A Guide to the

Australian Paint Manufacturing Industry

Australian Paint Manufacturers’ Federation Inc.

 INTRODUCTION

This guide has been prepared in response to the many enquiries the APMF receives from students,
at school and university, and from members of the public, for general information on the paint
manufacturing industry in Australia.

While every care has been taken to ensure the accuracy and scope of the information provided, the
APMF does not claim that this document is anything other than a basic introduction to paint
manufacturing in Australia.

We hope therefore that it meets your needs and leaves you better aware of the important role the
paint manufacturing industry plays in the Australian economy.

Michael H R Hambrook
Executive Director

Australian Paint Manufacturers’ Federation Edition 1 1

 Contents

1. Executive Summary

2. Supply

3. Production Process- The Manufacture of Paint

3.1 Ingredients
3.2 Pigments
3.3 Extenders
3.4 Resins/Binders
3.5 Solvents/Carrier
3.6 Additives

4. Driving Factors

5. Products and Markets

6. Market Growth

7. Imports and Exports

8. Contribution to the Economy

9. Technology and Innovation

10. Australian Paint Manufacturers’ Federation Inc.

11. The Regulatory Environment

12. References

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 1. EXECUTIVE SUMMARY

Commercial production of paint commenced in Australia in about 1850. However, it was not
until the twentieth century that local manufacturers were able to dominate the Australian
market. In 1927 it was estimated that 78% of Australia’s paint requirements were produced
locally. At that stage, 69 factories employed 1,300 persons with an annual turnover of
approximately $4 million.

By 1955, turnover had increased to $73.5 million and employment stood at 5,300. During
this period the range of products offered underwent considerable expansion. Titanium dioxide
became the main colouring pigment for white paint. Water based paints were introduced in the
1960’s for architectural use and they now dominate the market. The period 1955 to 1970
witnessed record growth. In 1975, the IAC report on “Paints, Varnishes and Lacquer”
identified 140 paint firms, employing 7,500 employees with an annual turnover of $265 million.

The last fifteen years have seen a different type of change. The period has been characterised
by market rationalisation. A number of mergers and takeovers have occurred as
manufacturers, both large and small, have sought to gain economies of scale. Within
companies, specialisation is also occurring so that building paints may be manufactured at one
site and marine paints at another. Some companies are hiving-off non-core product lines to
concentrate on what they believe they can do best.

From 1992 to 1999 the Australian paint industry experienced a period of steady growth, with
the production of architectural and decorative paint increasing from 102 million to 121 million
litres for the year ended 31 ST December 1999.

2. SUPPLY

Production over the last decade has fluctuated between 185 and 225 million litres. Production for
1999 totaled approximately 218 million litres. Architectural and Decorative paint production has
increased from less than 50 percent of production to over 55 percent. Other significant trends are
the decline in solvent thinned Architectural and Decorative paint from 12 percent to 8 percent and
conversely the rise in Water thinned from 37 percent to 48 percent. There has also been an increase
in Timber Finishes from less than 1 percent to over 5 percent and a decrease in thinners from 14
percent to 10 percent.

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 3. PRODUCTION PROCESS

Paint manufacture is a relatively simple batch process. Basically, this is a physical process
where raw materials such as pigment, a pigment vehicle, binder, solvents and additives are
mixed in quantities ranging from 1,000 litres to 20,000 litres. This process is not capital
intensive, which accounts for the low cost of entry into low technology paint manufacture.

Further, plant is multi-purpose rather than specialised, which means small producers can
manufacture a range of paints. A small paint company may manufacture under approximately
100 different trade names and yet account for less than 1% of the total Australian paint sales.
Capacity can be increased by the addition of discrete plant units.

Production in Australia is constrained by market size and range of products, which has
resulted in batch production rather than 24 hour continuous shift. The APMF’s Trade and
Product Directory lists almost 4000 product names.

Ingredients
There are four main components in any paint formula:
1) Powders
2) Resin or Binder
3) Solvent or Carrier
4) Additives

Prime Pigments
The prime pigments contribute colour / opacity (hiding powder) to the paint. The major prime
pigment used in building paints is titanium dioxide or “Titan”. Titanium dioxide is a white
pigment and its importance is due to the fact that 85% of building paints are manufactured in
white.

