Powder Coating Systems

What Is powder coating?

Powder coating is a form of metal finishing, used for industrial equipment. The dry powder material attaches to the metal surface through an electrostatic process.

Curing with heat ensures durability and creates an appealing finish.

A powder coating is widely used because of its functionality, flexibility, and aesthetic. You can also apply powder coating on other surfaces such as plastic and concrete.

Powder coating is a finish preferred for products with heavy-duty work or long-lasting lifespans. The most common application is present in steel fixtures to prevent rust. It’s also easy to incorporate color with the powder coat, making it not only durable but decorative.

Equipment Used in Powder Coating

There are different setups involved when powder coating. Even with all the equipment involved, there are usually three categories to classify them:

Pretreament

Powder Coating Systems Pretreatment

Different processes like air or sandblasting are utilized to clean debris, rust, and paint from the material.

The most common way to pretreat a material to be powder coated is with a spray washer with chemical solutions. This process allows for the powder coating to adhere well to the material.

A Dry-Off Oven is commonly used to evaporate any remaining chemicals off the item.

Application

Powder Coating Systems Application

Most apply the coat using a Powder Spray Gun. It is a tool that electrostatically charges the powder so that it can stick to the material. Compressed air moves the charged powder, which latches to the surface.

Some use the gun with a Powder Spray Booth, so they have a safe space to work.

It there are limited options, we may need a filter like a Powder Spray wall. A wall ensures protection and proper airflow when in operation.

Curing

Powder Coating Systems Curing

The curing step normally involves a curing oven. A large heated oven ensures that the powdered coat solidifies, hardens and bonds to the surface.

The time it takes to cure powder depends on the coating, thickness, shape, and size of the materials involved. It can take anywhere from ten minutes to an hour.

Batch Powder Coating

A batch powder coating system, as the name suggest, is done in batches and requires a more manual approach.

It involves the operator maneuvering different parts and completing coatings in sequence.

A batch system is needed for specific applications, unique designs, or are processing smaller quantities. It’s a versatile process that doesn’t require a lot of equipment.

A batch system also requires less space. It is generally a lower cost process. However, it requires more manpower, and lacks efficiency at a large scale.

Automated Powder Coating

When working with thousands of similar parts in a day, equipment that can handle much of the workload is recommended.

With an automated system one can coat large quantities of items in a single run.

This is best for those for rapid output.

With an Automated Power Coating system, flexibility is reduced.

The system is also more expensive. However automation is justified and pays for itself with high output production runs.

Advantages of Powder Coating vs Liquid Paint

Powder coatings provide many advantages over liquid paint

• There are more options with a powder coating finish compared to paint.
  One can choose to add gloss, a metallic finish, and even different textures. Some apply a thicker coat to add protection as seen in architectural designs.

• Powder coating may provide better performance than a coat of paint at a lower cost.
  One can even use a reclaimed or recycled powder coat and achieve the desired outcome. They’re also easy to dispose of as they contain no hazardous solvents.

• Powder coating is also tough against damage. Touch-ups are rarely needed.
  It resists scratches and has greater integrity compared to paint.

• Over time, powder coats may perform better than paint when it comes to retaining color and gloss depending on its exposure.
  It also resists corrosion and can handle over thousands of hours of corrosive salt spray in a single coat. Its properties also make it resistant to mold and mildew.

• Powder coats are also environmentally friendly when compared to paint.
  There are no toxic compounds within. Because you can recycle them, you produce less waste. Many modern coatings use green methods that produce fewer emissions during its lifespan.

• Additional advantages of powder coating for steel industries
  GZ Industrial Supplies discusses the top benefits of powder coatings for steel industries and the importance of metal finishing.

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