From solvent to water – robust coating selection under volatile raw material conditions
Executive technical summary
Volatility in oil and energy markets has once again highlighted the structural exposure of the coatings industry to petrochemical raw materials. Traditional solvent‑borne coating systems are inherently linked to oil‑derived binders and solvents and therefore show pronounced sensitivity to raw‑material price fluctuations.
This article provides a technical comparison of solvent‑borne, hybrid and waterborne coating technologies with respect to VOC level, raw‑material exposure and relative price sensitivity. The analysis is based on a common technical reference of 160 µm dry film thickness and an index‑based approach to price sensitivity. The results demonstrate that modern waterborne systems reduce not only VOC emissions but also structural raw‑material risk—without compromising industrial performance.
A structural challenge – not a temporary crisis
The coatings industry has historically been highly exposed to volatility in oil, gas and energy markets. This exposure is fundamentally rooted in coating formulation. Conventional solvent‑borne systems rely heavily on organic solvents, epoxy resins and isocyanates originating from petrochemical value chains.
When oil prices increase, the impact propagates rapidly through raw‑material sourcing, energy consumption, logistics and chemical processing. For industrial coating users, this translates into increased price volatility, reduced cost predictability and higher commercial risk. These effects are structural by nature and recur whenever market volatility returns.
VOC profile of industrial coating technologies
VOC content is a clearly defined material parameter and is declared as grams of VOC per litre of coating (g/L). Beyond regulatory compliance, VOC level also provides insight into the formulation’s petrochemical intensity.
Figure 1 – Declared VOC content (g/L) for selected coating technologies used as an industrial reference.
Relative raw‑material and price sensitivity (index‑based)
Absolute coating prices vary by region, volume and timing. To enable a robust technology comparison, raw‑material and price sensitivity is therefore expressed as a relative index. Index 100 represents low oil exposure and a comparatively stable raw‑material profile.
Figure 2 – Relative raw‑material and price sensitivity expressed as an index (100 = baseline).
VOC load per square metre – common technical reference
To translate material‑level VOC values into an application‑relevant comparison, VOC load has been calculated for a common reference layer of 160 µm dry film thickness (DFT). At identical film thickness, solvent‑borne epoxy systems typically result in approximately 30 g VOC/m², whereas comparable waterborne epoxy systems are typically below 4 g VOC/m². This corresponds to an 80–90% reduction in VOC load per coated area.
Methodology note
VOC values are declared as g/L according to regulatory definition. VOC load per square metre is calculated based on theoretical coverage at 160 µm dry film thickness. The reference layer represents a comparative model only and does not constitute a complete ISO 12944 coating system. Raw‑material and price sensitivity are expressed using relative indices to eliminate absolute price, currency and timing effects.
The differences between coating technologies should be understood as relative reductions in exposure and price sensitivity; in scenarios involving major supply disruptions, all technologies may be affected, but to different degrees.
Performance across ISO 12944 environments
Modern coating technology spans a wide performance range, from light‑duty systems in C2 environments through C3 and C4, and—within selected system configurations—up to demanding C5 environments.
At Nowocoat, coating systems are specified and supplied across this full spectrum. Notably, fully waterborne acrylic systems can be engineered and specified for selected C5 applications in accordance with ISO 12944. Performance is governed by total film build, layer functionality, surface preparation and application control—not by the presence or absence of organic solvent.
Depending on application method and process control, solvent‑borne systems may in certain cases still offer advantages in surface appearance and finish.
From technology selection to process implementation
In practice, the transition toward lower‑VOC and waterborne coating systems is rarely achieved by product substitution alone. The limiting factor is often the existing application and curing process.
A core part of Nowocoat’s approach is on‑site evaluation of the customer’s current coating line, including application equipment, ventilation, airflow, drying and handling sequence. Based on this assessment, coating systems and process parameters are adapted to enable a stepwise transition toward greener solutions while maintaining throughput, quality and reliability.
From a process perspective, the evaporation of water typically requires higher energy input than organic solvents, which may influence drying capacity and process economics in high‑throughput industrial coating lines.
Formulation‑driven coating solutions
A defining strength at Nowocoat is deep formulation expertise in polyaspartic high‑solids systems, waterborne epoxy coatings and single‑component waterborne acrylics. These technologies form the basis for engineered solutions rather than fixed catalogue products.
Nowocoat is among the few suppliers capable of actively modifying coating formulations to match individual customer process lines. This includes adjustment of curing profile, open time, gloss level, handling window and compatibility with existing drying and ventilation capacity.
In particular, polyaspartic systems require advanced formulation know‑how. The ability to fine‑tune reaction speed and surface finish for a specific production process is limited to very few coating manufacturers, yet often determines successful industrial implementation.
Optimised for robotic application
Robotic application places significantly tighter demands on coating systems than manual spraying.
Parameters such as viscosity stability, cure profile, atomisation behaviour, overspray control and surface wetting tolerance must be precisely aligned with robot parameters and line speed.
A key strength at Nowocoat is extensive experience in robot‑applied coatings, particularly within polyaspartic high‑solids systems, waterborne epoxies and single‑component waterborne acrylics.
These technologies are routinely engineered to perform reliably in fully automated lines.
Formulation adjustments are often decisive in robotic application, including:
- tuning of reaction speed to match robot takt time
- optimisation of open time for consistent film build
- control of gloss and surface appearance under constant spray patterns
- stability under continuous circulation systems
Especially for polyaspartic systems, the ability to adapt curing behaviour and application window for robotic spraying is limited to very few manufacturers.
This capability enables high‑throughput, low‑VOC solutions to be implemented without compromising line efficiency or finish quality.
Qualified solutions for demanding defence applications
Within the Nowocoat group, defence‑related coating solutions are supplied through our sister company AB Röa. Selected coating systems are developed, tested and qualified in accordance with relevant defence requirements, including applicable NATO STANAG standards.
Such qualification reflects a high level of robustness in areas such as corrosion resistance, chemical resistance and long‑term durability under controlled and repeatable test conditions. While defence applications represent a specialised domain, the underlying qualification criteria and performance requirements are directly transferable to demanding industrial environments.
For industrial customers, this provides additional assurance that coating systems engineered for low VOC content, robotic application and process‑specific optimisation are capable of meeting stringent performance and reliability requirements beyond standard industrial specifications
Conclusion – coating selection as risk management
The transition from solvent‑borne to hybrid and waterborne coating technologies is no longer limited to light or moderate exposure categories. Across ISO 12944 environments—from C2 through C3 and C4 and up to selected C5 applications—modern waterborne technologies deliver robust corrosion protection.
Lower‑VOC systems consistently demonstrate reduced petrochemical dependency and improved cost stability, while providing industrial performance comparable to traditional solvent‑borne coatings. In an increasingly volatile raw‑material landscape, coating selection has become an exercise in risk management rather than compromise.
Henrik Sørensen | Head of Industry, Nowocoat Group (including AB Röa)
