Interview: Revolutionising coatings formulation with digital tools with Sander Van Loon

Source:Sander Van Loon VLCISource:Sander Van Loon VLCI<br>Sander van Loon, founder of VLCI, discusses the power of digital tools in coatings formulation.

For readers who may not know you yet, who is Sander van Loon, and how did you become involved in the digitalisation of coatings formulation?
Sander van Loon: I am the founder of VLCI, a company that provides unique formulation R&D services and web applications by applying predictive sciences and high-throughput screening. Since I was 18, I always wanted to start my own laboratory to help companies develop products. After my career at PPG, I realised that dream in 2008 with the vision of “Boosting your chemistry.” This vision aims to accelerate formulation R&D and provide products or insights that create a real impact for our clients.

To achieve this, we acquired our first high-throughput (HT) equipment in 2009. However, we quickly realised that to generate useful results, the experimental input needed to be precise. In 2010, we incorporated predictive sciences such as Hansen Solubility/Similarity Parameters (HSP) and Hydrophilic Lipophilic Difference (HLD). These thermodynamic-based models assign fixed, predictive parameters to ingredients, helping us efficiently formulate solutions and dispersions using HSP and emulsions using HLD.

The advantage of these models is that they allow us to select the best matching ingredients from the outset, without needing to know the chemical structure of each component. We’ve built extensive datasets of commercial ingredients and use them to streamline formulation processes. Because HSP and HLD only describe how to formulate with ingredients, they don’t reveal intellectual property, making them an effective bridge between suppliers and formulators.

This approach led to the development of formulation web applications, enabling a more sustainable digitalisation process. In 2021, we launched our PrediApps platform, which provides access to the world’s largest shared HSP and HLD database. This allows users to select the best ingredients and maximise performance with minimal resources.

Why do you think so much of coatings formulation still relies on trial-and-error approaches?
Van Loon: It’s always challenging to change established ways of working. Formulation is often viewed as an art, with much of the knowledge held by individuals or scattered across disparate data sources. The sheer number of ingredients and combinations can be overwhelming, making it difficult to rationalise the process.

Suppliers frequently claim that their ingredients are versatile, but they rarely provide universal parameters for how to formulate with them. As a result, formulators often rely on trial-and-error, guided by their own experience and the data at hand. Collecting consistent data to draw reliable conclusions is time-consuming, especially when R&D departments face pressure to deliver results quickly and cost-effectively.

While trial-and-error methods have been effective in the past, they are becoming outdated in today’s fast-paced industry. We are seeing a shift towards science- and data-driven approaches, although these require time and effort to implement and adapt.

How does the HLD model complement HSP in formulation development?
Van Loon: Hansen Solubility Parameters (HSP) are primarily used in formulation R&D for coatings and inks, as they are applicable to solutions and dispersions. They help in selecting the best solvents, dispersants, and additives for improving specific properties, including in water-based formulations.

On the other hand, Hydrophilic Lipophilic Difference (HLD) is particularly useful for developing water-based coating resins, such as alkyds, epoxies, and acrylics. With HLD, you can identify the optimal surfactants or blends for creating stable emulsions with minimal surfactant concentration. This leads to smaller particle size, improved stability, and reduced kinetic energy requirements during emulsion production.

While HSP is excellent for determining ingredient compatibility in solutions and dispersions, HLD specialises in optimising emulsions. HLD is more applicable to resin suppliers, while formulators benefit indirectly from the improved water-borne resins developed using HLD. Once these resins are created, their HSP can be used to identify matching ingredients like coalescents or additives.

In your experience, how much experimental work, time, and cost can be saved through science-based formulation tools?

Van Loon: In general, what we see in the market is that most software tools can accelerate formulation R&D with a factor 10. This is what we have heard back from our clients too, who are implementing HSP or HLD. We have seen that by using HSP or HLD, the formulation space can also be reduced with a factor 10, generating much less waste and of course, significantly reduce the time spent in the laboratory.

When using our webapps, the selection of best matching or replacing ingredients can even go up to 100 time faster, so that is a drastic time reduction. Ingredient suppliers can now share their ingredient digitally via the webapps and formulators can use them instantly, which is further reducing their time and costs in sample evaluation. On top of all this, the number of ingredients and their concentration can be brought to a minimum, while achieving maximum performance.

All of this, can lead to a >10% cost saving in R&D. Some topics in HSP and HLD require a deeper study on how this can work to improve certain properties, so that can take some time before you start benefiting. But with a community working on various topics, we are further building up a guide book with rules on how to implement HSP and HLD, making the life of the formulator much easier. That’s our unique combination of a formulation lab and experience with a software tool.

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