Extender - An amazing value still comes at Lower Cost....even Today

1. Kaushal.Kansara
VIMAL MICRONS LIMITED

2.  Indian PaintIndustry – Current Scenario
 Introduction of Vimal Microns Limited
 Importance of Extender in Paint Industry
 Introduction of 2 Micron Calcium Carbonate –
CARB 201
 Introduction of 2 Micron Talc – TALC 2 M
 Introduction of CARB 10 B to Small Scale Paints
Manufacturers

3.  Total Market is more than Rs.15,000 Crore
 Decorative segment has an edge compare to
Industrial Segment in ratio of – 70:30
 Few Corporate Giants have share of almost 55 %
of the entire market
 Small Scale Paints Manufacturers are catering
around 45% of the market demand

4.  Per capita consumption of Paints in India is 1.25
kgs.
 Compare to other develop countries it is too low
 Growth of Small Scale Paints Manufacturer – more
than 20% during last couple of years.
 Market Prediction – Should double by 2013.

5.  Founded in 1995-96, under direction of
Mr.G.K.Patel.
 Flagship company of VIMAL GROUP OF
INDUSTRIES – Having turnover of more than 1700
Crore INR.
 Producing around 1,20,000 MT per Annum.
 Having Two state of the art units located at
Mehsana & Alwar.
 Specialize in Micronizing of Minerals such as
CALCITE, TALC, DOLOMITE, BARYTE, CHINA CLAY,
SILICA, WHITE WHITING & MICA.

7. SECONDARY PIGMENT :
Which can be used to improve
certain properties in Paints.

8.  Mineralogy (crystal structure, Mohs hardness, etc.)
 Oil absorption, brightness, pH, refractive index, etc.
 Chemical Properties
 Particle size and particle size distribution
 Particle shape and aspect ratio

9. Extender Chemical
Specific Particle Oil Refractive Particle
(Common Nomenclatu Ph Hardness Utility
Gravity Size Absorption Index Shape
Name) re
Calcium Fill, Corrosion
Calcite Carbonate 2.7 1.5 - 30 6 - 30 9 – 10 1.65 3 Various Control
Fill, stress
Magnesium mitigation, Film
Talc Silicate 2.8 2.5 - 40 30 - 50 8–9 1.58 1 Various reinforcement
Silica Fill, inertness,
(Amorphous flatting, abrasion
) Silica 2.6 5 - 40 20 - 50 6 -7 1.54 7 Nodular resistance
Silica Fill, flatting agent,
(Fumed) Silica 2.2 0.01 - 0.11 150 - 300 6 -7 1.54 7 Nodular rheology
China Clay, Aluminum
Kaolin Silicate 2.6 0.5 - 3.5 25 - 50 4.5 – 7 1.57 2.5 Platy Fill, opacity
Fill, barrier
Aluminum properties,
Potassium corrosion
Mica Silicate 2.8 5 - 20 50 -70 7.5 - 9.5 1.59 2 .83 Platy resistance
Barium
Baryte Sulphate 4.5 2 - 30 10 7 1.64 3 Nodular Fill, inertness
Calcium
Magnesium
Dolomite Carbonate 2.8 1.5 - 30 6 – 30 9 – 10 1.65 3.5 Various Fill,

10.  Mohs hardness is a relative measure of abrasion
resistance of a mineral.
 Talc is the softest mineral and diamond is the
hardest.
 Harder minerals will have better scrub resistance
and better burnish resistance.

11. 12
10
8
6
4
2
0
Talc China Clay, Kaolin Mica Calcium Carbonate Baryte
Dolomite Silica (Amorphous) Silica (Fumed) Diamond

12. The oil absorption of a mineral is a
characteristic of the mineral itself
and depends how finely it is ground.
The denser the mineral, the lower
the oil absorption. The oil
absorption indicates the amount of
the resin the mineral will absorb
and affects the viscosity of the paint
and the gloss.

