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Coatings Formulation Guide EPM051-5
Coatings Formulation Guide EPM051-5
Coatings Formulation Guide EPM051-5
Formulation
Guide
Formulating High-Quality
Coatings with Celatom®
Functional Additives
A
round the world,
makers of high-quality
architectural and
industrial coatings have
discovered the benefits of
Celatom® diatomaceous
earth (DE), also known as diatomite or
kieselgühr. In most industrially-developed
regions, DE is used in the majority of high-
quality interior and exterior formulations.
In recent years, strong economic growth
and booming construction markets in
developing countries have attracted the
attention of major international paint
companies. They have acquired local
companies and invested heavily in modern
facilities and advertising, in markets
that were traditionally served by local
or regional paint producers. In response,
local producers are seeking to increase
the quality of their products to remain
competitive. In many cases, Celatom® DE
has been an important component of their
new high-performance formulations.
1
A
regional coatings producer in Turkey
needed a deep matte architectural finish
for their market, and they desired to
improve the performance of their products to be
Case
more competitive with higher-quality imported
coatings. We introduced them to Celatom®
MW-27 as the most effective matting agent on
the market, and they began trials. They were
Studies:
impressed with the performance of MW-27 ―
not only to achieve a dead-flat finish, but also for
improved hiding capacity and scrub resistance.
The company launched a new line of interior
finishes incorporating MW-27, and developed
a major marketing campaign around their new
higher-quality products.
A
major international coatings
producer was using a
competitor’s natural DE
product, but when they learned about
the superior efficiency of Celatom®
CelaFlat+ (aka LCS-3), they began a
re-formulation and testing program. EP
Minerals' paint chemist worked with this
customer on their development program,
including testing their formulations in
our lab and also working side-by-side
in the customer’s paint lab. Together
we developed a new formulation that
achieved equivalent matting performance
using 30% LESS DE in their formulation
by using CelaFlat+. This allowed a lower
final pigment volume concentration and
improved scrub and burnish properties,
with equal or reduced cost.
2
Celatom® DE vs. Other Mineral Fillers
Diatomaceous earth is unique among industrial mineral fillers, because of its complex microscopic structure.
Most mineral fillers are produced by grinding and classification of natural crystals, which have forms which are
either blocky (e.g., calcium carbonate, and ground quartz), or plate-like (e.g., talc, clay and mica).
Unlike these typical minerals, DE is of biogenic origin, made by microscopic unicellular aquatic plants, called
diatoms. The individual diatom structures are made of nearly pure silica, with a complex, highly porous three-
dimensional structure.
Celatom® DE is not just a “filler”, but a multi-functional mineral additive and a key component in high-
performance paints. It does add bulk and reduce cost, but it also improves the overall performance of the
coating in a variety of ways:
There are other minerals that can contribute to some of these functions, but none offer this broad array of
benefits - resulting in a better overall product. Your paint will look better, be more durable, have a longer shelf
life, and it will be easier to apply by brush, roller, or spray.
4
Working together with Other Minerals
Celatom® DE functional additives are particularly effective when used in combination with different types
of extender pigments and minerals. For example, talc is made more efficient and provides better sheen when
used in conjunction with Celatom®. The sample formulations on the following pages illustrate the effects of
substituting all of a mineral with Celatom®, and also the effects of substituting only a portion of another mineral,
using the two minerals in combination.
Another major benefit is that Celatom® can be added in smaller amounts than other minerals, while maintaining
the same degree of matting, thus reducing the amount of extenders needed.
In general, the larger the particle size, the more flat the finish. For a semi-gloss finish, choose Celabrite or MW-
25. For a matte finish, CelaFlat+, Celawhite, MW-27, and MW-31 are the best choices. For a textured or non-
slip finish, we offer particle size ranges up to 100 microns.
In addition, our consistent high-quality and uniform particle sizes assure perfect batch-to-batch matching of
color and sheen, as well as clog-free performance in professional spray equipment.
