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US demand for powder coatings is forecast to grow 3.5 percent annually through 2013. The key motor vehicle market will be the fastest growing segment, followed by construction materials and lawn and garden equipment. Both thermoset and thermoplastic powder coatings will grow at the same pace.
This study analyzes the 375 million pound US powder coating industry. It presents historical demand data for the years 1998, 2003 and 2008, and forecasts for 2013 and 2018 by raw material, product (e.g., epoxies, epoxy/polyester hybrids, polyesters, polyurethanes, acrylic, silicone, polyvinyl chloride, nylon) and market (e.g., motor vehicles, appliances and housewares, furniture, industrial machinery).
The study also considers market environment factors, details industry structure, evaluates company market share and profiles 35 industry competitors, including Valspar, DuPont and Dow Chemical.
Thermosets to retain dominance over thermoplastics
Thermoset powder coatings represented more than 90 percent of total US powder coatings demand in 2008, due largely to their lower prices and good performance characteristics. Epoxy is the single largest product type, favored for its excellent corrosion- and chemical-resistance in interior applications. Epoxy/polyester hybrids are also well-represented and combine the best characteristics of straight epoxy and polyester powder coatings. The superior resistance to weathering of polyester and polyurethane powder coating formulations makes these the products of choice for exterior applications. Smaller volume types, such as acrylic and silicone coatings, are expected to register above-average growth from relatively small bases, with silicone benefitting from its use in high heat applications.
Thermoplastic powder coatings will account for the remainder of demand. The favorable performance characteristics of thermoplastic powder coatings -- such as chemical resistance, toughness and flexibility -- will support gains. For instance, fluoropolymer powder coatings offer the best weatherability and outdoor durability of all powder systems in the US and will benefit from use in the construction and industrial machinery markets where these properties are highly valued.
Motor vehicles will offer strongest market growth
The motor vehicle market will provide the strongest gains through 2013 based mostly on an expected rebound in motor vehicle output following the significant declines of the 2003-2008 period. Product developments that will allow for greater use of powder coatings in exterior body applications will also offer opportunities for growth in this market. On the other hand, demand in appliances and housewares will be restrained by market maturity, as well as continued declines in appliance shipments, which reflect the inroads that imports have made in both small and major household appliances. The furniture market will benefit from an improving outlook for furniture production, as well as the development of powder coatings that can be used on wood and plastic substrates.
Study coverage
Powder Coatings is a new Freedonia industry study which presents historical demand data (1998, 2003 and 2008) plus forecasts for 2013 and 2018 for both thermosets and thermoplastics by market. All data on powder coatings are reported in pounds and in current US dollars. In addition, this study assesses key market environment factors, evaluates company market share and profiles 34 participants in the US industry.
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Table of Contents
SECTION PAGE
INTRODUCTION ix
I. EXECUTIVE SUMMARY 1
II. MARKET ENVIRONMENT 4
General 4
Macroeconomic Overview 5
Demographic Outlook 9
Personal Consumption Expenditures 12
Manufacturing Sector Outlook 14
Historical Market Trends 17
Environmental & Regulatory Considerations 20
The Environmental Protection Agency 20
The Occupational Safety and Health Administration 22
World Powder Coatings Demand 22
III. RAW MATERIALS & TECHNOLOGY 25
General 25
Raw Materials 26
Resins 27
Thermosetting Resins 28
Thermoplastic Resins 31
Pigments 31
Additives 33
Crosslinking Agents 33
Flow Control Additives 34
Photoinitiators 35
Other Additives 35
Manufacturing 37
Application Technology 38
Electrostatic Deposition 40
Fluidized Bed 42
Curing Ovens 42
IV. OVERVIEW 44
General 44
Industrial Coatings Overview 46
Industrial Coating Types 48
Industrial Coating Formulations 51
