Powder coating equipment is used to apply a protective layer of powder to metal surfaces. The powder is applied using an electrostatic gun, which applies a negative charge to the powder particles. The metal surface is then grounded, which attracts the negatively charged powder particles. The powder is then cured using heat, which melts the powder and forms a smooth, durable coating.
There are many different types of powder coating equipment available, including manual guns, automated guns, booths, and ovens. The type of equipment you need will depend on the size and complexity of your project.
Manual guns are the simplest and most affordable type of powder coating equipment. They are typically used for small projects or for touch-ups.
Automated guns are more expensive than manual guns, but they can be used to coat larger projects more quickly and evenly.
Booths are used to contain the powder spray and to protect the surrounding area from overspray.
Ovens are used to cure the powder coating. They are typically heated to a temperature of between 300 and 400 degrees Fahrenheit.
If you are considering purchasing powder coating equipment, it is important to do your research and find the right equipment for your needs. You should also consider the cost of the equipment, the cost of maintenance, and the learning curve for using the equipment.
Here are some of the benefits of using powder coating equipment:
- Powder coating is a very durable finish that can withstand harsh weather conditions and abrasion.
- Powder coating is a very environmentally friendly finish, as it does not use any solvents or VOCs.
- Powder coating is a very versatile finish that can be used on a variety of different materials, including metal, plastic, and wood.
- Powder coating is a very cost-effective finish, as it can be applied quickly and easily.
If you are looking for a durable, environmentally friendly, and versatile finish, then powder coating is a great option for you.
Powder Coating Application
- Surface preparation: The metal surface to be coated must be clean and free of rust, grease, and other contaminants. The surface can be cleaned using a variety of methods, such as sandblasting, solvent cleaning, or alkaline cleaning.
- Powder application: The powder is applied to the metal surface using an electrostatic gun. The gun applies a negative charge to the powder particles, which are then attracted to the grounded metal surface.
- Curing: The powder is cured using heat, which melts the powder and forms a smooth, durable coating. The curing time and temperature will vary depending on the type of powder being used.
Benefits of Powder Coating
- Durability: Powder coating is a very durable finish that can withstand harsh weather conditions and abrasion.
- Environmental friendliness: Powder coating is a very environmentally friendly finish, as it does not use any solvents or VOCs.
- Versatility: Powder coating is a very versatile finish that can be used on a variety of different materials, including metal, plastic, and wood.
- Cost-effectiveness: Powder coating is a very cost-effective finish, as it can be applied quickly and easily.
Drawbacks of Powder Coating
- Initial investment: Powder coating equipment can be expensive to purchase.
- Learning curve: There is a learning curve associated with using powder coating equipment.
- Limited color selection: The color selection for powder coating is not as wide as the color selection for other types of finishes, such as paint.
Overall, powder coating is a great option for those who are looking for a durable, environmentally friendly, and versatile finish.
Sandblasting: Sandblasting is a process that uses compressed air to propel abrasive material against a surface to remove rust, paint, and other contaminants. This is the most effective method for surface preparation, but it can also be the most expensive.
Solvent cleaning: Solvent cleaning is a process that uses a solvent to dissolve and remove contaminants from a surface. This method is less effective than sandblasting, but it is also less expensive.
Alkaline cleaning: Alkaline cleaning is a process that uses an alkaline solution to remove contaminants from a surface. This method is effective for removing grease and oil, but it is not as effective for removing rust.
Degreasing: Degreasing is a process that uses a solvent to remove grease and oil from a surface. This method is often used as a pre-treatment step before another cleaning method, such as sandblasting or alkaline cleaning.
Pickling: Pickling is a process that uses an acid to remove rust and other contaminants from a surface. This method is effective for removing rust, but it can also damage the surface of the metal.
Passivating: Passivating is a process that creates a protective layer on the surface of a metal to prevent corrosion. This method is often used on aluminum and stainless steel.
The best method for surface preparation will depend on the specific application. For example, if you are coating a metal surface that will be exposed to the weather, then you will need to use a more aggressive cleaning method, such as sandblasting. However, if you are coating a metal surface that will be indoors, then you may be able to use a less aggressive cleaning method, such as solvent cleaning.
Here are some additional tips for surface preparation before powder coating:
- Make sure that the surface is clean and dry. Any contaminants on the surface will interfere with the adhesion of the powder coat.
