Foam control from production to

the final application

State-of-the-art additive solutions for highest aesthetic demands

BYK Seminar: Additives for aqueous and solvent-borne systems

Annika Winkelhausen, Business Development Floor Coatings

Defoamer theory
What is foam?

Source: © fotomek / www.stock.adobe.com

Page 2 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer theory
Causes of foam

Air from the substrate Absorbed air from fillers/pigments

(wood, concrete, ...)

Incorporated air Reaction bubbles

(caused by production process, application) (e.g., carbon dioxide in PU systems)

Page 3 2/18/2025 Additives for aqueous and solvent-borne systems

Mechanisms of foam stabilization
Influence of viscosity - Bubbles rise to surface

Bubbles rise to the surface with a velocity dependent of the viscosity of the liquid.

Larger foam bubbles are easier to defoam, microfoam is difficult to defoam.

r2
__
V~  Stoke's
law

V = Velocity of rise
r = Bubble radius
 = Viscosity of liquid

Page 4 2/18/2025 Defoamersfor aqueous and solvent-borne systems

Additives
Mechanisms of foam stabilization
Electrostatic / steric repulsing double layers

The critical thickness to break the lamella is 10nm

non-polar tail
Surfactant: Repulsion of surfactants prevents
polar head complete drainage of foam lamellas

Page 5 2/18/2025 Additives for aqueous and solvent-borne systems

Mechanisms of foam stabilization
Gibbs-Marangoni-Effect (elasticity)

compression of the stretching of the

lamella lamella

γ - Δγ
γ + Δγ

Surface tension (γ) depends on surfactant concentration at the surface. Higher elastic behavior means
stronger foam stabilization, because
Transport of surfactant / water mixture in the direction of the blue arrows. the system is balancing itself
Page 6 2/18/2025 Defoamersfor aqueous and solvent-borne systems
Additives
Mechanisms of foam stabilization
Gas diffusion

The size of neighboring foam bubbles differs

→ Inner pressure in small bubbles is higher than in large bubbles

p1 > p2

p1 p2

Gas diffusion: large bubbles grow at the expense of small bubbles (Ostwald ripening)

Gas diffusion can stop because of saturation of the interface with surfactant molecules

Page 7 2/18/2025 Defoamersfor aqueous and solvent-borne systems

Additives
Defoamer theory
Potential defects for production and performance of coatings

➢
Air Insufficient mixing and pigment dispersion
from the substrate Absorbed air from fillers/pigments
(wood, concrete, ...)
➢ Long production time (e.g. filling of drums)

➢ Poor application properties (e.g. brushing, rolling, spraying, …)

➢ Poor visual appearance (e.g. gloss reduction, craters, fish-eyes, …)

➢ Decreased performance properties (e.g. water or chemical resistance, …)

Page 8 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer theory
Destabilization of foam lamella

Foam stabilization Destabilization by Destabilization by Destabilization by

dewetting hydrophobic particles spreading

Defoamer droplets enter the foam lamella & destabilizes it

Page 9 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer theory
Spreading of defoamer

• Water surface is
marked by
hydrophobic powder

• Addition of one
droplet defoamer

→ Fast spreading

Page 10 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer chemistry
Different kinds of defoamer

Silicone defoamer

• VOC-free/ emission free

• Broad range of efficiency and compatibility
• Potential sensitive to extreme pH values (pH >12)

Polymer defoamer

• Minor influence on surface tension

• Stability in broad pH range (pH 3-13)
• VOC-free/ emission free

Mineral oil

• Typical application: Architectural coatings

• Too incompatible for high gloss systems

Page 11 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer chemistry
Silicone defoamer

Unmodified not suitable for R1: Organic modification

waterborne coatings!

Reduction of surface tension

Leveling Surface slip Defoaming Hammer tone

Compatible Incompatible

Page 12 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer chemistry
Organic modification of silicone defoamer

Aralkyl

Polyurethane Polyester CH3 CH3

(CH3)3Si O Si O Si O Si(CH3)3
CH3
z

Modification
Perfluor alkyl Polyether (EO/

Organic
PO)
y
Alkyl chains

Page 13 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer chemistry
Organic modification of silicone defoamer

CH3 CH3

(CH3)3Si O Si O Si O Si(CH3)3
CH3
z

Modification
Organic
y

Controling compatibility Polydimethylsiloxane

• Increased compatibility EO (PEG) • Reduced surface tension

• Decreased compatibility PO (PPG) • Defoaming action by spreading

Page 14 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer chemistry
Polymer defoamer

