Manual Powder Coating Line

Manual Powder Coating Lines consist of a manual powder coating booth with filters, a box-type oven, and a powder coating equipment

A manual powder coating line is a system used to coat metal objects with a protective and decorative layer of powder paint. The process involves several steps, including:

Surface Preparation: The metal object to be coated is thoroughly cleaned and degreased to ensure a proper bond between the powder and the metal surface.
Pre-heating: The object is pre-heated to a specific temperature to allow the powder to adhere properly and to improve the curing process.
Powder Application: The powder is applied to the pre-heated object using a powder spray gun. The powder is electrostatically charged, causing it to be attracted to the grounded object.
Curing: The object is placed in a curing oven, where the powder is heated to a specific temperature for a specific amount of time. This causes the powder to melt and flow, forming a continuous, durable coating.
Cooling: The object is removed from the curing oven and allowed to cool completely.

Advantages of manual powder coating lines:

Lower initial investment: Manual powder coating lines are typically less expensive to set up than automatic powder coating lines.
Flexibility: Manual powder coating lines can be used to coat a wide variety of objects, including irregular shapes and small batches.
Ease of use: Manual powder coating lines are relatively easy to operate, even for inexperienced workers.

Disadvantages of manual powder coating lines:

Lower throughput: Manual powder coating lines are slower than automatic powder coating lines.
More labor-intensive: Manual powder coating lines require more labor than automatic powder coating lines.
Potential for inconsistency: Manual powder coating lines are more susceptible to inconsistencies in coating thickness and quality.

Applications of manual powder coating lines:

Manual powder coating lines are commonly used in a variety of industries, including:

Automotive: Coating car parts, such as bumpers, wheels, and frames.
Appliance: Coating appliances, such as refrigerators, stoves, and washing machines.
Furniture: Coating furniture, such as chairs, tables, and cabinets.
Metal fabrication: Coating metal parts, such as brackets, housings, and enclosures.
Medical equipment: Coating medical equipment, such as surgical instruments and implants.

Considerations when choosing a manual powder coating line:

The size and complexity of the objects to be coated.
The desired production volume.
The budget.
The availability of skilled labor.
The layout of the workspace.

Conclusion

Manual powder coating lines are a versatile and cost-effective solution for a variety of powder coating applications. By considering the factors above, you can choose the right manual powder coating line for your specific needs.

This type of small line is ideal for small workshops where the number of parts to be painted is not high. An operator can paint the parts in order, then hang them on to the oven cart and after the cart is full, he can push the cart into the oven and cure them for 20 mins.

Manual Powder Coating Line

A manual powder coating line is a cost-effective and versatile option for businesses that require a powder coating system with a lower initial investment and a smaller footprint. It is suitable for low to medium production volumes and can handle a variety of workpiece shapes and sizes.

Components of a Manual Powder Coating Line

A typical manual powder coating line consists of the following components:

Pretreatment Booth: This booth is where the substrate is cleaned and prepared for powder coating. The pretreatment process typically involves degreasing, phosphating, and rinsing to remove contaminants and create a suitable surface for powder adhesion.
Drying Oven: The drying oven removes moisture from the pretreated substrate to prevent flash rust and ensure proper adhesion of the powder coating.
Powder Spray Booth: The powder spray booth is where the powder coating is applied to the substrate. It is typically equipped with electrostatic spray guns that charge the powder particles, attracting them to the grounded substrate for uniform coverage.
Curing Oven: The curing oven cures the powder coating, transforming it into a durable and hard finish. The curing temperature and time depend on the specific powder coating material.
Workpiece Handling System: The workpiece handling system includes racks, fixtures, or conveyors that support and transport the workpieces through the various stages of the powder coating process.

Process Flow of a Manual Powder Coating Line

The process flow of a manual powder coating line typically involves the following steps:

Workpiece Preparation: The workpieces are cleaned and degreased to remove dirt, grease, and oil.
Pretreatment: The workpieces are rinsed, phosphated, and rinsed again to remove contaminants and create a conversion coating.
Drying: The workpieces are dried in an oven to remove moisture and prevent flash rust.
Powder Application: The workpieces are placed in the powder spray booth, where they are electrostatically coated with powder.
Curing: The powder-coated workpieces are placed in the curing oven, where the powder melts, fuses, and crosslinks, forming a durable finish.

Advantages of a Manual Powder Coating Line

Manual powder coating lines offer several advantages over other powder coating systems:

Lower Initial Investment: Manual powder coating lines typically have a lower initial investment compared to automated systems, making them more accessible to smaller businesses.
Versatility: Manual systems can handle a wide range of workpiece sizes and shapes, providing flexibility for diverse production needs.
Ease of Operation: Manual systems are relatively simple to operate and maintain, requiring minimal training for workers.
Space Efficiency: Manual systems typically have a smaller footprint, making them suitable for smaller workshops and limited production areas.

Limitations of a Manual Powder Coating Line

Manual powder coating lines also have some limitations compared to automated systems:

Labor Intensity: Manual systems require more labor compared to automated systems, which can increase labor costs and reduce production efficiency.
Consistency: Manual application can lead to variations in powder coverage and finish quality compared to automated systems.
Output Limitations: Manual systems are typically limited in terms of production speed and throughput compared to automated systems.

Applications of Manual Powder Coating Lines

Manual powder coating lines are well-suited for various applications, including:

Small-scale manufacturing: Manual systems are ideal for smaller businesses with limited production volumes.
Custom powder coating: Manual systems offer flexibility for custom coating jobs with unique shapes and sizes.
Prototyping and testing: Manual systems are convenient for prototyping and testing new powder coating formulations or techniques.
Repair and restoration: Manual systems are useful for repairing or restoring powder-coated items.

Conclusion

Manual powder coating lines offer a cost-effective and versatile solution for businesses that require a basic powder coating system with a smaller footprint and lower initial investment. They are well-suited for low to medium production volumes and a wide range of workpiece shapes and sizes. While manual systems may require more labor and have some limitations in terms of consistency and output, they provide flexibility and ease of operation for various applications.

Cartridge Powder Coating Booth for the Manual Powder Coating Line

Powder paint booth with filters for Manual Powder Coating Line

Manual powder coating booths, also known as cartridge filtration booths, are an essential component of manual powder coating lines. They are designed to capture overspray and prevent the spread of powder dust in the work environment.

Benefits of Cartridge Powder Coating Booths

Effective Powder Recovery: Cartridge powder coating booths utilize filter cartridges to capture overspray, reducing powder waste and environmental impact.
Clean Work Environment: They effectively remove airborne powder particles, ensuring a cleaner and healthier work environment for operators.
Easy Maintenance: Cartridge filters are easy to replace, minimizing downtime for maintenance.
Compact Design: Cartridge powder coating booths are relatively compact, making them suitable for a variety of workspaces.
Cost-Effective Solution: They offer a cost-effective solution for powder coating applications, particularly for small to medium-sized batches.

Key Components of a Cartridge Powder Coating Booth

Booth Enclosure: The booth enclosure provides a contained space for powder application and overspray capture.
Filter Cartridges: Filter cartridges are the primary components responsible for capturing overspray. They are typically made of pleated or high-loft filter media, providing high filtration efficiency.
Blower System: The blower system draws air through the booth, creating a suction effect that pulls overspray towards the filter cartridges.
Powder Recovery System: A powder recovery system collects the captured overspray powder, allowing for re-use and reducing waste.
Control System: The control system regulates the blower speed and monitors filter performance, ensuring optimal operation.
Lighting System: Adequate lighting is essential for proper visibility and safe operation within the booth.

