Paints and coatings: Production route
Water, solvent or powder: how paint technologies differ
What this tab covers How it is made: the main production routes or, for product families, the main product types and technologies, compared on share of supply, inputs per tonne, plant scale, yield, co-products and unit cost.Paint is formulated, not synthesised, so the main 'routes' are technologies defined by the carrier and curing method. Water-borne emulsions dominate decorative paint. Solvent-borne systems remain in high-performance industrial, marine and wood uses because they wet surfaces and cure under harsher conditions. Powder coatings, melted and cured in ovens, have no solvent and are growing in metal finishing. Radiation-cured (UV/EB) and high-solids systems are smaller but growing. Regulation of volatile organic compounds (VOCs) has pushed the mix from solvent to water and powder for 30 years.
Routes compared
| Route | Share of supply | Inputs per tonne | Typical scale | Yield | Co-products | Unit cost |
|---|---|---|---|---|---|---|
| Water-borne coatings (acrylic, vinyl-acrylic and VAE emulsions) | about 44% of value (derived: $87.17 billion in 2024 against about $200 billion) | about 150-250 kg TiO2, 100-200 kg binder solids, 200-400 kg extenders, 300-400 kg water per t (indicative) | plants of 50-400 million litres a year; Asian Paints over 1,850 million litres total capacity | near 100% mass yield (mixing process) | wash water and off-spec batches, usually recycled into lower grades | raw materials about 55-65% of sales for Indian deco makers (gross margin 37-44% FY21-FY27, ICICI Direct; PL Capital) |
| Solvent-borne coatings (alkyds, epoxies, 2K polyurethanes, nitrocellulose) | roughly 40-45% of value (indicative, remainder after water-borne, powder and UV) | about 300-500 kg solvent per t at 50-70% solids (indicative) | same plants as water-borne, with solvent handling and explosion-proof equipment | near 100% | spent solvent and VOC emissions on application | solvent and resin prices track crude oil |
| Powder coatings (polyester, epoxy, hybrid) | about 7% of value (indicative, basis: a cited $14.29 billion powder market in 2023) | about 50-70% resin and hardener, 30-50% pigments and fillers (indicative) | 5-50 kt/yr lines | up to about 95% transfer with reclaim (indicative) | fines and scrap powder | higher resin cost per kg but no solvent; oven energy at the user |
| Radiation-cured and high-solids coatings (UV/EB, 100% solids) | a few per cent of value (indicative) | acrylate oligomers and reactive diluents plus 1-5% photoinitiator (indicative) | small specialty plants | near 100% | little; some monomers are skin sensitisers | expensive per kg, cheap per square metre on fast lines |
How each route works
Water-borne coatings (acrylic, vinyl-acrylic and VAE emulsions)Polymer particles made by emulsion polymerisation are dispersed in water with pigments and extenders. Film forms as water evaporates and particles coalesce. Used for almost all interior and most exterior wall paint, and growing in industrial primers and automotive basecoats.
low VOC and odour; slower drying in humid or cold weather, weaker on difficult substrates
Technavio 2026; ICICI Direct Q2FY23; PL Capital Jul 2026; composition indicative Solvent-borne coatings (alkyds, epoxies, 2K polyurethanes, nitrocellulose)Resins dissolved in hydrocarbons, ketones, esters or glycol ethers. Alkyds cure by oxidation; epoxies and polyurethanes by chemical cross-linking. Still standard for enamels in India, protective and marine systems, refinish and some wood finishes.
robust film and wide tolerance; VOCs, flammability and tightening rules
indicative Powder coatings (polyester, epoxy, hybrid)Resin, hardener and pigment are melt-extruded, ground to a fine powder, sprayed electrostatically onto metal and cured in an oven at about 160-200 C. Overspray is collected and reused. Used for appliances, furniture, aluminium extrusions and automotive parts.
no VOCs, thick tough films; needs heat-tolerant metal parts and ovens
Zona de Pinturas sidebar headline (2023 powder value, not verified); Tiger Coatings CO2 infosheet; indicative Radiation-cured and high-solids coatings (UV/EB, 100% solids)Acrylate oligomers and monomers cure in seconds under UV lamps or electron beams; high-solids systems cut solvent to below 30%. Used on wood panels, flooring, plastics, packaging and printing inks.
very low VOC and energy; limited to flat or line-of-sight surfaces
indicative Unit economics are indicative ranges from the sources named; costs move with feedstock and energy prices, plant size and region.