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Electrocoat – Formulation and Technology

European Coatings Library

Michael Brüggemann

Anja Rach


Formulation and Technology


Electrocoat is a widely used technology designed to paint all different kind of metal parts and car bodies effectively. It impacts our daily life, but it is not known to the public and even for paint chemists it is a technology for specialist only.

This book gives an overview and access to the paint deposition including the resin and paint technology, the electrocoat process, line design and provides a troubleshooting guideline for end users.

It is written for people looking for an introduction into electrocoat technology, for career-changers, and professionals using the electrocoat process to paint conductive metal parts.

In first chapter the book provides information about the historical context, the markets for use and the economic impact of electrocoat.

The 2nd chapter provides insights into the theory of electrocoat deposition, while Chapter 3 gives an overview about the resin technology of anodic and cationic electrocoats. Basic paint formulation for anodic and cationic electrocoats are explained in Chapter 4 in addition to a description of paint performance. It gives insights into electrocoat cure, into physical properties of the cured films, into corrosion protection given by electrocoats including throw power to protect inner parts of the painted article.

Chapter 5 gives an overview of electrocoat line design including metal pretreatment and line engineering background with an overview of essential parts of the process.

Answers important for running electrocoat lines and guidelines to solve some typical electrocoat problems are given in Chapter 6. It is intended to be practical and to provide some ideas on how to control and to maintain electrocoat bath and quality.

Finally, Chapter 7 gives a foresight of electrocoat technology for the coming years and compares it to paints applied by autophoresis.

The book provides useful information and insights into electrocoat technology and process. It gives an overview of the different technologies and paints to protect and to coat metal parts in a highly automated process. We hope it presents utilization to students, paint developers and professional industrial users.

We would like to thank all colleagues who have provided information on specific topics, figures and structures. Especially Prof. Dr. Thomas Brock being co-author in Chapter 2.

We thank Dr. Greggory McCollum, Dr. Richard Karabin and Dr. Steve R. Zawacky for their advice and for reviewing Chapters 3 to 5, Uwe Kuhlmann and Detlef Hildebrandt for the figures in Chapter 2, Klaus Platte for the recommendations in Chapter 6, and Skip Tornow for his review.


Viersen and Paderborn, January 2020


Michael Brüggemann

Anja Rach