Selection of a Cartridge Powder Coating Booth

Booth Size: The size of the booth should be appropriate for the size and number of objects being coated.
Airflow Rate: The airflow rate should be sufficient to capture overspray effectively.
Filter Efficiency: The filter efficiency should be appropriate for the type of powder being used.
Noise Level: The noise level should be considered if the booth is located in a sensitive area.
Safety Features: Ensure the booth has safety features such as emergency stops and fire suppression systems.

Maintenance of a Cartridge Powder Coating Booth

Regular Filter Inspection: Regularly inspect filter cartridges for signs of clogging or damage. Replace filters promptly as needed.
Airflow Monitoring: Monitor airflow rates to ensure optimal performance.
Cleanliness: Keep the booth interior clean to prevent dust buildup and potential fire hazards.
Electrical Safety: Ensure proper grounding and electrical connections for safety.

Conclusion

Cartridge powder coating booths play a crucial role in maintaining a clean and safe work environment during powder coating operations. By selecting the right booth and implementing proper maintenance practices, you can ensure efficient powder recovery, protect your workers’ health, and prolong the lifespan of your powder coating equipment.

Our cartridge powder coating booth is designed to capture excess powder during application. It is the culmination of many years of experience in designing and building machinery for powder coaters.

To comply with recent changes in legislation we have now upgraded our cartridge booth by fitting two centrifugal fans of 5.5kw capacity and six cartridge filters.

Manual powder coating booths are the easiest solutions for powder coating applications when you don’t have many colors and you don’t need to change colors often. Our manual powder coating spray booths are designed and manufactured either from galvanized sheets or mild steel sheets which are then painted.

There is an inside space for the painter to hang his parts and paint with his powder coating gun, while filters suck and clean the air in the medium and blow off the paint gathered on the filters once in a while.

Manual powder coating booths can be made starting from 2 filters and 3,4,5,6 and 8 filters maximum. We use 32x60cm cellulose powder coating filters in our booths. There is an electrical board, to control the blow-off valves to clean the filters and lights inside for the operator to see and check the painting quality

Our Powder Spray Booth Features

Manual powder spray booths, also known as powder coating booths, are enclosed workspaces designed to capture overspray and prevent the spread of powder dust during the powder coating process. They are typically used in conjunction with manual powder coating guns to apply a protective and decorative layer of powder paint to metal objects.

Essential Features of Manual Powder Spray Booths

Effective Powder Capture: The booth should effectively capture overspray powder particles to minimize waste and environmental impact.
Sufficient Airflow: A powerful blower system should provide adequate airflow to draw overspray towards the filter cartridges.
High-Efficiency Filter Cartridges: Pleated or high-loft filter cartridges should be used to ensure efficient removal of airborne powder particles.
Powder Recovery System: A powder recovery system should collect captured overspray powder, allowing for re-use and reducing waste.
Control System: A control system should regulate the blower speed and monitor filter performance to maintain optimal operation.
Adequate Lighting: Proper illumination within the booth is essential for safe and efficient powder application.
Emergency Stop Mechanism: An emergency stop mechanism should be readily accessible to halt operations in case of any safety hazards.
Fire Suppression System: A fire suppression system is crucial to mitigate the risk of fire hazards associated with powder coating.
Grounding and Electrical Safety: Proper grounding and electrical connections are essential to prevent electrical hazards.

Additional Features for Enhanced Functionality

Adjustable Airflow Control: Adjustable airflow controls allow for fine-tuning the air velocity according to the specific coating application.
Interchangeable Filters: Interchangeable filters enable the use of different filter grades to suit various powder types and coating requirements.
Integrated Pre-Filter System: An integrated pre-filter system can extend the lifespan of the main filter cartridges by capturing larger particles before they reach the main filters.
Automatic Filter Cleaning System: An automatic filter cleaning system can simplify maintenance by automatically cleaning or replacing filters when necessary.
Integrated Powder Dispensing System: An integrated powder dispensing system can streamline the powder application process by providing a centralized powder supply and dosing mechanism.
Remote Control Operation: Remote control operation allows for convenient control of booth functions from a distance, enhancing safety and efficiency.
Touchscreen Interface: A touchscreen interface provides a user-friendly way to monitor and adjust booth parameters.
Real-time Monitoring Sensors: Real-time monitoring sensors can provide valuable data on airflow rates, filter performance, and powder concentration levels.
Data Logging and Reporting: Data logging and reporting capabilities can help track booth performance over time and identify areas for improvement.

Conclusion

Manual powder spray booths offer a versatile and cost-effective solution for a variety of powder coating applications. By incorporating these essential and additional features, powder coating booths can enhance safety, improve efficiency, and minimize environmental impact while ensuring high-quality powder coating results.

100% filtration means that the air filtration system does not require ducting to the outside. This makes installation easier and also increases overall energy efficiency, as you don’t lose heated factory air.
Unlike water back booths, there is no ongoing expense of sludge removal.
The filtered powder is collected in a tray, making disposal easy.
Centrifugal fans are used to remove contaminated air, are more powerful than axial fans.
Large, quick-acting air valves direct a blast of air into each filter at intervals of 30 seconds to keep them working efficiently.
Option of auto-switch – when the powder gun is taken from the holster the fan automatically switches on, replace and it goes off. This device can substantially reduce energy consumption.
Completely manufactured at our Turkey workshop. Our machinery is manufactured to a high quality and is built to last.
Flat packed for easy transportation and installation.
Full compliance with HSE guidelines.
CE mark.
Fully guaranteed.
Service contracts are available.

For more information, you can send an e-mail to our e-mail address

Filtration is achieved by using cartridge filters in an open compartment. The filtered clean air (now devoid of powder particles) then passes through a sealed plenum chamber and via the centrifugal extraction fan back into the factory atmosphere. The system avoids any explosion risk that may be caused by passing powder-laden unfiltered air into a sealed chamber.
Sound Level Due to the level of airflow required the noise level determines that ear defenders are required.

Tests are carried out on the stability and structural strength of the spray enclosure. All operating and installation instructions are supplied on delivery

Powder Coating Booth Manufacturers

Powder Coating Spray Booth for the Manual Powder Coating Line

The manufacturing process for powder coating booths involves several steps:

1. Design and Engineering: The process begins with the design and engineering of the powder coating booth. This includes determining the booth size, airflow requirements, filter specifications, and other technical parameters based on the specific application and desired performance.

2. Material Preparation: The necessary materials for booth construction are gathered and prepared. This typically includes sheet metal panels, structural supports, filter cartridges, blower systems, electrical components, and any additional hardware or accessories.

3. Panel Cutting and Shaping: Sheet metal panels are cut and shaped according to the booth design using precision cutting tools or laser cutting machines. This ensures accurate dimensions and proper fit for the booth structure.

4. Frame Assembly and Welding: The structural frame of the booth is assembled by welding together the prepared panels and supports. This creates the main skeleton of the booth, providing strength and rigidity.

5. Filter Installation: Filter cartridges are installed within the booth enclosure to capture overspray during the powder coating process. The filter type and arrangement are determined based on the specific powder being used and the desired filtration efficiency.

6. Blower System Integration: The blower system, which provides the airflow for overspray capture, is integrated into the booth structure. This involves mounting the blower motor, connecting ductwork, and ensuring proper airflow distribution.