Hydrophobic
acting polymer Delivery forms:
Sufficient to act Solutions,
as defoamers 100%, emulsions

Broad variety
in chemistry, With or without
monomers and Silicone
final molecular
weight Also, in
conjunction with
hydrophobic
particles

Page 15 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer chemistry
Mineral Oil defoamer

Basic formulation

▪ Mineral oil dominates the

formulation

▪ smaller product range compared to

e.g. silicone defoamers Component %

▪ Also available as emulsions Mineral Oil 85 – 95

Hydrophobic particles 1-3
▪ In the past, mineral oil-based
defoamers contained APEO, the Emulsifier 3-6
current product recommendations
are APEO-free
Modified silicone 0,5 - 3

Page 16 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer: How to use?
Droplet size as function of incorporation parameters

Droplet size
Small Large of defoamer

Substrate Shear / Time Substrate Shear / Time Substrate

Too compatible/ over Optimized Too incompatible/ Poor

emulsified compatibility emulsification
• Poor defoaming • Good defoaming • Good defoaming

• Good leveling & no crater • Good leveling • Poor leveling & crater

Page 17 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer: How to use?
It is up to the right balance!

The perfect defoamer: perfect defoamer

incompatible but
▪ being incompatible no defects
defoaming (craters / de-wetting)
▪ low surface tension Substrate wetting

▪ good spreading ability

defects incompatible /
compatible
foam insoluble

Turbidity

foam stabilization

Foam issues Crater

Page 18 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer: The right handling
Do & Do not in handling of additives

Do Do not
Selection and handling Dilution of defoamers
Syneresis
✓ Check for available shear forces & Do not dilute with water or organic
duration of incorporation solvents
✓ Determine suitable levels High likelihood of performance loss
✓ Series of levels
✓ Typically 0.05 – 1.0% *
✓ In exeptional cases >1.0%* Ignore instructions on label Syneresis
✓ Check for undesired side effects Ignore storage and transport
✓ Test storage stability (e.g. 2W/40°C) temperatures
Water borne defoamer emulsions
shall be stored between +5 und
Follow instructions on label +40°C
✓ Homogenize defoamer before usage Phase separation

* Supplied form on total

Page 19 2/18/2025 Additives for aqueous and solvent-borne systems
Defoamer
Different test methods

Process related Application related Customer related

defoaming defoaming testing
Roller application
Brush application e.g.
Stomping machine
Spray application Foam behaviour after
Measurement of density
Test on spontaneous incorporation of colorants
defoaming
Pour out test

Page 20 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer
Roller application

Test method

▪ 30g sample

▪ Application
2.5 crosswise

▪ Film thickness
200-250g/m2

Page 21 2/18/2025 Additives for aqueous and solvent-borne systems

Defoamer
Different test methods

Pouring out into a petri-dish Application by trowel

The sample is mixed with the hardener for 1min. at 2m/s.
Then 30g of the sample is poured directly into a Petri dish.
After one night curing at room temperature the foam and the
surface of the samples are evaluated visually.

Fix tape around the The mixed sample is added

outside of the panel onto the PE panel

Spread the material with a Spread the material with a

notched trowel in a notched trowel
destructive way to
incorporate foam.
Page 22 2/18/2025 Additives for aqueous and solvent-borne systems
Page 23 2/18/2025 Additives for aqueous and solvent-borne systems
Foam-free surfaces
Product overview for water-based systems

high
BYK-1780 BYK-017* / BYK-1707 Silicone defoamer
BYK-044 BYK-1781 BYK-1730 with hydrophobic
BYK-018 BYK-012 BYK-1719 particles
BYK-1642 BYK-021

BYK-1785 BYK-1640 BYK-022 BYK-014 Silicone defoamer

BYK-1641 BYK-019* / BYK-1709
Shear force incorporation

BYK-1723 BYK-023 without hydrophobic

BYK-1786 particles
BYK-1616 BYK-092
BYK-1789
BYK-1710 BYK-1740
Polymer defoamer
BYK-1724 BYK-024 BYK-094
BYK-015
BYK-1770
BYK-1611 BYK-1745 BYK-1650 Polymer
defoamer +
BYK-1617 silicone tip
BYK-093
BYK-1711
BYK-028 Bio-based
defoamer
BYK-025 BYK-011 BYK-016
low
low Time of incorporation high

Page 24 2/18/2025 Additives for aqueous and solvent-borne systems

BYK-1740
Green benefits at one glance

100 % vegetable oil derivatives based on renewable

resources replacing exhaustible mineral oil

VOC-free (<1500 ppm)