- Remove any sharp edges or burrs. These can damage the powder coat during the curing process.
- Mask off any areas that you do not want to coat. This will help to prevent overspray.
By following these tips, you can ensure that your powder coating project will be a success.
The powder coating equipment for sale is our core business as a powder coating equipment manufacturer in Turkey. Our main markets are EU countries and the USA
Manual and Automatic Powder Coating Equipment
Manual powder coating equipment is the most basic type of powder coating system. It consists of a powder hopper, a feed pump, a spray gun, and a compressed air supply. The operator manually controls the powder flow and spray pattern. Automatic powder coating equipment is more complex than manual equipment and is typically used for larger production runs. It consists of a powder hopper, a feed pump, a spray gun, a control unit, and a compressed air supply. The control unit automatically controls the powder flow and spray pattern.
Here is a table that summarizes the key differences between manual and automatic powder coating equipment:
| Feature | Manual | Automatic |
|---|---|---|
| Control | Manual | Automatic |
| Production rate | Lower | Higher |
| Cost | Lower | Higher |
| Flexibility | More flexible | Less flexible |
| Quality | Can be good, but is more dependent on operator skill | More consistent |
Manual powder coating equipment is a good choice for small to medium-sized businesses that do not have a high volume of production. It is also a good choice for businesses that need a flexible system that can be used to coat a variety of products.
Automatic powder coating equipment is a good choice for large businesses that have a high volume of production. It is also a good choice for businesses that need a consistent and high-quality finish.
Ultimately, the best type of powder coating equipment for your business will depend on your specific needs and budget.
Here are some additional factors to consider when choosing between manual and automatic powder coating equipment:
- The size and complexity of your products
- The desired finish quality
- The production volume
- The budget
- The available labor
If you are not sure which type of powder coating equipment is right for your business, you should consult with a qualified professional.
Surface Pretreatment of Powder Coating Equipment for Sale
Everybody knows that cleaning and pretreating a surface is a key step in ensuring a fantastic coating job and we all want to put our best work out there – for ourselves and for our customers. At IFS Coatings, we always strive for the best with our coatings and we know how important applying those coatings to a well-prepared substrate is, so let’s look at some of the many ways in which we do that.
A good pretreatment process can be easy as 1-2-3. But, what are pretreatment systems? In short, they are the processes through which a surface is cleaned and prepared to be coated.
This process should be familiar to anyone that works with coatings and it benefits both customers and the coater. Pretreating creates a surface that the coating can adhere to, whether the coating is liquid or powder. Plus, pretreatments heighten the performance value of a coating, increasing its life and helping to prevent corrosion.
That is the hows and whys of pretreatments, but what about the whos and whens? We will start with the first. So, who should use pretreatments?
The answer is everyone. Anyone who wants to dust off their hands at the end of the day knowing they have shipped out a quality product should pretreat their substrates. Plain and simple, a substrate must be prepped before you apply any sort of coating to the surface. The point of pretreatment is to prepare the surface for a coating – of any sort – and prevent it from degrading down the line.
There are many different ways of pretreating and various types of pretreatment available and often it will depend on the substrate you’re coating, the end use of the part you’re coating or the size of your coating line. There are automatic and manual pretreatment processes, multi-stage and single-stage, and some that are better for steel than aluminum.
The good news is there is a wealth of information available and some great pretreatment suppliers with the knowledge to help you make the right decision for your line. So let’s look at the different stages of a great pretreatment system and then the various combinations of these stages that are possible. We’ll get into more details about these below – but, when should retreatments be performed?
Pretreatment Processes
All good pretreatment processes begin with a basic cleaning process. If nothing else, this is the stage that every job shop should perform.
The Cleaner Stage
Whether you are a new or old hat at prepping surfaces, you know that the cleaner stage is the most important and essential stage in prepping any substrate. Oil, grime, and dirt can ruin even the most carefully applied coatings, affecting the finish and how the product you are applying performs – in the long and short term. You don’t want your time and money wasted, nor do you want a dissatisfied customer breathing down your neck.
Cleaning is what every stage after this relies on, including successful powder application. The following pretreatment stages simply won’t work properly if this isn’t done properly. There are many different types of cleaners with acids and solvents being the most commonly used. Typically these cleaning solutions are sprayed onto the part or the substrate is dipped into a pool of the solution.
