Natural Wall Paint Masterbatch Obtained from Waste Coffee

In this study, waste coffee—a serious threat to our environment as a source of methane gas and a contributor to carbon footprint—was successfully processed through recycling to produce natural colorant masterbatch for use in building paint formulations. Waste coffee was collected from local establishments using designated containers, then sterilized, dried, and converted into powder form. In this manner, coffee essence was incorporated into building paints, demonstrating homogeneous distribution properties. The resulting masterbatches can potentially be applied in industrial paints similar to building coatings and will support increased market share for our country.

1. Introduction

Paints are defined as coatings applied for the purpose of imparting color to any object, as well as for insulation and protective purposes. Paints can be applied to almost all materials. In paint production, masterbatches are used as coloring agents. The function of masterbatches is to enable easy application of the desired color tone. The primary objective is to extend the durability of the desired color on the target surface following application. While synthetic-based materials have been used as masterbatches historically, recent years have seen growing demand for natural materials, particularly those produced through recycling methods from waste materials, for paint colorant production. The surfaces being treated—sometimes metal, polymer, ceramic, and particularly composite materials that have received increased attention in recent years—may require extended paint adhesion, prevention of mold and odor formation, thermal insulation, and in certain cases, superhydrophobic (water-repellent) or superhydrophilic (water-loving) properties. Synthetic paints synthesized with chemicals can present carcinogenic substances. Azo dyes are carcinogenic and allergenic aromatic amines that can endanger environmental and human health. Most synthetic paints are toxic and mutagenic. Masterbatch consists of a mixture of pigments, additives, and polymer materials (carrier resin). It is used for coloring plastics and paints in applications such as packaging, construction, consumer goods, automotive, textiles, agriculture, and packaging. Colored masterbatch, white and black masterbatch, additive-containing and filled masterbatch refer to different masterbatch types depending on properties and functionality. Polymer-based masterbatch is preferred to differentiate various plastics and paints. The global masterbatch market is expected to grow from USD 11 billion in 2018 to USD 14 billion by 2023 [1]. With steadily increasing market share, there is growing demand for masterbatch production processes and unique raw materials used. To meet rising demand, various initiatives from waste materials and natural plants have been undertaken to impart color properties to building chemicals. Many companies continue initiatives at various levels to develop new product lines. Products have been developed using activated carbon obtained from waste materials for masterbatch purposes. The objective here is to both create aesthetic appearance in the area where it is used or applied and demonstrate absorbent properties. Activated carbon acts as a natural cleanser, removing smoke and pollution from the environment. This is how it provides functional use. However, although the production procedure may appear simple, underlying R&D work and production investments can be substantially higher. There is evident demand in the construction sector and among other paint applicators for an easier process and more economical option that could deliver high technical performance levels through waste materials. For this purpose, we produced natural paint colorant using waste coffee—which increases carbon footprint and releases methane gas. Coffee production, particularly in Africa, is expected to lose 50% of production capacity by 2050. This means that as production decreases, coffee prices will rise. Additionally, as a 98% waste product, a single coffee establishment's branch generates 2–5 kg of coffee waste daily. Across one hundred branches, 200–500 kg of waste is generated daily. When we consider monthly and annual figures, we encounter a serious waste threat. Therefore, we undertook this work to raise awareness and promote more responsible consumption patterns, and by valorizing waste, we can create application areas capable of delivering high performance. In our study, masterbatch was obtained as a building paint color agent, and it is evident that as the application field expands from building to industrial paints and is supported through R&D and development efforts, concrete results will be readily obtained in practice.

2. Materials and Methods Materials

Waste coffee was collected from local coffee establishments.

Method – Masterbatch Production from Waste Coffee

Approximately 2 kg of waste coffee was collected daily at the end of business from local coffee establishments using designated containers. The collected coffee was washed twice in tap water, and following washing, rinsed for an additional half hour with distilled water. After the process, the waste material was sterilized with ozone gas and placed in a vacuum oven for drying. The dried coffee was ground with the aid of a ceramic mortar and ball mill, and following sieving, was reduced to an appropriate powder size of 40–63 micrometers. In this manner, the active ingredient was obtained for use as a masterbatch color additive in paints. Figure 2.1 shows the method for obtaining masterbatch from waste coffee. [caption id="attachment_158507" align="aligncenter"] Figure 2.1. Method for obtaining masterbatch from waste coffee[/caption]

3. Results and Discussion

Paint was colored by adding the masterbatch and applied over wood and foam to conduct combustion and water behavior tests. While the painted area did not burn, the wood and foam underwent combustion. Additionally, in water repellency testing, while wood and foam absorbed water, in our paint the pores were tightly packed and smaller, causing water droplets to roll off without contact. When applied to walls, particularly on exterior facades, water will not make contact, thus collecting and enabling potential use for irrigation and other purposes. The surfaces of wood and foam treated with masterbatch and our test procedures are shown in Figure 3.1. [caption id="attachment_158508" align="aligncenter"] Figure 3.1. Masterbatch-applied surfaces of wood and foam and our test procedures[/caption] 4. Conclusions In our study, masterbatch as a paint color agent to be incorporated into paints was successfully produced using a simple and economical method. Active ingredient was obtained from waste coffee as masterbatch and incorporated into paint to achieve painting over wood and foam. It was determined that the product successfully passed combustion and water repellency tests. We have filed a patent application for our developed product. Our product and subsequently expanded product lines will be able to address building chemicals and industrial paints as well as all application areas as color agents. Our next initiative will involve creating natural paint using one or several plant combinations. Through this, we wish to raise awareness among our companies regarding their performance in this field. Sources Erdi Buluş Lecturer İstanbul Arel Üniversitesi ArelPOTKAM Gülseren Sakarya Buluş Specialist Bahçeşehir Üniversitesi Business Engineering Doctoral Student