Waterborne Non-Stick Coating Additive Selection Guide: A Combined Approach to Wetting, Leveling, and Foam Control on Low-Energy Surfaces

1. Additive Challenges in Waterborne Non-Stick Coatings

Waterborne non-stick coatings often contain low-surface-energy components such as PTFE and wax powders, which can lead to defects like cratering, fisheyes, and uneven leveling during application. Meanwhile, the formulation may generate excessive foam due to surfactants and high-speed mixing, compromising the final film appearance. Therefore, coordinated selection of wetting agents, leveling agents, and defoamers is critical.

2. Wetting Agents: The Key to Penetrating Low-Energy Surfaces

Low-energy surfaces (e.g., PTFE-coated substrates) require wetting agents that effectively reduce dynamic surface tension.

• Recommended: Toynol® Superwet-320

0.1% aqueous solution: static surface tension as low as 26.2 dyn/cm. It rapidly wets difficult substrates, prevents cratering, and offers low-foam performance to minimize foam introduction.

• Alternative: Toynol® D-502

A foam-controlling wetting agent. 0.1% aqueous solution static surface tension ≈ 35.2 dyn/cm. Suitable for foam-sensitive systems, balancing wetting and foam suppression.

• Dosage: 0.3%–0.5% (based on total formulation weight).

3. Leveling Agents: Enhancing Film Uniformity and Gloss

In non-stick coatings, leveling agents must avoid introducing craters while promoting flow.

• Recommended: Toynol® FS-640

Acetylenic diol nonionic structure, combining wetting and leveling functions. It effectively eliminates orange peel and brush marks, with foam-suppressing capability, making it ideal for high-speed application methods such as roll coating and spraying.

• Dosage: 0.3%–0.5%.

4. Defoamers: Controlling Microfoam and Surface Defects

Fluorinated or wax components tend to stabilize foam, requiring defoamers with good compatibility.

• Primary choice: Toynol® Foamic 024

Nonionic organic polymer, silicone-free and mineral-oil-free, avoiding crater formation. At 0.2%–1.0% dosage it eliminates stubborn microfoam, suitable for high-appearance systems.

• For high-shear mixing: Toynol® DF-80PG

Gemini structure provides rapid foam breakage. Dosage: 0.1%–0.3%. Ideal for high-speed coating production lines.

5. Combined Use Recommendations

• For low-energy surfaces (PTFE/plastic substrates): Superwet-320 (wetting) + FS-640 (leveling) + Foamic 024 (defoamer). Dosage ratio: 0.3% : 0.3% : 0.2%.
• For microfoam-sensitive systems (e.g., spray coatings): D-502 (wetting with foam control) + FS-640 (leveling) + DF-80PG (defoamer). Dosage ratio: 0.4% : 0.3% : 0.1%.
• Addition sequence: It is recommended to add wetting agent and leveling agent first during paint mixing, then add defoamer last to avoid defoamer deactivation under high shear.

6. Common Issues and Optimization

• Craters: First check if wetting agent dosage is sufficient, or switch to Superwet-320/360 for improved dynamic wetting.
• Fisheyes/orange peel: Increase FS-640 dosage, or combine with 0.3% Superwet-604 to enhance leveling.
• Residual foam: Fine-tune Foamic 024 dosage up to 0.5%, or switch to DF-80PG for targeted microfoam elimination.

7. Conclusion

Selecting the combination of Toynol® Superwet series wetting agents, FS series leveling agents, and Foamic/DF series defoamers provides a systematic solution to wetting, leveling, and foam issues in waterborne non-stick coatings. It is recommended to conduct small-scale trials based on application method and coating characteristics to optimize final dosage. For further technical guidance, please contact Tianjin Hi-Perferal technical support.