The powder coating equipment package includes a powder coating spray booth, a curing oven, and a spray gun all in total a small powder coating line or system
The specific equipment that is included in a powder coating equipment package will vary depending on the specific needs of the user. For example, a small shop may only need a manual powder coating gun, while a large production facility may need an automated powder coating system.
Here is a more detailed description of each of the components of a powder coating equipment package:
- Powder coating gun: The powder coating gun is used to apply the powder to the surface of the object being coated. There are two main types of powder coating guns: manual and electrostatic. Manual guns are less expensive, but they are also more difficult to use. Electrostatic guns are more expensive, but they are also more efficient and produce a better finish.
- Powder coating booth: The powder coating booth is used to contain the powder and prevent it from spreading into the environment. The booth should be well-ventilated and have a filter system to remove overspray.
- Powder coating oven: The powder coating oven is used to cure the powder and harden it into a durable finish. The oven should be large enough to accommodate the objects being coated and should be able to reach the required curing temperature.
- Powder feeder: The powder feeder is used to supply the powder coating gun with powder. The feeder should be able to hold enough powder to coat the objects being coated.
- Compressor: The compressor is used to provide compressed air to the powder coating gun. The compressor should be large enough to provide enough air pressure to operate the gun.
- Powder recovery system (optional): The powder recovery system is used to collect overspray and reclaim it for future use. The powder recovery system can help to reduce waste and save money on powder.
The Powder Coating Equipment Package
The powder coating equipment package has today established itself as the most effective means of metal surface finishing. It has replaced liquid painting and various methods of electroplating due to the many advantages this process offers
- Substantial improvement in chemical corrosion
- Substantially improved resistance to mechanical abuse – better scratch resistance, abrasion resistance, and mechanical wear and tear
- Cleaner process for an improved environment
- Faster process for better productivity through the paint-shop
- Requires fewer skills for high-quality coatings
- Guarantees uniform and consistent results
- Substantially enhanced aesthetics for the higher sales value of the finished product
- Requires lower energy per Meter2 of surface coated
- Requires lesser care in storing and packing due to the toughness of the coat
- Is cost-effective
Powder Coating Equipment Package
Powder Coating Gun
A powder coating gun is a specialized tool used to apply powder coating to surfaces. It works by electrically charging the powder particles and then accelerating them towards the surface being coated. The electrostatic charge causes the powder particles to be attracted to the surface, creating a uniform and even coating.
Powder coating guns are available in a variety of styles and configurations to suit different applications. Manual guns are the most basic and affordable type, while electrostatic guns are more expensive but offer superior performance. Automated powder coating systems are also available for high-volume applications.
Powder Coating Booth
A powder coating booth is a ventilated enclosure used to contain the powder particles during the application process. The booth should be equipped with filters to remove overspray from the air and prevent it from contaminating the environment.
Powder coating booths are available in a variety of sizes and configurations to meet the needs of different applications. Small booths are suitable for hobbyists and small businesses, while larger booths are designed for industrial applications.
Powder Coating Oven
A powder coating oven is used to cure the powder coating, transforming it from a loose powder into a durable, hard finish. The oven should be large enough to accommodate the objects being coated and should be able to reach the required curing temperature.
Powder coating ovens are available in a variety of styles and configurations, including batch ovens, conveyor ovens, and infrared ovens. Batch ovens are the most common type of oven, while conveyor ovens are suitable for high-volume applications. Infrared ovens are a newer technology that offers faster curing times.
Powder Feeder
A powder feeder is a device that supplies the powder coating gun with powder. The feeder should be able to hold enough powder to coat the objects being coated and should be able to deliver the powder at a consistent rate.
Powder feeders are available in a variety of styles and configurations, including hopper feeders, drum feeders, and pressurized feeders. Hopper feeders are the most common type of feeder, while drum feeders are suitable for high-volume applications. Pressurized feeders are used for electrostatic powder coating systems.
Powder Recovery System
A powder recovery system is a device that collects overspray from the powder coating process and reclaims it for future use. The powder recovery system can help to reduce waste and save money on powder.
