Process Guide lines

And
Trouble shooting Manual

Indian contact:
V. Narayanan
Business Service Manager,
Akzo Nobel Coatings India Pvt. Ltd.
Phone: + 91 9972590800
E mail: Venkataraman.Narayan@akzonobel.com

1
 Introduction

“A stitch in time saves nine…”

We at AKZO NOBEL COATINGS INDIA PVT.LTD believe that it’s

important to co-create an experience with our customers by
understanding their needs and offering our services and interactions.

AKZO NOBEL specializes and offer it’s powder coatings in the

following markets: Auto-Components, Architectural, Domestic
Appliances, I.T., Furniture, Industrial and GTC .Our Market
Specialists contact details are listed in the handbook for your
reference.

Looking beyond the offer of powder coatings, AKZO NOBEL now

offer a host of value added services. Business Services is a unique way
of delivering value to our customers through research and innovation.
This is the “First Of A Kind Activity” initiated by AKZO NOBEL in
this particular field.

As a part of an education process, we have developed a manual on

“Process Guidelines and Trouble Shooting” which contains details on
all relevant aspects that a user of powder coatings should know. We
supplement this by organising training programs to enhance
knowledge and understanding on the use of powder coatings.

We are confident that this manual will be of great help in maintaining

your process and continuous improvement in the quality of powder
coating.

2
 Index
DESCRIPTION PAGE

History of Powder Coating .............................................................. 12

Benefits of Powder Coating ............................................................ 12

About Powder Coatings .................................................................. 13 - 15

Manufacturing of Powder Coatings
Handling Powder Coatings
Storage and Shelf life
Powder Coating Chemistries

Properties of Powder Coatings ...................................................... 16

Powder Coating Process................................................................. 17 - 18

Manual Batch Systems
Automatic Conveyorised Systems

Environments & Classifications ..................................................... 19

Interior Environments
Exterior Environments

Metal Cleaning & Pretreatment ....................................................... 20 - 21

The Purpose
The Process

Cleaning & Pretreatment Solutions ................................................ 22 - 23

Solvent Wipe
Abrasive Blasting
Alkaline Cleaner
Acid Cleaner
Iron Phosphate
Zinc Phosphate
Chrome and Non Chrome Conversion Coatings
Sealer Rinse
De-ionised Water Rinse

Pre-treatment for Substrates .......................................................... 24 - 25

Cold Rolled Steel (CRS)
Aluminium
Zinc Electroplated Steel
Hot Dipped Electroplated Steel
Zinc and Aluminium Die-Castings
Copper and Brass
Stainless Steel and Chrome

3
Drying and Handling Parts after Pretreatment .............................. 25 - 26

Hooks – Racks and Conveyers....................................................... 26 - 28

Design Considerations
Earthing / Grounding Parts
Cleaning and Stripping
Conveyor Design Considerations
Conveyor Cleaning and Maintenance

Air Compressors and Driers ........................................................... 29 - 30

Compressed Air Quality
Filters
Driers

Environment for Powder Coating ................................................... 31

Temperature and Humidity
Environmental Rooms

Primary Application Methods for Powder Coating ....................... 31

Corona Charging.............................................................................. 31 - 34
External / Internal Electrodes
Current control and Ion collectors
Nozzles
Advantages and Disadvantages of Corona Charging

Friction / Tribo Charging ................................................................. 34 - 35

Theory of Operation
Advantages and Disadvantages
Powder Chemistries and Tribo Charging

Fluidised Bed Powder Application ................................................. 35

Automating Powder Spray Application.......................................... 36

Reciprocators
Gun Positioners and Movers
Robots
Part Identification and Gun Triggering

Powder Transfer Efficiency (TE) – Spraying ................................. 37 - 38

Importance of maximising Transfer Efficiency
Factors Influencing Transfer Efficiency
Benefits of maximising Transfer Efficiency
Operating Guns Efficiently
Powder Output per Gun
Number of Guns required when Reciprocating

4
Spraying Powder Coatings Effectively .......................................... 39 - 40
Fluidising Powder
Powder Venturi Pump Operation and Adjustment
Applying the Appropriate Film Build
Adjusting Corona guns to control film build
Flow Rating guns

Troubleshooting Charts ................................................................. 41 - 44

Powder Spray Problems
Poor Fluidisation or “Dusting” in Hopper
Guns Spitting or Surging
Poor penetration
Poor Powder Attraction to Part
Film Thickness too Low
Film Thickness too High
Back Ionisation “Staring”

Coating Appearance & Performance Problems

Gloss too High
Gloss too Low
Poor Flow “Orange Peel”
Poor Hammer or Texture Development
Poor Adhesion
Discolouration
Foreign Matter in Cured Film
Craters / Pin Holes
Fish Eyes
Colour Spots in Cured Film

Powder Gun Maintenance ............................................................... 45 - 46

Cleaning
Impact Fusion
Pumps
Corona and Tribo Guns
Hoses
Manual Powder Spray Touch-Up .................................................... 47
Post Touch-Up
Pre Touch-Up
Spraying Metallic or Specialty Powders ........................................ 47 - 49
Preferential Charging
Reclaim Separation
Spraying Post Blended Powders
Powder Coating Coverage Calculator ............................................ 49 - 50
Specific Gravity of Powder Coating
Theoretical Coverage
Powder Losses
Powder Booth Recovery Efficiencies

5
Curing Powder Coatings ................................................................. 51
Under Curing
Over Curing
Cure Schedules

Ovens ................................................................................................ 51 - 52
Types
Design and Sizing Considerations
Boost Ovens

Powder Booth Design Considerations........................................... 53

Required Air Flow
Lower Explosion Limit
Booth Sizing

Cyclone Powder Booths.................................................................. 54 - 55

Single and Dual Cyclones
Multi Cyclones
Cyclone Recovery System Operation & Maintenance
Advantages of Cyclones
Disadvantages of Cyclones
Water Scrubbers

Cartridge Filter Powder Booths ...................................................... 56 - 57

Advantages and Disadvantages
Cartridge Recovery system Operation & Maintenance

Reclaiming Powder Coatings ......................................................... 57 - 59

Reclaiming Considerations
Contamination
Particle Size
Fines Build-Up
Specialty Powders
Sieving Reclaimed Powder
Vibratory Sieves
Rotary Sieves
Screen Sizes

Managing Reclaim Powder ............................................................. 59

Colour Changing .............................................................................. 59 - 60

Contamination .................................................................................. 60 - 61
Common Sources of Contamination

Re-Coating Powder Coated Parts ................................................... 61

6
Powder Coating On Site Test ......................................................... 62
Pretreatment Tests
Powder Coated Parts Tests

Laboratory Tests (Off-Site) ............................................................ 63 - 65

Colour Computer
Neutral Salt Spray
Humidity
QUV
Permeability
Reverse Impact
Tabar Abrasion
Particle Size Distribution (PSD)
Fluidising
Flexibility – Mandrel Bend Test
Erichsen Cupping
Differential Scanning Calorimeter (DSC)

Record Keeping and Documentation ............................................. 65

Test Standards and Associations…………………………………….. 66

Handling of Powder Coated Parts ................................................. 67

Care and Maintenance of Powder Coated Parts ........................... 67

Safety ................................................................................................ 67

Powder Coatings In Future 68

7
 The History of Powder Coating
Powder Coatings were developed in late 1940s and were initially applied by fluidised bed
method. Electrostatic spray was introduced in the 1960s and in the 1970s powder coatings
gained worldwide acceptance. Rapid growth throughout the world occurred in the 1980s.
The Powder Coatings industry today continues to expand and is widely recognised as an
environmental friendly, cost effective alternative to liquid paints, and a premium quality
finish.

The Benefits of Powder Coating

Environmental
Powder coatings generally produce no volatile organic compounds (VOC) emissions, and
most powder coatings are free of heavy metals and other hazardous materials.
Lower Capital Investment
A powder coating system is typically less expensive to install than a liquid system of the
same capacity.
Efficiency
Over-sprayed powder can often be recovered and reapplied resulting in over 99% material
utilisation.
Consistent Quality
Powder coatings are used as supplied, there is no solvent mixing or colour tinting required.
Easy to Apply
Powder coatings can be applied in a single application without drips, runs or sags. If a
problem is detected before the part enters the oven, it can easily be blown off and re-
sprayed.
Superior Performance
Powder coatings are generally harder and offer improved impact, abrasion, chemical
resistance, and superior exterior weather ability over most liquid coatings.
Cost Savings
The elimination of hazardous liquid waste disposal and the ability to reclaim over-sprayed
powder generally means that powder coatings offer cheaper applied cost.
Safety
Powder coatings have far less risk of fire and explosion as compared to liquid solvent
borne paints.

8
 About Powder Coatings

The Manufacturing Process

1. Weighing
2. Mixing / Blending
3. Extruder
4. Flat Bed Cooler & Nibbler
5. Grinding Mill
6. Sieving & Packing
7. Dust Filters

9
Raw materials such as - resin, cross linker, pigments, fillers, flow additives and matting
agents are weighed up and dry blended in high-speed mixers. The blended mixture is then
fed through an extruder that produces a homogeneous composite. This melted material is
flattened through chilled rollers and cooled on a flat belt conveyor. The sheet material is
then broken into chips and fed into a grinding mill that classifies powder into a specified
particle size distribution.
The final step is to sieve the powder through a very fine screen to remove any over sized
particles or contaminants.
At each stage of the production process the quality must be checked because once the
powder coating material has been produced, it cannot be changed or adjusted in any
significant way. The formulation and the manufacturing conditions are therefore critical.
Reworking of an ‘out of specification’ product is difficult and costly.

