Proprietary low cure powders
and IR technology has enabled
Decoral licensees to powder
coat and decorate MDF, which
has created breakthroughs in the
cabinet and display industries.
By Sharon Spielman
When a heat-sensitive substrate such
as medium density fiberboard (MDF) is
finished with a powder coating, temperature
is an important factor, of course, but
even more important than that, according
to Eric Koslow, national sales manager at
Decoral System USA Corp, Coral Springs,
Fla., is the MDF itself. In the finishing industry,
preparing the substrate to accept its
finish is crucial. When it comes to MDF, not
only is the preparation of the substrate key,
but the substrate itself must be high quality.
“There is high quality MDF and there is
cheap MDF. Good, quality MDF can withstand
curing temperatures; coupled with
our low-cure powders, we can achieve great
results,” he says. “Invest in what you want
your end product to be.”
From Anodizing to Dye Sublimation on
Powder Coated MDF
Decoral System, headquartered in
Verona, Italy, has gone from an anodizing
plant in the early 1970s, to a liquid and
powder finishing plant in the 1980s, to a
powder-only finishing operation in the late
1980s. Then, in the 1990s, the company
looked for a process that
would offer something new
to its customers, distancing
them from competitors.
That was when dye sublimation,
a process typically
only usable on flat sheets,
was explored by Decoral.
Since that time, the company
has developed, patented
and advanced the technology into tough
decorative powder finishes that can be applied
to a range of substrates, resulting in
many different textures, glosses and overall
finishes.
Most recently, Decoral has explored
finishing MDF, a heat-sensitive substrate.
And the ability to decorate three-dimen-
sional objects is what separates Decoral
from its competition, according to Koslow.
Over the past several years, Decoral has
introduced infrared (IR) 3D decorating.
According to Koslow, “The IR 3D machine
is designed specifically for the industrial
automated decoration of 3D powder coated
parts in high volume.” This includes
the application of any decoration to MDF.
Products such as cabinets, furniture, store
fixtures, shelving, louvers and more can
be made from MDF. The process applies a
realistic wood grain, marble finish, or even
custom logos and artwork, according to
Koslow.
The Process
In addition to MDF, really any substrate
that can be powder coated can utilize the
Decoral process, Koslow says. “This includes,
of course, aluminum, steel, die
casting, glass, ceramic, Nylon 66 and other
high-temperature plastic.” Just like in the
traditional powder coating process, the first
step is to prepare the substrate. The work
piece receives a traditional pretreatment
that is appropriate for proper adhesion and
the final environment. Proprietary powder,
formulated and made by Decoral, is applied
and cured. Electrostatic guns are utilized
to apply 2.5 mils of powder, which, when
applied to MDF, is then cured at 320°F for
up to 20 minutes. Polymerization is then
performed. The applied base coat is conducive
to creating sufficient hardness on the
final product. Moreover, it protects the substrate
from factors such as weather, corrosion,
abrasion, light and humidity, Koslow
explains.
Then the decoration process begins. A
preprinted transfer film with organic photosensitive
pigments and cellulose resin is
completely wrapped around work piece
with an airtight seal. The piece is then positioned
on the surface of a movable trolley.
Air is removed through a vacuum suction
system, which brings the printed film into
contact with the powder coated surface.
The trolley is conveyed into the integrat-
ed curing oven where the printed image
is effected, turning the ink pigments from
solid into gas and back into solid again inside
the paint layer. After cooling, the film
is removed. The final result is a piece that
mimics a one-dimensional printed image on
a three-dimensional surface.
Designating Decorations
Licensees are job shops, OEMs
and extruders throughout North and
South America and the entire world. “We
look for quality applicators that strive for
proper pretreatment to assure adhesion,”
Koslow says.
Companies that align themselves with
Decoral can tap into a global company that
is constantly innovating and offers countless
resources. “For instance,” Koslow says, “We
are your technical, marketing and sales support
team every step of the way.” Decoral exhibits
and markets at various national trade
shows, including the Powder Coating Show,
throughout the year, he says, and they give
all of the leads in a licensee’s region to them
at no cost.
Koslow also says that the company budgets
for Search Engine Optimization (SEO)
campaigns, driving thousands of potential
clients to its website. “We give all of these
leads to our Decoral licensee at no cost,”
Koslow explains. “And we perform marketing
campaigns to attract OEMs, builders
and architects to Decoral.”
Becoming a licensee requires no fee, just
a commitment to use Decoral’s films and
powders to ensure high quality standards
for color and finish, Koslow explains.
Other perks that licensees receive are
regular updates of products and applications
as they become available through the
company’s website and newsletter; a dedicated
secure portal for materials, inventory,
FAQs, updates and more on the company’s
website; assistance with any color matching
issues that licensees may face; and all the
necessary quality testing has been done.
“Decoral has a huge international certified
laboratory for any type of test,” Koslow
says. “This service is at your disposal free of
charge. Additionally, there is an entire quality
report section on our website for licensees
to access.”
Decoral installs the machines, provides
full onsite training of staff for two weeks,
and offers a full maintenance warranty.
When it comes to the powder used in
the process, Decoral produces all of its own
powder, which Koslow says enables them
to formulate powders specific to its clients’
needs. He says there are applications for
glow-in-the-dark powder, which include
street signs, emergency exits, bikes and
motorcycles, boats, planes, aisles and walkways,
theater exits, and any dark area that
needs back lit signage. Other powders that
Decoral now offer includes color-changing
powders, wrinkle-effect powders, and anti-
skid and anti-microbial powders.
“Our low cure powders and IR technology
enable our licensees to powder coat and
decorate MDF, which has created breakthroughs
in the cabinet and display industries,”
Koslow says.
“The most recent technology being offered
is called ‘Horizon.’ It uses UV cure
inks to apply a wood grain pattern onto
coated extruded profiles in a very efficient
high speed, low cost manner,” he adds.
For more on Decoral System USA Corp.,
visit: www.decoralamerica.com.
Sharon Spielman is editor of Powder
Coated Tough magazine. She can be
reached via email at:
sspielman@powdercoating.org.