Powder recovery systems are available in a variety of styles and configurations, including cyclone separators, filter systems, and electrostatic precipitators. Cyclone separators are the most common type of powder recovery system, while filter systems are more efficient but more expensive. Electrostatic precipitators are the most expensive type of powder recovery system, but they are also the most effective.
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Powder Coating Equipment Package
The powder coating equipment package is a simple process requiring minimal skills and training. The articles to be coated are first cleaned of all foreign matter from the surface. Mild steel components need to go through a phosphate conversion coating. Aluminum components go through a chromate conversion coating.
This, known as pretreatment, is employed for improved bonding of the powder coat to the material being coated to provide a longer life to the coat. The method used usually is a dip in chemicals and water in various tanks. Occasionally, the process may be automated through a spray pretreatment process.
The ‘pretreated’ articles are jigged and hung into the coating booth on a fixed or rotatable jig-holder. The manual coater coats the components from all sides. The articles are then moved out onto an oven trolley
(or directly into the oven).
The trolley, if used, is rolled into the oven when full. In the oven, at a temperature of 180-220oC, in 10-15 minutes, the powder melts, polymerizes fuses, and cures into the final tough uniform, and consistent powder coat that has high aesthetic value. At the end of the curing schedule, the trolley is rolled out of the oven and allowed to cool down. The articles are then removed from the paint shop.
Details about the powder coating equipment
Complete powder coating systems come in two versions – a batch system and a conveyorized system. The primary difference is the mode of material movement from operation to operation. Powder coating itself may be by manually held spray guns or by automated guns fixed-mounted or reciprocator-mounted. A complete powder coating system requires the following components:
Pretreatment System
Consisting of tanks or tubs containing chemicals or water in which the articles are dipped to clean and prepare the surface for powder coating. The size of the tanks depends on the size and quantity of articles to be coated. The specific process depends on the metal makeup of the article.
AIR COMPRESSOR – fitted with appropriate filters and provides clean and dry compressed air to the powder coating system.
A 3HP or a 5HP air compressor is normally adequate for a batch coating system using 1 coating machine. Conveyorized systems with the multi-gun application may require a larger capacity air compressor
Powder Coating Equipment Package Spray System
THE POWDER SPRAY SYSTEM (also known as the powder coating machine) – is considered the heart of the powder paint shop. Normally an electrostatic powder spray system is used. This sprays electrostatically charged powder into the spray booth where the articles to be coated are hung. Electrostatic forces provide a uniform and consistent coating quality. Major strides have been made in the design of these machines offering major benefits to the user
Powder Coating Equipment Package Spray System
The powder coating booth is where the powder is applied to the workpiece. The booth should be large enough to accommodate the largest workpiece that will be coated, and it should have a good air filtration system to remove overspray.
The powder spray gun is used to apply the powder to the workpiece. The gun should be adjustable to control the amount of powder that is applied, and it should be easy to clean.
The powder coating hopper is where the powder is stored. The hopper should be large enough to hold enough powder for the job, and it should be easy to fill and empty.
The powder feeder is used to feed the powder from the hopper to the powder spray gun. The feeder should be adjustable to control the amount of powder that is fed to the gun.
The powder recovery system is used to recover overspray. The recovery system should be able to recover at least 90% of the overspray, and it should be easy to clean.
The curing oven is used to cure the powder. The oven should be large enough to accommodate the largest workpiece that will be cured, and it should have a good temperature control system.
A powder coating equipment package can be a great investment for businesses that need to coat a variety of workpieces. The package can help to improve the quality of the coating, reduce costs, and increase productivity.
Powder Curing Oven in a Powder coating Equipment Package
A powder curing oven is a crucial piece of equipment in a powder coating system. It is used to cure the powder coating, which is a dry paint that is applied to metal objects using an electrostatic gun. The oven heats the powder to a temperature of between 150 and 200 degrees Celsius, which causes it to melt and flow onto the object. The powder then cures, or hardens, to form a durable, protective finish.
There are two main types of powder curing ovens: batch ovens and conveyor ovens. Batch ovens are typically used for smaller production runs, while conveyor ovens are used for larger production runs. Conveyor ovens are more efficient than batch ovens, but they are also more expensive.
Here are some of the benefits of using a powder curing oven:
- Durability: Powder coating is a very durable finish that can withstand wear and tear.