Non-volatile matter: 100 %

Designed to formulate modern “green coatings”

Meets worldwide Ecolabel standards BYK-1740

Formaldehyde-free (according to VdL RL-03)

Biodegradable

Page 25 2/18/2025 Additives for aqueous and solvent-borne systems

BYK-1740
Outstanding defoaming during production process
Test system:
Millbase after grinding (20 min. at 12 m/s) Millbase of an
emulsion paint
based on styrene-
acrylate, PVC 61%

W/o defoamer 0.2% Mineral oil defoamer 0.2% BYK-1740

100% bio-based

Page 26 2/18/2025 Additives for aqueous and solvent-borne systems

BYK-1740
Excellent defoaming during application
Test system:
Roller application of final paint emulsion paint
based on styrene-
acrylate, PVC 61

Incorporation
W/o defoamer + 0.1% Mineral oil defoamer + 0.1% BYK-1740 3 min at 2 m/s

Applikation:
Roller application,
200-250 g/m2

Evaluation:
Macro und Micro
foam after
application

Suitable as process defoamer and to prevent foaming during application

Page 27 2/18/2025 Additives for aqueous and solvent-borne systems
BYK-092
Benefits on a glance

VOC-free silicone defoamer

Introduction in grind or let-down

Outstanding applicability in different systems

Strong defoaming action already at low dosages

Suitable for different application methods (Roller, Brush, Spray …)

BYK-092

High transparency in clear coat

No/ minor influence on cratering tendency

Page 28 2/18/2025 Additives for aqueous and solvent-borne systems

BYK-092
Superb transparency in clear coat systems

Roller application on transparent PET-foil Test method

Test system:
High gloss clear
coat based on
Setaqua 6756
0.3% BYK-092 0.3% BYK-092
W/o defoamer Incorporation
before storage after 2W/40°C 3 min at 2 m/s

Application:
Roller application,
on transparent
PET foil

Evaluation:
Macro und Micro
foam,
transparency

Defoaming action in conjunction with low impact on transparency

Page 29 2/18/2025 Additives for aqueous and solvent-borne systems
BYK-092
Excellent defoaming action in highly filled systems

Test method
Emulsion paint based styrene crylic binder, Emulsion paint based on vinyl acetate & Test system:
PVC 61% ethylene, PVC 84% Emulsion paints
5 5 With different PVC
level

4 Incorporation
4 3 min at 2 m/s

Application:
3 3 Roller application

Evaluation:
2 2 Macro- und Micro
foam
1: Good result
1 5: Poor result
1

0 0
Control w/o
Control BYK-092
BYK-092 Siliconedefoamer
Standard defoamer Control w/o BYK-092 Standard defoamer
defoamer defoamer

/ Macro foam before storage / Macro foam after 2W/ 40°C

/ Micro foam before storage / Micro foam after 2W/ 40°C

Page 30 2/18/2025 Additives for aqueous and solvent-borne systems

BYK-178X family
Benefits on a glance

VOC-free silicone defoamer

Eliminate micro-foam generated during application

Excellent for various applications in particular HVLP / Airless / Airmix

Excellent defoaming in several systems, e.g. – Pure acrylics -

Aqueous UV-Systems - Water-borne 2-pack PU-systems

BYK-178X
High transparency and clarity in clear coats

Family contain concentrates and emulsion defoamer

Page 32 2/18/2025 Additives for aqueous and solvent-borne systems

General Overview
Defoamer for airless/airmix applications

higher BYK-1789* BYK-1780*

BYK-1781*
Defoaming Properties

BYK-1786
BYK-1785
Silicone defoamer with
hydrophobic particles

Silicone emulsion defoamer

with hydrophobic particles
BYK-1770*
Silicone defoamer
without particels

lower
*100% solids content
low Incompatibility
high

Page 33 2/18/2025 Additives for aqueous and solvent-borne systems

Foam formation depends on the application method

200µm 200µm

Conventional Application Airless Application

• Less foam • A lot of foam

• Mainly macrofoam (>100µm in • Predominantly microfoam
diameter) (Size 10 µm to 70 µm in diameter)
• Few microfoam • No or minor macrofoam formation

Magnification 220x; WFT 250µm

Page 34 2/18/2025 Additives for aqueous and solvent-borne systems

BYK-1786
Foam evaluation in different aqueous systems

Micro foam in clear coats Micro & macro foam in acrylic high gloss
Test method
Airless application emulsion top coat
Test System
Roller application See title
5 5
Dosage
1.0% as supplied on total
formulation by post addition