Titanium dioxide has a high refractive index which means it bends light and hence, adds to
hiding power. Titanium dioxide pigments used in paints are inorganically coated to enhance its
durability and other properties for use in the paint industry.

Other prime pigments are mainly used to add colour. These fall into two main groups:

Earth pigments
Earth pigments which are manufactured naturally or synthetically and tend to be relatively
inexpensive.

Organic Pigments
These are manufactured by chemical processes and are bright reds and yellows. However

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 they can be extremely expensive. They normally provide poor hiding power.

Extenders
Extenders are mainly used to modify the gloss level of paints as the more pigment in a paint
film, the flatter the sheen will be.

Due to the high cost of Titanium Dioxide and its fine particle size, extenders are used to lower
the sheen or gloss. Extenders can also be used to add body to a paint and to increase is filling
properties.

The main extenders used are:

? Calcium Carbonate
? Barytes
? Talc
? Diatomaceous earth.

How the pigment affects gloss:

TABLE A

GLOSS FLAT
Layer of resin on top of pigment Resin Pigment protruding through resin diffuses
reflects light back. No extenders present. light.

Resin or Binder

The binder can be thought of as a glue which holds the pigments together and sticks them to
the surface. Its other major function is to provide many of the physical film characteristics such
as durability and flexibility.

Two distinct groups of binders exist, those that are found in oil based paints and those used in
water based paints.

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 Oil Based

The major group of binders used in oil based paints are Alkyds. These are modified vegetable
oils. The major vegetable oils used to produce alkyd resins are:

Wood/Tung oil drying oils

Linseed oil

Sunflower oil
Safflower oil semi-drying oils
Soya oil

Castor oil non-drying oil

These oils contain compounds which have active double bonds. These double bonds react
with oxygen in the air to form bridges between molecules in the resin which results in the drying
or curing of the resin. The more active double bonds in an oil, the faster it will dry.

It is not desirable that a resin dry too quickly as, if the surface dries more rapidly than the resin
underneath, the surface will wrinkle. For this reason, Tung oil alone is rarely used in paint
manufacture. Linseed oil alkyds yellow very badly in poorly lit conditions and so, Soya oil is
the main oil used to make Alkyd resins. It is cooked up with a number of other synthetic
ingredients to produce an Alkyd.

Many different types of Alkyds can be manufactured. However, they have certain common
advantages and disadvantages.

Advantages:

? Forms a tough durable film coat,

? High gloss levels are achievable,
? Resistant to moisture, grease and oil,
? Penetrate well; can be used on chalky surfaces.

Disadvantages:

? Dry film becomes harder and less flexible with age and this can lead to cracking and
peeling,
? Oil provides a food source for mildew,
? Solvent thinned - more odour, harder to clean up, less environmentally friendly.
? Subject to chalking when exposed to U.V. light.

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 Water based:

Unlike oil based paint resins, water based resins are not solutions but are dispersions or
emulsions of resin in water. This accounts for their white appearance.

These resins are synthetic and there are a number of resin types which are used in the
formulation of water based paints. The major types are:

? Poly Vinyl Acetate (PVA)/Acrylics

? 100% Acrylics.

These resins exist as polymers and dry by coalescence rather than oxidisation. When the paint
is applied, the water carrier evaporates, forcing the polymer particles together, which fuse to
form a film.

Water based resins are thermoplastic, which means they ha rden as the temperature falls.
Below 10?C. Water based resins have the following advantages and disadvantages:

Advantages:

? Easy clean up with water,

? Flexible film moves with the substrate,
? Normally dries faster than an oil based paint,
? Good colour retention.
? Film breathes, allowing moisture in or on the substrate to pass through.
? Longer exterior life than oil based paint.

Disadvantages:

? Not as tough as Alkyds,

? Cannot get a high gloss,
? Does not penetrate the surface as well as oil - should not be applied directly over chalky or
crumbly surfaces.

In general, PVA/Acrylic resins are used as interior wall paints, and 100% Acrylic resins are
used in exterior gloss or timber finishes.

Solvent or Carrier

The solvent or carrier in a paint serves to allow the resin and pigments to be applied to a
surface. It evaporates after application and does not form part of the applied film.

In water based paints, the carrier is water. In oil based paints, the carrier is usually a turps like

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 solvent. Due to the vario us types of turps like solvents which have different drying times, the
solvent in oil based paints can affect the application properties and drying of the applied
products.