- Corrosion resistance: Powder coating is also very resistant to corrosion.
- Chemical resistance: Powder coating is resistant to a wide range of chemicals.
- UV resistance: Powder coating is resistant to UV rays, so it will not fade over time.
- Environmentally friendly: Powder coating is an environmentally friendly process, as it does not use solvents.
If you are considering purchasing a powder curing oven, there are a few factors to consider, such as the size of the oven, the type of heating system, and the temperature range. You should also consider the features that are important to you, such as digital temperature control and a timer.
Thousands of EMS equipment and systems are presently in use globally in countries like U S A and Canada in N America, Singapore, Malaysia, and Indonesia in F E Asia, S Arabia, UAE< Bahrain in Mid East Asia in Sri Lanka in S Asia, and Kenya and Tanzania in E Africa apart from India in direct competition with leading International brands worldwide.
The advantages EMS systems offer include high levels of quality standards, consistent performance records of existing users and extremely reasonable prices. Every component of your EMS powder coating system offers you unmatched technical as well as commercial benefits. The following pages will show you how you can benefit from an EMS system in your powder paint shop
The Pretreatment for Powder Coating Equipment Package
Pretreatment is used to prepare the metal surface of the articles before they are powder coated. Pretreatment achieves two basic goals …
• Removal of foreign matter from the surface and
• Conditioning the surface to make it suitable for optimal quality coating results.
Attention to pretreatment is essential to maximize the benefits of powder coating. Depending on the application, varying degrees of sophistication of the pretreatment set-up may be employed – from a single-stage cleaning
the process to a comprehensive multi-stage conversion coating deposition.
The most popular means of pretreatment is by dipping the articles in tanks containing the appropriate chemicals or water. Different metals require different processes and your choice of a pretreatment system will depend on the metal makeup of your articles to be coated.
Powder Coating Equipment
All EMS electrostatic powder spray systems use only the in-built 100 kV technology – benchmark technology in powder coating today – worldwide. The 100 kV integrated spray gun improves transfer efficiencies, productivity, and powder consumption substantially when compared to other less-than100 kV technologies. EMS offers two models in the 100 kV stream – to assist you in choosing the one most appropriate to your specific needs
EMS Powder Coating Equipment
With the EMS Powder Coating Equipment, users now have access to the 100 kV state-of-art technology ion powder coating – at amazingly low prices. The EMS Powder Coating Equipment, a full-fledged production machine, offers the unbeatable advantages and benefits of modern technology and makes it affordable to all, even the small powder coater. Light and well-balanced, the 201 100 kV integrated hand spray gun allows effortless coating, hour after hour..
The EMS Powder Coating Equipment will absorb most power voltage spikes and surges and filter out most unwanted power signals. The control panel is designed for optimal performance without the need for extensive operator training.. The machine that works and works and works – year after year after year.
The EMS PCE is a result of an intensive study under actual shop-floor conditions in a wide range of user establishments for a variety of end products. It is an advanced 100 kV electrostatic powder coating machine. It is packed with unmatched features.
- The detachable HV cascade in the 100 kV in-built generator is field-replaceable.
- The ProSieve (optional), an online high-performance powder sieving system, provides uncontaminated powder for coating.
- A set of backup compressed air filters
- Ask for a demonstration or a visit to an EMS PCE user near you and see how this machine can transform not only the quality of your work but also the profitability of your powder paint shop.
Powder Recovery Booth
The equipment that decides the economical viability of your powder coating paint shop is the powder recovery booth. The economies of your paint shop depend on the genuine recovery of oversprayed powder for reuse. If you are an end-user or using only a few colors (maybe 1 to 3), you want to closely study the possibility of using the EMS powder recovery booth as it offers advantages to you.
Cartridge Type Powder Spray Booth
EMS Series recovery systems are the latest generation state-of-art filter cartridge-type powder recovery systems. With an effective cartridge-type recovery system like the EMS booth, you are assured of at least 98+% (and virtually 100%) of recovery of powder. Conventional and often poorly executed recovery booths may not be able to offer more than 75-80% of recovery of reuse while making tall claims of 85 or even 95% recovery efficiencies.