13.  The dry brightness and color of a mineral
in oil will affect how the mineral appears
in a coating. A mineral can have
excellent dry brightness but change color
when put into a resin. Color in oil can
vary from cream to gray or even
green, depending on the mineral. The
color is usually an effect of minor
impurities.

14. pH is a function of the metallic ions
in the structure. Aluminum in the
structure makes the mineral acidic.
Calcium, potassium, barium or
sodium make the mineral alkaline.
Some minerals, such as calcite or
serpentine, are soluble in acids and
can’t be used in coatings that have
pH <7.

15.  Extenders do not enhance the true opacity or
color of the coating film. The refractive index is
a measure of how light is bent when it passes
from one medium to another. The higher the
refractive index, the more the light is bent
which results in greater opacity. Rutile TiO2
has a high refractive index and gives good
opacity to paints. All extenders have refractive
indexes that fall in a range between 1.45 and
1.65, they have a significantly lower refractive
index than TiO2 and don’t contribute to the
opacity, but they can be used in conjunction

16.  While the physical aspects of extenders are of
particular importance to their use in Paints, so is their
chemical make up. Whiting may be of value as a
pigment for anti-corrosive paints, Larger particle sized
pigments, which are favored for metal primers, give
coarser films with better flow and tooth for improved
intercoat adhesion. Fine, wet ground and precipitated
Carbonates are used in gloss finishes and
enamels, while intermediate sized pigments are
favored for semi-gloss pigments and flats. Whiting of
intermediate fineness is also used in exterior house
paints, where the pigments improve mildew
resistance, reduce chalking as well as assist in
controlling cost. Larger sized grades of whiting are said
to give good color retention in exterior house paints.

17.  Mica has also been used as an extender. As mica is
more chemical resistant than aluminum, this
extender is particularly valuable where the paints
is exposed to conditions of extreme pH.
 China Clay may be used more effectively in
inhibitive systems. China clay that are platy like
the Talc, will also tend to reinforce the film, and
are said to improve the sanding of industrial
primers.

18.  Baryteis a small inert nodular pigment that packs
well and gives excellent enamel holdout
properties. Baryte is available in two
forms, naturally ground Baryte and the less
common but whiter precipitated grade, which is
usually finer and higher in oil absorption than the
natural product. Baryte is the heaviest extender
with the lowest oil absorption characteristics. It is
widely used in low VOC systems, but needs some
additional support in order to control settling.

19.  The particle size of a mineral can be expressed in
several ways, depending on the method by which it is
measured.
 Common methods of measuring particle size are
Hegman fineness, screening, sedimentation and laser
light scattering method.
 Laser Light Scattering method is the latest and most
advance method.
 Each method will yield a distinct result.
 When comparing data of different minerals, be sure
that the particle size distributions are measured the
same way.

20.  Hegman fineness measurements indicate only size
of the coarsest particles. This is a good first
approximation of the fineness of grind and the
dispersion of the mineral pigments in the paint.
 Hegman fineness does not tell anything about the
overall distribution of the particle of the mineral.

21.  Screen residue only indicates the % coarser than
some given mesh size. Typical mesh sizes are
100, 200, 325, 450 and 500 mesh. These are equal
to 150 μm, 75 μm, 44 μm, 32 μm and 30 μm
respectively.
 Screenings can be done dry or wet. Wet
screenings usually yield a smaller quantity
retained than dry screenings.

22.  The screen residue measures the quantity of
particles retained, it does not tell anything about
the size of those retained particles except that they
are larger than the screen openings.
500 Mesh (30 µm)
 The screen residue does not tell anything about the
sizes of the particles that pass through the screen
except that they are smaller than the screen
openings.

23. Sedimentation methods measure
particle size by Stokes Law and yield
results expressed as equivalent
spherical diameter.
The median equivalent spherical
diameter of the mineral is often
given. The median is the size where
50 % of the particles are larger and
50 % are smaller.

24.  Laser diffraction measurement methods give a different
particle size and particle size distribution than
sedimentation methods.
 Particle size is usually expressed as D10, D50 and D99.
(the percent finer than the stated micron size)
 Laser diffraction methods usually give a coarser particle
size than sedimentation methods.