Handling Powder Coatings

Every powder coating manufactured should have a Material Safety Data Sheet (MSDS)
and a Product Data Sheet. These documents will provide detailed information on the safe
handling and proper use of the specific powder.

Storage and Shelf Life

It is recommended that the powder coating to be stored at below 30 oC and relative
humidity 40-60%.

Higher temperatures and longer storage periods will result in absorption of moisture.

Most powder coatings have a shelf life of 12 months but if stored properly many
formulations will maintain their properties for far longer.
Some highly reactive powders (Fast / Low cure) formulations will have a more limited shelf
life.
Consult Product Data Sheets.

Types of Powder Coatings

Thermoplastic coatings: do not chemically react upon temperature increase, but they
melt and flow out onto the substrate. Application is usually in the industrial market coating
wire, pipes and accessories.

Thermosetting coatings: also melt upon temperature increase, but under go a

simultaneous chemical reaction and polymerize through cross-linking into a resistant film.
Once this chemical reaction has occurred the powder coating film cannot melt again.
These coatings are used in both the decorative and the industrial market.

10
Powder Coating Chemistries
The most widely used Thermoset powder chemistries are:
TGIC Free Polyester
TGIC (triglycidyl isocyanurate) containing Polyester
Hybrid – Epoxy / Polyester
Epoxy

Polyester powders: feature characteristics of long-term exterior durability, high

performance mechanical properties and over bake resistance. Polyester powder is widely
used for decorative components where good resistance to the ultraviolet rays from sunlight
is important. Many automotive trim components and other exterior components are coated
with polyester powders.

Typical applications include:

Agricultural Equipment, Appliances, Construction Equipment, Electrical Enclosures, Lawn

and Garden Equipment, Lawn Furniture, Recreational Equipment, Under-hood
Automotive, Wheels and Rims

Epoxy polyester hybrid powders: are epoxy powders by origin containing a high
percentage of special polyester resin (sometimes exceeding 50%). These hybrids have
properties similar to those of epoxy powder. However, their additional advantage is that
they have improved resistance to over bake yellowing and improved weather ability.
Hybrid powders are now regarded as the main backbone of the powder coatings industry.

Typical applications are:

Store fixtures, Office Furniture and Partitions, tool boxes

Epoxy powders: can be formulated to give high gloss and smooth coatings. Epoxy
Powder Coatings exhibit inherent toughness, corrosion resistance, chemical resistance,
flexibility, adhesion and abrasion resistance. Epoxy powder is normally used where a
tough durable film is required and the product will not be exposed to direct sunlight for long
periods of time. An epoxy coating will form a chalk like appearance on the surface with
lengthy exposure to sunlight.

Typical applications are:

Appliances, Business Machines, Electrical Enclosures, Hospital Equipment, Office

Furniture, Oil Filters, Power Tools, Shelving, Tool Boxes

11
Powder Coating Properties

PROPERTY POLYESTER HYBRID EPOXY

Weather ability Excellent Fair – Poor Poor
Corrosion Excellent – Very
Very Good Excellent
Resistance Good
Chemical
Very Good – Good Very Good Excellent
Resistance
Heat Resistance Poor Very Good – Good Very Good
Impact Resistance Good Very Good Excellent – Very Good
Hardness HB – 2H HB – 3H HB – 5H
Flexibility Very Good Very Good Excellent – Very Good
Adhesion Excellent Excellent Excellent

Gloss Range (measured at 60 degrees)

Full Gloss > 80%

Semi Gloss 60% - 80%
Satin 40% - 60%
Low Sheen 20% - 40%
Matt < 20%

12
 The Powder Coating Process
Process Steps

Metal Cleaning and Pre-treatment

Drying
Applying Powder Coating
Recovering Over-Sprayed Powder Coating
Curing

Manual and Automatic Systems

The production throughput, part size, available capital and floor space will determine if a
batch or in-line conveyorised system is most practical.

Manual Batch Systems

For smaller volume production or very large parts a manual batch process is more
practical and far less expensive.
A typical batch system has the following process steps & equipment:
Dip tanks for metal cleaning and pre-treatment
Air dry or gas convection oven to dry parts
Open faced powder booth with manual gun
Gas fired batch oven for powder curing

13
 Manual Batch System

Automatic Conveyorised Systems

For higher volume production requirements an automatic process is more practical.
A typical automatic system has the following process steps and equipment.
Overhead conveyor to transport parts through all processes
In-line washer (3 to 9) stages for metal cleaning and pre-treatment
Gas fired convection dry off oven
Cool down time before powder coating
Powder coating application and powder recovery system
Gas fired curing oven
Cool down time before UN-loading

Automatic Conveyorised System

14
 Environments & Classifications
Reference – ISO 12944
In selecting the appropriate pre-treatment and powder coating (coating system) for a given
application, the atmospheric conditions must be considered.

Interior Environments
I1 – LOW HUMIDITY
Includes areas with low or average humidity < 20% RH.
I2 – HIGH HUMIDITY
Includes areas with high humidity >40% RH.
I3 – HARSH ENVIRONMENTS
Areas with harsh and polluted environments

Exterior Environments
E1 - MILD
Includes areas with low level pollution, mostly rural

E2 – MODERATE
Includes urban industrial area. Moderate SO2 levels in coastal areas with low salinity.

E3 – COASTAL
Includes industrial areas and coastal areas with moderate salinity and SO2
levels>30mg/m3

E4 – SEVERE
Includes industrial areas with Humid and aggressive atmospheres, with SO 2
levels>30mg/m3 coastal and offshore areas less than 1 km form coast with high UV, high
humidity and salt > 12 mg per litre rain water.

15
 Metal Cleaning & Pre-treatment
The Purpose
Cleaning and pre-treatment of the substrate promotes better adhesion of the powder
coating and will improve the corrosion resistance of the substrate. It removes surface
contaminants Eg. Rust, Scale, Grease etc. & ensures uniform treated substrate.
Iron or Zinc Phosphate on steel, or the Chromate Conversion Coatings on aluminium are
critical components to the overall performance of the powder-coated part.

The Process
Depending on the performance and production requirements the process can be anything
from solvent wiping to a 9-stage in-line washer system.
The chemical concentration, temperature and exposure time will determine the cleanliness
and the level of conversion coating that is deposited onto the substrate accounts for the
performance. Parts should not be allowed to dry between the cleaning / pre-treatment
process as flash rust or deposits will form and this will adversely affect performance.
Stages of any Pre-Treatment system include:
1. Cleaning
2. Rinsing
3. Conversion Coating
4. Seal Rinsing
5. Drying
6. Cooling
The choice of pretreatment requires consideration of:
1. Substrate type (HDG, AZ, CRS, Al etc)
2. Surface condition – type of contaminants
3. Application method
4. Coating Performance – service life
5. Economics
6. Environmental Issues

16
Following types of Pre-treatment Systems are in practice:

1. Spray Pre-Treatment System

Advantages Disadvantages

1. Can be easily 1. Higher capital &

automated maintenance cost

2. System can be in line 2. More difficult to protect

with powder coating parts with complex
geometry
3. Better cleaning 3. Small items pre-treated
less effectively

4. Lower chemical & 4. Troubleshooting with

energy cost more expertise

2. Dip Pre-Treatment System

Advantages Disadvantages

1. Low Cost installation 1. Not easy to automate

2. Can be off line (Space 2. Slow Processing

Saving)
3. Better protection in 3. Tends to give dust
difficult areas coating

4. Small components easily 4. Large tanks require long

batched heating time

5. Simple to maintain 5. Use more energy

6. Flexible chemistries can 6. Quality can vary

be used

17
 Cleaning & Pre-Treatment Solutions
Solvent Wipe
Some smaller operations or those processing very large parts that cannot be dipped or
sprayed will solvent wipe to remove oil or lubricants. Chlorinated solvents are often used
but there are many health and safety concerns that must be taken into consideration.
Solvent wiping will generally improve adhesion and the finished appearance, but it offers
no corrosion protection to the metal substrate.
Alkaline Cleaner
Removes organic soils such as; oils, waxes, lubricants, drawing compounds and die
casting release agents.
Acid Cleaner
Removes inorganic soils such as: rust, smut, heat scale, oxides, stains and particulates
from sanding, blasting or deburring operations
Abrasive Blasting
Removes contaminants, and the rough surface will improve powder adhesion. As with
solvent wipe it offers no corrosion protection of the metal substrate. Parts should be free of
oils or other substances that may become impregnated into the parts. Shot blast material
can become contaminated if recycled. Excessive surface profile can cause pin holing with
some powder formulations.
Iron phosphate
The most common conversion coating used enhances the powder coating adhesion and
forms a protective barrier that retards corrosion creep.
Typical coating weight is 0.5 grams per square metre.
Salt Spray performance on steel between 150 and 400 hours.
Process is essentially pickling of steel in phosphoric acid.

Zinc Phosphate
Offers superior corrosion protection, but is considerably more expensive to maintain than
Iron Phosphate. Most commonly used in the Automotive and Appliance industries.
Typical coating weight is 2 grams per square metre.
Salt Spray on steel in the range of 1000 hours.
Accelerators (i.e. Oxidizers) are an important addition to Zinc Phosphating
solutions.