This is often the case with poorly designed and copycat cartridge-type powder recovery booths. How the EMS powder recovery system function: The powder overspray recovery system is located in the rear section of the powder spray booth (on the face opposite to the sprayer). The front section is the coating booth. The workpieces, duly jigged are hung on the jig holder in the coating booth (manually or on a conveyor) and sprayed with powder.
A specially designed low-pressure, the high-capacity fan sucks air, and the powder overspray through the coating booth to the recovery system in a horizontal flat airflow pattern. The specially designed PTFE-coated polyester-based filter cartridges entrap virtually all the powder particles. The remaining powder particles, if any, are trapped in the final filters (if installed – optional), allowing virtually clean air to the shop-floor atmosphere through the fan system.
Electronically controlled high-pressure reverse pulse air jets located above each filter cartridge regularly and automatically clean the powder-laden filter cartridges. This throws the powder from the filter cartridges back into the powder spray booth and is collected in the powder bin located under the booth. This process, known as cartridge scavenging is a continuous and online process. The collected powder can be manually (or automated) sieved and reused.
Cyclone Type Powder Recovery Booth
EMS-type recovery booths are ideal for coaters employing a large number of colors with frequent color changes. These recovery systems offer genuine recovery of up to 95-98% of powder – depending on the powder being used.
EMS Cyclones are designed for powder coatings – unlike many cyclones available as ‘dust collectors’ – capable of collecting only the heavy powder particles and hence giving economic efficiencies of only 75-80%. EMS booths are powder coated to provide a tough and smooth surface to the continuous flow of highly abrasive powders.
The cyclone structure itself is designed and built using a unique ‘break-away’ design enabling quick dismantling for a complete cleaning for ease in color change. Added to this is that the entire booth is built in panel form for ease in transport. As per International and national legal requirements for pollution control, every EMS booth is supplied with an after-filter system as a standard accessory.
The after-filter system traps all the oversprayed powder not recovered in the cyclone and ensures that the air exhausted from the recovery booth is clean enough to be circulated back into the shop floor.
Powder Curing Oven
Powder curing ovens from EMS Powder Coating Equipment – whether fuel-fired or electrical – are extremely energy efficient, lowering the power bills as well as saving scarce fossil fuels. Ovens from EMS Powder Coating Equipment are guaranteed for stated performance characteristics. Uniform temperatures throughout the entire internal working area of the oven ensure uniform powder curing.
This becomes a very critical factor in powder coating. Lower than required temperatures may mean an incomplete powder curing process, leading to the powder coat peeling off (and the product suffering unnecessarily). Higher than stated temperatures could lead to the powders’ important resistance to chemical corrosion and mechanical abuse components burning off.
Powder Coating Oven
This would translate into a lower life to the product being coated. Each EMS Powder Coating Equipment powder-curing oven is customized to individual needs to maximize the utilization of the equipment. All EMS Powder Coating Equipment ovens have circulation airflows inside the oven of critical design. It is high enough to ensure that the temperature inside the oven is uniform while at the same time, low enough to ensure that airspeeds inside do not reach levels where there is a fear of the uncured and to-be-cured powder particles being blown off of the surface of the components inside the oven.
EMS Powder Coating Equipment offers electrical convection ovens starting from small box-type ovens of size 0.9M x 0.9M x 0.9M to large box-type ovens of size 6.5M x 1.5M x 1.5M. Larger ovens are available in two choices of heat energy sources – electrical and/or fuel-fired. EMS Powder Coating Equipment conveyorized tunnel ovens are offered with fuel as the source of heat energy.
EMS Powder Coating Equipment’s fuel-fired hot air generators are some of the most energy-efficient hot air generating systems available. These can be supplied as a separate entity or integrated with the oven itself to save on valuable shopfloor space. EMS Powder Coating Equipment ovens are built on a strong and solid structure.
These ovens can be supplied as single-piece types of equipment or in the disassembled state to be assembled on-site. Often the size of the oven and/or the mode of transport/shipment will decide this. EMS Powder Coating Equipment ovens (or for that matter, all powder curing ovens) are not meant for liquid painting or varnish curing ovens and should not be used for such applications.