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Low Curing Temperature Powder Coatings for Outdoor Applications

Periodic Reporting for period 1 - PULVERCOAT (Low Curing Temperature Powder Coatings for Outdoor Applications)

Reporting period: 2015-02-01 to 2015-05-31

Our company, PULVERIT, is specialized in the development, manufacturing and sale of thermosetting powder coating since 1973. Our extensive experience and constantly search for innovative products and new applications has enable us to be leaders in the powder coating sector in Italy. Our main product lines comprise epoxy, epoxy-polyester, polyester and polyurethane powder coatings for general metal finishing, architectural applications, household appliances and industrial vehicles.

PulverCoat is an innovative project with the objective of industrializing a powder coating curing at low temperatures (110ºC-130ºC) for short curing times, enabling the use of powder coatings on heat sensitive substrates (like wood and plastic) and yielding important energy savings for our customers. Furthermore, our coating has excellent outdoor resistance, anti-scratching and anti-graffiti properties.

In order to confirm the feasibility of our project, we, PULVERIT, have carried out a 4-month study focusing our efforts on 3 main areas:

In order to confirm the feasibility of our project, we, PULVERIT, have carried out a 4-month study focusing our effort on 3 main areas. Technically, we have reviewed the specifications of Pulvercoat and defined a set of tests, parameters and target values that will be used during Phase 2 execution. We have improved the viscosity of the polyamide resin and defined the optimal mixing, extruding and milling parameters. We have also prepared a complete Execution Plan for the development of PulverCoat products, including planning, organization, risk analysis and budget. Commercially, we have assessed the existing and new targeted markets, including the competition, to consolidate our marketing strategy. A technology watch and patent search has been performed to ensure our Freedom-to-Operate. Finally, on the economic side, financial forecasts, based on the marketing and price policy, have been drafted to evaluate on a 5-year-projection.
During our 4-month Feasibility Study, and based on the original Work Plan proposed in the Phase 1 proposal, several activities have been carried out.

Firstly, technically, further improvement in the formula were done and the optimal unsaturation content was defined. We have defined the basic testing set that will be used during the Phase 2 execution and also revised the mixing, extrusion and milling processes, as well as the certifications to be obtained. Following these developments, a preliminary risk analysis has been conducted to ensure that no issues have been left aside and thus that future development will be with a low and controlled risk. Our team has prepared a complete Execution Plan for the development and exploitation and the Smart GearBox range; we also confirm the required third party subcontractors to support us in the execution of the Phase 2 project.

Commercially, we have focused on the potential new applications for our powder coating (on wood and plastic surfaces) which has allowed us to further prepare our marketing and pricing strategy. We have also made a first approach to end-users that could be testers of our coating for metal, wood and plastic applications. Furthermore, a complete Freedom-to-Operate was performed to search for existing IP rights that could infringe with our technology. This analysis has confirmed the novelty of PulverCoat and the absence of existing thread for its commercialization. The results obtained pushed us to filing a patent in Italy and Poland.

Financially, we have defined our growth strategy for the 2018-2022 period and forecasted our financial projections with highly positive turnover increase. Different sources of funding have been evaluated as well, leading to our decision to present a Horizon 2020 SME Instrument Phase 2 in June 2015.
We hope to introduce the new products into the market in 2018.
The low curing temperature of PulverCoat will enable energy savings from 30% to 70% to our customers (job coaters and goods manufacturers) and will enable PULVERIT to place in the market of powder coatings for wood and plastics and allow us to reach a first line position due to the lack of products meeting the low curing temperature demand.