Rethinking Matting in Coatings: The Role of Polyethylene-Based Micronized Wax Additives as a Performance-Driven Alternative to Silica

Matte finishes have long been appreciated for their visual appeal across architectural, wood, and industrial coatings. Yet, the challenge persists: how do we preserve the aesthetics of low-gloss finishes while also improving their durability?

Traditional silica-based matting agents have served the industry for decades, but growing demand for performance enhancement, formulating efficiency—such as ease of dispersion, lower dust generation, minimal viscosity build-up, and longer service life has pushed the boundaries of what’s acceptable. In this context, polyethylene-based micronized wax additives—such as Honeywell’s NduroMatt® portfolio—are emerging as disruptive alternatives, delivering both functional superiority and formulation simplicity, as Honeywell NduroMatt^® can act as a multi-functional additive replacing several individual ingredients.

This article explores the evolving science of matting, contrasts polyethylene waxes with conventional silica matting agents, and outlines a performance-driven approach to formulating next-generation coatings.

The Challenges with Traditional Silica-Based Matting Agents

Traditional silica-based matting agents—available in precipitated, fumed, or wax-treated forms—have been the default choice for decades. Their popularity is rooted in their ease of availability and matting efficiency. However, their limitations in mechanical robustness, burnish resistance, scuff, mar, abrasion, and scrub performance are increasingly apparent in end-use applications.

Silica particles are brittle and porous, which can cause them to crack or create tiny surface flaws when the coating is rubbed or stressed. This leads to issues like gloss rebound, mar visibility, and reduced coating integrity over time. Moreover, due to their high oil absorption, they can significantly alter formulation viscosity and often require high shear mixing, leading to increased energy consumption during production. Additionally, silicas are friable and reduce formulation clarity. High shear mixing can fracture particles and inadvertently increase gloss levels. In waterborne coatings especially, these agents are prone to foam generation and poor dispersion stability.

As performance expectations rise, particularly in premium coatings for high-traffic areas or wood surfaces subject to cleaning, silica’s trade-offs have become harder to justify.

Enter Polyethylene-Based Micronized Waxes

Polyethylene polymer-based additives offer a fundamentally different approach to matting. Unlike silicas, polyethylene polymer-based additives provide matting by imparting a uniform microtexture to the coating surface, improving light diffusion.

Honeywell’s NduroMatt line exemplifies this class of matting agents. Designed as multi-functional additives, these micronized waxes not only deliver superior matting performance but also significantly enhance mechanical properties—especially burnish resistance, mar resistance, abrasion resistance and scuff resistance. The range includes the 100, 200, and 300 series, covering both waterborne and solvent-based applications and allowing formulators to tailor particle size and polarity for optimal performance.

Comparative Performance Insights

• Burnish Resistance
  Using the modified MPI #139 test (500g load, 250 cycles), Honeywell NduroMatt demonstrates a significant improvement in burnish resistance compared to fumed and precipitated silicas. For example, a matte coating with 5% Honeywell NduroMatt 200 post-added—exhibits minimal gloss recovery after abrasion, indicating high surface integrity retention.

• Scrub and Mar Resistance
  Honeywell NduroMatt-enhanced formulations outperform silica-based equivalents in scrub testing (ASTM D2486), with reduced visual defects and gloss change. This makes them particularly valuable in washable wall paints, furniture, and kitchen cabinetry—applications where repeated contact and cleaning are unavoidable.

• Viscosity Control and Dispersion
  Another key differentiator is formulation behavior. Polyethylene waxes show low oil absorption and minimal impact on viscosity. This translates to easier incorporation—often requiring lower energy mixing—and improved batch-to-batch consistency.

• Storage Stability and Stain Resistance
  Silica can settle over time, causing challenges in storage and re-dispersion. In contrast, coatings formulated with Honeywell NduroMatt display excellent shelf stability during extended room temperature storage, maintaining uniformity and performance without additional agitation. Furthermore, stain resistance testing—using common agents such as coffee, lipstick, and mustard—shows that polyethylene waxes, which are non-porous polymer particles, limit color change and staining in comparison to off-the-shelf formulations.
• Structural Design and Versatility

Honeywell NduroMatt additives are available in particle sizes ranging from 6 to 18 microns, allowing for optimization based on dry film thickness. For thin films (e.g., spray-applied furniture coatings), smaller particles like Honeywell NduroMatt 102 or 202 are ideal, while thicker architectural coatings may benefit from the larger 300, 301 or combination of 300 & 301 grades. This modularity enables formulators to engineer visual and mechanical performance in tandem.

Notably, the 300 series introduces polar-functionalized polyethylene waxes for enhanced compatibility in highly polar systems, including aqueous systems. This advancement addresses a historical challenge of wax additives—poor wetting and floating in aqueous or high-polarity environments—making them applicable to modern low-VOC and DTM (direct-to-metal) coatings.

Addressing Environmental and Regulatory Considerations

With increasing regulatory scrutiny on hazardous air pollutants and VOC content, polyethylene-based additives provide a safer alternative. Unlike silicas that often require additional surfactants or solvents for dispersion, Honeywell NduroMatt additives can be incorporated with minimal auxiliary agents. Their chemical structure is inert and non-reactive, contributing to a low environmental footprint and regulatory compliance in key markets.

The Strategic Significance: From Incremental Improvement to Platform Innovation

As formulators continue to shift from “commodity” to “performance-differentiated” coatings, the demand for multi-functional additives is accelerating. The success of Honeywell NduroMatt reflects a broader trend—leveraging advanced material science to consolidate additive functions, improve application efficiency, and elevate end-user value.

Rather than treating matting as a single-function property, Honeywell’s approach positions it as a performance platform. Each Honeywell NduroMatt series is not just a replacement for silica but a formulation strategy—integrating matting, protection, and processing benefits in a single material.

Conclusion

As matte coatings become mainstream across consumer and industrial applications, the expectation of durability can no longer be an afterthought. Micronized Polyethylene wax-based additives like, Honeywell NduroMatt, offer a compelling and field-proven alternative to conventional silica-based matting agents—delivering robust surface protection, better handling, and superior performance in demanding environments.

In many ways, the coatings industry is rethinking its material toolbox. What once was a choice dictated by tradition or cost is now a matter of performance, efficiency, and innovation. With polyethylene waxes, and Honeywell NduroMatt in particular, formulators are equipped to meet this new standard.

We invite you to explore the potential of polyethylene-based micronized waxes in your next project and consider how leveraging these advanced materials can enhance your formulations.

About the author

Rajesh Wadhwani is the Global Offering Manager at Honeywell, who leads the development, commercialization, and global adoption strategy for the NduroMatt® platform. He works with cross-functional teams—including R&D, application engineers, and regional sales, to help industry transition toward value-based formulations, where additive functionality contributes to total lifecycle performance and sustainability. He is actively involved with research and testing labs for rigorous benchmarking against market-leading silicas and iterating formulation parameters to meet regional VOC and performance standards.