18
Conversion Coating Comparison:

S.No. Iron Phosphate Zinc Phosphate

Average Coating Weight 0.1 to 0.5 gms/m2 Average Coating Weight 0.5 to 4 gms/m2
1

Surface structure is amorphous, required less Surface structure is Crystalline, required

2 powder to cover more powder to cover

Salt Spray resistance 500 hrs Salt Spray resistance 1000 hrs
3

4 Sludge formation is moderate Sludge formation is Heavy

5 Maintenance is minimal Maintenance is Higher

Paint adhesion is Very good Paint adhesion is Very good to excellent

6

Chrome and Non chrome Conversion Coatings

Primarily used on aluminium, enhances corrosion protection and improves the powder
coating adhesion.
Typical coating weight is 0.3 grams per square metre.
Salt Spray a minimum of 1000 hours.

Sealer Rinse
Final rinse stage (chrome or non-chrome). Further enhances conversion-coating
performance by removing residual chemicals and acting as a passivation treatment.
Improves adhesion and corrosion protection.

De-ionised Water Rinse

Used in place of or after Sealer rinse, it is free of any contaminants that may adversely
effect the pre-treatment and further optimises coating performance.

19
 Pre-Treatment for Various Substrates
Cold Rolled Steel (CRS)
Alkaline cleaners are used to remove oils and greases. If rust is present an acid cleaner
will also be required. Conversion coatings such as Iron or Zinc Phosphate are most
commonly used to promote better adhesion of the powder coating and enhance corrosion
protection.

Aluminium
Alkaline and / or Acidic cleaners are used to clean and etch the substrate. Chromate
Phosphate (green) or Chromium Oxide (yellow) Conversion coatings enhance corrosion
protection.

Zinc Electroplated Steel (Typically less than 25 microns of Zinc coating)

There are many different types of Zinc coated steel, some material is supplied with a
chrome passivation coating that may not be suitable to powder coat over. Some products
are supplied already phosphated and may require only cleaning, other products will require
both cleaning and conversion coating - Zinc Phosphate or Chromate.

Hot Dipped Galvanised Steel (Typically over 80 microns of Zinc coating)

Alkaline and or Acidic etch cleaner and conversion coating - Zinc Phosphate or Chromate.
Note: Hot Dipped Galvanised can cause problems with out gassing “popping” of the
powder coating. This is caused by trapped gasses in the Zinc that release during the
powder curing cycle. Preheating to de-gas the substrate prior to powder application may
be required. Some products are treated with a Chromate Passivation coating, this can
cause adhesion problems, it can usually be removed with an Alkaline or Acid etch cleaner.
Pre Phosphated materials should be cleaned and Re-Phosphated.

Zinc and Aluminium Die-Castings

Alkaline Cleaner and Zinc Phosphate or Chromate conversion coatings are most
commonly used. Note: Castings are most often porous and trapped gasses can be
released during the curing cycle of the powder coating. As the gasses pass through the
powder coating they can leave pinholes in the cured powder film. Pre heating castings to
20oC above the powder cure temperature before applying powder will often de-gas the
casting and produce a superior finished product.

20
Copper and Brass
Acid cleaner or abrasive blasting can be used to remove the oxide layer and improve
powder-coating adhesion. (Phosphate pre-treatment is not effective). Chromating may be
an option.
Stainless Steel and Chrome
Polished smooth surfaces will reduce powder adhesion; these substrates should be etched
or shot blasted. (Phosphate pre-treatment’s are not effective).

Drying Parts after Pre-Treatment

Cleaned and Pre-treated parts can be air-dried or oven stoved to evaporate moisture and
dry the parts. Part orientation should be taken into account for the most effective draining.
It is essential that parts are completely dry prior to the powder coating
application.
Gas fired convection ovens are most often used to heat the parts up to 100oC to
evaporate moisture.
Parts should be powder coated as soon as possible after the pre-treatment and
drying process for best results.
Chromate conversion coatings on aluminium should not be exposed to
temperatures above 90oC during the drying process.

Note: Other pre-treatment may have temperature limitations, exceeding this limit may
adversely affect the performance of the pre-treatment. Consult the pre-treatment
chemical supplier.

Water Dry off Oven

21
 Handling Pre-treated Parts
Pre-treated parts should never be handled without clean lint free gloves.

Once parts have been cleaned and pre-treated they should be powder-coated as soon as
possible for best coating performance and finished appearance.

Hooks – Racks & Conveyors

Design Considerations
Properly designed hooks and racks will maximise powder coating coverage, consistency
and transfer efficiency.
Hook or rack contact point to conveyor chain or load bar should be shielded or
have enough clearance above the powder booth so that the over-sprayed powder
will not build up and insulate the hook or rack from earth.
Hooks should accurately maintain the parts position through the entire process
for consistent and uniform pre-treatment and powder coating deposition.
Racks and hooks should be designed to provide maximum part density for most
efficient operation and highest first pass transfer efficiency.
While maximising part density is desirable, sufficient space between the parts is
required for penetration coverage.

The general rule is to have the space between parts twice the desired depth of
penetration.
Racks and hooks should be constructed of the smallest gauge material possible
so they will not rob powder away from the parts.
Racks should not to sway and twist during the pre-treatment spray process. Part
positioning for drainage must also be taken into account.
Hooks and racks should be designed to withstand the chemical or heat stripping
process.

22
Earthing / Grounding Parts
A good earth (Less than 1 Meg ohm) is recommended to maximise powder transfer
efficiency and for safety issues. A Meg Ohm meter with 500-volt output should be used to
test part earth.
Using a Meg Ohm Meter – Measure conductivity between a part on one hook and a part
on another hook, this will test conductivity path through hooks and conveyor. Measure
conductivity between load bars and between parts and building or electrical earth to check
complete circuit
Copper rub bars or brass bristle strips are often mounted above the conveyor slot opening
of a powder booth. As the hooks enter the powder booth they rub along the earthed bar or
bristles and this ensures the hooks are properly earthed.

Cleaning and Stripping Hooks and Racks

Regular removal of powder build-up on hooks and racks is required to maintain a good
earth. There are several methods:
Chemical Stripping (Epoxy powders can be difficult to chemical strip)
Burning (Fluidised sand or burn off oven with flame extinguishing system)
Shot Blasting

A light coloured ash can remain on the hooks and racks after burning and this should be
removed by a high-pressure water wash. If it is not removed it can contaminate the washer
tanks and block washer spray nozzles.

23
Conveyor Design Considerations
Conveyors should be shielded or positioned with enough clearance over the top of the
powder booth so there is little chance of powder coming into contact with the rail, chain,
trolley assemblies or load bars. These components provide the electrical pathway to earth
and should they become insulated with powder they will require removal and stripping.

There can be a significant amount of fall off contamination from overhead conveyors that
will result in finish defects and reject parts. S hooks and sanitary pans are used in almost
every appliance or other Class A finish operation.
Load bars can provide greater flexibility and help maximise line density.

Conveyor Cleaning Maintenance

Brass brushes are often mounted just ahead of the washer system to help keep the chain
clean. High-pressure water or steam is sometimes used just inside the entrance to the
washer.
Some enclosed conveyor rails have special designed cleaning brushes that can be
inserted in the chain; these will continuously clean the conveyor while it is running.
Bearings require regular lubrication; the wrong type of lubrication or excessive amounts of
lubrication can cause it to drip onto the parts. Automatic conveyor lubrication systems are
often used to inject a precise amount of lubricant into the roller bearings while the
conveyor is operating.
Conveyor chains are exposed to high temperatures inside the ovens, special oils/
lubricants are usually required.

24
 Air Compressors & Driers
All powder guns require compressed air to pump the powder from a hopper or box feeder
to the guns. Compressed air is also used to clean cartridge or bag filters in recovery
systems. The quality of the compressed air is critical and properly maintained air driers
and filters are required to produce air to an acceptable standard for powder coating
equipment. Contaminated air can cause equipment failures and adversely effect the
powder coating finish quality.

Compressed Air
It is essential that adequate and consistent compressed air pressure and volume be
maintained. Fluctuations in pressure and volume may cause inconsistent powder output
through the guns and inadequate filter cleaning in the recovery system.

Recommended Compressed Air Quality

+4 deg C dew point or below.
Less than 0.1 PPM oil.
No particulate contaminants greater than 0.3 microns.

Filters
Coalescer type filters should be used to remove water and oil before air enters air drier.
These can be fitted with automatic drains.
A filter to remove particulates is also recommended.

Air Driers
There are two suitable types:
Refrigerated
Desiccant – Twin tower
(It is recommended that the air drier be positioned within 30 meters of the powder coating
equipment).

25
Refrigerated Air Drier Principle of operation

air-
air-to-
to-air heat exchanger
(precooler/reheater)
precooler/reheater)

separator or
coalescing filter
drain

air-
air-to-
to-refrigerant
heat exchanger

hot gas bypass

refrigeration
equipment

Desiccant Air Drier Principle of operation

Purge air is bled

from dried
Dry compressed compressed air
air exits through
top of dryer

Dry purge air

is expanded to
atmospheric
Compresse
Moisture- pressure and
d air is dried
laden purge blown down
through the
air is through the
on-line
exhausted to off-line tower
tower
atmosphere to regenerate
the desiccant

A timer
Moisture-laden
circuit
compressed air
controls the
enters through
valves which
bottom of dryer
switch each
tower on-line
or off-line

26
 Environment for Powder Coating

Recommended Environment for Powder Coating Application

18 to 26 Degrees C
40 to 60 % Relative Humidity

Environmental Rooms
In most factories there are many air-borne contaminants that can be drawn into the
powder booth and adversely affect the quality of the finished parts. If the highest quality
finish is required than the powder coating system must be contained in its own
environmental room.
These rooms are typically freestanding structures inside the factory with filtered air inlets.
A slight positive pressure prevents air borne contaminants from entering the room.
Any air conditioning or make-up air introduced into the environmental room should be
defused through ducting and vents to reduce its velocity and the air currents inside the
room. Excessive air velocity around powder booths will disrupt the booths airflows and
cause powder to escape into the environment.