Note:

Even though the carrier in water based paints is water, these paints resist water once the film
has cured. However, they should not be applied in situations where they will be exposed to
moisture immediately after application, eg. when rain or condensation are imminent.

Additives

There are many different additives used in the manufacture of paint in order to determine its
final performance, characteristics. For example, Zinc Oxide is used to resist mildew, to
provide UV protection, to inhibit tannin staining and to add strength to the final film.

Some of the more common types of additives are:

*Fungistats: prevent the growth of mildew,

*Coalescents: help produce a uniform film (water based paints)
*Dryers Anti skin: assist in oxidation for oil based paints
*In can preservatives: prevent bacterial attack,
*Thickeners: modify viscosity, enhance application properties of water
based paints,
*Wet edge additives: prevent paint from drying too quickly - water based paints,
*Surfactants: unused to maintain dispersion of powders and resins in water
based paints.

4. DRIVING FACTORS

There are three factors that mainly drives the development of the paint and coatings technology.
These in no particular order of importance are:

1. Health, safety and environment legislation.

2. The development of performance oriented products.
3. Cost.

Health, safety and environment legislation relates to the need to comply and indeed to anticipate new
health, safety and environment legislation. However the need to meet this regulation and to provide
products to give the performance desired by customers frequently come together and can be seen as
one and the same thing. This would entail making paints meeting environment legislation while at the

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same time meeting customers performance requirements. For example, legislative pressures in the
USA to reduce VOC content of paint presupposes a move from paints of lower solvent to higher
water based. Another example is that of the automotive refinish industry, which moved towards high
solid content paints and moved towards water based paints. The same sort of example can be
applied to many product ranges. This would increasingly meet the performance requirements of the
customer. This is because water based paints are easier to use and less hazardous in the workplace.
Apart from this, they are cheaper to store and do not require a dangerous goods store. They are
also easier to clean up.

Hence with the blending in of factors 1. and 2. Mentioned above, there is an increasingly happy
relationship between industry and government and customers. This is evidenced through an
expanding and exciting range of products coming onto the market.

5. PRODUCTS AND MARKETS

Paint production in Australia can be broadly divided into two major segments;
architectural/decorative paints and industrial paint and coatings. Based on annual statistics for
the year ended 1999, architectural and decorative paints account for 55.71% of production,
with industrial paints, heavy duty coatings and timber finishes comprising 44.29% of output.
The industrial and heavy duty coatings are usually formulated and produced for specific needs.

The processing line, from raw materials to the end user, is relatively straightforward. Some
manufacturers sell a proportion of their product, direct to the end user, through retail outlets.
A greater proportion is sold to trade painters and painting contractor companies via trade
depots. An even larger segment is sold to retailers, both large chain stores and local hardware
stores. The main distribution categories are shown in Table B.

The Australian market is insulated from the world paint market by a number of factors which
provide effective barriers to entry. The main factor is inhibiting in parts are the cost of freight,
a 5% tariff barrier, and the extremely high initial costs of establis hing a new product in the retail
sector. Existing manufacturers are further protected from competition by their established
position and knowledge of the market. Other advantages include brand loyalty, and
technologies developed for Australian climatic conditions. The need to be familiar with
Australian standards for formulation, labelling and packaging requirements is another barrier to
importers.

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 TABLE B

PRODUCT GROUP USERS SALES AND

DISTRIBUTION
ARCHTECTURAL AND PUBLIC EX FACTORY
DECORATIVE TRADE PAINTERS RETAILERS “AS ABOVE”
GOVERNMENT TENDER
GENERAL INDUSTRIAL MANUFACTURING:- DIRECT
AGRICULTURAL SALE TO END USER
IMPLEMENTS,
APPLIANCES (WHITE
GOODS)
HEAVY DUTY COATINGS ALUMINIUM EXTRUSION DIRECT SALE TO END
INDUSTRY, USE/ OR BY TENDER
MINING PROCEDURES
SHIP BUILDING
BRIDGES
OIL RIGS
PIPELINES
GOVERNMENT
AUTOMOTIVE- OEM AND NEW CAR PRODUCTION DIRECT WITH
RE-FINISH RE-FINISHING/SMASH MANUFACTURERS
REPAIR SHOPS DIRECT SALE TO END
USER
COIL COATS PRODUCERS OF SHEET DIRECT SALE TO END
METALS EG ALUMINIUM USERS
INDUSTRY
CAN COATINGS CAN COATS FOR FOOD DIRECT SALE TO END
AND BEVERAGES USER
SOFT TUBE COATINGS