Heating the cleaning solution will often cause the cleaning agent to work better. Using the parameters given to you by your pretreat supplier are going to be key. On top of that, making sure you run the process immediately and don’t let the newly cleaned part sit is important. You can’t clean it, walk away from it for 10 minutes and come back to it and spray it some more, then let it sit before it dries. You have to build a continuous process based on the product that you’re using.
The Rinse Stage
After cleaning comes to the rinsing stage. Getting rid of all of that dirt, grime and likely the occasional dead bug is important, but so is removing the remnants of whatever chemical you used to clean the surface. This is key to keeping the coatings uncontaminated. While these rinses can be done with plain city tap water, using Reverse Osmosis (RO) or Deionized (DI) rinses is preferred. This simply means water that has been treated, removing fluorides,
The Conditioning Stage
Preparing the surface to accept the product for the best results possible requires some sort of conditioning agent. Essentially, the conditioner is applied, sets the surface to a certain pH level, and then locks that pH level in. Doing this creates a surface that is ready to accept the next layer of preparation.
The Zinc Phosphate Stage
We’re calling it the zinc phosphate stage, as zinc phosphate is highly regarded as an excellent chemical conversion coating, but it could also be iron phosphate or zirconium, which will also do a good, protective job. What this stage does is, not surprisingly, create a layer of zinc phosphate on the substrate. This is sort of like laying down a protective barrier that will prevent corrosion and oxidization of the metal, giving it a longer life
The Sealer Stage
Sealing helps the paint adhere to the surface, which means a higher quality finish on the end product, both initially and down the line. There are several kinds of sealers, including chrome sealers, non-chrome sealers, and dry-in-place sealers. These allow for a stronger performance with corrosion resistance – an essential quality for any substrates that will be exposed to the elements.
It should be noted here that chrome is extremely hazardous and dangerous to work with. Specialist equipment and training are required to work with it. In some states in the US, the use of chrome has been banned. At the end of this stage, you will want to do another rinse, but it must be an RO or DI rinse – meaning no chlorides or fluorides in the water
The Drying Oven
The final stage is simply drying the part. It may sound obvious, but it is extremely important. The newly prepped substrate must be dry, otherwise, the powder will not apply correctly. A dry-off oven basically quickly removes any moisture left on the part from the last rinse. The longer moisture stays on the part, the more susceptible it is to a layer of ‘flash rust forming.
Getting the part dry quickly reduces the chance and also slightly heats the part ready for powder application. Clearly, the 8 stage process we just walked through is a major undertaking and an automatic line process, with all the cost, space, water treatment, and maintenance requirements that come with it. For large volume lines where consistency of pretreatment, high corrosion performance, and warranties this multi-stage pretreatment process will deliver excellent results.
However not every coater either needs or wants to delve this deeply into pretreatment. Fortunately, the pretreatment suppliers have created a selection of smaller spray systems that also offer great results. One alternative may be a shorter cycle that follows the following stages
- Spray cleaner
- Phosphate conditioner (this combines the conditioning and zinc phosphate stages into one)
- Rinse
- Dry off
Or a shorter cycle again utilizes the “all in one” approach which uses ‘wand’ style equipment (like the weed killer spray solutions you see in hardware stores) and includes: - Spray clean/condition/phosphate (the pretreatment supplier provides the solution and equipment to enable this one-stage pretreat)
- Rinse
- Dry off
Good for lower volume lines, both these options will still give a good pre-treat performance and still provide significant corrosion performance when compared with non-treated metals. Of course, it’s always important to follow the advice of the pretreatment supplier and again, ensure the process is completed continuously. You can’t walk away mid-process, leave it, and then come back to it. It simply won’t work. These chemical pretreatment options are usually appropriate for aluminum substrates. Pretreating steel tends to follow mechanical pretreatment.
Shot Blasting as Pretreatment
Good news for those that do not like working with caustic chemicals! Shot blasting is another way to clean a substrate and is perfect for steel or for parts where the size of the part of the line makes chemical pretreatment impossible. Shot blasting is pretty self-explanatory – the substrate is ‘blasted’ with different types of shot; walnut shells, sand, metal soda ash – you name it, there are many different types of shots! What sort of shot you use depends on the substrate you are prepping.
For example, heavier, aggressive shots can damage aluminum, even warp it. Alternatively, finer, mild shots on cold rolled steel can turn a relatively short job into a much longer one. Your shot supplier will be able to advise you on the best type of shot for your needs. The key with shot blasting is to aim for a “bright white clean”.