Incorporation
4 4 3 minutes at 2 m/s

Application
Sprayed by Graco Airless
Spray Equipment
3 3 onto Plexiglass panels
Nozzle size: 11/1000 inch
Pressure: 110 bar
Wet film thickness: ~175 µm

Application
2 2 Roller application by
Moltopren roller

Evaluation
1 = very good
1 1 5 = worse

0 0
Control BYK-1786 Competitor Control BYK-1786 Competitor 1
Micro foam in acrylic emuslion macro foam micro foam
Micro foam in acrylic co-polymer

Page 35 2/18/2025 Additives for aqueous and solvent-borne systems

BYK-1781
Excellent Transparency and recoatability

1% BYK-1781 1% Market Standard

Transparency
acrylic
copolymer

Recoatability
of customer
system

Page 36 2/18/2025 Additives for aqueous and solvent-borne systems

 Defoamer
selection for
solvent-borne and
solvent-free
coatings
End Use Deco and Floor Coatings

Page 42 2/18/2025 Additives for aqueous and solvent-borne systems

BYK Defoamer for solvent-borne and solvent-free systems
General overview

high
BYK-1796 BYK-1811 silicone defoamer
BYK-1799
BYK-1818 BYK-1815 BYK-1816 BYK-1810
BYK-1880 polymer / silicone
BYK-1856 defoamer
BYK-1759
BYK-1851 BYK-1852
BYK-1765 BYK-1760 BYK-1758 polymer defoamer
BYK-1790
Shear forces

BYK-054 T BYK-A535 BYK-1794

BYK-1795 BYK-1791
BYK-077
BYK-057 BYK-085
BYK-A530 BYK-1788 BYK-081

BYK-055 BYK-1748 BYK-141 BYK-070

BYK-088
All silicone based defoamer:
Cyclic siloxanes content below 0.1%
BYK-073

Incorporation time

Seite 43 2/18/2025 Additives for aqueous and solvent-borne systems

BYK-Additives for epoxy Floor Coatings
BYK-1796 – High performance defoamer

Silicone defoamer for solvent-borne and

Highly effective
solvent-free applications
defoamer
• Active substance 100 %

• Hydrophobic particles Yes

Low dosage
• Density (20°C) 1.00 g/cm3 levels needed
BYK-1796

• Flash Point > 100 °C

For high filled

systems
Page 44 2/18/2025 Additives for aqueous and solvent-borne systems
BYK-Additives for epoxy Floor Coatings
BYK-1796 – High performance defoamer

100% 2-pack epoxy formulations require an effective and fast

defoaming process even at high viscosities.

High viscous resin and hardener components lead to foam

building and foam stabilization in the production process and
application.

BYK-1796 can create foam-free applications, even at high

Resin: Bis-A resin
layer thicknesses. Hardener: Polyamide

BYK-1796 is added to the resin component. Foam is evaluated directly after

mixing the resin and hardener component and after curing of the formulation.

Left: control
Right: 0.5% BYK-1796

Page 45 2/18/2025 Additives for aqueous and solvent-borne systems

BYK-Additives for epoxy Floor Coatings
BYK-1796 – High performance defoamer

Note
2-pack solvent-free
epoxy flooring, highly filled with quartz sand
based on: EPON 828 / D.E.R.354
and Aradur 43-1 BD

Efficiency Defoamer

EFFICIENCY (1 = WEAK, 3 = STRONG)

BYK-1796

2 BYK defoamer

0
0.25 0.5 0.75 1

Control BYK-1796 DOSAGE DEFOAMER [%]

0.3% delivery form on Comp. A

Page 46 2/18/2025 Additives for aqueous and solvent-borne systems

BYK-Additives for epoxy Floor Coatings
BYK-1796 - Benefits

• BYK-1796 is an excellent defoamer and air release agent

• shows its effectiveness during both production and processing of the paint

• is especially suitable for solvent-borne and -free applications, like epoxy and polyurethane

systems

• is very effective in various systems especially in those with high viscosity and applied with

high film thicknesses

Recommended Levels

0.1 – 1.0% additive (as supplied) based upon formulation

Page 47 2/18/2025 Additives for aqueous and solvent-borne systems

BYK-Additives for polyurethane Floor Coatings
BYK-1794 - Emissions-free and silicone-free polymer defoamer

BYK-1794 offers a perfect balance between

defoaming efficiency & less impact on turbidity.