6. MARKET GROWTH

From the mid seventies, growth in the industry has been characteristic of a mature market.
Total volume growth has been around 1.7% per annum over the past decade. However,
growth within specific categories of paint have varied greatly. In the USA, the growth rate
over the same period has been around 3% p.a. In Asia, the growth of paint production has
averaged 4.4% over the past fifteen years. The major paint producing countries in Asia are
Japan (39%), China (25%), South Korea (11%), and Taiwan (8%).

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 TABLE C

PAINT PRODUCTION IN ASIA

Other
17% Japan
Taiwan 39%
8%

South Korea
11%
China
25%

Changes in the world end-use pattern for paints have been predicted over the rest of the
decade, as shown in Table D in quantity terms, based on a consideration of trends in the main
user sectors over the period concerned.

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 TABLE D

CHANGES IN THE WORLDWIDE END-USE PATTERN OF PAINTS TO 2000

%1992 %1996 %2000

Building and construction 47.2 45.3 44.7

Transport production 4.2 4.1 4

Transport re-finishIng 4.2 4.3 4.5

Domestic appliances 2 2.5 2.8

Wood finishes 7.8 7.2 5.5

Marine and maintenance 3.9 3.9 3.8

Other industrial paints 27.8 29.7 31.5

Miscellaneous 2.9 3 3.2

TOTAL 100 100 100

7. IMPORTS AND EXPORTS

IMPORTS
Over the last decade, imports have been continuously increasing. According to statistics released by
the Australian Bureau of Statistics, approximately 13 million litres of paint was imported in 1999.
This represents approximately a 20 percent increase on the previous year.

EXPORTS
Exports of paint have dropped from 10.9 million litres in 1997 to 8.3 million litres in 1999. These
figures constitute solvent and water based paints. The proportions of these paints in the given figures
are approximately half.

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 8. CONTRIBUTION TO THE ECONOMY

Paint manufacturing is a small but very important sector of Australia’s manufacturing industry.

The industry makes a significant contribution to the Australian economy through its purchase of
locally produced materials. These include primary inputs such as titanium dioxide, talc, zinc
dust, linseed oil, and lyrates intermediates such acrylic emulsions, alkyd resins and driers,
cardboard packaging, metal and plastic cans, labels, pamphlets and brochures.

The following figures give an indication of the contributions of the industry to the Australian
economy:

? the paint industry is also a green industry having of its own volition, agreed on a VOC
(volatile organic compound) reduction strategy through to the year 2000.

9. TECHNOLOGY AND INNOVATION

The most significant trend over the past 20 years has been the growth of water based paints
and the decline of solvent based paint production. Whilst this trend has been most noticeable
in architectural/decorative markets, it is expected that far greater use of water based
technologies in industrial applications will occur in the future due to environmental/and health
and safety considerations.

Ten years ago it was said that very few Australian companies undertook basic research relying
instead on formulae and technology acquired from overseas affiliated. While local
manufacturers still import overseas technology it is increasingly modified to meet local
performance requirements. In a reverse situation some Australian manufacturers are now
exporting locally developed technology to Asia.

Although technical innovation in any science-based industry is slow and continuous, it is

possible to monitor changes by researching the industry journals such as;

Paint & Resin International- Michaelman

Journal of Coatings Technology-Federation of Societies for Coatings Technology
Modern Paint and Coatings-Intertec Publishing Corporation
Surface Coatings Australia -Surface Coatings Association Australia Inc.

These changes can be considered as a natural evolution of the industry, from being based

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 originally on naturally occurring materials (such as oleoresinous varnishes and enamels and the
nitro-cellulocics) through the synthetic resins (such as alkyds and acrylics) to the plethora of
types and are in current use.

