How Many Additives Are Needed in 100kg Paint Formula?

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When formulating paint, raw materials like resin and pigment often take the spotlight — but it’s the additives that truly define quality, stability, and application performance.

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In a 100 kg paint formula, the total additive content typically ranges from 1% to 5% (that is, 1–5 kg of additives), depending on the paint type, resin system, and desired properties like wetting, leveling, anti-foaming, and dispersion.

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Additives may be small in proportion, but they have a huge impact on viscosity, color uniformity, and film appearance. Let’s break down how many additives are actually needed in a 100 kg paint batch — and how to determine the right balance for your system.

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Why Paint Additives Matter

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In paint formulation, every component has a role — pigments give color, resins bind, solvents dissolve, and additives fine-tune performance.

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Additives help paints flow better, disperse pigments evenly, resist corrosion, and maintain long-term stability. Without them, paints would foam, separate, or leave brush marks.

Common Functions of Paint Additives:

1. Dispersants: Stabilize pigments and prevent settling.
2. Wetting Agents: Improve surface coverage and adhesion.
3. Defoamers: Eliminate bubbles during mixing and application.
4. Leveling Agents: Enhance film smoothness.
5. Thickeners: Control viscosity and prevent sagging.
6. Anti-corrosion Agents: Protect metal substrates.
7. Biocides & Preservatives: Prevent microbial growth in water-based systems.

Donghong Chemical’s phosphate ester surfactants — such as NP-10 and AEO-3 — are widely used as wetting and dispersing agents in high-quality coatings.

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Basic Calculation: Additives in a 100 kg Paint Formula

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Let’s start with the core question — how many additives go into a typical 100 kg paint formulation?

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The general range is 1–5% of total paint weight, translating to 1–5 kg of additives per 100 kg. The exact amount depends on formulation type:

Paint Type	Typical Additive Range (%)	Additives (kg in 100 kg Paint)	Notes
Waterborne Acrylic Paint	3–5%	3–5 kg	Requires dispersants, defoamers, coalescents
Solvent-Based Alkyd Paint	1–3%	1–3 kg	Lower surfactant load, more driers
Epoxy Primer	2–4%	2–4 kg	Anti-corrosion & leveling essential
Polyurethane Coating	1–2%	1–2 kg	Uses wetting and anti-cratering agents
Metallic Paint	3–5%	3–5 kg	More dispersants and anti-settling agents

Key Principle:
Additives should be the smallest yet most effective part of the formula — enough to stabilize and enhance performance, but not excessive to cause incompatibility or cost inflation.

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Typical Additive Composition Example (100 kg Paint)

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To visualize how additives fit into your paint formulation, let’s examine a typical water-based acrylic paint recipe.

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In this 100 kg formula, the total additive load is around 4.2 kg, distributed among several key functions:

Additive Type	Function	Dosage (%)	Weight (kg)
Dispersant (NP-10 Phosphate Ester)	Pigment dispersion & wetting	0.8	0.8
Wetting Agent (AEO-3 Phosphate Ester)	Substrate wetting, adhesion	0.5	0.5
Defoamer	Bubble removal	0.2	0.2
Leveling Agent	Film smoothness	0.3	0.3
Thickener	Rheology control	1.0	1.0
Coalescent	Film formation	1.5	1.5
Preservative	Microbial protection	0.1	0.1
Total Additives	—	4.2%	4.2 kg

The rest of the paint (95.8 kg) consists of resin, pigment, water/solvent, and fillers.

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Dive Deeper: The Role of Phosphate Ester Surfactants in Paint Additives

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Phosphate esters are some of the most versatile surfactants used in coatings — multifunctional, eco-friendly, and performance-enhancing.

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They serve as wetting, dispersing, and anti-corrosion agents, improving coating smoothness, gloss, and adhesion.

Key Donghong Chemical Products:

1. NP-10 Phosphate Ester — For pigment dispersion and low-foam wetting in acrylic and epoxy coatings.
2. AEO-3 Phosphate Ester — For enhanced adhesion and wetting in waterborne paints.
3. TEP (Triethyl Phosphate) — Flame retardant and solvent additive for PU and epoxy systems.
4. P204 (2-Ethylhexyl Phosphate) — Improves metal adhesion and anti-corrosion performance.

Benefits of Phosphate Ester Additives:

• Excellent acid and alkali stability
• Biodegradable and low-VOC
• Compatible with most binders and resins
• Enhances flow, leveling, and pigment dispersion

Recommended Dosage: 0.5–1.0% of total paint weight (0.5–1.0 kg per 100 kg paint).

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How Additive Levels Affect Paint Properties

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Small percentage changes in additives can cause major formulation differences.

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Here’s what happens when additive levels deviate from the optimal range:

Additive Level	Result in Paint System	Outcome
Too Low (<1%)	Poor wetting, unstable dispersion	Uneven gloss, pigment settling
Optimal (1–4%)	Balanced viscosity, smooth finish	Stable film, consistent color
Too High (>5%)	Foam, delayed drying, phase separation	Reduced hardness, higher cost

Donghong Chemical’s phosphate ester surfactants maintain strong performance even at low concentrations, helping formulators reduce additive load without sacrificing quality.

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Dive Deeper: Balancing Additives with Resin and Pigment

In a 100 kg formula, additives interact directly with resins and pigments. The balance among these three determines paint quality:

Component	Typical Ratio (%)	Function
Resin (Binder)	25–40	Film formation and adhesion
Pigment & Filler	20–40	Color, opacity, texture
Additives	1–5	Stability and performance
Water/Solvent	15–35	Adjust viscosity and drying time

For optimal results, additives should be pre-dispersed with pigment slurry or added during let-down to maximize their efficiency.

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Practical Tips for Additive Optimization

1. Start Low: Begin with the minimum recommended dosage (0.3–0.5%) and increase as needed.
2. Test Compatibility: Not all additives mix well with every resin — always check stability.
3. Watch Foam Levels: Too much surfactant increases foam; balance with defoamers.
4. Control pH: Phosphate esters perform best between pH 6–9.
5. Track Viscosity: Overuse of dispersants or thickeners can shift rheology beyond control.

Example:
In a 100 kg batch, increasing NP-10 dosage from 0.8 kg to 1.2 kg can improve pigment dispersion — but beyond 1.5 kg, viscosity and leveling may worsen.

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Donghong Chemical’s Expertise in Paint Additives

Donghong Chemical (Guangdong, China) specializes in industrial phosphate esters and surfactants used globally in coatings, textiles, and lubricants.
Their products offer stable quality, low color (≤30 APHA), and high purity (≥99%), ensuring consistent performance in paint formulations.

Advantages:

• 20,000-ton annual capacity with automated esterification
• ISO9001/ISO14001 certified production
• REACH & RoHS compliance
• Technical support for formulation adjustment

Conclusion: Small Percentage, Big Performance

In a 100 kg paint formula, the total additive load typically ranges from 1 to 5 kg, depending on the paint type and desired performance.
Each additive — from phosphate ester dispersants to defoamers and thickeners — plays a unique role in ensuring paint stability, appearance, and application ease.

By maintaining precision in additive selection and concentration, formulators can produce paints that perform consistently under demanding conditions.

Donghong Chemical’s phosphate esters offer proven solutions for efficient wetting, dispersion, and anti-corrosion control — helping manufacturers get the most out of every 100 kg batch.

For formulation assistance or product recommendations:

📧 Email: dohollchemical@gmail.com
📱 WhatsApp: +86 139 0301 4781

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Donghong Chemical — Expert manufacturer of phosphate esters and coating additives, powering high-performance paint systems worldwide.