Minimizing Disruption, Maximizing Output: Total Solutions for Powder Line Applications

As a coating solution, powder is one of the most durable options available, able to withstand harsh environments for long lengths of time while maintaining color, gloss and corrosion protection. These features, along with sustainability advantages like formulations made without solvents, are driving powder’s popularity.

Powder’s versatility and performance are dependent on a variety of factors, including proper application technique and optimal line maintenance.

Understanding the challenges inherent in the powder coating process is paramount as problems can halt production and create far-reaching implications for manufacturers in terms of dissatisfied customers and lost revenues.

Reclamation Systems
One of the advantages of powder coating technology is the ability to reclaim and reuse overspray. While it is optimal to recycle as much powder as possible from a sustainability and material cost standpoint, there are some circumstances that make it less feasible.

For many coaters, it comes down to a cost versus time savings equation. Color swaps can be time consuming since a full cleaning of guns, hoses and pumps is required before a new color module can be added. In some cases, coaters may choose to reclaim only the most widely used color.

In other situations, the decision to reclaim powder depends on the limitations of the equipment. For instance, a cartridge booth with a single removable color module makes reclamation more difficult since the operator must separate the color module for each reclaimed color. A full cleaning is needed before being replaced by the next color module.

For coaters who reclaim, proper maintenance of the system is necessary to avoid film build issues and finish defects.

A clean environment free of debris is essential. While some contaminants can be sifted out in the powder recycling process, it is difficult to remove all of them, particularly if they are small enough to pass through screens used in the reclaim system.

Taking the time to sweep the booth or application area at regular, scheduled intervals can help to ensure that small contaminants like lint and fibers are unable to reach the part or interfere with the powder application process.

Prevention Through Best Practices
The first step in addressing a coating line problem is an inspection of the application setup, starting with basics such as checking to ensure that hooks are clean and parts to be coated are properly grounded.

Because powder is an abrasive material, powder equipment requires proper maintenance to ensure sufficient fluidization and atomization of the coating.

Coating applicators should also frequently replace worn equipment with new high-quality parts for better finish quality and application ease.

Creating and adhering to a regular maintenance schedule where settings are properly inspected can help avoid problems. With standard procedures in place, an application line is inherently more efficient and far less likely to experience preventable complications.

Proper application technique and clean working habits are essential to minimizing powder line disruptions. By focusing on the details on a regular basis, manufacturers can keep productivity high and stoppages low.

Despite the best practices, problems with powder coating lines do occasionally occur. A partnership with an industry leader such as PPG provides powder coating applicators with invaluable technical service expertise to solve tough challenges, improve finish quality and optimize the powder application process.

A Unique Technical Support Program
To help applicators maximize finishing efficiencies, reduce logistics costs, and solve touch coatings challenges, PPG offers highly regarded on-demand technical, lab, and testing services, along with troubleshooting.

One of PPG’s most valued and trusted support services is the Secure Launch Excellence™ program, launched over a decade ago to assist new and existing customers in trialing new coatings and colors on their lines. This program is unique in the coatings industry.

The comprehensive four-step program is designed to reduce time, waste and costs associated with multiple trials, ensuring that a coating works on a production line the first time it’s applied to a part, meeting precise specifications for color, finish, application and environmental requirements.

Each year, on average, 50-60 companies utilize this highly successful program across a wide range of industries, including consumer electronics, general finishing, transportation, and heavy-duty equipment.

Power of a Partner
Our powder coating expertise and reliable, responsive technical service help our customers maximize application efficiencies and elevate the performance and durability of their products.

As a complete coating solutions provider, PPG is equipped to help companies—from small manufacturers to global OEMs—streamline every aspect of their finishing operations.