Because of the low density and high matting efficiency of Celatom® DE, a high degree of matting can be
achieved with lower mineral content. The resulting lower pigment volume concentration (PVC) means a
stronger and more durable, higher quality coating, at an equivalent or reduced cost. In addition, Celatom® DE
will provide all of the other benefits described above.
Median Particle
9.0 11.0 13.0 16.0 11.0 12.4
Diameter (microns)
Density (lbs/ft3)
Wet Bulk 31 30 27 25 22 2.2
Dry Bulk 10 10 12 13 9.5 9.5
Density (g/l)
Wet Bulk 500 480 430 400 350 350
Dry Bulk 160 160 190 210 152 152
GE Brightness 91 90 90 90 83 85
CaCO3
Talc
Flux-Calcined
DE
Natural
DE
• Alternatively, to maintain the equal solids, 25 parts of Celatom® MW-25 and 75 parts of calcium
carbonate may be used in combination
• Much lower gloss
• Better opacity and scrub resistance
• Reduced burnish resistance vs. talc alone or Celatom® alone
Formulation
MW-25 + CaCO3
Paint ID Talc only MW-25 only
(Equal solids)
Paint Properties
% PVC 45 40 45
% Solids by weight 47.6 42.9 47.6
% Solids by volume 35.1 32.5 35.1
Density (kg per liter) 1.258 1.234 1.222
Stormer, KU 95.9 98.6 99.7
ICI, poise 2.014 2.225 2.117
Grind 5 4.5 3.8
Film Properties
Gloss, 20° 1.3 1.3 1.2
Gloss, 60° 5 4.6 3.3
Sheen, 85° 10 4.7 1.8
Contrast Ratio, 3-mil film 0.96 0.971 0.948
L* 95.89 96.29 95.85
a* -0.89 -0.77 -0.69
b* 2.84 3 3.04
Scrub resistance, cycles 973 1476 1283
Burnish resistance
Initial 85° 15.0 7.6 3.6
85° after burnish 17.3 8.8 4.3
% Increase in gloss after burnish 15.3 15.8 19.4
7
Interior Acrylic
Talc Replacement
Sample Formulations
MW25 + CaCO3
Paint ID Talc Only MW-25 Only
(Equal Parts)
8
Interior Acrylic (PVC = 65%)
Partial Replacement of Calcined Clay and Ground CaCO3
• Replace 25 parts of CaCO3 carbonate and 25 parts of calcined clay with 25 parts of Celatom®
MW-25 (by weight)
• Improved flatting (decreased sheen and gloss)
• Equivalent hiding power (opacity)
• Slight improvement in scrub and burnish resistance
Paint Properties
Film Properties
Gloss, 20° 1.2 1.2
Gloss, 60° 1.9 1.7
Sheen, 85° 1.2 0.9
Contrast Ratio, 3-mil film 0.978 0.964
L* 95.94 96.7
a* -0.77 -0.74
b* 3.03 3.24
Scrub resistance, cycles 350 396
Burnish resistance
Initial 85° 1.9 1.4
85° after burnish 4.4 2.9
% Increase in gloss after burnish 131.6 111.3
9
Interior Acrylic
Partial Replacement of Clay and Ground CaCO3
Sample Formulations
10
Interior Semi-Gloss Acrylic Paint
Partial Replacement of Microcrystalline Silica
• 20% to 30% of Microcrystalline Silica (MS) in semi-gloss paint can be replaced with Celatom® MW-25
• Reduced cost
• Equivalent Performance
Formulation
Imsil A 15 25 20 17.5
Celatom MW-25
®
- 5 7.5
Paint Properties
% PVC 21.3 21.3 21.3
% Solids by volume 37.6 37.6 37.6
Density (kg per liter) 1.271 1.266 1.268
Stormer, KU 95 98 99
ICI, poise 1.400 1.408 1.420
Film Properties
Gloss, 20° 5.7 5.8 6.6
Gloss, 60° 38.1 33.6 31.9
Sheen, 85° 64.2 54.3 49.8
Contrast Ratio, 3-mil film 0.969 0.946 0.958
L* 96.01 96.83 96.43
a* -0.22 -0.27 -0.23
b* 1.44 1.20 1.20
Scrub resistance, cycles 2581 2635 2705
Burnish resistance
Initial 60° 49.5 38.2 37.9
60° after burnish 50.2 40.1 38.8
% Increase in gloss after burnish 1.4 5 4.5
11
Interior Semi-Gloss
Partial Replacement of Ground Quartz Silica
Sample Formulations
Premix
Dowicil 3.0 3.0 3.0
Propylene Glycol 32.0 32.0 32.0
AMP 95 1.5 1.5 1.5
Strodex PK 05G 3.5 3.5 3.5
Drew L-495 1.9 1.9 1.9
Tamol 731A 7.4 7.4 7.4
Celatom MW-25
®
- 5.0 7.5
Imsil A 15 25.0 20.0 17.5
12
Using Celatom® DE for TiO2 Extension and Opacity
• Example: Flat acrylic latex formulation (Simplified test formulation)
• Replace a portion of the TiO2 with Celatom® CelaFlat+, MW-27, and CelaBrite®
• PVC = 29%
• Conclusion: 5% to 10% replacement is reasonable and effective, with minimal negative effects on
coating color, opacity, and performance.