7. Electrical Wiring and Controls: Electrical wiring is installed throughout the booth to connect the blower system, lighting fixtures, control panels, and any other electrical components. Proper grounding and safety measures are implemented to prevent electrical hazards.

8. Powder Recovery System Installation (Optional): If a powder recovery system is required, it is installed to collect the captured overspray powder. This typically involves mounting the powder recovery hopper, connecting ducting, and integrating the system with the blower system.

9. Final Assembly and Testing: All components are carefully assembled and tested to ensure proper fit, function, and safety. This includes checking blower performance, filter integrity, electrical connections, and overall booth operation.

10. Quality Control Inspection: The completed powder coating booth undergoes a thorough quality control inspection to verify compliance with design specifications, safety standards, and performance requirements. Any identified issues are addressed before the booth is released for use.

Safety Instructions for Spray Booths

Ensure that a clear unrestricted supply of air is available to ensure that the
extraction fan is able to work efficiently.
Do not obstruct the fan outlets in any way.
If spraying wet paint, the fans must be ducted outside.
Do not store any goods on the roof of the spray booth.
Protective clothing, including ear defenders and suitable breathing masks, must be worn when spray painting.
Filtration Efficiency
The cartridge-type filters (powder-only booths) are designed to filter 99% of all particles down to 5 microns. Important Notice
Powder paint manufacturers supply powder in particle size whereby 90% of the particles are in a size range of 200 microns. Some particles however will inevitably be much
smaller. The particle size of fewer than 5 microns will migrate through almost any filter.

Operating Instructions for Cartridge Filter Spray Booths
A clean air supply rated at a minimum of 6 bars is required.
The air supply must be filtered but not lubricated as unfiltered air could lead to fragments of dirt and debris being delivered to the diaphragm valves. This may lead to the rubber diaphragm being perforated or the valve sticking open. Both of these faults will result in a constant stream of air passing through the filter.

Powder Spray Booth for Manual Powder Coating Line

Powder spray booths are essential components of manual powder coating lines, providing a controlled environment for applying powder coating to metal objects. They play a crucial role in capturing overspray, preventing the spread of powder dust, and ensuring a safe and efficient coating process.

Primary Application Areas of Powder Spray Booths

Metal Fabrication: Powder spray booths are widely used in metal fabrication shops to coat metal parts, components, and structures with protective and decorative powder coatings.
Automotive Industry: Powder spray booths are extensively used in the automotive industry to apply powder coatings to car parts, such as bumpers, wheels, frames, and underbody components.
Appliance Manufacturing: Powder spray booths are employed in appliance manufacturing to coat refrigerators, stoves, washing machines, and other appliances with durable and aesthetically pleasing powder finishes.
Furniture Production: Powder spray booths are utilized in furniture manufacturing to coat metal furniture components, such as chairs, tables, shelving units, and decorative elements.
Medical Equipment Manufacturing: Powder spray booths are used to apply powder coatings to medical equipment, such as surgical instruments, implants, and enclosures, ensuring a clean and hygienic finish.
Aerospace Industry: Powder spray booths play a vital role in the aerospace industry, coating aircraft components with protective and corrosion-resistant powder coatings.
Electronics Manufacturing: Powder spray booths are utilized in electronics manufacturing to apply conductive or insulating powder coatings to circuit boards and electronic components.

Additional Applications

Powder spray booths are also used in various other industries, including:

Construction: Coating metal building components, pipes, and fixtures.
Agricultural Equipment Manufacturing: Coating farm machinery and implements.
Tool and Die Making: Coating metal tools and dies for durability and wear resistance.
Architectural Metalwork: Coating architectural metalwork, such as railings, gates, and ornamental pieces.
Protective Coatings: Applying powder coatings for protection against corrosion, wear, and environmental factors.

In summary, powder spray booths are versatile and essential tools in a wide range of industries, enabling the application of durable, high-quality powder coatings to various metal objects. Their ability to capture overspray and maintain a clean work environment makes them indispensable for safe and efficient powder coating operations.

The factory timing calibration is set at 0.2 of the second pulse duration and an interval time of 15 seconds between each filter pulse. Under heavy and prolonged use it may be necessary to modify these parameters, this decision is usually determined if the efficiency of the booth begins to diminish and re-programming by Siemens P.L.C. must be done only after consultation with EMS Powder Coating Machinery.

Under normal working conditions, the cylinder cartridge filters have a minimum 1-year life span, replacement filters are kept in stock at EMS Powder Coating Machinery and replacement is facilitated by a 12 mm nut on the underside of each filter.

The filter should be blown with a hand air gun once each week with care taken to clean the top of the filters, an area the automatic cleaning seems to miss. The optimum pressure required by the self-cleaning mechanism is 60 – 90 P.S.I., however, this may be lowered to a minimum of 30 P.S.I. if notice restraint is a factor.

The pulsing will be noticeably quieter at this level, but the cleaning is not as comprehensive. To assist in cleaning in this situation it is advisable to run the machine at a higher pressure, say 90 P.S.I., for a period of 15 minutes at a convenient time. If wet paint is used the life of the cartridge filters will be reduced. Only spray within the confines of the booth. Check the sealing of the filters on a regular basis.

If the powder is escaping through the booth, the cartridge filters are not sealing correctly. Due to having to use high-pressure centrifugal fans to obtain the necessary airflow of 0.7m per second per 1m, the noise level determines that ear defenders are required.

Powder Spray Booth for Manual Powder Coating Line

The spray booths manufactured by EMS Powder Coating Machinery are tested in airflow in the following ways: A hand-held anemometer is used to take readings at a distance of 400mm from the face of the booth and at intervals of 300mm longitudinally. The combined total is then divided by the number of readings. The suction force equals an average of 0.7 per second or above.

Important Notes

The anemometer readings will vary over the face of the booth. The performance will drop when the filters become resistive. Due to the high airflow and the high pressure required necessitating centrifugal fans with forwarding curved impellers, the resultant noise level will mean that ear defenders are required. It is strongly advised that our patented automatic switching device is used. Tests in production indicate that over 60% of the time suction is not required, our switching device switches off the fans when the gun is in the holster, thus saving operating costs.

A Small powder coating booth with recovery are cost-effective finishing environment for small-batch powder applications and powder coating systems. Featuring a primary and redundant filtration system, EMS Powder Coating Equipment’s powder coating booths capture high volumes of powder overspray with even small powder sizes for powder sprays that go to waste. This is a big plus in comparison to booths for wet paint. Batch powder coating booths are ideal, especially for small parts such as alloy wheels

The open-front design saves floor space and allows for easy transportation in and out of the booth.

The function of the Powder Coating Booth

The booth function is characterized by the protection of the coating process from external influences, combined with keeping the area around the booth is clean. The booth function is based on a powerful exhaust air system, which aspirates air from the booth interior through filter cartridges.

The resulting negative pressure produces an airflow from the outside of the booth to the inside, thus preventing powder from escaping into the environment. In order to have a full understanding of the booth operation, the booth functions are individually described in the following sections.

Exhaust Air System of the Powder Coating Booth in a Manual Powder Coating Line

The exhaust fan of the exhaust system is located in the fan housing above the filter cartridges. It sucks air from the booth interior through the filter cartridges and returns the clean air through the filter pads to the environment. The filter pads in the fan housing are intended for visual inspection only. Should one of the filter cartridges become damaged or develop a leak, the powder will be deposited on this filter stage.