Advantages & Disadvantages of Powder Coatings 53
Pricing Trends 57
V. PRODUCTS 60
General 60
Thermoset Powder Coatings 63
Performance Characteristics of Major Thermosets 66
Epoxies 68
Epoxy/Polyester Hybrids 71
Polyesters 73
Polyurethanes 76
Acrylic 79
Silicone 80
Suppliers of Thermoset Powder Coatings 82
Thermoplastic Powder Coatings 83
Performance Characteristics of Major Thermoplastics 85
Polyvinyl Chloride 87
Nylon 90
Other Thermoplastic Powder Coatings 92
Ethylene Acrylic Acid Copolymer 93
Fluoropolymer 93
Polyethylene 94
Polypropylene 95
Thermoplastic Polyester 95
Suppliers of Thermoplastic Powder Coatings 96
VI. MARKETS 98
General 98
Motor Vehicles 100
Motor Vehicle Overview 101
Powder Coatings Demand 104
Exterior Applications 107
Advantages 110
Disadvantages 110
Engine & Mechanical Applications 111
Interior Applications 112
Appliances & Housewares 113
Appliances & Housewares Overview 113
Powder Coatings Demand 115
Major Appliances 118
Small Appliances & Related Equipment 119
Housewares & Fixtures 120
Furniture 120
Furniture Industry Overview 121
Powder Coatings Demand 123
Industrial Machinery 125
Machinery Overview 126
Powder Coatings Demand 127
Lawn & Garden Equipment 130
Lawn & Garden Equipment Overview 130
Powder Coatings Demand 132
Construction Materials 134
Construction Overview 135
Powder Coatings Demand 138
Residential Building Applications 141
Nonresidential Building Applications 142
Nonbuilding Applications 142
Other Markets 143
Sporting Goods & Recreational Equipment 144
Sporting Goods & Recreational Equipment Overview 145
Powder Coatings Demand 146
Electrical & Electronic Equipment 148
Electrical & Electronic Equipment Overview 149
Powder Coatings Demand 151
All Other Markets 153
VII. INDUSTRY STRUCTURE 155
General 155
Market Share 156
Acquisitions, Divestitures & Industry Restructuring 162
Distribution 165
Marketing & Competitive Strategies 166
Research & Development 169
Company Profiles 171
Akzo Nobel Non Stick Coatings, see Whitford
Akzo Nobel NV 172
AmeriCoats 175
Anderson Development, see Mitsui Chemicals
Arkema SA 176
Atomized Powder Coatings, see Protech/Oxyplast
BASF SE 178
Bayer AG 179
Becker Powder Coatings, see Sherwin-Williams
Cardinal Industrial Finishes 181
Cytec Industries Incorporated 182
Diamond Vogel Paints 183
DIC Corporation 185
Dow Chemical Company 187
DuPont (EI) de Nemours 191
Eastman Chemical Company 196
Enviro-Powder, see Protech/Oxyplast
Environmental Coatings Incorporated 197
Evonik Industries AG 198
Govesan Manufacturing, see Protech/Oxyplast
Henkel AG & Company KGaA 200
Hexion Specialty Chemicals Incorporated 201
Huntsman Corporation 203
Louisiana Pigment, see Huntsman
Mitsui Chemicals Incorporated 205
Nippon Paint Company Limited 206
Nordson Corporation 207
NPA Coatings, see Nippon Paint
Pioneer Powder 209
Powder Technology Incorporated 210
PPG Industries Incorporated 212
Protech/Oxyplast Group 214
Reichhold Incorporated 217
Rohm and Haas, see Dow Chemical
Royal DSM NV 218
RPM International Incorporated 220
Sherwin-Williams Company 222
Spraylat Corporation 224
Sun Chemical, see DIC
TCI, see RPM International
Thermoclad Company 225
3M Company 227
TIGER Coatings GmbH & Company KG 228
Trimite Powders, see Weilburger Coatings
Valspar Corporation 230
Weilburger Coatings GmbH 232
Whitford Corporation 233
Additional Companies Mentioned in Study 235
LIST OF TABLES
TABLE NUMBER PAGE
SECTION I -- EXECUTIVE SUMMARY
Summary Table 3
SECTION II -- MARKET ENVIRONMENT
1 Macroeconomic Indicators 9
2 Population & Households 12
3 Personal Consumption Expenditures 14
4 Manufacturers' Shipments 17
5 Powder Coatings Demand, 1998-2008 19
SECTION III -- RAW MATERIALS & TECHNOLOGY
1 Raw Material Demand in Powder Coatings 27
SECTION IV -- OVERVIEW
1 Industrial Coatings Demand 48
2 Industrial Coatings Demand by Type 50
3 Industrial Coatings Demand by Formulation 53
4 Advantages & Disadvantages of Powder Coatings 56
5 Powder Coatings Prices 59
SECTION V -- PRODUCTS
1 Powder Coatings Demand by Type 63
2 Thermoset Powder Coatings Demand by Type & Market 65
3 Comparable Performance Characteristics of Major Thermoset
Powder Coatings 68
4 Epoxy Powder Coatings Demand by Market & Application 71
5 Epoxy/Polyester Hybrid Powder Coatings Demand by Market 73
6 Polyester Powder Coatings Demand by Market 76
7 Polyurethane Powder Coatings Demand by Market 78
8 Acrylic Powder Coatings Demand <
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