25. Particle Size Distribution
100
80
Volume (%)
60
40
20
0
0.1 1 10 100 1000
Particle Size (µm)
No Name Supplied, Saturday, December 18, 2010 1:59:43 AM

26.  Differencesin shape and size of different
extenders can lead to many practical benefits. The
make up of the extender package was largely
predicated on cost reduction. Since then, if only
slowly, we have come to understand that care in
apportioning the available extender volume
between the various extenders available to the
formulator can result in films with enhanced
mechanical and even performance characteristics.
Different paint types having different usage and
performance requirements benefit from different
types of extenders.

27.  Some of the most effective fillers in terms of
low oil absorption are the nodular extenders
such as , Calcium Carbonate, baryte and
amorphous silica (as opposed to the fumed
and diatomaceous types). These materials
provide little value in aesthetics, however, as
do the finer Calcium Carbonate, which are
used effectively in combination with TiO2 to
enhance opacity. This is achieved by
optimization of the manner in which the film
scatters light, and is discussed below. That
being said, nodular pigments contribute little
to the mechanical properties of the film.

28.  Flat,platy extenders such as Mica and some Talc and
clays are also highly absorbent, again because of their
very high surface area per unit weight compared to
nodular extenders such as Silica, Baryte or Calcium
Carbonate. These extenders tend to enhance the
mechanical properties of the film by lateral
reinforcement. It has also been reported that platy
extenders of this type not only reinforce the film but
minimize the accretion of internal stress by allowing
better dissipation of stress along the plane of the
pigment. Flat, platy pigmentation orientated parallel to
the substrate also tends to decrease the porosity of
the applied film, sealing it and reducing the tendency
of high PVC primer films to bubble when recoated.

29.  Mineral particles come in any of several basic shapes :
.
Sphere Cube Needle
Block Plate / Flake Fiber

30.  Needle/Fiber Aspect
D
Ratio : Ratio of mean
L
length to mean diameter
 Plate Aspect Ratio : Ratio
of mean diameter of a
circle of the same area as T
D
the face of the plate to
the mean thickness of
the plate

31.  Aspect ratio is a description of the overall shape
of the particle. It describes the length to diameter
ratio, the face to thickness ratio, etc.
 Cubes or spheres have 1:1 aspect ratio
 Blocks have 2:1 to 4:1 aspect ratio (length:width)
 Needles or fibers have 5:1 to 200:1 aspect ratio
(length:width)
 Plates or flakes have 20:1 to 200:1 aspect ratio
(face:edge)

32.  Talc is a platy magnesium silicate mineral.
Its properties include high oil
absorption, softness and high brightness .
 We are having an excellent quality deposits
of Talc situated at Himachal Pradesh and in
Rajasthan.
 The use of talc in coatings contributes to
gloss control,TiO2 spacing, anti-
settle, sandability of primers, inter-coat
adhesion and corrosion/blistering
resistance.

33. PARTICLE SIZE ANALYSIS VIMCRO TALC 2 M
PHYSICAL ANALYSIS
Residue 400 # Nil
Residue 500 # 1.0% Max
Dry Brightness Min. 97.0%
Bulk Density [untapped] 300 – 400 Gm/Lit
Oil Absorption 40.0 – 45.0 Gm/100 Gm
Water Demand 45.0 – 50.0 ml/100Gm
Specific Gravity 2.7
pH of Sat. Solution 9.0 – 10.0
Moisture Content Max. 0.5%
CHEMICAL ANALYSIS
% of MgO 29.81%
% of SiO2 60.32%
% of AI2O3 0.67%
% of CaO 1.69%
% of Fe2O3 0.47%

34.  Natural calcium carbonate (GCC) is one of the
most abundant filler minerals.
 It forms in several crystal shapes. Shapes include
blocky (chalk), scalenohedral (calcite), short
needle acicular (aragonite).
 Calcium carbonate has high brightness, low oil
absorption, can be ground to ultra fineness, and is
relatively inexpensive.
 It is widely used in all kinds of paints and coatings,
especially in interior and exterior paints.
 Calcium carbonate is unstable in acidic conditions
and soft (poor abrasion resistance).