The efficiency of the exhaust system depends on how severely the filter cartridge is clogged. For this reason, the suction efficiency is determined and indicated by measuring the differential pressure between the clean air side and the booth environment (pressure monitoring). A pressure rise means an increasing clogging of the filter cartridges.

Filter Cleaning

Filter cleaning is the process of removing dirt, debris, and other contaminants from a filter to restore its efficiency and extend its lifespan. Filters are used in a wide variety of applications, including air filtration, water filtration, and fuel filtration. When a filter becomes clogged with contaminants, it can no longer effectively perform its function. This can lead to a number of problems, such as reduced airflow, increased pressure drop, and contamination of the filtered medium.

There are a number of different methods that can be used to clean filters. The most appropriate method will depend on the type of filter and the type of contaminants that are present. Here are a few of the most common methods:

Manual cleaning: This is the simplest and most cost-effective method of filter cleaning. It involves physically removing the filter from its housing and then brushing, washing, or vacuuming the contaminants off the filter media.
Backwashing: This method is commonly used to clean water filters. It involves reversing the flow of water through the filter, which helps to dislodge contaminants from the filter media.
Sonication: This method uses sound waves to create vibrations that can dislodge contaminants from the filter media. It is often used to clean filters that are difficult to clean by other methods, such as filters with small pores or filters that are made of delicate materials.
Chemical cleaning: This method involves using chemicals to dissolve or break down contaminants on the filter media. It is often used to clean filters that are contaminated with oily or greasy substances.
Regeneration: This method is used to clean activated carbon filters. It involves passing hot steam through the filter, which removes the contaminants that have been adsorbed onto the activated carbon.

The frequency with which a filter needs to be cleaned will depend on the type of filter, the operating conditions, and the level of contamination. As a general rule of thumb, filters should be cleaned when the pressure drop across the filter increases by 25% or more.

Here are some tips for cleaning filters:

Follow the manufacturer’s instructions: The manufacturer of your filter will provide specific instructions on how to clean it safely and effectively.
Wear gloves and eye protection: When cleaning filters, it is important to wear gloves and eye protection to protect yourself from contaminants and chemicals.
Clean filters in a well-ventilated area: Some cleaning methods can generate fumes, so it is important to clean filters in a well-ventilated area.
Dispose of contaminants properly: Dispose of contaminants properly after cleaning filters. Do not dispose of contaminants in a way that could harm the environment.

By following these tips, you can ensure that your filters are clean and that they are performing their function properly.

Each filter cartridge is equipped with a cleaning device and can be cleaned while the booth is in operation. The cleaning procedure is activated manually by the relevant switch on the control cabinet.

The cartridges are cleaned by compressed air impulses and injected by pressure pipes inside the cartridges. The powder drops onto the booth floor, from where it arrives into the powder trolley or the powder collector.

The filter cleaning air is supplied from the pressure tank in the exhaust air
unit and must amount 5 bar (recommended), and not exceed 6 bar. The cleaning process and consequently the blow-off duration per filter cartridge and the pause time, before the next cartridge is blown off, are controlled by an electronic control unit. The blow-off time for the cleaning impulse must amount to 10-30 ms and is preset by the factory:

Blow-off time = 20 milisecs (factory setting)
Pause time = 10 s (factory setting)

Powder Circuit

In the context of powder coating, a powder circuit is a closed-loop system that transports and recirculates powder during the coating process. It consists of several components that work together to ensure efficient and consistent powder application.

Key Components of a Powder Circuit:

Powder Feeder: The powder feeder is responsible for metering the powder from the storage hopper into the powder circuit. It typically uses a rotating auger or a vibrating plate to deliver a controlled amount of powder.
Powder Conveying System: The powder conveying system transports the powder from the powder feeder to the application gun. It typically uses a combination of air pressure and vacuum to move the powder through a network of tubes and hoses.
Powder Delivery Hose: The powder delivery hose connects the powder conveying system to the application gun. It is designed to minimize friction and ensure a smooth flow of powder to the gun nozzle.
Powder Application Gun: The powder application gun is the device that applies the powder to the object being coated. It typically uses electrostatic charge to attract the powder particles to the grounded object, ensuring even and consistent coverage.
Powder Recovery System: The powder recovery system collects overspray, which is the excess powder that does not adhere to the coated object. It typically uses filters to capture the powder particles and then returns them to the powder feeder for reuse.

Benefits of Using a Powder Circuit:

Efficient Powder Utilization: Powder circuits minimize powder waste by recirculating overspray, reducing the need for fresh powder and lowering overall costs.
Consistent Powder Application: Powder circuits ensure consistent powder application by delivering a controlled amount of powder at a constant rate, minimizing variations in coating thickness.
Improved Work Environment: Powder circuits help to maintain a clean and controlled work environment by capturing overspray and reducing the risk of powder dust contamination.
Reduced Fire Hazards: Powder circuits can contribute to fire safety by preventing the accumulation of powder dust, which can be a potential fire hazard.

Applications of Powder Circuits:

Powder circuits are widely used in a variety of powder coating applications, including:

Automotive Industry: Coating car parts, such as bumpers, wheels, frames, and underbody components.
Appliance Manufacturing: Coating refrigerators, stoves, washing machines, and other appliances with durable and aesthetically pleasing powder finishes.
Furniture Production: Coating metal furniture components, such as chairs, tables, shelving units, and decorative elements.
Metal Fabrication: Coating metal parts, components, and structures with protective and decorative powder coatings.
Medical Equipment Manufacturing: Coating medical equipment, such as surgical instruments, implants, and enclosures, ensuring a clean and hygienic finish.
Aerospace Industry: Coating aircraft components with protective and corrosion-resistant powder coatings.
Electronics Manufacturing: Coating circuit boards and electronic components with conductive or insulating powder coatings.

A powder trolley is a prerequisite for working with a closed powder circuit. In the closed powder circuit, the gun is connected to the powder trolley. The powder is fed from the powder trolley via the gun to the workpiece. The over-sprayed powder drops to the booth floor or is retained by the
filter cartridges, from where it also drops down inside the booth when the filters are blown off. The powder is scraped manually into the powder trolley, where it can be reused for coating operation.

Powder Trolley

Powder Coating Booth for Manual Powder Coating Machine

A powder trolley, also known as a powder cart or powder transfer cart, is a mobile unit used to transport and store powder coating material. It is a versatile and essential tool for powder coating operations, providing efficient powder handling and contributing to a safe and organized workspace.

Key Components of a Powder Trolley:

Powder Hopper: The powder hopper is the main storage container for the powder coating material. It is typically made of durable materials such as stainless steel or polyethylene and is designed to hold a specific amount of powder.
Powder Discharging System: The powder discharging system allows for controlled release of powder from the hopper. It typically consists of a valve, a dispensing nozzle, and a hose connection.
Grounding System: The grounding system ensures that the trolley is electrically grounded to prevent static buildup and potential sparks during powder handling.
Mobile Frame and Wheels: The mobile frame and wheels provide maneuverability for transporting the trolley around the powder coating workspace. The frame is typically made of sturdy metal, and the wheels are designed for smooth rolling and stability.
Safety Features: Safety features may include brakes to prevent unintended movement, spill containment trays to catch powder leaks, and warning signs to indicate potential hazards.