Primary Application Methods for Powder Coatings

Corona Charging
Friction (Tribo Charging)
Fluidised Bed

Corona Charging
Theory of Operation
Corona Charging is the most widely used method to apply powder coatings. A high voltage
electrical source charges the surrounding air creating the corona electrical field, as the
powder particles pass through this field they pick up the charge and are attracted to the
earthed substrate.

The voltage is typically adjustable up to 100KV (One Hundred Thousand Volts).

27
Most corona guns produce a negative charge; it is claimed that the negative corona
charging offers superior transfer efficiency and produces less free-ions than a positive
corona charge.

External and Internal Electrodes

The most common is (external) A single electrode at the tip of the gun produces the
corona field that charges the powder particles as they pass through the field. Powder is
usually directed around the corona by a conical deflector or a flat spray nozzle. Not as
common is the internal corona; this is usually a series of electrodes positioned inside the
barrel of the gun, the powder charges as it passes through these electrodes. The claimed
benefit of internal corona charging is reduced electrical field lines that cause faraday cage
problems and less free-ions that can cause back ionisation.

Current Control and Ion Collectors

Most Corona guns will draw between 30 and 100 microamps, the current increases as the
corona field (gun tip) gets closer to earth source (earthed part). Some guns incorporate
current limiting or current control that is designed to offer application benefits in
maximising voltage / charge under higher current load, or allowing for a preset current and
or voltage.
Another recent feature is the “Super Corona” or “Ion Collector” This is an earthed
device attached to the gun and is designed to capture some of the excess free ions
generated by the Corona. It is claimed to reduce back ionisation and improve powder
penetration coverage.

28
Nozzles
Most gun models offer an optional selection of nozzles, typically a range of different size
conical or flat spray nozzles. The conical nozzles are more versatile and good for general
application. Flat spray nozzles are best suited for large flat surfaces such as appliance
panels or office furniture. Some gun models offer special nozzles that can be very effective
in certain applications.

Advantages of Corona Charging

Most powders will accept Corona Charge.
Less sensitive to temperature & humidity.
Easier and faster colour change.
Higher output than Tribo guns - fewer guns required.
Film thickness can be simply changed by voltage variations.
Light, robust spray guns.

29
Disadvantages of Corona Charging
Electrical field lines can make penetration into Faraday Cage areas difficult.
The free-ions generated by the corona field - It is claimed that only a small
percentage of the charged ions actually attach themselves to the powder
Particles as the pass through the Corona field. The excess free-ions can inhibit
penetration and cause “Back Ionisation” / “Starring” that may result in a rougher
surface finish or film defects.

Friction / Tribo Charging

Theory of Operation
Tribo guns work by exchanging ions between the powder particles and the friction material
in the gun. As the powder particles come into contact with a material that easily accepts a
charge such as PTFE or (Teflon), the Powder particles become positively charged. The
charged powder is than attracted to the earthed part. Not all powder coatings will Tribo
charge efficiently. Powder coatings are generally formulated and manufactured to more
efficiently accept a Tribo charge.

Advantages of Tribo charging

Good Faraday coverage, there are no electrical field lines to inhibit penetration.
Less potential for Back Ionisation, no free-ions are produced.

30
Disadvantages of Tribo charging
Powder coating should be specially formulated to enhance Tribo charge
performance.
Charge acceptance is very sensitive to excessive humidity in the environment.
Reclaim powder / finer particles of powder do not charge well.
Difficult to clean the guns for colour change

Powder Chemistry and Tribo Charging

1. Epoxy Stronger Tribo Charging
2. Epoxy Polyester Hybrid
3. Polyester Weaker Tribo Charging

Fluidised Bed Powder Application

Fluidised Bed Application is most commonly used for heavy film builds – 200 to 500
microns.
The parts are first preheated and then dipped into a fluidised bed of powder coating, the
powder particles will immediately melt and adhere to the substrate. Film thickness is a
function of substrate temperature and exposure time in the fluidised powder.
Further curing after powder application is usually required.
If high volumes of larger parts are processed it may be necessary to use refrigerated
chilled compressed air for fluidising to prevent the powder from clumping or melting inside
the hopper.

31
Automating Powder Spray Application
Automatic guns can either be in a fixed position, or be fitted to reciprocators, gun
positioners / movers or robots.
Reciprocators – allow guns to coat larger surface areas and can improve coverage and
uniformity.
Gun Positioners / Movers – are used to move guns in / out to maintain a consistent
distance from the parts. Multi axis movers can follow parts as they travel through the
powder booth.
Robots – Can be used to eliminate manual touch-up.
Part identification and gun triggering - can be beneficial in large production processes
by reducing the amount of over-sprayed powder, minimising film builds, and increasing the
overall process efficiency.

32
 Powder Transfer Efficiency (TE) - Spraying

Importance of Maximising First Pass Transfer Efficiency

Virgin powder will generally transfer far more efficiently than reclaimed powder; this is
primarily due to particle size shift. Reclaimed powder usually has a higher percentage of
smaller particles that will not hold as much charge and therefore not transfer to the part as
well as the larger particles. Reclaim powder has also been exposed to the environment
and potential contaminants that may affect film appearance.

Factors Influencing Transfer Efficiency

Part Earthing
Part line density
Part complexity
Powder formulation and particle size
Powder gun efficiency, positioning, pattern, and powder throughput
Booth air flow and design
Environment - temperature and humidity

33
Benefits of Maximising First Pass Transfer Efficiency
Generates less reclaim powder
Less wear on guns and filters
More consistent coverage and film build
Cleaner finish
Conserves powder

Operating Guns Efficiently

Proper maintenance, adjustment, positioning and spray pattern of the automatic powder
guns will maximise TE. The most common mistake is to operate at excessive gun pump
pressures. Spraying high volumes of powder at higher velocities through a corona gun will
result in reduced powder charge and transfer efficiency.

Powder Output per Gun – (corona spray)

The following is a general guideline as there is some variance between gun models.

Low output for highly complex parts 9 Kg/Hour

Medium output 11Kg/Hour
High output for simple flat panels 14 Kg/Hour

Gun Hoses
NOTE Hose length has a significant effect on powder output, the longer the hose the
less powder output at the same pump settings.

Number of Guns Required when Reciprocating

As a general guide take your Line Speed in metres/Min and multiply this by the vertical
hanging length in metres, then divide this by 0.8

Example: For 2.4 metres per minute line speed with a vertical hanging length of 1.2
metres
2.4 X 1.2
0.8 = 3.6 or (4 guns per side)

34
 Spraying Powder Coatings Effectively

Fluidising Powder
In most cases manual and automatic guns are fed powder from a fluidising hopper. Proper
fluidising is essential for a good consistent spray pattern. Powder hoppers, either round or
square are constructed with a porous membrane in the bottom, compressed air passes
through the membrane and suspends and separates the individual powder particles.
Properly fluidised powder should be completely aerated from top to bottom of the hopper,
and with only moderate bubbling on the surface.

Powder Venturi Pump Operation and Adjustment

Pneumatic Venturi pumps draw the fluidised powder from the hopper and pump it through
feed hoses to the guns. There are typically two (2) airlines from each gun controller that
operate the pump.
One of the airlines is called (Flow-Rate, Injector or Feeding) air; this is usually
positioned directly in line with the venturi throat and controls the amount of
suction or amount of powder output.

The other air line is called (Atomising, Diffuser or Dosage) air; and it usually
enters the pump at 90 degrees and helps to even-out the powder delivery for a
more uniform spray pattern.
The Flow Rate air should be set first for the desired volume of powder output.
The Atomising air should then be adjusted just high enough to produce a good
spray pattern without any puffing and spitting.
As the Atomising air pressure is increased the volume output of powder is
reduced so the Flow-Rate may need to be adjusted up slightly.

As a rule of thumb, Atomising air should be operated as low as possible, excessive

Atomising pressure only increases powder velocity through the gun giving the powder less
time in the Corona field to pick up a charge. There is however certain applications such as
deep penetration where higher atomising air will prove more effective.
Worn pump venturi throats are very inefficient and increased operating pressures will be
required to produce sufficient powder volume output, this will cause a significant reduction
in transfer efficiency. Some manufactures offer venturis in a range of different materials
that will wear better under certain conditions.

35
Applying the Appropriate Film Build
Too thin a film build will allow the substrate to show through the coating and provide
inadequate protection. Too heavy a film-build is wasteful and can adversely effect the
coating appearance and mechanical performance.
Most standard powder coatings are formulated to be applied at a cured film-build
of between 40 and 80 microns.
When a warranty is offered by the powder-coating supplier, there will be a
specified cured film thickness range that must be adhered to.
Very bright colours such as Reds and Yellows will often require a heavier film-
build as compared to other colours to hide the substrate.
Some lighter shade colours can produce slightly different colour appearance at
lower and heavier film-builds.
Powder coatings with surface contours such as ripples, wrinkles and
hammertones usually require heavier average film-builds due to peaks and
valleys. The valleys can show through to the substrate at lower average film-
builds.
Controlling the applied film-build is one of the most important aspects of the
powder coating process. Thickness measurements should be taken regularly and
results immediately relayed to the operators so adjustments can be made.

Adjusting Corona Guns to Control Film Build

Position gun tip to part distance to between 150mm and 300mm for maximum
coverage and transfer efficiency.
Operate pump pressures as low as possible to achieve desired film-build.