This is where the surface has been removed to the extent that a bright, ‘white’ looking surface is revealed. Okay, it’s not actually white; it’s essentially a gleaming surface, but it’s best known as the “bright white clean”.
When the part is blasted, a blast profile is created and which helps the powder to adhere to the part. This is a great way to remove mill scale, rust builds up (rust can occur when the part is just lying around waiting to be coated), oils, dirt, weld splatter, and more. Shot blasting also produces heat. A lot of heat. Be mindful of this, especially if you’re working with thin or aluminum parts. On the other hand, this can make it a good alternative for larger or thicker parts that take longer to heat up.
Shot Plus Primer
An alternative, pretreatment to plain shot blasting is to combine a shot blast with a zinc-rich or epoxy primer. Using this method, you clean the substrate with the shot blast and lay down a corrosion-resistant layer through the primer that the coating can adhere to. Primers do a great job of adding a protective layer beneath the top coat.
Not only do they prep the surface for the top coat to be applied, but they add a protective barrier that will help with corrosion protection and ensure that you clean the substrate absolutely, otherwise any coatings that you apply will be rendered useless.
Take note, that zinc-rich primer does not apply as easily as a top coat. It doesn’t always fluidize as top coat powders do, but you can overcome this with patience and experience – you may have to adjust your gun settings a little – and maybe a bit of swearing, in time.
The Different Types of Powder Coatings
Whether you’re new to powder coatings or an experienced pro, you’re probably well aware that powder coating is a fantastic painting method that creates a tough, durable and beautiful finish. No matter whether you’re using a single gun and small oven or a large fully automated line, the process is basically the same.
A powder spray gun is used, which when triggered gives an electrostatic charge to the powder particles passing through it. As the parts to be coated are grounded, the powder is attracted towards the part via the electrostatic process. Once the powder is applied the parts are cured in an oven, which melts and cross-links the powder over the surface of the part and creates a tough, scratch resistant and beautiful finish. There are literally thousands of different applications for powder coatings.
Powder coating is used mainly on metals, so is perfect for industrial parts, medical devices, architectural applications, automotive refinishing, bicycle parts, household appliances, furniture, enclosures, trailers, lighting…the list goes on! There are many different types of powders used, each with their own characteristics and applications, so making sure you have the right type of powder, and THEN choose the color is very important for a successful application.
Check out the different types of powder and the benefits they will bring to the parts. There are so many advantages to using powder coatings – too many to cover in this blog post – but some of the obvious ones include lack of solvents. This means no volatile organic compounds (VOCs) are released, a great advantage especially when compared to traditional liquid paints.
This makes them safer to work with, dispose of and transport and brings unbeatable environmental advantages to you and your customer. Powder coating allows for much thicker coatings than liquid paint, without running or sagging.
With liquid paint, horizontal and vertical painted surfaces often have differences in appearances, but powder coating typically provides a uniform visual appearance regardless of orientation. Powder coating allows for much thicker coatings than liquid paint without running or sagging. With liquid paint, horizontal and vertical painted surfaces often have differences in appearances, but powder coating typically provides a uniform visual appearance regardless of orientation.
Powder coating also offers a wide range of specialty effects that are hard to achieve through traditional methods. The list goes on, and we could get into better scratch resistance, toughness, and hardness than traditional liquid paints, but let’s take a look at some of the different powders used that help achieve these characteristics.
Epoxies
Epoxies were the first widely used powders. They are very durable, offer excellent hardness and have arguably the best chemical and corrosion resistance of all available powders. Another plus of this type of powder is its ease of use and a wide range of cure schedules. Epoxies adhere to metals extremely well, with various pretreatments of the metal providing excellent adhesion, including phosphate coating and sandblasting.
The drawback of epoxy powders is that they do not weather well. Exterior exposure can cause them to fade and chalk in the sun. They weather poorly and will often start to degrade on the surface after a few months. This makes epoxies better suited to indoor applications. A final note on epoxies is that many primers are epoxies due to their adhesion strength and corrosion resistance. Since they do not handle the sun well, their use as a pre-coat underneath another paint type utilizes their strengths while covering their weaknesses.