Benefits of Using a Powder Trolley:

Efficient Powder Handling: Powder trolleys facilitate efficient powder transfer from storage to the powder coating application area, reducing manual effort and streamlining the coating process.
Organized Workspace: Powder trolleys help maintain an organized workspace by providing a dedicated location for storing and transporting powder, minimizing clutter and improving overall efficiency.
Reduced Powder Waste: Powder trolleys help minimize powder waste by keeping the powder contained and preventing spills or leaks.
Improved Safety: Powder trolleys contribute to safety by keeping powder dust contained and reducing the risk of electrostatic discharge or other hazards associated with loose powder handling.
Enhanced Mobility: Powder trolleys allow for easy movement of powder around the workspace, eliminating the need for manual lifting and carrying of heavy powder containers.

Applications of Powder Trolleys:

Powder trolleys are widely used in various powder coating applications, including:

Automotive Industry: Transporting powder for coating car parts, such as bumpers, wheels, frames, and underbody components.
Appliance Manufacturing: Moving powder for coating refrigerators, stoves, washing machines, and other appliances.
Furniture Production: Transferring powder for coating metal furniture components, such as chairs, tables, shelving units, and decorative elements.
Metal Fabrication: Conveying powder for coating metal parts, components, and structures with protective and decorative powder coatings.
Medical Equipment Manufacturing: Distributing powder for coating medical equipment, such as surgical instruments, implants, and enclosures.
Aerospace Industry: Transporting powder for coating aircraft components with protective and corrosion-resistant powder coatings.
Electronics Manufacturing: Moving powder for coating circuit boards and electronic components with conductive or insulating powder coatings.

The powder trolley is installed at the rear of the booth, under the booth floor. The powder trolley can be rolled out and pressed against the booth in its working position. Herein, the powder is fluidized, then sucked up by the injector, and fed to the gun. The powder which has dropped to the booth floor is fed back into the powder trolley through a vibrating sieve. Thereby, contamination in the powder is eliminated. The sieve can be switched on with the button when required.

Start-up of the Powder Coating Booth in a Manual Powder Coating Line

Starting up a powder coating booth in a manual powder coating line involves a series of sequential steps to ensure proper functioning and optimal performance during the powder coating process. Here’s a step-by-step guide to starting up the powder coating booth safely and effectively:

Inspection and Cleaning: Before starting up the booth, conduct a thorough visual inspection to check for any signs of damage, loose components, or obstructions in the airflow path. Clean the booth interior and exterior, including the filters, to remove any dust, debris, or accumulated powder residue.
Filter Check: Inspect the filters for any signs of clogging or damage. If necessary, replace the filters with new ones to ensure efficient overspray capture and maintain a clean work environment.
Blower System Activation: Activate the blower system to establish proper airflow within the booth. Check the blower speed and ensure it is within the recommended range for optimal overspray capture.
Electrical System Check: Verify that all electrical connections are secure and that the booth is properly grounded to prevent electrical hazards. Ensure that the control panel is functioning correctly and that all safety features are operational.
Powder Feeder Preparation: Prepare the powder feeder by filling it with the appropriate powder coating material. Follow the manufacturer’s instructions for setting the powder feed rate and ensuring proper powder flow.
Powder Application Gun Check: Inspect the powder application gun for any damage or blockages. Ensure that the electrostatic charge is properly adjusted and that the nozzle is clean and free of debris.
Lighting Check: Verify that the booth lighting is adequate for proper visibility and safe operation during powder application.
Emergency Stop Mechanism Check: Ensure that the emergency stop mechanism is readily accessible and functioning correctly to halt operations in case of any safety hazards.
Fire Suppression System Check: Verify that the fire suppression system is properly activated and ready to function in case of a fire emergency.
Ventilation System Check: Ensure that the ventilation system is operating properly to remove fumes and airborne powder particles from the booth and maintain a safe working environment.
Test Coating: Perform a test coating to ensure that the powder coating equipment is functioning correctly and that the powder is applying smoothly and evenly to the test object.
Regular Monitoring: Continuously monitor the booth’s performance during powder coating operations, checking airflow, filter status, and overall system functionality. Make adjustments as needed to maintain optimal performance.

By following these steps and conducting regular maintenance, you can ensure the safe and efficient operation of your powder coating booth, contributing to a productive and safe powder coating process.

Filling the powder trolley

The following section describes how the empty powder trolley is to be filled. The powder trolley can only be filled manually. Before filling the trolley, it may be necessary to carry out a coarse cleaning of the booth. In order to eliminate powder contamination, fresh powder should not be filled directly into the trolley; the following procedure is recommended:

Switch on the booth with the button
Switch off the electrostatic control units
Switch on the sieve with the button
Evenly distribute portions of fresh powder directly over the
sieve. The powder is passed through the sieve and freed
from any contamination
Repeat this procedure until the required amount of powder is
in the container
Check the powder level through the control flap of the
powder container
The filling capacity by empty powder trolley is approx. 15 kg plastic
powder (average value).

Procedure

Release the compressed air circuit (input pressure must amount to at least 6 bar)
Switch on the booth (switch on the main switch, and press the button), see also chapter “Switching on the booth
Adjust the operating parameters on the pneumatics cabinet: Sieve pressure reducing valve (4): approx. 2-3 bar, depending on the powder type Fluidizing pressure reducing valve (3): approx. 0,5-1,5 bar, depending on the powder, the powder should lightly “boil” (check this through the inspection flap of the powder container)
Check the fluidization and regulate, if necessary. The adjustment of the required fluidization air pressure depends on the powder type, the air humidity and the ambient temperature. For this reason, only an arbitrary fluidization setting is possible and should be readjusted, according to previous experience for the powder type being used

Maintenance

Daily Maintenance Works

Blow off the hose with compressed air
Clean the outside of the gun and check for wearing parts
Coarse cleaning of the booth (see therefore chapter “Coarse booth cleaning”)
Check the vibration sieve in the powder trolley and remove any contamination
Clean the filter cartridges (see therefore chapter “Filter cleaning”)

Weekly

Clean the filter cartridges and check for visible damages, if necessary, replace (see chapter “Replacing the filter cartridges“)
Check the filter pads on the exhaust air exits of the fan housing, a large powder deposit indicates a defective filter cartridge, replace the defective filter cartridge or the complete filter set (see chapter “Replacing the filter cartridges“)
Clean completely the booth (no wet cleaning!)
ATTENTION:
A booth cleaning should not take place immediately after the powder trolley have been filled with fresh powder; danger of overflow!
Empty the powder trolley
Check the oil/water separator and empty, if necessary (if oil is present, the customer should check the air compressor)

Biannually

Inspect the exhaust fan (motor and blade wheel) for dust and powder deposits. A service port is provided on 4-kW motors.

Replacing the Filter Cartridges in a Manual Powder Coating Line

Powder Coating Cartridge Filter

A filter cleaning operation must take place before every filter cartridge replacement:

Start up the booth
Press the switch (filter cleaning) and wait until all filter cartridges have been blown off, then press the switch again to switch off the cleaning (see therefore chapter “Filter cleaning”)
Switch off the booth

Procedure for Replacing the Filter Cartridges

Remove the shield (Classic Standard 4 and Open only)
Loosen the fixing screws a couple of turns with the correct size spanner. Do not unscrew completely!
Hold the filter cartridge in both hands, turn slightly and hang it out from the holding screws
Place the filter cartridge away
Clean all parts, especially the seating surfaces

Assembly:

Unpack the new filter cartridge
Hang the filter cartridge onto the fixing screws and turn to the
stop
Tighten the fixing screws evenly, so that the sealing ring
touches all round evenly and the filter cartridge hangs
vertically

Powder Booth Characteristics for Manual Powder Coating Line

18-gauge galvanized steel panels
Smooth interior for easy maintenance
Primary filtration system with a full set of filters, grids, and manometer for filter maintenance
High durable powder coating filters
High-performance, direct-drive plug fan
Four-tube, T8 LED light fixture(s)

OPTIONS

Pre-coated white panels
Additional sidewall or ceiling light fixtures
Polyester or Nano coated polyester filters
Electromechanical control panel

Our cartridge spray booth is designed to capture excess powder during application. It is the culmination of many years of experience in designing and building machinery for powder coaters.