Operate at maximum voltage unless there is a clear benefit in running a lower

voltage.
Reducing the powder output from the guns is preferable to reducing the voltage output to
reduce film-builds. Lowering the Voltage will apply less powder but it will also generate
more reclaim that may create other problems. There are some unique situations when
lowering the voltage is beneficial such as re-coating and Faraday Penetration.

Flow Rating Guns

The actual powder volume output from each gun can be measured using vacuum cleaner
bags, a stopwatch and a gram scale. Zero the scale with vacuum cleaner bag, turn Kv off
and place the vacuum cleaner bag over the front of the gun. Trigger the gun on for 30
seconds, weigh the bag with the powder and multiply by two. This is the actual powder
output per minute.

36
 Troubleshooting Powder Spray Problems
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION
Poor Fluidisation A) Improper fluidising air A) Increase or decrease fluidising air supply
Or “Dusting” in adjustment to hopper
hopper B) Compacted or damp powder B) Stir Powder / Check for moisture in
compressed air supply
C) Plugged fluidising tile C) Replace tile
D) Powder too fine D) Reduce amount of reclaim powder, have
powder supplier check particle size
Guns Spitting or A) Poor fluidising A) See above
Surging B) Pump not adjusted properly B) Increase atomising / diffuser air
C) Supply air to pump leaking C) Check all air tube connections for leaks
D) Obstruction in pick-up tube or D) Clean pick-up tubes and hoses; ensure
hose there are no kinks or sharp bends in the
hoses.
E) Worn pump venturi throat E) Replace worn parts
F) Powder too fine F) Reduce amount of reclaim powder
Poor Penetration A) Insufficient powder A) Increase pump flow-rate pressure
B) Powder being blown out B) Lower pump atomising pressure
C) Parts spaced too close C) Increase space between parts
D) Poor earth D) Clean hooks or racks
E) Incorrect spray pattern E) Try different nozzles
F) Improper gun positioning F) Re-position guns
G) Voltage too high G) Reduce gun Kv output
H) Powder too fine H) Reduce the amount of reclaim powder
Poor Attraction of A) Gun voltage too low A) Increase Kv output, measure voltage
Powder to Parts output with Kv meter
B) Poor earthing B) Clean racks and hooks
C) Powder spray pressures too C) Decrease pump atomising / diffuser air
high
D) Moisture in compressed air D) Service compressed air drier
E) Hooks or racks robbing E) Redesign hooks and racks, allow more
powder from parts space between parts
Film Thickness too A) Powder output too low A) Increase pump pressures
Low B) Powder charge too low B) Increase gun Kv output
C) Poor earth C) Clean hooks and racks, measure earth
D) Hooks or racks robbing D) Redesign or reduce the size of the hooks
powder from parts or racks
E) Improper gun position E) Maintain 150mm to 300mm gun tip to
part distance
Film Thickness too A) Powder output too high A) Turn down pump pressures, move guns
High farther away from parts
B) Excessive coating time B) Increase conveyor speed, reduce gun
voltage as last resort
Powder “Staring” A) Excessive film build A) Reduce powder output from guns
Back Ionisation B) Poor earth B) Clean hooks and racks, check earth
C) (If re-coat) C) Reduce gun Kv output

37
 Coating Appearance & Performance Problems
PROBLEM POSSIBLE CAUSE
Gloss too High A) Cure temperature too low
B) Oven cycle too short
Gloss too Low A) Oven temperature too high
B) Time in oven too long
C) Contamination with
incompatible powder
Poor Flow A) Heat up rate too slow
“Orange Peel”
B) Low film build
C) Back ionisation
POSSIBLE SOLUTION
A) Increase oven temperature
B) Decrease line speed
A) Reduce oven temperature
B) Increase line speed
C) Remove all contaminated powder,
thoroughly clean all equipment & re-
charge with virgin powder
A) Ensure oven is up to temperature
st
when parts enter oven, increase 1
zone oven temperature
B) Increase powder output or decrease
line speed
C) Ensure part is properly earthed,
decrease gun voltage, move guns
farther away from parts, measure film
build – too heavy may cause back
ionisation
38
Poor Hammer or A) Heat up rate too slow A) Ensure oven is up to temperature
Texture when parts enter oven, increase 1st
Development zone oven temperature
B) Too much reclaim powder B) Add more virgin powder

Poor Adhesion A) Powder under cured A) Increase oven temperature

B) Dirty substrate B) Check water break and wipe parts
with white rag to identify dirt or oils,
ensure parts are properly cleaned
and pre-treated

Discolouration A) Cure temperature too high A) Reduce oven temperature or

increase line speed

39
Foreign Matter in A) Inadequate substrate
Cured Film cleaning
B) Airborne contaminants
C) Lumpy or heat affected
powder
Craters / Pin A) Oil or other contaminant on
Holes parts
B) Substrate out-gassing
C) Contaminated compressed
air
D) Contaminated powder
Fish Eyes A) Silicon or oil contaminant
Colour Spots in A) Contamination from
cured film equipment
B) Powder falling from conveyor
or hooks
C) Airborne powder drawn into
booth or landing on parts
A) Check cleaning and pre-treatment
B) Ensure powder spray environment is
clean
C) Sieve powder through appropriate
size screen
A) Check cleaning and pre-treatment
B) De-gas substrate, use casting grade
powder
C) Ensure compressed air is free of oil,
moisture, or other contaminants
D) Clean all equipment and re-charge
with virgin powder
A) Check cleanliness of parts
B) Ensure compressed air supply is
clean
C) Inspect plant for possible source of
airborne silicon contaminant
A) Remove all contaminated powder,
clean hopper, pumps, hoses, guns,
booth interior etc.
B) Clean conveyor and strip hooks
C) Improve housekeeping practices,
take care when colour changing in
other systems
40
 Powder Gun Maintenance
Both Corona and Tribo guns require regular cleaning and maintenance to perform
optimally.
Recommended cleaning frequency is only a guideline; every system is unique and may
require more or less frequent cleaning and maintenance.
Cleaning and Impact Fusion
Impact fusion is heat-fused powder that has built-up onto the surfaces inside powder guns,
hoses and pumps. Heat generated by friction as the powder is conveyed through the
pumps hoses and guns causes the powder to melt. Higher pump operating pressures will
increase friction and generate more impact fusion.
If impact fused powder is not cleaned from the parts, it will continue to build and eventually
block passageways and reduce powder output from the guns. All powder pathways should
be cleaned regularly to remove impact-fused powder.
Some powder formulations are more prone to impact fusion than others, mainly those with
lower Glass Transition temperatures.
Compressed air and soft brushes should be used to clean impact fused powder. Avoid
using anything that will scratch or cut the parts as this will further promote impact fusion.

Pumps – Gun Feed and Transfer Pumps

Disassemble pumps to clean and inspect internal parts for wear every 4 hours of
continuous operation.
Replace worm venturi throats as recommended by the equipment manufacturer.
Check for air leaks in tubes and fittings.

Corona Guns
Disassemble guns to clean and inspect internal parts for wear every 4 hours of
continuous operation.
Note: Compressed air should not be blown into the gun when feed hose is
connected, this can cause damage to the gun controller if powder enters
pneumatic components.
Replace any worn parts as recommended by the equipment manufacturer.
If gun controller has a Micro Amp display, this should be regularly monitored to
help identify potential problems with gun charging. A very high reading (90 plus)
indicates a short circuit, a very low reading (0 –10) indicates an open circuit.
Note: Read current with maximum Kv while gun tip is at least 250mm from parts
or booth wall.
Have actual gun voltage output measured every 6 months or at first sign of fault.

41
Tribo Guns
Disassemble guns to clean and inspect internal parts for wear every 4 hours of
continuous operation.
Replace any worn parts as recommended by the equipment manufacturer.
Some Tribo guns have reversible charge tubes; the life of these charge tubes can
be greatly increased if they are regularly reversed.
Most Tribo guns have a current feedback meter that measures Micro Amps; this
gives an indication of how well the powder is accepting a charge. This is the only
method to gauge the performance of the Tribo gun.

Hoses
Powder feed hoses should be cleared with compressed air every 4 hours of
continuous operation.
Powder feed hoses should be removed and (crushed) to break up impacted
powder every 30 days.
Hoses should be as short as possible with minimal bends.

42
 Manual Powder Spray Touch-Up
Depending on the complexity of the parts and the feasibility of fully coating automatically,
manual operators may be required to reinforce certain areas of the parts. Manual touch –
up can be before or after the automatic guns.

Post Touch-Up (after automatics)

Advantages
Requires less operator skill.
Should the automatic guns for any reason miss an area of the part, the operator
can save it.

Disadvantages
More difficult to apply powder into Faraday Cage areas.

Pre Touch-Up (before automatics)

Advantages
More uniform film build and better finish appearance.

Disadvantages
Part presentation and automatic gun operation must be precise and predictable.
Operators must be completely familiar with every part and its touch-up
requirements.

Spraying Metallic or Specialty Powders

Many powder coatings are manufactured by blending a base powder with other materials
or additives to create a special effect. These powder coatings can be more difficult to apply
and to reclaim.
Metallic powders or other multi component powders may require unique application
techniques and special equipment to apply them effectively. Some of these powders can
not be reclaimed, or can only be reapplied when mixed in low concentrations with virgin
powder.
This is due the imbalance between the base powder and the metallic flakes or other post
blended materials that may have occurred during the initial spray application and / or by
processing through the recovery system.

43
Different brands and models of Corona guns charge the metallic flakes differently,
either laying the flakes down or standing them more on edge. This can produce
inconsistent finish appearance.

