product manufacturers wanting to explore the use of expanded TPU (eTPU). Together, Huntsman and T. Michel Formenbau will offer a complete end-to-end material selection and steam-mold service – providing advice on the best materials to use for specific applications plus mold design, production and testing. The two companies will also work together on research projects, exploring eTPU and steam-molding improvements that could make life easier for plastic processors wanting to use this lightweight technology in different application areas.

Under the terms of the agreement, Huntsman will also use T. Michel Formenbau’s technical center in Lautert, Germany to test and demonstrate the processing performance its own eTPU products. On site, Huntsman will assess new products to ensure their compatibility with the very latest steam-molding techniques. It will also conduct steam-molding trials and demonstrations for customers wanting to evaluate existing materials such as smartLite® PF 1560 TPU. This super lightweight, particle foam technology is widely used in sports shoes but has broader potential across a variety of industrial markets.

Huntsman chose to work with T. Michel Formenbau because of the extensive range of molding equipment available at its technical center. T. Michel Formenbau specializes in the development of EPS / EPP foam molding tools; PUR foam molding tools; injection molding tools; deep drawing tools; and injectors for particle foams. The business has also invested in the latest laser equipment, enabling it to create molds that deliver special surface textures.

Olaf Michel, Global Technology Manager at Huntsman Polyurethanes, said: “As a global company we have extensive testing equipment available in-house – but we also know it’s important to collaborate with external companies. In the case of T.Michel Formenbau, it’s invaluable to tap into their knowledge, use their equipment, and get feedback on our materials. We first made contact with the business in 2015 and quickly realized the potential for a longer-term relationship. Initially, our work together focused on testing our eTPU materials for the footwear sector. Moving forward, we’ll continue that work but we’ll also be actively exploring how eTPU can be used across a broader range of applications.”

Thorsten Michel, General Manager of T. Michel Formenbau, said: “The very best research is not undertaken in isolation. It’s collaborative and based on strong partnerships, knowledge exchange and the optimization of materials and processes. These elements are the cornerstone of all the research projects we undertake. This approach, combined with the equipment available at our Lautert technology center, means we can quickly satisfy the research objectives of our partners – whether we’re testing particulate foam materials or other plastics for light construction applications. We look forward to working with the team at Huntsman on a variety of joint research projects.”

T. Michel Formenbau GmbH & Co. KG was founded in 2000 and employs around 50 people. The business creates bespoke molds for plastic processors – offering them an end-to-end tooling service that covers product development, process development, mold manufacturing, laser texture, filling injectors, measuring probes and sampling. The company’s work spans all types of precision mold making – from the smallest, intricate tooling designs to large-scale molds for major engineering projects. With the help of two new laser-texturing machines, T. Michel Formenbau can also give its customers a wide range of options when it comes to surface design. Using this equipment means there are no limits to the creation of personalized and individual surfaces on molds. Filling injectors, tool cooling systems and numerous measuring probes (such as the patented MIC probe (2in1)) can also be provided by the T. Michel Formenbau team.

March 1, 2018

Urethane Filled Bike Tire

Schwalbe Takes Airless Tyres To Next Level

Sales & Trends 550

UTRECHT, the Netherlands – Schwalbe is launching its Airless System. With it Europe’s biggest in bicycle tyres is taking airless to the next level. And maybe even to a much wider use of these puncture-free tyres than ever before.

Schwalbe Takes Airless Tyres To Next Level
New Airless System and its special assembly tools are sold exclusively to specialist retailers that are certified by Schwalbe. – Photo Schwalbe

Schwalbe’s Airless System consists of an outer tyre combined with an airless inner one. It’s not only targeting bicycle ‘fleet owners’ or public bikes but also cycling commuters or regular cyclists and even e-bikers as Schwalbe claims that it offers puncture free riding and is also capable to easily handle the higher speeds and weights of e-bikes.

Driving characteristics

Schwalbe’s Airless System tyres offer a lifetime of some 10,000 kilometers at regular use without maintenance, no punctures and no need for pumping. The Airless System “Brings an intuitive feel of an air pressure of around 3.5 bar making the driving characteristics comparable to those of an inner tube,” claims Schwalbe.

“With regard to comfort, longevity and maintenance-free system, our Airless System offers a real alternative to the inner tube for the first time”, states René Marks, Schwalbe product manager touring.

Thousands of mini air cushions

Solid inner tube systems already exist. What makes this new Airless System so extraordinary are, says Schwalbe “The technical properties of the foam particles, consisting of thermoplastic polyurethane (E-TPU), known under the Infinergy brand of BASF. Incidentally, it is the same material that is used in the soles of Adidas BOOST running shoes. The Airless tube has excellent damping and flexibility characteristics and offers lots of comfort.”

“Exactly these suspension characteristics makes the difference in comparison with the foams used for solid tubes so far,” explains René Marks. “The physical force with which the compressed material returns to its original shape is more than twice as high with this E-TPU foam than with existing systems. The cause: the E-TPU foam consists of thousands of sealed air balls. Together they form a highly elastic air cushion. That presents great advantages over current materials for solid inner tubes and makes it a real alternative to the inner tube.”

The technical advantages only cause a slight loss of performance, so the rolling resistance and the weight are slightly higher than for inner tubes. However, wherever a 100% maintenance-free system has the priority, the Airless System beats the inner tube.

Exclusively for specialist retailers

The Schwalbe Airless System is to be mounted with a special assembly tool. The installation time is not much longer per tyre as usual. Installation is only possible for bicycle dealers and only by bicycle technicians, who are certified after a Schwalbe training. This training will start in May 2018, initially only in the Netherlands and Germany.

Schwalbe’s Airless System consists of a 40-622 sized tyre, an Airless tube of white thermoplastic polyurethane and a blue Airless ring. This ring ensures compatibility of the system with different rim sizes. The system is suitable for rims with a rim width of 19 to 21 millimeters. The Schwalbe Airless System retails for 84.90 euros.

Published by Jack Oortwijn on 1 Mar 2018
last update: 1 Mar 2018
http://www.bike-eu.com/sales-trends/nieuws/2018/3/schwalbe-takes-airless-tyres-to-next-level-10133030