• 100 % solids, emission-free, VOC-free

• Meets AgBB standard, plus Swiss & French

regulations

• Highly effective defoamer for polyurethane, without defoamer 0.5 % BYK-1794

polyaspartic or epoxy-based systems

• Recommended for pigmented & non-pigmented

systems

• Effective during production & further processing

without defoamer 0.2 % BYK-1794

Page 48 2/18/2025 Additives for aqueous and solvent-borne systems

BYK-Additives for polyurethane Floor Coatings
The right equipment: dissolver vs. vacuum dissolver

Control [Dissolver] Control [Vacuum dissolver; -1bar]

Pictures were taken with a camera, no magnification

Page 49 2/18/2025 Additives for aqueous and solvent-borne systems
Circle: 30x magnification with DigiMicro 2.0 Scale
BYK-Additives for polyurethane Floor Coatings
The right equipment: dissolver vs. vacuum dissolver

0.50% BYK-1794 [Dissolver] 0.50% BYK-1794 [Vacuum dissolver; -1bar]

Pictures were taken with a camera, no magnification

Page 50 2/18/2025 Additives for aqueous and solvent-borne systems
Circle: 30x magnification with DigiMicro 2.0 Scale
Sustainability
Regulatory
drivers
Regulatory – Main driver for upcoming developments
Challenges in the coatings market - environmentally friendly coatings

• Regulatory topics are coming

up all over the world Fluorine-free

defoamer

• More and more regulations

influence the development of

VOC / SVOC /
new products.
Emission-free

• At BYK, we rise to these

challenges in order to always Ecolabel

be up to date.
compliance

Page 52 2/18/2025 Additives for aqueous and solvent-borne systems

PFAS-containing defoamers
Properties

✓ Excellent defoaming properties (wide formulation range) in

BYK-061
≤ 1.0% in DIBK & BuAc solvent-borne and solvent-free systems

✓ Spontaneous defoaming

BYK-065 ✓ Anti-pinhole effect

0.7% in Cyclohexanone
✓ Reduction of surface tension

✓ Positive influence on leveling and surface appearance

BYK-066 N
0.7% in DIBK ✓ No negative influence on transparency (provided

compatibility)

BYK-067 A ✓ Good storage stability

≤ 1.0% in PG

Page 53 2/18/2025 Additives for aqueous and solvent-borne systems

PFAS-free defoamers
Performance is at par with PFAS-containing defoamers

BYK-1810
✓ Excellent defoaming properties (wide formulation range) in 1% in BuAc

solvent-borne and solvent-free systems

BYK-1811
✓ Spontaneous defoaming 10% in BuAc

✓ Anti-pinhole effect
BYK-1815
✓ Reduction of surface tension
10% in BuAc

✓ Positive influence on leveling and surface appearance

✓ No negative influence on transparency (provided compatibility) BYK-1816

10% in BuAc
✓ Good storage stability
BYK-1818
1% in BuAc

Page 54 2/18/2025 Additives for aqueous and solvent-borne systems

Recommendations by end use
General Industrial Coatings

Highly recommended
Architectural Coatings
BYK-1815 – the all-rounder
• 1. recommendation
Floor Coatings • for clear and pigmented coatings

BYK-1810 – the strongest

• especially for 2-pack PU BYK-1815 BYK-1810 BYK-1816
General Industrial Coatings
BYK-1816 – the specialist
• for pigmented 2-pack PU topcoats
Wood and Furniture Coatings
Recommended

BYK-1811 BYK-1818
Marine and Protective Coatings
- the strong - the
millbase compatible
defoamer defoamer
Adhesives and Sealants

Page 55 2/18/2025 Additives for aqueous and solvent-borne systems

Results by end use
General Industrial Coatings

Results in a high-solid 2-pack PU system

Dosage as supplied

Control 0.3% BYK-066 N

0.3% BYK-061 0.3% BYK-1815

Page 56 2/18/2025 Additives for aqueous and solvent-borne systems

New PFAS-free defoamers

BYK-1815

BYK-1811
BYK-1810 BYK-1816
BYK-1818

Benefits Recommended end uses

✓ Excellent defoaming properties

✓ Spontaneous defoaming

✓ Anti-pinhole effect
✓ Reduction of surface tension

✓ Good storage stability

Page 57 2/18/2025 Additives for aqueous and solvent-borne systems

Foam control from production to the final application
Summary

• Optimisation of production & application conditions

• Minimize foam stabilizing raw materials
Foam (surfactants etc.)
prevention

Defoamer • Silicone defoamer

selection • Polymer defoamer
• Mineral oil defoamer

Right
handling • Time of addition
• Duration of incorporation
• Check available shear forces
• Series of levels is recommended
Perfect
result

Page 58 2/18/2025 Additives for aqueous and solvent-borne systems

Thank you for
your attention.