Preferential Charging

This occurs when one or more of the post blended components of the powder
charges more or less efficiently than another. For example: Metallic flakes
generally accept a charge and transfer to the earthed substrate more efficiently
than the base powder material. Therefore, the reclaim powder may have
substantially less metallic flake and if re-applied will look very different than the
virgin powder finish.

Reclaim Separation

Multi component post-blended powders can be separated when processed

through the powder booth recovery system. This occurs when one or more of the
materials have higher or lower density or smaller or larger particle size. For
example: Very small metallic flakes may be separated from the base powder by
the air currents in the booth, or by the cyclone recovery system. This can make
the reclaimed powder UN-useable.

Spraying Post Blended Powders

Always use a fluidising hopper, fluidising ensures even distribution of the metallic
flakes for consistent finish appearance.
Metallic flakes can build-up on the electrode and when these agglomerations
release they cause large surface defects on the finished part. Some newer model
corona spray guns have “Tip Air” that can help prevent metallic flakes from
building up on the electrode.
Some corona guns have optional metallic nozzles with “External Electrodes”
these electrodes are outside the powder flow and less susceptible to metallic
flake build-up.
Often a lower Kv setting will more uniformly charge the metallic and base powder
for more effective application.
Highly concentrated metallic powders can short out corona guns; this will greatly
reduce the voltage output causing poor transfer efficiency. Some powder gun
manufactures offer special adaptor kits for this problem.

Dry Spray
This occurs when the base powder does not cover the metallic flakes, the metallic flakes
flow to the surface and the result is a dull appearance and a rough texture. Reducing the
powder gun voltage may help. Consult powder supplier.

44
Exterior Exposure
Most Metallic and Special effect powders are not suitable, or may require a clear powder
coating over top for exterior use. Always refer to the product data sheet or consult the
powder supplier.

Powder Coatings Coverage Calculator

Specific Gravity
Specific Gravity (SG) is the density of the powder relative to water. The lower the SG the
greater the coverage (mileage) at the same applied thickness. The typical range for
powder coatings is between 1.3 SG and 1.7 SG depending on the levels of pigment and
extender.

Theoretical Coverage

To calculate the theoretical (100% efficiency) coverage in square metres of a given

powder, use this formula.

Example: Black polyester with a specific gravity of 1.5 applied at 50 microns.

1000 / (1.5 x 50) = 13.33 square metres coverage at 50 microns.

To calculate the cost of the powder to cover one (1) square metre divide the cost per Kg of
the powder by the square metre coverage per Kg as calculated above.

Example: Cost is Rs150 per Kg of a powder applied at 50 microns that will coat 13.33
square metres.
150 / 13.33 = 11.27 rupees per square metre

45
Powder Losses
(Must be taken into consideration when calculating applied powder costs)

Average Range
Transfer Efficiency 10% to 75%
Booth Recovery System 1% to 15%
Hooks and Racks 2% to 25%
Spillage and Waste 1% to 5%
Rework <1% to 5%

Powder Booth Recovery Efficiencies

The most efficient system is a Cartridge Filter booth with a dedicated colour module,
greater than 99% efficiency can be achieved.
A very efficient Cyclone system can operate in the high 90s but most operate in the range
of between 85% to 94% reclaim efficiency.
A cartridge recovery system with a dedicated colour module can potentially operate in the
high 90s, the other extreme is Wire Goods processed through a non-reclaim recovery
system, this could operate as low as 25% powder utilisation.
Racks and Hooks also consume powder and reduce mileage.
The recovery system (booth) can be tested to determine its operating efficiency; Rack and
Hook surface area can be estimated. These and any other loss factors must be taken in to
account when calculating the actual applied cost of the powder coating.

46
 Curing Powder Coatings
After the powder coating is applied the parts must be processed in a curing oven to reflow
and convert the powder particles into a continuous cured film. Different powder chemistries
and formulations require different curing cycles. It is essential that the specified cure
schedule be followed to ensure that the powder coating is fully cured and will perform
optimally.
Under-cure can sometimes be visually recognised by increased gloss level.
Over-cure can sometimes be recognised by lower gloss or discolouration.
Cure cycle – Example: 10 minutes at 200oC. This refers to the metal temperature.
Therefore, depending on the density of the substrate, shorter or longer oven dwell times
will be required in a conventional oven. Regular testing of cured film and periodic oven
recordings are recommended to ensure the powder coating is being properly cured.

Ovens
Oven Types
Direct and Indirect Gas Fired Convection
Electric Convection
Gas Infrared
Short and Medium Wave Electric Infrared
Induction

Direct fired gas convection ovens are the most commonly used for both dry off and curing.
Gas is typically less expansive to operate than electric, and convection heating is more
forgiving than infrared.

Primary Design and Sizing Considerations

Cure ovens typically operate at up to 250oC
A temperature uniformity of + - 5oC within the oven is desirable.
Minimal air velocity so as not to disturb powder before it gels. Below 2 m/sec is
recommended.
A minimum capability of 10 minutes metal temperature at the required powder
cure temperature.
Adequate air change overs to stay below LEL (lower explosive limit).

47
Boost Ovens
As businesses grow and production levels increase, often time’s line speeds are increased
and curing oven dwell times are reduced. To compensate the oven temperature is raised
to achieve an adequate cure. This can cause problems when the line stops and parts over-
cure, causing a reduction in gloss or coating discolouration.
A cost-effective solution can be installing an Infrared boost oven in front of the existing
convection oven. Infrared boost ovens can raise the part temperature quickly and allow the
undersized cure oven to operate at a lower more forgiving temperature.
Gas Infrared and Medium to Longer wave electric Infrared ovens are more suitable for
larger complex parts.
Short wave / High Intensity Infrared can be very effective for simple – flat, or very small
parts where all surfaces are within line of sight of the heating elements.
Boost ovens should always be interlocked with the conveyor to prevent parts from
discolouring / over curing should the line stop while parts are inside oven.

Oven Maintenance
All types of ovens need to be cleaned and maintained to ensure they consistently operate
efficiently.
Gas convection oven burners require periodic adjustment and cleaning, air circulation fans
may have belts that will require tightening and bearings that require lubrication.
Oven temperature recordings using a device that measures both air as well as part
temperature should be carried out regularly to ensure proper powder cure is achieved.

Gaps in convection oven panels can be sealed using Dow Corning 736 RTV. Local oven
builders have recommended this sealant.

Oven Cleaning

The interior of convection ovens can become dirty; the debris can loosen and contaminate
the powder coated parts as they pass through the oven.

Polyurethane based powders can cause a build-up of E-Caprolactam (a bi product

generated when this powder cures) inside the oven; this build-up needs to be removed
using a vacuum cleaner. Frequency of cleaning depends on production throughput.

Infrared oven reflectors will become dirty causing the oven to be less efficient. Depending
on the type of deflector they may require cleaning and polishing.

Oven interiors that have corroded and have loose scale can be cleaned with wire brushes
and coated with deodorised fish oil to seal the affected areas. Fish oil is available locally
from Blackwoods.

48
 Powder Booth Design Considerations
Over-sprayed powder that has not been attracted to the parts must be contained and
collected. An effective powder booth recovery system will contain all of the over-sprayed
powder within the booth canopy.
Excessive booth airflows will prevent the charged powder from depositing on the
parts and reduce transfer efficiency. Insufficient booth airflow will not contain the
over-sprayed powder inside the booth.
Australian standard requires a minium of .4 metres per second air velocity
through all openings in the powder booth.
The maximum concentration of powder within the booth should be 50% below the
LEL – Lower Explosion Limit of the powder. Most powder coatings have an LEL
of between 35 and 90 g/m3. Akzo Nobel recommends that a maximum of 10
g/m3 of air should not be exceeded. A general rule is not to exceed 1 gun per
cubic metre of booth interior.
If multiple powders are to be reclaimed in the same booth, design features for
fast and thorough cleaning should be incorporated.
Smooth seamless interior walls, rounded corners, seamless ducting, and non-
conductive booth walls will speed colour change times.
There should be adequate clearance between the overhead conveyor and the
conveyor slot in the top of the powder booth. This will prevent any over-sprayed
powder that may migrate out of the booth from coating the conveyor, chain and
load contact points. A minimum of 450mm clearance between the conveyor rail
and the top of booth is recommended.
A minimum clearance of 450mm from the top of the parts to the powder booth
ceiling is also recommended to prevent excessive over-sprayed powder from
collecting on booth ceiling, and from migrating out of the conveyor slot.
There should be adequate clearance between the manual operator openings and
the automatic gun slots to prevent over-sprayed powder from the automatic guns
coating the operators. Adequate space between the manual operators will
prevent them from coating each other.
The booth canopy should be wide enough to allow at least 250mm between the
automatic gun tips and booth wall behind the guns. This will prevent the powder
from being attracted away from parts and back to the walls of the powder booth.
The booth canopy should be wide enough to allow at least 250mm-gun tip to the
part distance.
Cyclone technology is more suitable for shorter colour runs where multiple
powders are to be reclaimed.
Cartridge technology is more suitable for larger colour runs where fewer colours
are to be reclaimed.
Cyclones systems are a good choice when there are many colours to reclaim.
Cartridge Filters systems are a good choice for larger production runs of fewer
colours.

49
 Cyclone Powder Booths
Air along with reclaimed powder is drawn into the cyclone a centrifugal force spins the air /
powder mixture around the interior of the cyclone. Heavier powder particles settle in the
bottom and are collected in a container and reused or discarded. Alternatively the powder
can be automatically pumped back to the gun feed hopper for re-application.
The smaller lighter particles along with the air are drawn up through the centre tube and
from there go to a water scrubber, cartridge filter collector or a bag house. This powder is
considered waste.
Efficiencies of cyclone systems will generally range from between 85% and 95%.