The present stage of evolution of the coatings industry began in the early 1970s, primarily as a
result of increased concerns over the impact of certain chemicals on the environment, notable
the effects of solvent emissions which accelerated a trend towards the development of water-
based and other types of coatings able to meet various statutory requirements. The
technologies which evolved can be categorised into six distinct groups, as follows:

? improved low solids (<70%), solvent-based systems Comment [MHH1]: Michael

H.R. Hambrook
? high solids systems (>70%), solvent -based systems AUSTRALIAN PAINT
? water-borne coatings MANUFACTURERS’
FEDERATION
? reactive (two-part catalysed) systems Comment [MHH2]:
? powder coatings
? radiation cured systems (ultra-violet and electron beam.)

One surface coating that is relatively new and growing at 5-8% per annum, is powder
coatings. Many segments of the market, notable automotive coatings are heavily affected by
economic cyclic activity, Marine paint growth rates have remained virtually static since 1980.
There has been a decline in the demand for wood stains since 1970.

As a broad generalisation the relative importance of the alternative coatings technologies for
the whole of the Asia-Pacific region si shown in Table ‘E’ together with the likely shift in
importance over the reset of the present decade. These figures relate to all of the region, with
the exception of Japan, the inclusion of which would tend to distort the pattern.

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 TABLE E

RELATIVE IMPORTANCE OF DIFFERENT TECHNOLOGIES

1992 1996 2000

% % %

Conventional Solvent-Borne 58 43 30
High Solid Solvent-Borne 4 6 8
Water-Based 33 43 50
Powder Coatings 5 7 9
Reactive Systems · 1 3
Radiation-Cured _____ _____ _____

TOTAL 100 100 100

It is seen that powder coatings are expected to exhibit exceptional growth over the years
ahead according to Information Research Limited (IRL). IRL estimate the present usage of
these materials to be in excess of 93,000 tons in Asia-Pacific, with the demand by country
being indicated in Table F.

TABLE F

DEMAND FOR POWDER COATINGS IN THE ASIA-PACIFIC REGION

(1992-2000)
(TONS)

COUNTRY 1992 1996 2000 AAGR(%

p.a.)

China 30,000 127,500 244,500 30

Japan 28,000 62,000 98,000 15
Malaysia 1,000 2,700 5,950 25
Singapore 1,500 3,850 9,000 25
Thailand 2,750 8,150 22,450 30
Australia 5,500 13,500 32,800 25
New Zealand 2,000 4,880 12,000 25
Others 22,925 54,135 99,925 25

Total 93,675 276,715 524,625 24

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 New technologies are being developed in Europe, America and Japan designed to provide
enhanced product performance and to meet the ever changing demands of consumers. These
will require local paint manufacturers to commit substantial amounts of their own R&D
resources to the adaptation and introduction of those new technologies into their Australian
operations, especially industrial coatings in the automotive (OEM and refinish), coil and
powder coatings.

10. AUSTRALIAN PAINT MANUFACTURERS’ FEDERATION INC.

On 11 June 1925 at the N.S.W. Chamber of Manufacturers, it was moved by Mr. H.G.
Taubman “that a Paint and Varnish Manufacturers” section of the Chamber be formed. In
1933 the paint manufacturers decided to distance themselves from the Chamber of
Manufacturers and adapted the name “The Paint Varnish and Lacquer Manufacturers
Association of NSW.” At about the same time other paint and varnish manufacturing
associations were being established in Victoria, South Australia, Western Australia and
Queensland.

The Australian Paint Manufacturers Federation (APMF) was established in 1947 to bring all
these interests together under one body. Its aims are:

? to advance the theory and practice of paint technology in Australia;

? to promote efficiency and safe working practices;
? to foster internat ional co-operation and standards;
? to advance, encourage and protect interests of members.

In 1991, the decision was taken to include as Associate Members any manufacturer, broker
or importer of materials or equipment used in connection with the manufacture, merchandising
or application of adhesives and sealants, colorants, industrial coatings, inks, lacquers, paints
resins and varnishes or related or kindred products.

Until the mid 1980’s, branches of the APMF were in operation in the major states of
Australia. In 1986, a decision was taken to operate one office in Sydney on a national basis.
The APMF, which is governed by a council representing both large and small manufacturers
and managed by an Executive Director and a small staff. It is concerned with all paint related
issues particularly in the health, safety, environment, packaging, distribution, storage and
technical areas. It is the principal means of liaison between Government, various statutory
authorities and the industry.

