Protecting your Products and your Brands Overview of

Protecting your Products and your Brands Overview of Microbial Control Drywall Finishing Council September 18, 2012

Discussion Topics § “In-Can Protection” for Gypsum Finishing Products § § Need for In-Can Protection Failure Issues Testing protocols Ecolabels § “Mold Control” for Wall Board and Finishing Products § Paper § Gypsum Core § Testing protocols § Importance of Plant Hygiene and Raw Material Protection

In-Can Preservation 3

Types of Microorganisms Microbes Key Organism for In-Can Preservation Bacteria Fungi Mold Filamentous Algae Yeast Single cell 4

Bacteria Growth Requirements § Water § Degradable nutrient source containing carbon § Latex emulsion § Cellulosic thickener § Favorable temperature § ~25 to 37°C § Varying oxygen concentrations § Favorable p. H § Bacteria: acidic or alkaline § Fungi: acidic 5

In-Can Issues due to Lack of Preservation § Odor § Discoloration § Viscosity change § Off-gassing § Lack of product performance for consumer 6

In-can Preservation Example Solvent Water Additives Binder Pigments Unpreserved paint Spoiled paint § Historically solvents have aided product preservation Solvent Water Low VOC Additives Binder Pigments 7

Wall Finishing Products Needing Protection § Premixed Compounds § Similar to Paint example § Potential contamination from Raw Materials § Bacterial inoculation in product use § Dry Mix Compounds § Product is contaminated in mixing process § Contractors retain mixed product for days/weeks 8

Detecting and Enumerating Bacterial Contamination in Products and Raw Materials § Dip slides § Streak plates Applicable to manufacturing facilities and formulation labs § Agar plate swabs § Dilution plating (agar) § Total viable counts (TVCs) 9

Dip Slides § Agar on a paddle § Bacterial agar side 1 § Fungal agar side 2 § Common brands § Hycheck § Easicult (TTC indicator dye) § Quick and easy to use § Solid surfaces § Water-based materials § Best used for +/- contamination evaluations 10

Dip Slide Bacteria Enumeration § Approximate CFU/m. L measurements can be determined in liquid materials (very rough estimate) § CFU/m. L = Colony Forming Units per milliliter = number of cells § Difficult to read due to product viscosity and colony color § Dilution of product may be required (sterile water) § TTC indicator dye is helpful Paint: assume ~1 m. L deposited ~1 x 101 ~5 x 101 ~102 - 103 >103 Latex or slurry: assume ~0. 25 m. L deposited ~5 x 101 ~2. 5 x 102 ~102 - 103 CFU/m. L measurements ~103 - 104 >104 11

Streak Plates § Swab product on agar § Sterile swab § Agar plate (TSA) Commercially available § ~0. 1 m. L spread evenly on agar surface § More accurate than dip slides § Approximate volume known § Easier to read due to spreading of product § Standard challenge test “streaks” § Rating score commonly used instead of CFU/m. L values 12

Streak Plate Scores Sample A Sample B Sample C Sample D Passing score: 0 or 1 Failing score: 2 - 4 Score: 4 3 0 0 Plating Results Score Approximate CFU/m. L No detectable survival 0 < 1 x 101 1– 9 colonies 1 1 x 101 - 9 x 101 10– 99 colonies 2 1 x 102 – 9. 9 x 102 100– 300 colonies 3 1 x 103 - 3 x 103 >300 colonies (smear) 4 > 3 x 103 13

Dilution Plating § Total viable counts (TVCs) § Product sample is serially diluted to thin out the microbe population § Exactly 100 µl is evenly spread on an agar plate surface § Cells grow into colonies for counting and CFU/m. L determination § Accurately enumerate from 101 to 109 CFU/m. L § Time consuming as compared to streak plates and dip slides 14

Dilution Plating 10 -6 dilution Sample A Sample B 10 -7 dilution 10 -8 dilution 3 x 108 CFU/m. L 8 x 108 CFU/m. L 15

High-Throughput Challenge Evaluations Dow Proprietary Methodology § Validated to standard agar plate tests § Generate large amounts of comparative performance data § Quickly evaluate combinations for synergy or antagonism § Important for biocide optimization studies as VOC content becomes lower § In-can preservative plus co-biocide § Compare lab strains vs. manufacturing facility contaminants 16

Ecolabels – Steps towards Sustainability § Originated primarily in USA and Europe § Rapid global expansion – over 330 ecolabels § Ecolabels certify final consumer products, however have lists of accepted ingredients and/or ecological criteriea § Most prohibit ingredients that could be classified as: carcinogens, mutagens, reproductive toxins, hazardous air pollutants, or ozone-depleting compounds 17

Sustainability Staircase Future Sustainability Most Sustainable More Sustainable Not Sustainable 18

