Switching from solvent-based coatings to waterborne coatings can reduce costs and volatile organic compound (VOC) emissions.

Coatings contain one or more solvents as a primary ingredient. Solvents dissolve the paint materials to form a liquid mixture that can be sprayed. Once applied to a part, the solvent evaporates, leaving behind the paint film. Water is frequently used as a solvent in waterborne coatings. Contrary to its name, waterborne coatings typically contain other solvents, or "cosolvents," which can make up as much as 30 percent of the product.

Waterborne coatings have been around in one form or another for decades but have demonstrated greatly improved performance characteristics in recent years. Some common waterborne resins include acrylics, epoxies, alkyds, and polyurethanes.

If you think you might have an application for waterborne coatings, following are some suggested evaluation steps.

1. Determine the specific minimum performance requirements for the coating and make sure the selected waterborne products meet all the requirements. If there is not a commercially available coating that will meet specifications, a coating manufacturer may be willing to work with you on new formulations.
2. Request technical literature from the vendor including MSDS sheets, VOC content, regulations covering the product and its constituents, safe handling procedures, and equipment requirements. Next, evaluate whether the new alternative is really safer, less hazardous, and reduces regulatory obligations. Work through the VOC and hazardous air pollutants (HAPS) calculations for any proposed coatings.
3. Consider changes in transfer efficiency, coating thickness, and solids content using waterborne coatings, especially when estimating changes in purchasing and environmental reporting requirements. In electrostatic systems, there may be a lesser attraction between the part and the paint when using waterborne coatings, therefore reducing transfer efficiency. Solids content may be higher or lower with the waterborne coatings and dry film thickness requirements vary. Also, research potential changes to surface preparation and drying temperature and time constraints.
4. Perhaps the biggest factor in a company’s decision should be the evaluation of return on investment. To compare strictly the total paint costs (TC₁, TC₂) of the changeover knowing existing and proposed paint costs per gallon (C₁, C₂), transfer efficiencies (t₁, t₂), dry film thickness requirements (d₁, d₂), and VOC content (V₁, V₂) the following equation may be helpful. This equation incorporates only one aspect of the overall cost of the painting operation, but is a useful initial calculation.

TC₂($) = TC₁($) x [C₂($/gal) x d₂ (mils) x V₁(%) x t₁(%)] / [C₁($/gal) x d₁ (mils) x V₂(%) x t₂(%)]

5. Changing materials will require some modifications to existing equipment and operating procedures. These capital and operating cost changes should be included in the economic evaluation. As an example, drying times may increase with the change to waterborne coatings. This can affect conveying systems, ovens, throughput, and energy costs. Electrostatic spray systems must be isolated from the ground because waterborne coatings are highly conductive. Recirculation systems may have to be replaced with stainless steel pumps and piping to avoid corrosion. Higher pressures may be needed to atomize the paint, which will in turn decrease transfer efficiency. Plan implementation such that costs to ongoing operations will be minimized, and work closely with a coatings and spray equipment supplier or a consultant to ensure the change is made effectively.

Waterborne coatings could be the best choice to reduce emissions and decrease costs. However they are just one of several coatings options available including high-solids, 100 percent solids, U/V curable, CO₂ cosolvent, autophoretic, and powder coating. Each type has its benefits and disadvantages and there is no one perfect coating for any application. Keep this in mind when evaluating your options.