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Prof. Ludwik Synoradzki has been the head of the Laboratory from the very beginning. In this interview, the Professor and Marcin Koziorowski (YLIA) are talking about ikorol, which is an LPE product protecting surfaces and eliminating the need to carefully remove old paint and rust. ikorol is the holder of the diploma of the Polish Corrosion Association which also awarded this invention the honourable title of the Product of the Year 2015 during the competition for the best anti-corrosion product.

How long does it take to develop and market a product which leaves a research institute to be sold in shops?

We began working on ikorol over 20 years ago. In 1995, we were approached by our colleagues from the Department of Precision Mechanics who needed a corrosion inhibitor for anti-corrosion paints. As soon as we found which component was needed, we developed the indispensable technology. Having made sure that all was functioning without a problem we released the substrate ready for further development. As part of our targeted project (years 1998-2003) we built an entire research and production installation (in 2000). The corrosion inhibitor produced by us was added directly to paints advertised as possessing anti-corrosion properties. Unfortunately, the development was not so rapid as we had expected. Therefore, we had this idea of producing something which would act as a primer under the final paint coating.

Do all the inventors come from the Warsaw University of Technology?

L.S.: No. Apart from me, Krzysztof Bujonowski Dr.Eng (chief process engineer) and Jerzy Wisialski Dr.Eng (chief designer) come from our university. The remaining two experts do not come from here: Jacek Bordziłowski Dr.Eng (corrosion and anti-corrosion protection expert), and Agnieszka Królikowska Dr.Eng (corrosion and anti-corrosion protection specialist), WUT graduate.

What are the biggest benefits of using ikorol?

L.S.: ikorol extends the life expectancy of paints from 5 to even 10 years and improves the adhesion of new coatings to the surface and old paint. But you have to remember that a surface treated with ikorol needs painting. Only then will we achieve the effect of synergy. Moreover, the product is used directly on rust and there is no need to carefully clean and prepare the surface. Of course, you cannot do it with rust peeling off but no rust-coloured layer stands a chance against ikorol. It can be used in situations where grinding and sandblasting are out of the question due to static electricity possibly resulting in an explosion, for example in refineries. Therefore, our portfolio contains such jobs as painting the fuel tanks in Płock, painting high voltage pylons where the final paint coating remains stretchy. Our big recipients say that they really appreciate the fact that we paint once every few years and there is no need for repainting those constructions that are so difficult to paint.

Which technologies speed up the drying process of subsequent layers?

M.K.: We recommend putting an even layer which is as thin as possible, that is when you will get the best results. Two coatings are recommended only in the case of a thick layer of rust. In the course of our research we observed that a layer of rust treated with ikorol is active for another 2 years. During this time, ikorol keeps penetrating deep into the layer binding rust in deep corrosion pits and cracks more and more effectively. Moreover, the adhesion of paint coatings to the surface keeps improving for up to 2 years.

Is it possible for rust to return after being treated with ikorol?

L.S.: Yes, if we are talking about chips or scratches. However, we should remember that a paint coating or a varnish layer are indispensable as their mechanical resistance is much bigger than that of ikorol. ikorol is a binder joining the old coating with the new one. The active ingredient of the preparation has a complexation fragment and a fairly long bicarbonate chain. That’s why it binds rust and other metal compounds and then the paint itself. The active ingredient – oximes in this case – is also used in the process of extraction of heavy metals - such as copper and zinc - from wastewater.

How long before ikorol gets dry?

L.S.: About 60 minutes. This is a very short drying time and no competitor is close to matching it. Besides, ikorol is never entirely dry. It is supposed to remain sticky. It is this strong point that allows it to penetrate and bind even the lowest layer. In paints the active ingredient was mixed with the whole of the paint so its concentration on the surface painted was relatively low. However, using ikorol we always have the optimum concentration of the binder, which does not add to the thickness of a paint coating.

When applying the product is there a smell caused by the chemical reaction?

L.S.: We can only smell the solvent due to the isopropanol that it contains. The remaining ingredients are not really volatile. ikorol is environment-friendly. It contains no acids and no heavy metals and its production does not generate waste. This innovative technology was developed in such a way as to put the active ingredient in a carrier that is as friendly as possible to health and the environment.

Have you tried to apply the product to surfaces other than steel or galvanised steel?

M.K.: Due to its complexion properties our product can be used on copper and zinc which is very difficult to paint on. ikorol improves its adhesion and stops the phenomenon of white corrosion, in other words – zinc corrosion. The production of gates often involves galvanisation and the product will prevent a paint coating from peeling off. We can use ikorol when renovating objects because a thin and transparent coating will protect them from oxygenation and corrosion. It can be applied to the surface of museum exhibits or valuables. ikorol is available in liquid and spray form.

Have you thought about other forms, for example a kind of paste that would act as a unique concentrate?

M.K.: We have not stopped looking for more ways in which our product could be applied. We are considering the automotive industry where manufacturers have a whole range of products at their disposal, for example for internal profiles in cars or for inner wheel housing. We would like to modify ikorol in a way that would allow us to use our active ingredient in the best possible way, for example in the manufacturing of anti-corrosion lubricants. We are also thinking about anti-corrosion mousse for filling cracks. Our next challenge will focus on volatile corrosion inhibitors which leave no stains and which could be used for the purposes of military equipment maintenance.

L.S.: We are thinking about an ikorol product family. Let me add that to sell the product through supermarkets you need product diversification, for example spray cans of different capacity. That is why we are working on a wide range of anti-corrosion products with the same properties as those of ikorol and of its active ingredient. So it could be paste form just as well.

Have you managed to earn from the sale of the product yet?

L.S.: For the time being our earnings are not quite satisfactory. Our income must at least cover our costs. Apart from packaging, the whole production process takes place at the Warsaw University of Technology. You buy the product online visiting ikorol’s online shop. We have no sales department as such but we successfully sell the product to retail and big industrial customers.

Your plans for the future?

L.S.: Generally, we intend to export the product worldwide. You can use it to treat rusty footbridges which – even in New York – can be seriously neglected, just like in our country. Therefore, we have lodged a foreign patent application. Unfortunately, this is a costly procedure in the region of PLN 200,000. The Polish patent application process allows the University to cover some of its costs but it provides no funds to cover foreign patents. You have to remember that patent applications need to be filed separately in each country and that a particular patent is valid only where granted. The same goes for certificates. Each industry has its regulations and recommendations. Therefore, a separate recommendation is needed every time. This means additional expenses.

This is where we enter the world of commercialisation and technology transfer on a large scale. The Warsaw University of Technology has established the Institute of Applied Research (IAS), which is a special purpose vehicle expressly authorised to deal with these things. It is with its help that we found a strategic partner – the company YLIA Ltd. It will deal with winning the market for our products or looking for funds facilitating the construction of a production installation. Owing to this company we were able to lodge that foreign patent application. YLIA allows us to take ikorol to a completely different level.

Latest news: a spin-off company called ikorol ltd. was established in May, with the authors of this technology as its shareholders - IAS on behalf of the University and YLIA as a business partner. The company ikorol will market the product both in the country and abroad and will increase its production if necessary.

As told to: Izabela Koptoń-Ryniec

source. WUT Bulletin