To comply with recent changes in legislation we have now upgraded our cartridge booth by fitting two centrifugal fans of 5.5kw capacity and six cartridge filters.

Our Powder Coating Booth Features

100% filtration means that the air filtration system does not require ducting to the outside. This makes installation easier and also increases overall energy efficiency, as you don’t lose heated factory air.
Unlike water back booths, there is no ongoing expense of sludge removal.
High quality in every sort of finishing systems
The filtered powder is collected in a tray, making disposal easy.
Centrifugal fans are used to remove contaminated air, and are more powerful than axial fans.
Large, quick-acting air valves direct a blast of air into each filter at intervals of 30 seconds to keep them working efficiently.
Option of auto-switch – when the powder gun is taken from the holster the fan automatically switches on, replace and it goes off. This device can substantially reduce energy consumption.
Completely manufactured at our UK workshop. Our machinery is manufactured to a high quality and is built to last.
Flat packed for easy transportation and installation.
Full compliance with HSE guidelines.
CE mark.
Fully guaranteed.
Service contracts are available.

Auto-Switch

Infra-red detection device built into the holster for the powder gun. The auto-switch shuts off the booth when the gun is housed and switches it on when the gun is taken out of the holster. This device makes big savings in power and also reduces the noise coming from your spraying area.

Lighting

Lights are not included in the standard price – price on the application.

Track System

A track system is easily fitted to link your spray booth to one of our ovens. Depending on your individual circumstances, these may be either single runners or flight bars and we can supply them in a range of lengths.

Price on application

Silencers

Silencers reduce the noise from our spray booths by 10 decibels. A 2-meter booth requires 1 silencer, a 3-meter booth requires 2 silencers.

Please note that this spray booth requires compressed air to function correctly.

We can arrange for our spray booths to be shipped worldwide; we charge for shipping at cost.

Gas Powder Coating Oven for Manual Powder Coating Line

Batch-type electric powder coating oven for powder coating for manual powder coating line

A gas-type powder coating curing oven is a specialized piece of equipment used in the powder coating industry to cure powder coatings onto metal substrates. It utilizes gas combustion to heat the interior chamber to a high temperature, typically between 150°C and 200°C, where the powder particles melt, flow, and fuse to form a continuous, hard, and durable coating.

Key Components of a Gas-Type Powder Coating Curing Oven:

Heating Chamber: The heart of the oven is the heating chamber, which is typically constructed from high-temperature-resistant materials like stainless steel or refractory bricks.
Gas Burners: Gas burners are the primary source of heat, typically utilizing propane, natural gas, or liquefied petroleum gas (LPG). They are positioned strategically within the chamber to ensure even heat distribution.
Circulation Fans: Circulation fans help to circulate the heated air throughout the chamber, ensuring that all surfaces of the coated parts receive uniform curing temperatures.
Temperature Control System: A precise temperature control system regulates the oven’s temperature, ensuring that the curing process occurs within the specified range for optimal coating adhesion and performance.
Conveyor System (Optional): For batch curing, conveyor systems are employed to transport the coated parts through the oven at a controlled speed, ensuring that they spend the appropriate time at the desired temperature for curing.

Benefits of Gas-Type Powder Coating Curing Ovens:

Quick Heating: Gas burners provide rapid heating, allowing for faster curing cycles compared to electric ovens.
Uniform Heating: Circulation fans ensure even heat distribution across the chamber, preventing hot spots and potential coating defects.
Cost-Effectiveness: Gas is generally a more cost-effective fuel source than electricity.
Versatility: Gas-type ovens can accommodate a wide range of workpiece sizes and shapes.
Environmental Considerations: Gas-fired ovens can be equipped with pollution control systems to minimize emissions.

Applications of Gas-Type Powder Coating Curing Ovens:

Manufacturing of metal parts: Automotive, appliance, furniture, and machinery industries extensively use powder coating for corrosion protection and aesthetic enhancement.
Construction and building products: Gas-cured powder coatings are employed for architectural applications like railings, fences, and facades.
Industrial equipment: Powder coating is prevalent in industries like agriculture, mining, and heavy machinery for durability and corrosion resistance.

Safety Precautions:

Proper ventilation: Ensure adequate ventilation to remove fumes and prevent the buildup of harmful gases.
Extinguishing systems: Equip the oven with fire extinguishers and emergency shut-off valves in case of fire hazards.
Regular maintenance: Conduct regular inspections and maintenance to maintain the oven’s safety and efficiency.
Training and certification: Operators should undergo training and obtain relevant certifications to handle gas-fired equipment safely.

Powder coating of metals is often favored by manufacturers because its finish is tougher than conventional paint. Powder coating is abrasion resistant and will not crack, chip, or peel as conventional paint will. Powder coating is typically done through a two-step process: First, the coating is applied to the part electrostatically with powder coating equipment, and then the newly powdered part is cured in an industrial gas powder coating oven under heat to form a skin.

This process is very efficient since the powder wraps around the back of the part for better coverage and ensures 95% material usage of the powder. The powder coating is a dust-like substance that behaves quasi-fluid. with the help of this material property, the powder coating flows through the hoses and gun of powder coating equipment and reaches the part already ionized with – ion.

This helps the particle hang on the part and stay there till the part is grounded again. The parts that are coated with powder are either manually, or automatically with the help of a conveyor taken into the gas oven, which inside there is a 200 C temperature to melt the powder coating on the parts

Benefits of powder coating and curing in an oven: Heavy-duty construction and quality components Excellent uniformity and heating rates for consistent, high-quality curing results No powder blow-off – reduces rework Uniform heat distribution provides quality cured finishes and optimum cure cycles Quick heat-up rates so you can cure more loads per day Roof-mounted blowers conserve valuable floor space at your facility Fully adjusted and factory tested prior to shipment to reduce installation and start-up times Available with our exclusive energy-efficient oven upgrade

Small Gas Powder Coating Oven in a Manual Powder Coating Line

Small gas powder coating oven for manual powder coating line

Small gas powder coating ovens are used in manual powder coating lines to cure powder coatings. They are typically smaller than batch ovens and are designed to accommodate a single workpiece at a time.

Benefits of using a small gas powder coating oven in a manual powder coating line:

Space saving: Small ovens take up less space than batch ovens, making them ideal for smaller workshops or production lines.
Flexibility: Small ovens can be easily moved to accommodate different workpieces and production needs.
Energy efficiency: Small ovens use less energy than batch ovens, making them a more cost-effective option for smaller production runs.
Ease of use: Small ovens are relatively easy to operate and maintain.

How to use a small gas powder coating oven in a manual powder coating line:

Prepare the workpiece: The workpiece should be clean, dry, and free of contaminants.
Apply the powder coating: The powder coating can be applied using a spray gun, electrostatic applicator, or other method.
Place the workpiece in the oven: The workpiece should be placed in the oven so that it is evenly exposed to the heat.
Cure the powder coating: The powder coating should be cured according to the manufacturer’s recommendations. This typically involves heating the workpiece to a temperature of between 150°C and 200°C for 10 to 20 minutes.
Remove the workpiece from the oven: The workpiece should be allowed to cool completely before handling.