The APMF also fulfils a vital function in advising members of changes to relevant legislation,

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 regulations or tariff provisions and provides a full industrial relations service. Relevant
production and other figures, and analyses of these, are regularly circulated to members.

To guide the development of industry responses to these important issues, the APMF is
assisted by various committees including Packaging, Storage and Distribution Committee, the
Health, Safety and Environment Committee and the Technical Committee.

11. THE REGULATORY ENVIRONMENT

Australian industry is one of the most regulated in the world and paint is no exception. If a
chemical is not already listed on the Australian Inventory of Chemical Substances it has to be
cleared through the National Industrial Chemicals Notification and Assessment Scheme. The
Standard for the Uniform Scheduling of Drugs and Poisons regulates the use of certain
chemicals and prescribes various warning and safety instructions which must appear on paint
can labels. The Trade Measurements Act regulates the use of measurements where such
information must appear on the label and what ullage is permissible. Labels must also comply
with the Australian Code for the Transport of Dangerous Goods and the Agricultural and
Veterinary chemicals legislation in the case of anti- fouling paints. Then, of course, all products
are subject to duty of care provisions of the Trade Practices Act.

Paints are manufactured in premises that have to comply not only with all the normal rules
regulating manufacturing operations but with the particularly onerous dangerous goods storage
and handling regulations of each state. Products sold into the workplace must be accompanies
by a material safety data sheet prepared in accordance with the Worksafe Australia guide.
Liquid and solid wastes emanating from manufacturing operations are subject to very tight
controls enforced by State Water Boards, Environmental Protection Authorities and local
Councils. The list is not exhaustive, merely a general indication of the overall regulatory
framework.

In spite of this mass of regulation the Australian paint industry is not faced with some of the
draconian regulations which apply in other countries. For example, we do not yet have the
VOC and clean-up regulations of North America, not the same anti-graffiti restrictions which
apply in some overseas cities banning or severely restricting the sale of aerosol paints.

We enjoy very good relations with all regulatory authorities and have a long track record of
managing the issues rather than addressing them only when draft legislation is tabled in
Parliament. On this basis the Australian paint industry can look forward with confidence to
next decade. It is also likely that the policies and strategies now being put in place by
Australian paint manufactures will see the Australian paint industry achieve a leadership role in
the Asia Pacific area.

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 REFERENCES

“High Growth Predicted For Asia Pacific Region,” The Coatings Agenda Asia-Pacific 1996/97

“Overseas focus f or growth,” European Chemical News, October 1996

“Forecasting Paint Production in Australia 1970 - 1990,” Australian Paint Manufacturers’

Federation, Sydney, October 1990.

The Rauch Guide to the U.S. Paint Industry, Rauch Ass.

ICI Paints, (1989) “The World Paint Market Towards 2000,” Journal of the Oil and Colour
Chemists, 8:311.

A Profile of the Asia-Pacific Paint Industry, Information Research Limited, London, December
1992.

Paint & Resin, A Profile of the European Paint Industry (8 th Edition) and Industrial Coatings in
the USA, December 1988.

Decorative Products World, Paint: Forecast and Trends, March/April 1988.

Financial Times Survey, World Paints and Coatings, March 27, 1991.

Modern Paint and Coatings, Market Analysis Predicts Continuing Moderate Growth for Paint
and Coatings, January 1991.

Journal of Coatings Technology, New Horizons in Coatings Science and Technology, September
1989.

Journal of Coatings Technology, Coatings Progress in the Mid 1980’s, February 1987.

The Coatings Agenda Asia Pacific 1996/97, Campden.

AUSTRALIAN BUREAU OF STATISTICS

Plastics, Rubber, Paints Detergents and Industrial Chemicals, Catalogue 8362.0

Manufacturing Industry Australia 1993-94, Catalogue 8221.0

Manufacturing Industry 1990-91, Catalogue 8221.0

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Manufacturing Industry Details of Operations Australia, 1988-89, Catalogue 8203.0

Manufacturing Industry Concentration Statistics Australia, 1987-88, Catalogue 8207.0

Manufacturing Industry Selected Items of Data by Employment Size Australia, 1987-88, Catalogue
8204.0

Manufacturing Commodities Principal Articles Produced, Australia, 1986-87, Catalogue 8303.0

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