Biobased and Recycled Materials in Coatings:

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The coatings and inks market faces increasing pressure to reduce environmental impact. Customers and legislation demand solutions with lower volatile organic compound (VOC) content, a smaller carbon footprint, and the use of renewable or recycled raw materials. Fortunately, modern chemistry offers alternatives that do not require compromising performance. Biobased polyols, plant-based resins, or recycled pigments and fillers are becoming common components in formulations. How do these materials work in practice, and what should be considered when selecting them?

Why Is It Worth Switching to Biobased Raw Materials in Coatings?

The coatings market faces increasing pressure to reduce its environmental footprint, not only due to regulatory requirements but also because of demand from manufacturers and end customers. Biobased raw materials—substances derived from renewable sources such as plant oils, cellulose, or starch—offer an effective way to replace fossil derivatives without compromising quality. Their main advantage is a lower carbon footprint; studies show that biobased components can reduce CO₂ emissions by up to 30–50% compared to traditional petrochemical raw materials. Additionally, they often exhibit better biodegradability, which is crucial for applications requiring easy recyclability or compostability.

Another argument in favor of biobased raw materials is their compatibility with existing production processes. Many can be processed under the same conditions as conventional components, minimizing the need for investments in new technologies. For example, plant oils modified into alkyd resins provide comparable durability and gloss to their synthetic counterparts but with a significantly lower environmental impact. For coatings manufacturers, this means the ability to offer "greener" products without the need for major changes in production or increased costs.

Recycled Raw Materials in Coatings: Where and How to Use Them Effectively?

Recycled raw materials are becoming an increasingly attractive alternative for coatings production, particularly in segments where circular economy principles are emphasized. Typical examples include recycled solvents, pigments from recycled plastics, or fillers from industrial waste such as fly ash or slag. Their use not only reduces the amount of waste sent to landfills but also conserves primary raw materials and the energy required for their extraction and processing. For instance, recycled solvents can have up to 40% lower energy demands in production compared to their newly synthesized equivalents.

However, when integrating recycled raw materials into coatings, it is crucial to ensure their quality and consistency. Fluctuations in the composition of recycled materials can negatively affect the properties of the final product, such as viscosity, coverage, or resistance to weathering. Therefore, it is essential to implement strict incoming quality controls and standardized processing procedures. In practice, a combination of recycled and biobased raw materials has proven effective – for example, using recycled pigments in combination with biobased binders, which allows achieving an optimal balance between ecology and performance.

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How to ensure that eco-friendly coatings meet technical requirements?

Switching to biobased or recycled raw materials must not compromise the technical properties of coatings. A key factor is the careful selection of raw materials and their mutual compatibility. For example, biobased resins based on vegetable oils must be modified to achieve comparable hardness, elasticity, and chemical resistance to synthetic alternatives. This often requires optimizing the formulation, such as adding additives to improve mechanical properties or UV stabilizers.

Another important step is testing according to applicable standards and industry benchmarks. This includes tests for weather resistance, substrate adhesion, abrasion resistance, or chemical resistance. For recycled raw materials, it is also necessary to verify that they do not contain undesirable contaminants that could affect the stability or safety of the coating. Manufacturers should collaborate with raw material suppliers who provide transparent information about the origin and processing of their products, including certifications such as REACH or eco-labels like the EU Ecolabel.

The Future of Coatings: Trends and Innovations in Sustainable Solutions

The future of coatings will be significantly shaped by innovations in sustainable raw materials and technologies. One of the most promising trends is the development of hybrid systems that combine biobased and recycled components with advanced nanomaterials. For example, graphene or nanocellulose can significantly improve the mechanical properties of coatings while reducing the amount of raw materials required. Another direction is the research into self-healing coatings that use biobased polymers capable of repairing microcracks, thereby extending the lifespan of surfaces and reducing the need for repairs.

Regulatory pressure and market demand will continue to push manufacturers toward greater transparency and reducing their ecological footprint. It is expected that by 2030, most coatings will contain at least 30% biobased or recycled raw materials. For manufacturers, this means the need to invest in research and development, as well as in educating customers, who often overestimate the risks associated with eco-friendly alternatives. The key to success will be to demonstrate that sustainable coatings can be not only more environmentally friendly but also technically equivalent or even superior to traditional solutions.

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Formulation optimization: How to combine biobased and recycled raw materials for maximum effect

When transitioning to more sustainable coatings, it is crucial to find a balance between ecological benefits and technical performance. Biobased raw materials, such as vegetable oils, cellulose, or lignin, offer a low carbon footprint and renewable origin, but their properties may differ from traditional petrochemical alternatives. For example, vegetable oils can improve coating flexibility, but their resistance to UV radiation or chemicals may be lower. The solution is to combine them with recycled fillers, such as micronized glass or mineral particles, which enhance mechanical resistance and durability.

A practical example is the use of biobased resins in combination with recycled pigments from industrial waste. Such a formulation can achieve up to a 50% reduction in CO₂ emissions while maintaining comparable coverage and durability to conventional coatings. It is important to test the compatibility of raw materials under laboratory conditions, for instance by verifying viscosity, drying time, and adhesion to the substrate. Manufacturers should also consider the availability of raw materials and their price stability to avoid disrupting the production process.

Certifications and Transparency: How to Demonstrate the Sustainability of Coatings to Customers

Customers in the industrial sector are increasingly demanding proof of the ecological origin of raw materials and the overall environmental impact of a product. Certifications such as EU Ecolabel, Cradle to Cradle, or biobased certifications according to EU standards provide independent verification of sustainability. These certifications assess not only the proportion of renewable or recycled raw materials but also the energy intensity of production, emissions of volatile organic compounds (VOCs), and the recyclability of packaging.

Transparency is key in communication with customers. Manufacturers should state the percentage of bio-based or recycled raw materials and provide information about their origin, such as whether they are by-products of the food industry or recycled materials from industrial waste. It is also important to indicate whether the raw materials comply with REACH and CLP requirements, ensuring their safe use. For B2B customers, sharing life cycle assessment (LCA) results, which quantify the environmental footprint of a product from raw material extraction to disposal, is also beneficial.

Challenges and Limitations: Where Sustainable Coatings Encounter Technical Limits

Although bio-based and recycled raw materials offer numerous advantages, their use in coatings is not without challenges. One of the main issues is quality consistency, particularly with recycled materials, which may contain impurities or have variable compositions. This can lead to uneven coverage, reduced adhesion, or shorter coating lifespan. The solution lies in thorough raw material pretreatment, such as filtration, grinding, or chemical stabilization, which ensures uniform properties.

Another challenge is resistance to extreme conditions, such as high temperatures, humidity, or chemical environments. Bio-based resins may be more susceptible to UV degradation or microbial attack, limiting their use in exterior applications. Manufacturers often combine bio-based components with additives, such as UV stabilizers or biocides, to extend the coating's lifespan. Testing under real-world conditions, such as on weather-exposed test panels, is also crucial to verify long-term stability.

Looking for a sustainable solution for your coatings?

GCG Group supplies a wide portfolio of raw materials for eco-friendly coatings and inks, including bio-based and recycled alternatives. For each raw material, we provide detailed technical and safety data sheets and advise on selecting the optimal solution for your application. Contact us – or browse our catalog of over 1,300 products right away.