Formulation
Paint ID a b c d e f g h i j k l m n
TiO2 Replacement
0 5 10 15 20 25 30 35 - - - - - -
by CelaFlat+ (%)
TiO2 Replacement
by MW-27 or - - - - - - - - 0 2 4 6 8 10
CelaBrite (%)
Water 20.0 20.0 20.0 20.0 21.0 22.0 23.0 24.0 20.0 20.0 20.0 20.0 20.0 20.0
Tamol 731A 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
Potassium
0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
Hydroxide
Drew Plus 381 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
Dowicil 75 0.1 0.1 0.1TiO0.1
2 Replacement
0.1 0.1 0.1 by
0.1LCS-3
0.1 0.1 0.1 0.1 0.1 0.1
Tiona 595 17.0 16.15 Sample
15.3 14.45 Formulations
13.6 12.75 11.9 11.05 17.0 16.66 16.32 15.98 15.64 15.3
Celatom® CelaFlat+ 10.0 10.85 11.7 12.55 13.4 14.25 15.1 15.95 - - - - - -
Celatom® MW-27
- - - - - - - - 10.0 10.34 10.68 11.02 11.36 11.7
or CelaBrite
Disperse for 15 minutes using Cowles, then add:
Water 4.0 4.0 4.0 4.0 3.0 2.0 2.0 2.0 4.0 4.0 4.0 4.0 4.0 4.0
Ucar 367 40.0 40.0 40.0 40.0 40.0 40.0 40.0 40.0 40.0 40.0 40.0 40.0 40.0 40.0
Mix for 5 minutes, then add together and mix:
Acrysol RM5
4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0
associative th
Water 4.0 4.0 4.0 4.0 4.0 4.0 3.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0
Total 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0
13
A Graph of Sheen, Contrast Ratio, and b* vs. TiO2
Reduction with CelaFlat+
2.5
1.5
0.5
0
0 5 10 15 20 25 30 35 40
% TiO2 reduction
Paint Properties
Stormer, KU 83 82 84 84 86 83 85 85
ICI, poise 1.961 1.10 1.192 1.183 1.125 1.158 1.567 1.575
Film Properties
Gloss, 20° 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
Gloss, 60° 3.5 3.4 3.0 2.6 2.4 2.3 2.3 2.3
Sheen, 85° 3.1 2.6 2.2 2.1 2.1 1.9 1.8 1.7
Contrast Ratio, 3-mil film 0.980 0.969 0.976 0.965 0.968 0.965 0.969 0.983
L* 94.9 94.9 94.6 94.7 94.5 94.5 94.6 94.4
a* -1.6 -1.8 -1.7 -1.7 -1.7 -1.6 -1.6 -1.6
b* 1.3 1.4 1.4 1.4 1.8 2.0 2.3 2.4
14
A Graph of Sheen, Contrast Ratio, and b* vs. TiO2
Reduction with MW-27
1.2
0.8
0.6
0.4
0.2
0
0 1 2 3 4 5 6 7 8 9 10 11
% TiO2 reduction
Paint Properties
Stormer, KU 89 86 87 86 88 89
ICI, poise 0.856 0.75 0.965 0.958 1.022 0.866
Film Properties
Gloss, 20° 1.1 1.1 1.1 1.1 1.2 1.2
Gloss, 60° 2.1 2.1 2.0 2.0 2.1 2.1
Sheen, 85° 0.6 0.6 0.6 0.6 0.6 0.6