35. PARTICLE SIZE ANALYSIS VIMCRO CARB 201
PHYSICAL ANALYSIS
Residue 400 # Nil
Residue 500 # 0.05% Max
Dry Brightness Min. 94.0%
Oil Absorption 20.0 – 25.0 Gm/100 Gm
Water Demand 22.0 – 30.0 ml/100Gm
Bulk Density [untapped] 650 – 750 Gm/Lit
pH of Sat. Solution 9.0 – 10.0
Specific Gravity 2.7
CHEMICAL ANALYSIS
% of CaCO3 95.0± 1.0%
% of MgCo3 3.0 ± 1.0%
% of Acid Insoluble 1.5 ± 0.5%
% Loss On Iginition 43.0 ±1.0%

36. PARTICLE SIZE ANALYSIS VIMCRO CARB 10 B
PHYSICAL ANALYSIS
Residue 400 # Nil
Residue 500 # Nil
Dry Brightness Min. 95.0%
Oil Absorption 23.0 – 27.0 Gm/100 Gm
Water Demand 24.0 – 32.0 ml/100Gm
Bulk Density [untapped] 650 – 650 Gm/Lit
pH of Sat. Solution 9.0 – 10.0
Specific Gravity 2.7
CHEMICAL ANALYSIS
% of CaCO3 95.0± 1.0%
% of MgCo3 3.0 ± 1.0%
% of Acid Insoluble 1.5 ± 0.5%
% Loss On Iginition 43.0 ±1.0%

37. Natural barium sulfate, known as
baryte, is a high brightness, high specific
gravity, low oil absorption extender.
The specialty of Baryte is High Refrective
Index.
Baryte is also known for its excellent
compatibility with Coloured Pigments.
It finds use in powder coatings because of
its high specific gravity, good brightness
and low oil absorption.

38.  Hydrated Aluminum Silicate – Popularly known
as Kaolin is widely used by
Paints, Paper, Ceramic & Rubber Industries.
 Because of its Lamellar form, it gives good
coverage.
 China Clay is chemically inert mineral.
 It has Higher thicksotropic nature as well as
good water absorption capacity.
 The modified version – Calcined China Clay
improves Opacity.

39.  Dolomite is a natural form of Calcium
Magnesium Carbonate with high degree of
Whiteness.
 It is also noted for its remarkable wettability
and dispersibility as well as its moderate Oil
Absorption.
 It gives good Whiteness to the Paints, because
of its Higher Bulk Density, Less Reactive.

40.  Mica is a platy mineral. There are several
different forms of mica :
Muscovite, Phlogopite, Biotite, etc.
 Fine dry ground mica is used in joint cement
and texture paints for mud crack resistance.
 Fine wet ground mica is used in exterior latex
paints for tint retention and weatherability.
 Mica is used as the base for special effect
pigments.

41.  Natural silica is the most abundant mineral
family on Earth. Common varieties include
quartz, sandstone, silica sand, tripoli, opal and
novaculite (microcrystalline quartz).
 It has low oil absorption, good brightness, high
purity, and excellent abrasion resistance.

42. Aesthetic Properties :
 Gloss Control
 Sheen
 Opacity
 Brightness
 Dirt Pick-up and Cleanability
 Textures & Smoothness

43. Mechanical & Physical Properties :
 Hardness
 Impact Resistance
 Resistance to applied stress
 Film reinforcement
 Porosity
 Cracking and Checking resistance

44. Wet Paint & Proccessing Properties :
 Viscosity
 Flow and Leveling
 Ease of Dispersion
 Sedimentation and Settling

45. Performance and Resistance Properties :
 Abrasion and Scrub Resistance
 Permeability
 Corrosion Resistance
 Chemical Resistance
 Thermal Properties (Insulation & Conductivity)
 Electrical Properties(Insulation &Conductivity)

46. Other :
 Cost Control
 Filler – Spacer