What equipment is used for powder coating?

A Beginner's Guide to Powder Coating Equipment Systems

If the product you intend to powder coat has significant debris such as rust, laser scale, or existing paint, you will likely require a Blast Room. A blast room is a designated enclosure where you utilize compressed air to propel abrasive materials against the surfaces of your components. Depending on the scenario, you would typically opt for an appropriate blast media like grit or steel shot to eliminate all unwanted debris from your part until a clean metal surface is achieved, ready for powder coating. Blast rooms prove especially beneficial for job shops handling raw materials that are not immaculate, such as plate steel or tube stock with oxidation or welding residue. (To find out more about selecting the right blast room, click here.)

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If oil, solvents, or any chemical residue covers the surface of your products, you should consider a Wash Station. This is where you spray your parts with a detergent and/or a chemical pre-treatment agent, such as iron phosphate. It's common practice to wash with hot water or steam initially before applying the chemistry for preparation. A wash station enhances powder adhesion and elevates finish quality, even for parts that have already been blasted. While some wash stations necessitate manual application of the chemicals via a spray wand, others are automated, moving parts through cleaning, rinsing, and preparation stages via a conveyor.
In certain operations, pretreatment may utilize a Dry-Off Oven. This appliance resembles a curing oven; however, it specifically heats the washed parts to evaporate water or any remaining chemistry on their surfaces. This step also helps the components attain an optimal temperature for the powder application.

Pretreatment equipment is invaluable for enhancing your operations and can significantly impact your work quality. Nonetheless, an elaborate system isn't always necessary for powder coating. While a clean surface is essential before applying powder, costly pretreatment setups are not mandatory for entry-level operations, where hands-on cleaning methods like using a tack rag and solvent will suffice.

Application: Powder Guns and Powder Spray Booths

The application of powder coating is nearly always executed with a specialized Powder Spray Gun. For effective powder coating, the powder must be electrostatically charged, and this charge can only be applied using a spray gun designed expressly for powder coating. Compressed air transports the powder from a hopper or directly from its storage box, blowing it out as a concentrated cloud. Upon exiting the gun, the powder becomes electrostatically charged, wrapping around the grounded part. This characteristic makes powder coating equipment notably user-friendly for beginners.

To engage in powder coating, a powder coating gun is indispensable. Numerous types of powder spray guns are available in the market. It is advisable to invest in a professional-grade powder gun, as these tend to provide greater reliability and superior results.

Once equipped with a powder gun, you will also need a suitable location for its use. When spraying powder, some will inevitably land on the floor and disperse into the air rather than on your products, known as overspray. The purpose of the Powder Spray Booth is to prevent this overspray from contaminating your workspace.

The powder spray booth is crafted to keep your shop tidy while offering a well-lit environment for powder application. Each booth is equipped with one or more exhaust fans that utilize filters to capture a portion of the overspray. If the exhaust system functions correctly and the filters are well-maintained, the airflow should effectively contain the overspray within the enclosure, allowing the operator clear visibility during the application. In environments that include welding or blasting, filtered doors on the spray booth can help keep airborne contaminants away from your powder-coated finish.

Various booth configurations exist, and selecting the ideal one depends heavily on the items being coated, available floor space, and workflow requirements. Powder spray booths may feature an open face or doors on one end and can even be structured as tunnel-style enclosures with filtration incorporated into the floor or walls. If you face limited space, a Powder Spray Wall might provide the airflow and filtration necessary. A spray wall acts as a large filtration system, essentially a spray booth without walls or a ceiling.

If you aim to recycle your powder, ensure that your powder spray booth includes a reclamation system. This system typically relies on pleated cartridge filters, aiding in recovering some overspray for reuse. This approach can be very economical if you plan to use a single color and type of powder for your application. The exhausted powder accumulates in the filters, which are then dislodged into a recovery bin. Advanced systems might automatically recondition the powder, mix it with virgin powder, and return it to the supply hopper for the powder gun(s). For reclaiming multiple colors, removable filter modules are required, but purchasing numerous reclaim modules can be costly since each module only reclaims one color.