Safety precautions when using a small gas powder coating oven:

Always wear appropriate safety gear, including gloves, safety glasses, and a respirator.
Never operate the oven in an area with flammable materials.
Do not exceed the oven’s temperature or time ratings.
Allow the oven to cool completely before attempting to clean or maintain it.

Here are some additional tips for using a small gas powder coating oven:

Use the correct type of powder coating for the workpiece.
Apply the powder coating evenly to the workpiece.
Ensure that the workpiece is completely dry before placing it in the oven.
Do not overcrowd the oven.
Monitor the oven temperature closely during the curing process.
Allow the workpiece to cool completely before handling.

With proper care and use, a small gas powder coating oven can be a valuable asset to any manual powder coating line.

The dimensions of our small powder coating oven start from 1,2m x 1,2m x 1,2m. This is for lab powder coating applications. The lab-type oven is used to cure powder coating for samples and small items in a small number

Powder coating companies that are doing custom coating can have some special requests for small items and samples. They don’t want to heat up a big oven for this and require a small lab-type box oven. This small oven can also be used for powder coating at home. Some people try to make their own DIY powder coating oven but this usually takes a long time for construction and can have some serious mistakes in manufacturing that can cause inefficiency and even danger to human life.

The powder coating cost usually increases in such DIY powder coating oven types. If the curing won’t be effective, you will need to use a powder coat remover to get the powder off the powder-coated metal has the entire powder coating process once again. The powder coating prices are not that low to let you repeat the same process again and again.

Gas Powder Coating Oven Characteristics for a Manual Powder Coating System

Gas powder coating ovens are essential components of manual powder coating systems, providing the necessary heat to cure powder coatings and transform them into durable, protective finishes. These ovens come in various sizes and configurations to accommodate different production needs, but they share several essential characteristics that make them suitable for manual powder coating applications.

Key Characteristics of Gas Powder Coating Ovens for Manual Powder Coating Systems:

1. Compact Size and Portability:

Manual powder coating systems often operate in smaller workspaces, so gas powder coating ovens are designed to be compact and portable. They typically have smaller chambers compared to batch ovens, allowing them to fit easily into tight spaces and be moved around as needed.

2. Single Workpiece Capacity:

Due to the manual nature of the coating process, gas powder coating ovens for manual systems are typically designed to accommodate a single workpiece at a time. This allows for more personalized attention to each piece and ensures even curing throughout the process.

3. Adjustable Temperature Control:

Powder coatings require specific curing temperatures to achieve optimal adhesion and performance. Gas powder coating ovens for manual systems offer precise temperature control, allowing operators to adjust the heat to match the requirements of the particular powder coating being used.

4. Efficient Heating and Heat Distribution:

Gas burners provide rapid heating, enabling the oven to reach the desired curing temperature quickly. Additionally, circulation fans ensure uniform heat distribution within the chamber, preventing hot spots and ensuring consistent curing across the workpiece.

5. User-Friendly Controls and Safety Features:

Manual gas powder coating ovens are designed to be easy to operate, with clear controls and intuitive interfaces. They also incorporate essential safety features, such as emergency shut-off valves and temperature limiters, to prevent accidents and ensure operator safety.

6. Energy Efficiency:

Gas powder coating ovens are generally more energy-efficient than electric ovens, making them a cost-effective option for manual powder coating operations.

Applications of Gas Powder Coating Ovens in Manual Powder Coating Systems:

Gas powder coating ovens play a crucial role in various manual powder coating applications, including:

Coating of small metal parts: They are ideal for coating small metal components, such as brackets, knobs, and housings, found in a wide range of industries.
Customizing and refurbishing items: They are frequently used for customizing or refurbishing individual items, such as furniture pieces, bicycle frames, or automotive parts.
Touch-ups and repairs: They are well-suited for touch-ups and repairs of powder-coated surfaces, ensuring a seamless finish match.
Small-scale production runs: They are suitable for small-scale production runs, allowing for flexible production schedules and adjustments to meet fluctuating demands.

Temperature Controller

An Electronic Temperature Controller controls temperature conditions. It is a non-profiling type 1/16 DIN single channel controller that features automatic control. Either a time proportioned heat output or a 4-20 ma control signal is used for precise temperature control

Overtemperature Protection

An Electronic Temperature Controller is provided for temperature protection. The Electronic Temperature Controller will remove power to the heating system when an over-temperature condition is detected. Alarm circuitry may be included as an option

Electric Powder Coating Oven for Manual Powder Coating System

Process Timer

A Process Timer is provided, which has five user-selectable timing ranges from 0.01 seconds to 9999 hours. The timer will automatically start timing once the process setpoint temperature is reached. When the total preset time has elapsed, power to the heat control circuitry will be disabled.

Additional Features

EMS Powder Coating Equipment ovens are designed with the capability to incorporate many other optional features for safety purposes, enhanced process control, and a simplified operator interface. Consult a Gruenberg Applications Engineer or our Service Department for more information or questions.

Operating Parameters and Requirements

This equipment is designed to operate safely when the following environmental conditions are met:

Indoor use only.
Within a temperature range of 5°C to 90°C (max).
Maximum relative humidity 90%.

The listed chamber specifications are based on operation at 24° C ambient temperature, the altitude at sea level, and a 60 Hz power supply. Chamber operation utilizing a 50 Hz power supply may derate the listed performance specifications. Equipment damage, personal injury, or death may result if this equipment is operated or maintained by untrained personnel.

Operators and service personnel must be familiar with the location and function of all controls and the inherent dangers of the equipment before operating or maintaining it. TPS shall not be liable for any damages, including incidental and/or consequential damages, regardless of the legal theory asserted, including negligence and/or strict liability.

Observe all safety warnings and operating parameters listed in this manual, as well as all Caution, Danger, and Warning signs or labels mounted on the equipment to reduce the risk of equipment damage and personal injury.

Location and Installation of the Gas Powder Coating Oven of a Manual Powder Coating Line

Electric Powder Coating Oven for Manual Powder Coating System

Installation Considerations:

Gas Connection: Connect the oven to a properly sized and regulated gas supply line. Ensure that the gas line is compatible with the type of gas used by the oven and that it meets all applicable safety standards.
Electrical Connection: Connect the oven to a dedicated electrical circuit with the appropriate voltage and amperage rating. Ensure that the electrical wiring is properly grounded and protected by fuses or circuit breakers.
Exhaust System Connection: Connect the oven’s exhaust duct to an appropriately sized exhaust fan and ductwork system. Ensure that the exhaust system can effectively remove fumes and VOCs from the workspace.
Temperature Control System Installation: Install and calibrate the temperature control system according to the manufacturer’s instructions. The temperature control system should accurately regulate the oven’s temperature within the specified curing temperature range.
Safety Features Installation: Install and test all safety features, such as emergency shut-off valves, fire suppression systems, and temperature limiters. Ensure that these safety features are functioning correctly and are in accordance with local safety regulations.
Operator Training: Provide adequate training to all operators on the safe and proper use of the gas powder coating oven. This training should cover topics such as operation procedures, emergency protocols, and safety precautions.
Regular Maintenance: Implement a regular maintenance schedule for the gas powder coating oven. This should include inspections, cleaning, and lubrication of components as recommended by the manufacturer.
Compliance with Regulations: Ensure that the installation and operation of the gas powder coating oven comply with all applicable environmental regulations and local building codes.