Contrast Ratio, 3-mil film 0.973 0.971 0.946 0.949 0.937 0.945
L* 96.39 96.44 96.49 96.69 96.20 96.21
a* -0.35 -0.28 -0.28 -0.27 -0.40 -0.39
b* 1.12 0.69 0.81 0.69 0.69 0.70
15
A Graph of Sheen, Contrast Ratio, and b* vs. TiO2
Reduction with CelaBrite
1.8
1.6
1.4
1.2
0.8
0.6
0.4
0.2
0
0 2 4 6 8 10
% TiO2 reduction
Paint Properties
Stormer, KU 86 85 86 84 85 85
ICI, poise 0.869 0.890 0.965 0856 0.902 0.952
Film Properties
Gloss, 20° 1.1 1.1 1.1 1.1 1.1 1.1
Gloss, 60° 2.3 2.3 2.1 2.1 2.1 1.9
Sheen, 85° 1.2 1.2 1.2 1.1 0.6 0.5
Contrast Ratio, 3-mil film 0.972 0.952 0.942 0.969 0.950 0.948
L* 96.16 95.80 95.46 96.10 95.65 95.20
a* -0.28 -0.28 -0.25 -0.13 -0.29 -0.28
b* 0.86 1.15 0.87 1.19 0.82 0.98
16
Metal Coil Coatings
Replacement of Ground Quartz Silica
• Application: Solvent-based acid-catalyzed
polyurethane top coat
• Acid catalysis requires inert fillers with
Formulation
a neutral pH
Ground Celatom®
• Generally cannot use calcium carbonate Paint ID
Silica CelaFlat+
or talc
Paint Properties
Stormer, KU 74 84.3
• Functions of Celatom® DE are similar to
ground silica Film Properties
• Inter-coat adhesion Gloss, 20° 86.9 61.1
• Flexibility (resistance to cracking and Gloss, 60° 98.6 91.4
chipping) Sheen, 85° 119.8 114.4
Contrast Ratio, 3-mil film (76 µm) 0.790 0.804
• Impact resistance
L* 94.86 94.78
• UV protection (reduced chalking) a* -0.61 -0.72
b* -0.87 -0.45
• Advantages of Celatom® CelaFlat+ ASTM D 4145 Flexibility 90° 90°
ASTM D2794 - Impact
• Longer shelf life, more stable dispersion, (1.8 kg weight, 1.27 cm diameter) 10 cm 10 cm
reduced hard settling
• Better and more consistent brightness
and color
Sample Formulations
Paint ID Ground Silica Celatom® LCS-3
Ingredients Grams Grams
• Polymac 220-1001 455.0 455.0
• Cymel 303FL 75.0 75.0
• Tiona 595 287.0 287.0
• Eastman CAB 551 - 0.2 4.0 4.0
• PM Acetate 33.5 33.5
• Optifilm Enhancer 400 20.0 20.0
• Nacure 1051 4.0 4.0
• Minusil 30 21.0 -
• Celatom® CelaFlat+ - 21.0
• Dowanol PMA 33.5 33.5
• Aromatic 150 fluid 67.0 67.0
Total 1000 1000
17
The table below lists the suppliers of the various
trademarked ingredients used in the sample formulations:
18
9785 Gateway Dr. • Reno, NV 89521
Tel: (775) 824-7600 • Fax: (775) 824-7601
Email: incredible_minerals@epminerals.com
www.epminerals.com
©2019 EP Minerals • EPM051-005