Single and Dual Cyclones

These are larger cyclones (3000 to 6000 CFM each) and are generally ducted into the
base of the powder booth and utilise either a cartridge filter collector or water scrubber as
an after filter. Some cyclones will hinge open to access the interior for cleaning. This is a
recommended feature if reclaiming powder.

Multi Cyclones
Smaller cyclones (500 to 1000 CFM each) are built into a single module that can be
attached directly to the powder booth sidewall or remotely positioned and connected to the
powder booth base by ducting. A cartridge after filter collector is most commonly used.
The benefits of Multi Cyclones are faster / easier colour change due to the smaller size
and accessibility. The smaller cyclones are generally more efficient.

Powder Booth with Cyclone Recovery System

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Cyclone Recovery System Operation and Maintenance
Reclaim powder is collected at the bottom of the cyclone in a bucket or surge
hopper that automatically pumps the powder back to the feed hopper for re-
application, or to a scrap drum for disposal.
Powder that passes through the cyclone (powder fines) is collected by the after
collector – Cartridge Filter or Water Scrubber, and is considered waste.
Cyclones generally have no moving parts and require only cleaning for colour
changing. Interior surfaces that are impacted by high velocity powder can
develop a heavy build-up of impact fused powder. This impact-fused powder if
allowed to build heavy enough will break loose and cause contamination.
Some cyclones have a fan built into the top of the cyclone and these may require
regular cleaning and greasing of the bearings. Other systems have the fan
located in the after collector.
The ducting between the powder booth and cyclone may also develop heavy
impact fused powder build-up that will require removal to prevent potential
contamination.
It is common practise to spray to waste the first (10Kg Approx) of powder
collected by the cyclone before reclaiming to minimise the risk of contamination.

Advantages of Cyclones
Generally less expensive than cartridge systems.
Have capability of reclaiming infinite amount of colours.
Removes fine powder particles that can sometimes cause problems.

Disadvantages of Cyclones
Depending on cyclone efficiency as much as 15% of reclaimed powder can be
lost.
Colour changing can be time consuming and difficult because of ducting.
Although very rare, cyclones can explode.

Water Scrubbers
Most water scrubbers are installed after cyclones and are used to capture the ultra fine
particles that pass through the cyclones. Water scrubbers work by creating a series of
water curtains or umbrellas that the air and powder must pass through before exiting the
system. The water traps the powder and washes it down into a tank where it must be
manually removed as powder sludge. Water is continuously circulated from the sump to
the spray nozzles.

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 Cartridge Filter Powder Booths
Cylindrical cellulose or synthetic filters separate over-sprayed powder particles from
processing air. Powder is pulsed from between the pleats and surface of the filters by a
compressed air pulse valve positioned over the interior of the filter. Re-claimed powder is
collected in fluidised beds under the filters and can then be pumped back to the gun feed
hopper or to a waste container. Filtered air is then processed through a secondary set of
filters.
Cartridge systems are typically over 99% efficient.
Advantages
Highest reclaim efficiency.
Quick colour changes with dedicated modules.
A single spray to waste module can be used for smaller non-reclaim colour runs.
No risk of explosion.

Disadvantages
A dedicated filter module is required for every reclaim colour and this is costly.
Extra colour modules take up floor space.
If not carefully managed, powder fines can build up and create problems.

Powder Booth with Cartridge Recovery

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Cartridge Recovery System Operation and Maintenance
A fan draws air and over-sprayed powder through the cartridge filters, the
cartridges separate the air and the powder. The powder is pulsed from between
the pleats of the cartridges and recovered inside the filter module. The air is
generally passed through a secondary set of filters and returned to the factory.
Cartridge filters are reversed pulsed with dry compressed air during operation
and should not be cleaned in any other way.
The life expectancy of the cartridge filters should be at least 12 months if the
system is properly designed and maintained.
Filters can be easily damaged during installation, always follow manufactures
instructions.
Reverse compressed air pulsing valves can fail and should be inspected
regularly to ensure all cartridge filters are being properly cleaned.
Most systems have adjustable pulsing; there are (3) separate adjustments that
can affect the cleaning of the cartridge filters. The equipment supplier should be
consulted on most effective adjustment for each of the following:
1. Pulse Pressure 2. Pulse On-Time 3. Pulse Off-Time
It is recommended that all cartridge collector systems be fitted with a gauge to
measure differential pressure across the filters. This will give an indication of how
clean or blocked the cartridges are.
Motor and Fan bearings may require greasing.

Reclaiming Powder Coatings

Over-sprayed powder can be recovered and re-applied, this is providing good
housekeeping procedures are practised, and the recovery system is designed for powder
reclaiming.

Reclaiming Considerations
Virgin powder is manufactured to a specified particle size distribution and this varies
depending on the application and the manufactures production practices. When virgin
powder is applied through both Corona and Tribo guns, a higher proportion of the larger
particles are deposited onto the parts. This is due to the larger particles holding more
overall charge than the smaller particles, and the smaller particles being more likely to be
drawn away in the booths air currents.
Cyclone recovery system will classify (remove) a certain amount of the fine
particles depending on its design efficiency.
Cartridge recovery systems will recover virtually all over-sprayed powder
including the very fine particles. Reclaim powder will generally apply less
efficiently than virgin powder.

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Contamination
Colour, incompatible powders, dirt, fibres and other foreign particles can easily
contaminate the powder while it is being exposed to the equipment and environment.
Good housekeeping practices and operating procedures are essential to successfully
process reclaimed powder.

Particle Size
Reclaimed powder always has a shift in particle size distribution from virgin powder; this
can alter powder transfer efficiency, finish appearance and handling characteristics.

Fines Build-Up
Fine particles in higher concentrations can cause many handling and application problems.
Fines build-up is more common in Cartridge filter systems.

Specialty Powders
Powders such as metallic’s, spangles, and textures may be manufactured using a post dry
blending process and may be difficult to reclaim. This is primarily due to preferential
charging and recovery system classification. Consult the powder-coating supplier.

Sieving Reclaimed Powder

It is recommended that recovered powder be processed through a sieve to remove larger
foreign contaminants that may adversely affect finish quality. It is also good practice to
sieve virgin powder to condition it prior to use. The two types of sieves used are Vibratory
and Rotary.

Vibratory Sieves
An electrical or pneumatic vibrator shakes a screen in an up / down motion to pass the
powder through the screen. Models range from very basic designs to complex high
efficiency large capacity models incorporating ultrasonics to help keep the screen clean.
Basic models will sieve through a 400 to 900 micron screen, upper end models to as small
as 100 microns.

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Rotary Sieves
An electric motor drives an auger that channels the powder into a cylindrical sieve screen
where paddles then push the powder through the screen. Any particles too large to pass
through the screen are deposited into a waste bucket. Rotary sieves are typically used
when sieving below 300 microns is desired.

Screen Sizes
Depending on the finish quality requirement commonly used screen opening sizes range
between 105 and 400 microns. For a Class A Finish, i.e. Appliance - a 140-micron or
smaller opening would be recommended.

Managing Reclaim Powder

In order to maintain consistent finish results it is important that the reclaimed powder be
blended in a consistent ratio with virgin powder. Ultimately, the virgin / reclaim ratio is
dependent on systems application transfer efficiency.
If an average of 60% of the sprayed powder is attracted to the parts, than the average
Virgin to reclaim ratio should be 60% Virgin and 40% Reclaim powder. Controlling the
virgin / reclaim balance can be done manually or automatically by using bulk feeding and
level sensing equipment.

Operating Recommendations
Maximise First Pass Transfer Efficiency – Line density, Part presentation,
Earthing, Gun Positioning, Gun settings.
Squeegee powder from booth interior as often as possible.
Maintain a minimal amount of reclaim powder in the system, always be
transferring reclaim powder back to the gun feed hopper.
Add Virgin powder in small regular doses to keep the gun feed hopper full.
Maintain transfer pumps, hoses and sieve screens to ensure consistent reliable
performance.

Colour Changing
Many powder-coating operations process any number of different colours. Some will
change colour many times per day and others every few days or weeks.
Changing colours can be very labour intensive, time consuming and costly.
Every effort should be made in scheduling production to allow for the longest colour runs
possible.

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Equipment to Reduce Colour Change Times
Tools such as squeegees, rags, air nozzles, vacuum cleaners
Dedicated gun feed hoses for dark and light colours or for every colour
Spare hoppers or dedicated hoppers for every colour
Extra set of gun feed pumps
Extra set of guns
Roll away booth canopies
2 complete roll away – on / off line systems (fastest colour change)

Contamination
Contamination is one of the most common and troubling problems in the powder coating
process; there are many potential sources of contamination in most powder coating plants.
Extreme care and good house keeping procedures must always be practised to minimise
the risk of contamination.

Common Sources of Contamination

Other Powder Coatings

Powder within the system or in opened boxes can become contaminated by other powders
that are used on the site or in the same equipment. This can result in coloured spots or if
chemistries are incompatible, Fisheyes, Craters or reduction of gloss. If equipment is not
thoroughly cleaned between colour changes contamination is certain.
Plant Environment
Powder booths operate under negative pressure; they draw in plant air to collect over
sprayed powder. Any air borne contaminants in the factory can therefore be drawn into
booth and cause contamination. Airborne plant contaminants can also settle onto the parts
after the cleaning and pre-treatment process.
Parts / Substrate
Tooling oils, dirt, rust, weld slag, burrs etc. if not completely removed from the substrate
will cause surface finish imperfections.
Hooks, Racks and Conveyors
Powders build up on hooks and racks, and grease or scale on conveyor chain can fall onto
the parts.