Oven Classification – Electric Heated Units: NFPA 86 Class B ovens are heat utilization equipment operating at approximately atmospheric pressure wherein there are no flammable volatiles or combustible material being heated in the oven.
Oven Classification – Gas Heated Units: NFPA 86 Class A: “Class A ovens and furnaces are heat utilization equipment operating at approximately atmospheric pressure wherein there is a potential explosion or fire hazard that could be occasioned by the presence of flammable volatiles or combustible materials processed or heated in the furnace.”
Do not locate units in areas of wide ambient temperature variation such as near vents or outdoor entrances.
Do not place the unit near combustible materials or hazardous fumes or vapors.
Do not install the unit in a corrosive environment. A corrosive environment may lead to poor performance and deterioration of the unit.
Ventilation: The oven should be installed in an area where there is good air ventilation. Allow a minimum of 5 inches between any wall and any oven side.
Do not position the oven in a manner that would make it difficult to operate your main power disconnect switch.
Make sure the oven is leveled when set up. The floor of the chamber should be leveled with a Spirit Level to +/- 1/8” (3.175 mm) front to back and side to side.
Sometimes control panels are removed to facilitate shipment. When required, replace the panel securely and reconnect numbered electrical wires to matching numbered terminal blocks.

Very Important! Upon completion of the initial installation of the chamber and upon completion of any maintenance procedure, make sure that all access panels that have been removed are reinstalled securely before operating the unit.

Gas Powder Coating Oven for a Manual Powder Coating Line

Exhaust Connection for Gas Powder Coating Oven

An exhaust port connection consisting of a 6” O.D. collar is installed with the exhaust blower assembly at the top of the oven. The exhaust housing includes a manual damper. A vent duct should be connected to the exhaust port collar and run to a location outside of the building (as necessary). This should be done in accordance with all local code regulations. Make sure the connection is secure.

Gas Supply Connection for Gas Powder Coating Oven

Gas-fired ovens may use either natural gas or liquid propane for combustion to heat the oven. You must follow your specific supply specifications listed on your General Arrangement Drawing D001 and when listed here

Important! Please read the entire Gas Heating System section and all vendor manuals / cut sheets to familiarize yourself with all gas components before making your gas supply connection. The gas supply connection is made to a ball valve with a ½” FPT type connection. Make sure the connection is secure and is checked for leaks before operation.

Gas Supply – Liquid Propane: Pressure = xxx PSIG, xxxx CFH
Gas Supply – Natural Gas: Pressure = xxx PSIG, xxxx CFH

Air Circulation of Gas Powder Coating Oven

Gas-fired heating systems are normally installed in walk-in modular ovens. A high-volume airflow system is employed to provide maximum temperature uniformity. The type of air circulation system used depends on the configuration of the unit. Single module units can only employ a horizontal front-to-back airflow type pattern using centrifugal type blower wheels to generate air circulation. Double module units can employ two different types of air circulation systems, as listed below.

Horizontal front-to-back pattern using centrifugal type blower wheel.
•Compound horizontal pattern using propeller-type fans.

The heating and generation of airflow occur in the conditioning plenum, which is normally located on the right side wall of the oven. Blower wheels or fans are driven with extended shafts by motors mounted in the control cabinet.

Heating is achieved by a gas burner that directs a flame down into a vertical perforated flame tube mounted in the manifold next to the conditioning plenum. Thermocouples used for temperature sensing are normally mounted in the workspace on the plenum panel.

Airflow Description

Gas ovens using centrifugal type blower wheels for airflow generation employ a horizontal front-to-back type airflow system. The burner manifold is designed with a vertically mounted flame tube along with perforations on the back side of the manifold. Processed air is drawn into the burner manifold and conditioning plenum, and is heated as it mixes with hot air emitted from the flame tube.

Fresh ambient air is also drawn into the plenum where it mixes with the heated air. Conditioned air is discharged into the workspace through perforations near the front of the plenum housing. The air flows back through the workspace in a horizontal manner to condition the product and then returns to the plenum for reconditioning.

A portion of the processed air is exhausted through a port in the chamber ceiling by the exhaust blower. An air intake port with a manual slide damper is installed in the ceiling of each module to allow fresh ambient air to replenish the exhausted air. Slide dampers are mechanically locked to a predetermined minimum opening.

Heating System of Gas Powder Coating Oven

Thermoblock Burner of a Gas Powder Coating Oven

Important Note: Due to the diverse array of configurations available in a gas heating system, this section will describe basic system requirements, standard equipment used, and fundamental operation.

Application: EMS Powder Coating gas heated ovens are designed to operate with either a natural gas supply or a liquid propane supply according to NFPA 86 (National Fire Protection Association) safety standards. To meet NFPA main gas train requirements, a Closed Position Indicator CPI is used for electrical indication of the safety valve’s closed position. A direct-fired type gas system is used in which the flame is shot through a burner manifold in the conditioning plenum.

Recirculating oven air is heated as it is drawn through the flame. Direct-fired systems are typically greater than 90% efficient. Since products of combustion enter the workspace with this type, it is reserved for those processes that are not emission sensitive. However, many safety precautions are employed with a direct-fired system to compensate for the presence of an open flame. The following sections detail the standard gas heating components used and their operation. The actual components used will vary with your application, so it’s important to check your oven specifications.

Exhaust Blower of the Gas Powder Coating Oven of a Manual Powder Coating Line

Gas Powder Coating Oven Exhaust Chimney of a Manual Powder Coating Line

An exhaust blower is standard with all direct-fired systems to serve two purposes. Initially, the blower is used along with a purge air timer to purge oven air for a fixed time before the gas burner is fired. When the purge cycle time is complete, the exhaust blower is used to maintain a constant exchange of oven air with fresh ambient air. Ambient air is drawn into the oven through slide dampers mounted atop each module.

A differential pressure switch is used to monitor airflow generation by the exhaust blower, and subsequently for correct operation of the blower motor. These devices use a diaphragm to sense pressure and to mechanically trigger a SPDT Snap Switch when the proper pressure is developed across the blower wheel (or fan). Correct rotation of the motor is necessary for the switch to operate properly. If a loss of pressure / airflow were detected, the switch would open and remove power from the gas burner.

Loss of airflow may result from a motor malfunction, a loose blower wheel (or fan), or constricted air intake or exhaust ports. Blower Spark-Proof Design: The blower housing is designed with a non-sparking type construction. The housing and inlet rings are made of aluminum while the blower wheel is made of stainless steel. Should the blower wheel come off its shaft and strike the blower housing or inlet ring, no sparks can be generated between the two metals.

Gas Burner – Combustion Blower

The three elements necessary for combustion are fuel, oxygen, and ignition. The combustion blower supplies a constant flow of fresh air to the burner. The air is mixed with gas by various methods in order to establish ignition and to sustain complete combustion. The combustion motor starts immediately when the OVEN ON switch is closed. A combustion airflow switch monitors airflow from the combustion blower. This is a differential air pressure type, which will shut down the burner if a loss of airflow is detected.

Gas Burner: A burner is defined as a device used for the introduction of fuel and air into an oven at the required velocities, turbulence, and concentration to maintain ignition and combustion of fuel. A Blast type burner is normally used. This burner delivers a combustible mixture under pressure, normally above 0.3 inch W.C. to the combustion zone. Various flame safety devices are installed within the burner.