Regardless of the booth type you choose, a powder spray booth is crucial for achieving quality results and maintaining reasonable throughput for your coating operation. (To gain insights into the appropriate size for a powder spray booth, click here.)

If your finish requirements are stringent, you may also need a Clean Room, also known as an Environmental Room. This is typically a climate-controlled space built around the area designated for powder application. The primary aim of a clean room is to eliminate airborne contaminants and regulate temperature and humidity during the powder application process, preventing any contamination, clumping, or consistency issues. Clean rooms are recommended particularly in dirty shop environments or if your products necessitate precise specifications for adhesion or salt spray tolerance. (To learn more about these requirements, click here.)

Curing: Powder Curing Ovens

Following the powder coating of your product, the final phase involves placing it into a specially designed Powder Curing Oven. These ovens generally operate between 325°F and 450°F. Once the desired temperature is reached and stabilized, the coated parts are exposed to specifically heated air for a predetermined duration. Upon completion of the curing process, the items are removed and allowed to cool before handling.

Interested in exploring more about powder coating equipments? Contact us today for an expert consultation!

Some curing ovens employ infrared emitters to heat the surfaces of coated parts, yet these electric-powered or gas catalytic ovens tend to be expensive to purchase and maintain. In contrast, conventional ovens often utilize electric heating elements or systems fired by natural gas or LP-fueled heat, primarily relying on heated air that circulates over the parts for convection curing.

The duration required for curing the powder can vary markedly based on the size, shape, and thickness of the coated parts. A small, lightweight bracket may need only ten minutes to cure, while a 20-inch segment of heavy-walled pipe might require over an hour for proper curing.

Choosing the right oven is critical if you aim to achieve professional-quality powder coating. Brand-name powder curing ovens are specifically engineered to yield top-tier coating results and are designed for energy efficiency. Since it’s likely you will utilize your oven for several hours weekly, the cost implications of an inefficient model can quickly impact your profit margins.

Like powder spray booths, powder curing ovens come in a variety of sizes and configurations. (For insights into the appropriate size for your powder coating oven, click here.)

Professional Powder Coating Systems Layouts

Typically, there are two fundamental configurations for any powder coating line: batch or automated.

A Batch Powder Coating Line is often a system where parts are prepared, coated, and cured in batches encompassing multiple pieces, with operators managing dozens or even hundreds of items simultaneously. Usually, products are hung on rolling metal racks, which transport them throughout the coating process. (Remember, high-temperature or metal casters for your racks are critical!) With a batch system, parts are often moved manually from one stage to the next, and the term 'batch coating system' is frequently used to describe operations where larger items are coated individually through manual or machine transport.

Conversely, an Automated Powder Coating Line utilizes similar appliances as a batch system but connects many or all stages via a motorized conveyor, moving parts at a consistent pace. Products are typically loaded onto the conveyor at a fixed point and progress through each stage where either manual operators or automated devices clean and prep the parts, applying the powder through the process. Once coated, parts traverse through the curing oven and cool down while they move along the conveyor to a designated unloading area.

(To understand whether a batch or an automated coating line is most suitable for your business, you can learn more about the pros and cons of each system by following this link.)

Powder Coating Equipment from Reliant Finishing Systems

This Beginner's Guide to Powder Coating Equipment aims to answer your essential questions about what powder coating entails, how it is carried out, and what you require to launch your first powder coating line. Should you wish to delve deeper, please contact us at (888) 770-. Reliant Finishing Systems' specialists are ready to assist! We will guide you through the setup process of your powder coating shop or help integrate coating capabilities into your existing fabrication shop or manufacturing unit. Whether you are acquiring your first powder coating system or upgrading to a fully automated line, you can rely on Reliant for sound advice and high-quality, cost-effective equipment.

Updated Content Dec 9,

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