Surface Protection 19

Surface Problems …. Microbial Growth Algal Growth Humidity Nutrients Fungal Growth Temperature Sunlight

Types of Microorganisms Microbes Bacteria Fungi Mold Key Organism for Surface Protection Algae Yeast 21

Mold Issues with Wallboard and Finishing Products § Gypsum is hygroscopic and therefore can act as a reservoir of moisture to sustain mold § Both paper liners and additives to gypsum core and finishing products serve as carbon sources for mold § Presence of moisture necessary for mold growth

Other Potential Issues with Mold § Vinyl Wallcovering with either fabric or cellulosic backings § Wallcovering adhesives and sealants § Coating surfaces § Wood used in basic construction

Control of Mold § First line of defense are engineering considerations. Mold spores are everywhere and conditions of moisture must be right. § Since impractical at times and tight controls are not easily kept, “Material Preservation” is needed. § If possible, as many of the susceptible building materials should contain an effective fungicide that has a good environmental profile, is compatible with the substrates and of course safe to incorporate and an acceptable risk to the end use customer.

Prevention of Dry Film Contamination: Add Effective Biocides § Physical properties requirements § § § Low water solubility p. H stable Compatible with wide range of products No effect on product properties No color Low mammalian toxicity and low ecotoxicity § Efficacy § Against targeted microbes 25

Laboratory Methods for Measuring Fungal Resistance of Surfaces ASTM D-3273: Resistance of a surface to mold growth via exposure in an environmental chamber (Coatings Test)

ASTM G-21: Determining the Resistance of Synthetic Polymeric Materials to Fungi § Method designed for polymers § Direct inoculation § Aspergillus niger, Penicillium pinophilum, Chaetomium globosum, Trichoderma virens (Gliocladium), Aureobasidium pullulans § Samples in petri dish with agar § 0 -4 scoring

ASTM 5590 : Resistance of Coatings to Fungal Growth

TAPPI T 487: Fungus Resistance of Paper and Paperboard TAPPI T 487 VARIOUS TREATMENTS

Industrial Hygiene 30

Industrial Hygiene (IH) § Improving a manufacturing site’s physical condition, cleaning practices and sanitization procedures with respect to controlling and minimizing microbial contamination § Dual approach § Manual cleaning § Biocide treatments § Proactive microbial control § Minimize manufacturing facility (“wild”) strains § Maximize in-can preservative longevity and product shelf-life 31

Importance of IH § “Green” movement § Products are more susceptible to spoilage § Use of natural materials § Minimization of ingredients § Less robust in-can preservative systems § Eco-certification programs § Lower biocide use levels § Increased use of less effective biocides § More difficult to eliminate waste (“wash”) water § Equipment cleaning § Use in finished products 32

Consequences of Poor IH Practices § Manufacturing facility impact § Plugged filters, transfer lines, and spray nozzles § Equipment corrosion § Pump/machine failure § Facility operations interrupted § Decreased production rate § Finished product contamination § Consumer complaints § Product recalls 33

Reducing Microbial Dissemination § Internal industrial hygiene auditing § Visual inspections (spoilage, odor) § Establish a stringent microbial sampling process (monthly) § Dip slides (raw materials, paint) § Swabbing to agar plates (equipment, raw materials, paint) § In-house testing capabilities § 3 rd party laboratory for microbial analysis § Plant audit by biocide supplier § 1 x per year 34

Reducing Microbial Dissemination § General housekeeping § Focus hygiene efforts on high water content areas § Clean aqueous spills immediately § Eliminate stagnate water (floor, trenches) § Equipment storage § Avoid resting equipment on the floor § Transfer hoses, weigh-off buckets, sample dippers § Close tank lids and cap hoses, lines, ports § Flush, drain, dry, cap/cover 35

Conclusions § Dry wall applications present real opportunities for advanced Microbial Control § In Can Preservation § Mold Control § Manufacturers can gain real value by partnering with a key biocide supplier 36

Dow Microbial Control Industry Leadership • Largest portfolio of globally registered biocide active chemistries – Biocides to protect the finished product from mold and mildew (e. g. fungicides, algaecides) – “Wet-state” preservatives – in-product and process – Biocides for decontamination (clean-up) and disinfection • Best in class microbial testing capabilities • Global manufacturing and supply • Global product registration and stewardship – Product handling/safety expertise, regulatory support 37

Customer Application Centers: Laboratory Facilities Buffalo Grove, Illinois, USA Spring House, Pennsylvania, USA Buchs, Switzerland DMC Center of Excellence: Microbiological Methodology DMC Center of Excellence: Actives Delivery DMC Center of Excellence: Formulations Dubai, United Arab Emirates Shanghai, China Soma, Japan Querétaro, Mexico São Paulo, Brazil Mumbai, India Singapore Altona, Australia Warsaw, Poland