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Compressed Air Supply
Because all powder application equipment requires compressed air to operate, and the air
is directly exposed to the powder, any oil or moisture in the compressed air will
contaminate the coated parts.
Compressed air should be maintained to the standard detailed under compressors and
driers.

Re-coating Powder Coated Parts

Parts that have been rejected for various finish imperfections can often be re-coated
depending on the nature of the fault and the type of powder.
Most common reasons for rejects are:
Light coverage
Gun spitting
Improper cleaning or pre-treatment
Contamination

A second coating can usually be applied directly over the first coat; there are some
considerations and exceptions however.
First coat can act as an insulator to the earthed part and back ionisation can
occur (Staring). Reducing corona gun KV output will usually help overcome this
problem.

Complete re-coating of entire part is required for finish appearance uniformity.

Raised surface finish defects must be removed by sanding or other methods to

prepare surface for re-coating.

Some powders will not have good intercoat adhesion – (adhesion between
coats), re-coating may not be possible and parts may then require stripping. It is
essential to test adhesion any time parts are re-coated.

If powder coated parts are processed through pre-treatment, some pre-treatment

processes will leave residue on the powder-coated surface and may adversely
affect re-coated finish appearance and intercoat adhesion. Consult pre-treatment
chemical supplier.

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 Powder Coatings on Site Test
Depending on the coating specification, there are recommended on-site tests that should
be performed to help ensure the applied powder coating will meet the specified
performance requirements.
Listed below are some of the most common in-plant tests.

Cleaned and Pre-treated Parts

Water Break test – Visually inspect the parts as parts as they exit the final rinse
stage. Surface should be completely wetted out, water breaks or droplets indicate
that the parts are not properly cleaned.

White Rag test - Rub a white rag on dry pre-treated part to evaluate cleanliness.

Finished Powder Coated Parts

Solvent cure test – Usually straight MEK or a less aggressive solvent is applied
to the powder coated part and resistance to the solvent is used to evaluate the
degree of cure.

Adhesion test – Cross Hatch tape pull test to evaluate the powder coating
adhesion to the substrate.

Thickness - There are many instruments available to accurately measure dry

film builds. This is essential to ensure proper film builds are being applied.

Permeability - Usually for exterior applications, finished sample is placed in a

pressure cooker with water, tests for adhesion.

Impact test – Evaluates powder adhesion and flexibility.

Hardness – Pencil hardness test evaluates powder hardness and cure.

Colour and gloss - Matched to coating supplier’s standard panels.

Visual finish appearance - inspection of colour, gloss, flow, edge coverage,

texture etc. to powder coating supplier’s standard.

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 Powder Coatings - Laboratory Tests
Descriptions of the most common laboratory tests used to evaluate powder-coating
performance on parts.

Colour Computer (LAB)

Comparison to standard:
Positive L = Lighter
Negative L = Darker
Positive A = Too Red
Negative A = Too Green
Positive B = Too Yellow
Negative B = Too Blue
Delta E = the total difference in colour.

Neutral Salt Spray

Evaluates the corrosion protection performance of the pre-treatment and powder coating
adhesion. (Primarily a pre-treatment test). Parts are scribed through the coating to the
metal substrate and placed into the salt spray chamber. Parts are exposed to salt / water
100% humidity environment for a predetermined time or evaluated periodically as per
customer’s requirements. At the completion of the test the part is evaluated and loss of
adhesion from either side of the scribe is reported.

Humidity
Parts are scribed through the coating to the metal substrate and placed in the humidity
chamber exposing the part to 100% humidity at 38 oC for a predetermined time. Parts are
evaluated for loss of adhesion and blistering.

QUV
Powder coated panels are exposed to cycles of Ultra Violet at 50oC and condensation at
40 oC. Typically 4 hour cycles of each. Parts are then evaluated for Colour and Gloss
retention.

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Permeability
Part is placed in a pressure cooker with De-ionised water. Part is evaluated for loss of
adhesion.

Reverse Impact
Powder coated panel is subjected to impact from the UN-coated side and given a rating in
Joules that the coating will resist cracking.

Taber Abrasion
A pre-weighed powder coated panel is rotated under a weighted abrasive material for a
preset time. At completion of the test the panel is weighed to determine the amount of
coating loss.

Particle Size Distribution (PSD)

A small sample of powder is processed through a laser, which can measure the actual size
of the particles. A D10 of 8 means that 10% of the powder is 8 microns or smaller. A D50
of 36 means that 50% of the powder is 36 microns or smaller.

Fluidising (R-Factor)
A pre weighed amount of powder is placed into a small fluidising test hopper. The height is
measured before and after applying fluidising air. While the powder is fluidising it is
allowed to flow through a small tube into a container for a preset amount of time. This
powder is weighed and a calculation is done to determine the R factor. The higher the
number the better the powder will fluidise.

Flexibility - Mandrel Bend Test

A powder-coated panel is formed around a mandrel and evaluated for cracking, and loss
of adhesion.

Erichsen Cupping
A slow reverse impact test measures coating flexibility and a result is given in millimetres
just before the coating cracks.

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Differential Scanning Calorimeter (DSC)
Used to evaluate the degree of cure (not suitable for TGIC free polyester powders). A
small sample of cured powder film can be scraped from the part and placed in DSC. The
DSC measures thermal reactivity to determine if the powder sample was fully cured.

Record Keeping & Documentation

It is strongly recommended that records be kept on all maters pertaining to the powder
coating process.
Documentation can be an invaluable reference when problems occur.

Detailed records should be maintained on the following:

Production Throughput – Record conveyor line speed and the volume of parts
and or square metre of substrate processed per shift.
Pretreatment Chemicals – Record chemical concentrations, pH and heated
tank temperatures.
Maintain records on tank cleaning and purging.
Ovens - Record oven settings and document any maintenance performed, retain
all oven temperature recordings.
Powder Coating – Record powder product, batch, box numbers and the date
and time used.
Powder Application - Record gun positions, gun settings, reciprocator speeds,
and conveyor speed for different type parts.
Powder Booths - Record filter differential pressure, filter pulsing pressures,
transfer pump settings, fluidising pressures.
Film builds – Record low, high and average coating film-builds.
Quality Assurance – Maintain records on all coating performance testing, both
on-site and off-site.
Rejected Parts – Maintain a record of all rejected parts detailing the cause ie.
Light / heavy powder, gun spit, contamination, etc.
Equipment Maintenance – Document replacement spare parts usage and any
repairs performed.

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 Test Standards & Associations

Commonly Referred Test Standards

ASTM – American Standard Test Method
BS – British Standard
AAMA – American Architectural Manufacturers Association

Performance Tests and most Common Specifications

S.NO TYPE OF TEST TEST STANDARD

1. Neutral Salt Spray ASTM B117

2. Humidity ASTM D 2247

3. QUV ASTM G154

4. Permeability AS3715 89 Appendix J

5. Impact ASTM D2794 -93

6. Taber Abrasion ASTM D 4060 - 07

7. Flexibility ASTM D522 –93A

8. Erichsen Cupping BS3900-4E

9. Solvent Cure Interpon T980.3

10. Adhesion ASTM D3359 – 02

11. Thickness ASTM D 1005 – 95

12. Pencil Hardness ASTM D 3363 – 05

13. Gloss ASTM D 523 – 89

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 Handling of Powder Coated Parts
Although properly applied and processed powder coated parts are generally quite durable,
they can still become damaged during handling and shipping transport. Cardboard as an
example is very abrasive and the vibration experienced during transportation on a truck
can scratch and mar the coated surface. Parts should never be handled or packaged while
still hot or warm after exiting the cure oven. Parts should be allowed sufficient time to cool
down to ambient temperature before being handled. Packing materials such as plastic
bags and wrapping, coated paper and padding are often used to protect coated parts
during handling and transport.

Care & Maintenance of Powder Coated Parts

Powder coated surfaces should be kept clean by regular washing with a solution of warm
water and non-abrasive pH neutral solution. Surfaces should be thoroughly rinsed after
cleaning to remove all residues. A soft cloth or sponge should be used – nothing harder
than a natural bristle brush.
Cleaning frequency should be between 6 months and as often as every month depending
on the atmospheric conditions.

Safety
Many different processes take place in any powder coating plant and each has its own
safety concerns and requirements.
Powder coatings and chemical solutions should have both product data sheets and
Material Safety Data Sheets (MSDS). These documents should provide in detail the
recommended use and safe handling procedures and these should always be adhered to.
Equipment suppliers should be individually consulted for safety procedures involving the
use and maintenance of their equipment. Local government agencies can also provide
information on safety regulations and requirements for their regions.
Parts and all related powder equipment should be properly earthed to prevent charge
build-up and arching, which could potentially ignite powder coatings.
In the unlikely event that a fire occurs all associated equipment and compressed air supply
should immediately be switched off.

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 Powder Coating in the Future
Much development work is being done to reduce powder temperature and dwell time
curing schedules. Ultra Violet curing powders are also being developed for the timber and
plastics markets that represent the greatest future growth for powder coating.
Thin and Ultra Thin Film products continue to be developed and should become more
widely used. These new technologies will significantly reduce the applied cost and make
coil and blank coating more feasible for powder coating.
New powder manufacturing technology will allow faster turnaround on special colours.
Powder application equipment suppliers will be introducing more efficient guns and faster
colour change recovery systems.

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