An emulsion is a mixture of two or more liquid raw materials that are immiscible (unmixable). Two of the main types of emulsions are water-based and solvent-based. A water-based emulsion is an emulsion in which water is the continuous phase or the primary carrier. Particles of other liquids or additives, such as oil, are then suspended in the water. 

Water-based paints are one of the most common examples of these emulsions. These specialty chemical mixtures are also used in the textile and chemical industries, the formulation of printing inks, and in sealants, adhesives, and binding agents. Manufacturers across virtually all industries use emulsions.

These emulsions are growing in popularity due to their environmental and health benefits. This blog will explore their key applications and advantages and how industrial manufacturers can use them.

Understanding Water-Based Emulsions

An emulsion consists of one liquid (the dispersed phase) dispersed into another (the continuous phase.) In a water-based emulsion, the continuous phase is water. Since emulsions are unstable, they do not form spontaneously. Energy input–such as mixing or shaking–is required. The continuous phase can consist of various materials, of which resins and oils are two of the most common.

Solvent-based products are a common alternative to water-based products. In a solvent-based emulsion, the continuous phase is a solvent, such as mineral spirits, into which additives such as oils, chemicals, or other materials are dispersed.

Water-based emulsions are safer for the environment and human health than solvent-based alternatives. They can perform at least as well as their solvent-based counterparts and may be a better choice in some circumstances. 

The Key Industrial Applications of Water-Based Emulsions

This section will explore some of the main applications of water-based emulsions in the industrial and manufacturing sectors. 

Paints, Sealants, and Coatings

Many industrial paints, sealants, varnishes, primers, and protective coatings are now water-based. These materials can be added to surfaces to create or enhance desired properties.

Two common examples are water-based acrylic resins and water-based styrene acrylic, an emulsion that combines styrene and acrylic monomers with water. Using a water-based paint or coating such as an acrylic resin or styrene acrylic resin can enhance the durability, water repellency, and corrosion and abrasion resistance of surfaces. Acrylic resins and styrene acrylic resins are also found in graphic arts materials such as artists’ paints and interior and exterior paints.

Manufacturers often prefer water-based coatings because they are eco-friendly and safer for workers and customers.

Adhesives and Binders

Water-based adhesives and binders, which are common in packaging, woodworking, and construction, offer strong adhesive properties for various materials with minimal environmental impact.

For example, vinyl acetate is added to water to make polyvinyl acetate (PVA), a common adhesive also known as white glue, wood glue, or carpenter’s glue. Manufacturers across numerous industries, from construction to textiles, use this versatile material.

Textile and Leather Processing

Many fabric finishes and leather treatments used in the textile industry are now water-based. For example, water-based wax emulsions can be added to materials to create excellent water resistance and improve the strength and tactile properties of clothing and textiles. These finishes can enhance fabric’s water resistance and softness without the need for toxic chemicals.

Paper and Printing Inks

Water-based emulsions can be used in the paper and printing industry to make products such as printing inks and glossy coatings for paper. These options ensure better adhesion and water resistance while allowing for eco-friendly printing.

Metal-working and Machining

Manufacturers often use water-based cutting fluids, rust-prevention coatings, and industrial lubricants. These fluids and lubricants reduce wear and tear on metal machinery while being safer for workers and the environment.

Construction

Manufacturers and contractors in the construction industry use various water-based products. For example, styrene butadiene (often called SBR rubber or SBR latex) is a flexible adhesive rubber made from styrene and butadiene monomer suspended in water. It is used for a range of applications including as a carpet backing, to modify asphalt, and as an additive to concrete to improve its properties, amongst other uses.

Agriculture and Food Packaging

Water-based emulsions are used in biodegradable coatings for produce preservation, making our produce last longer without risks to human health or the environment. They also play an essential role in safe packaging adhesives.

The Benefits of Water-Based Emulsions

For manufacturers in all industries, there are numerous benefits to choosing water-based emulsions over solvent-based options. In this section, we will look at four of the most important. 

Eco Considerations and Volatile Organic Compounds

In the years we have been serving industrial manufacturers, we have noticed that our clients are becoming increasingly eco-conscious. Manufacturers care about their impact on the planet and want to reduce their footprints.

Water-based emulsions emit significantly fewer volatile organic compounds (VOCs) than solvent-based products. VOCs are found in most household products and are released into the air when you use the products. 

This lack of VOCs improves indoor air quality and reduces environmental pollution. They are less likely to contaminate water sources, and cleaning them up requires only soap and water instead of hazardous solvents. 

In addition, even solvent-based solutions using organic solvents can harm the environment.

Worker Safety

Since water-based emulsions emit few or no VOCs, they release fewer harmful fumes into the air that workers breathe. VOCs can cause damage to the eyes, skin, and respiratory system over time. This means that water-based products are far safer for the workers who use them. 

Water-based products are also safer for customers, making them ideal choices for consumer products such as clothing, inks, and home paints.

Cost

Because they are less hazardous to the environment, to workers, and to customers, water-based products often do not require specialist hazardous waste disposal. This lowers production costs and increases profit margins for companies and manufacturers. 

Versatility

Water-based emulsions are highly versatile, offering impressive customizability for a range of industries, performance needs, and intended uses. Their adhesion, durability, heat resistance, moisture resistance, and aesthetic appearance (if any) are all customizable to make them suitable for any specific application by altering the formulation. 

Water-Based Solutions for a Cleaner, Greener Future 

As sustainability and protecting the planet become increasingly pressing concerns, industrial manufacturing companies are increasingly turning to water-based products over less environmentally friendly solvent-based options. From paints and coatings to clothing materials, electronics, inks, and more, these eco-friendly solutions will continue to play a crucial role in the industrial manufacturing space.

As a market leading manufacturer and distributor of quality products for clients seeking value throughout their supply chain, IGI offers a range of water-based coatings formulated for the paper packaging industry under our Enviro Coatings brand. Our Aquaban, Barrier Grip, and Vapor Guard products have been developed to provide varying levels of barrier performance depending on customers’ needs. 

Please get in touch with us to learn more about anything we have covered in this post or how IGI’s range of products can help manufacturers like you meet your sustainability goals.