Polyesters
Polyesters are the most commonly used powders and offer great value for money. The two most widely used types of polyester powder: TGIC (tri glycidyl isocyanurate) and non-TGIC, which is also known as TGIC-free or sometimes a ‘Primid’. Both TGIC and TGIC-free polyesters offer good mechanical resistance, including great flexibility and impact resistance, and good chemical resistance. One draw of this powder is its low cure temperature.
This low-temperature requirement makes it better for sensitive items. Polyesters will also provide good overbake resistance to yellowing, which makes them really easy to use and Standard Polyesters will offer 1-3 years of good UV resistance, so they work well for all interior and some exterior applications. A huge advantage of standard polyesters is the enormous choice of colors, gloss levels and special effects they’re available in. It’s almost limitless!
Polyesters have solid all around properties and are a common first choice for many applications. It seems kind of obvious, but TGIC-free polyesters offer all the advantages of TGIC polyesters, without the TGIC! They can also give a higher first pass transfer efficiency, but are more sensitive to excess film thickness and provide less overbake resistance than TGICs.
As the workhorse of powder coatings, it’s not surprising that there aren’t that many drawbacks to polyesters. If you’re coating pieces that will be permanently outside and therefore need good wearability and durability, then consider the super durable polyester instead. Limited exterior durability is a standard polyester’s main disadvantage.
Super Durable Polyesters
Super Durable Polyesters have fast become the superhero of polyester powders. As the name suggests these excellent value powders offer superior durability when compared with a standard polyester. They are designed to hold their color and gloss to within set limits for 5 to 10 years more when compared to a standard polyester.
Not only is their color and gloss protection better, but they also provide better humidity and corrosion resistance. These Super Durables have become hugely popular over the last few years as their increased capabilities and great value for the money have made them popular for interior applications where improved fade resistance is required and all manner of outdoor applications.
Epoxy-Polyester Hybrids
Epoxies and polyesters are often mixed together to form hybrids. These hybrids remain closely related to pure epoxies but offer superior weather degradation properties. These hybrids can be mixed in various ratios to emphasize the characteristics of either the epoxy or polyester. The polyester will enhance the overbake resistance when compared with a straight epoxy and they also create ultra-smooth, thin films. The combination of the resins can also make them more economical than a pure epoxy.
The polyester does reduce the corrosion and chemical resistance of the epoxies and doesn’t really add any outdoor weatherability to the product. Hybrids are widely used on items that require good cosmetic appeal along with good functional properties. Hybrids can be used in some of the same areas that epoxies are used, but are typically found on indoor appliances and other household items like furniture, shelving, interior lighting, and power tools. Domestic appliances like stoves, washers, and dryers are a common application for hybrids.
Fluoropolymers
Fluoropolymers are typically used in architectural markets due to their phenomenal weathering properties and world-class color and gloss retention. Their corrosion resistance and excellent weatherability make them extremely popular for exterior architectural applications like curtain wall, windows, doors and more.
The two most common types of Fluoropolymers found in powder coatings are FEVE and PVDF. PVDF Fluoropolymers always need a primer beneath them – whether liquid or powder and are much more difficult to bond when creating metallic powders. FEVE resins are the most popular within the powder community for their superior one coat capability and incredible exterior performance.
FEVE based Fluoropolymer metallics can also be bonded so that when applied, the metallic flake is more evenly distributed throughout the powder for a more consistent appearance. Fluoropolymer powders are usually only available to members of a Certified Applicator program, as up to 20-year warranties are available on these products when applied by a certified applicator to architectural aluminum.
One popular brand of fluoropolymer is powder, which is a high performance, FEVE based Fluoropolymer and adds better abrasion resistance to the standard fluoropolymer characteristics. The powder can be seen on a huge range of projects from the DSNY building and the beautiful new slender skyscraper at 111 57th in Manhattan, to 9th and Lenora in Seattle and the Winstar Casino in Oklahoma.
Urethanes
Urethanes are chemically similar to polyesters, with a difference in curing agents. Urethanes offer a very smooth finish and very good exterior durability as well as excellent chemical and corrosion resistance which makes them ideal for things like fuel tanks. Other common applications include agricultural equipment, air conditioners, car rims and doorknobs. They are used on door knobs, oven knobs and other such applications because fingerprints are not as visible.
One drawback of urethane paint is that at higher mil thicknesses it can begin to outgas and become brittle. You may also notice an odor during application and cure and smoke can also be created in the oven during cure, so keep an eye on your application and cure parameters when applying. Urethanes are also usually more expensive than other types of powders due to the resin cost.
