As the popularity of powder coating grows, industries are moving towards a new age of making the finishes aesthetically pleasing, long-lasting and outstanding. And yet, the results are costly. You must have a powder-coating spraying booth.
It’s the only way to guarantee uniformity and super quality. So, hang on as this guide is set to educate you on how powder coating spray booth works.
What’s a Powder Coating
So we know powder coating happens inside a booth. But what does it entail? It's all about using an electrostatic gun with finely ground powder pigments and other coloring components. As such, its typically applied against a substrate. Then the substrate is heated in an oven wherein the powder will melt, spread and undergo curing to form a finish.
What are the components of a powder spray booth?
Enclosure
Normally a powder-coating spray booth will have some casing. This is designed to hold the power within the booth.
Exhaust unit
This is purported to filter out overspray and air articles. Normally, it comprises a fan and filter.
Powder gathering unit
This unit gathers excess powder particles. As such, it has a cyclone separator and a filter which secludes powder within the airstream for reusing or disposal.
Lighting fixture
You need to see when doing the powder coating. This comes in handy during the inspection of the coated product. And so, the light remains strategically placed for better visibility.
What's involved in the spray booth during the powder coating process?
Step 1 - Surface Preparation
You are going to do surface preparation outside the spraying booth. Remember, the booth is a controlled environment designed for the powder coating. Surface preparation, however, will require a separate area where you will do solvent, chemical, or abrasion cleaning. This will remove contaminants; afterwards, you may take it to the booth.
Step 2- Electrostatic powder application
Now in the spray booth, you must use the powder coating gun to apply a positive charge to the pigment powder. This is done while spraying the powder on the fixed substrate. As a result, you get uniform coverage with minimal powder wastage.
Step 3- Application technique
As the operator, even if you are in the booth, you must apply the charged pigment powder in a sweeping motion. That is, you need that consistent thickness and distribution.
Step 4- Excess powder Collection
It's inevitable. There must be excess powder termed as overspray. This happens when you miss the target. Negative pressure from the exhaust system will pull the excess powder to the gathering unit.
Step 5- Curing
When you have applied the coating, the substrate will be taken to the curing chamber or oven. Here the heat causes the powder to melt and spread to form a smooth finish. However, the curing process and time depend on your desired finish and powder.
Step 6- After the cure assessment
The cured substrate, upon cooling, has to be examined for imperfections. This step only guarantees that the coated product is up to the standards.
Step 7- Recycling and disposal of excess powder
The powder now in the gathering unit may be recycled. That's if it's passed through the reclaiming systems. It’s a cost-effective approach, but if it can't be reused, it can be safely disposed of following environmental standards.
Take away
The powder coating spraying boot remains the spine of the powder coating process. You need it to save the environment, reduce powder wastage, and ensure consistent and evenly spread finishes. So having a grasp on the processes in which the powder spraying booth helps in the powder coating process is essential.
It puts you in that position where you know that getting the right Powder spray booth from the market is a step next to success. Even so, which manufacturer should you buy from?
The market is filled with tons of powder coating equipment manufacturers ready to make a run for your money. But one that stands out is Ramseier Coatings. We have crafted their CM Series Manual Spray Booth with decades of experience.
It's super-efficient, with swing wing filters for filtration and easy maintenance. It is best for air compression and noise reduction and boasts a good lighting system alongside the extraction unit.
Our distributors and service centers are all over the world.
In order to ensure that our customers can get more professional advice before and after the sale of spray products, we will also provide timely maintenance support and spare parts supply to customers through the service network.
Few on the market Test Service
Test centre has been set up in our factory in China where customers can perform tests and simulation works. Our demo labs are equipped with the latest powder equipment for trial use by our customers.
The KPC series powder center integrates powder supply, powder recovery and sieving functions in a compact housing, and is equipped with an extraction device to ensure a clean working environment in the workshop. The KPC allows operators to change colors quickly and efficiently in a short time. The PLC control system will automatically clean the powder hose and internal powder path of the spray gun to reduce downtime and powder contamination problems. The extraction device of the KPC can be integrated with the KPC or with the main filter unit.
KMB "Magic Box" series fast color change powder spraying system is designed to solve the color change troubles of customers. The whole system adopts advanced plastic structure and automatic recycling control system, which can save color change time, improve equipment utilization rate and create profit return rate.
ACB high efficiency spray booth system has unique design and advantages. The bottom air duct of the booth adopts the ‘even flow’ flap structure, the side panels of the booth adopt the advanced design without automatic gun opening, and the systematic supporting design creates the ideal powder atomisation area of ‘flexible spraying’, which has a gentle air flow, providing an ideal working environment for powder coating. This provides an ideal working environment for powder coating. This design and functionality makes the ACB high efficiency spray booth system highly efficient and operable in powder coating operations, able to meet the coating needs of different workpieces, while also demonstrating excellent performance in cleaning and recycling, providing a strong guarantee for high quality powder coating operations.
ColorWing wing-type spray booth has unique design and advantages. It is mainly suitable for spraying workpieces in vertical hanging mode, such as aluminum profiles, highway guardrails, etc. ColorWing wing-type spray booth uses the patented design of "wing-type wall panel" and "wind tunnel" cleaning mechanism, which is efficient and fast when cleaning and changing colors.
The CQB high-efficiency spray booth system adopts a sandwich-style all-plastic structure with a bright and elegant design. The manual workstation is open and external, which is convenient for manual operation. The workpiece outlet is designed with a PVC solid door, which is closed during cleaning to shorten the cleaning time. The bottom recovery adopts a "uniform flow" multi-channel design to even out the exhaust airflow, thereby achieving better powder application efficiency.
The CQB high-efficiency spray booth system adopts a sandwich-style all-plastic structure with a bright and elegant design. The manual workstation is open and external, which is convenient for manual operation. The workpiece outlet is designed with a PVC solid door, which is closed during cleaning to shorten the cleaning time. The bottom recovery adopts a "uniform flow" multi-channel design to even out the exhaust airflow, thereby achieving better powder application efficiency.
Sieve and separate the powder sent back by the recycling system to remove impurities, and then send it to the powder supply system for reuse in the spray gun system
Sieve and separate the new powder to make the new powder more evenly mixed
Different mesh sizes can be configured according to the customer's different products and the number of spray guns, and vibrating screens of different diameters can be selected to improve product spraying efficiency
According to the characteristics of coil spraying, such as large amount of powder, uniform coating, thin coating and corrosion resistance, ultrasonic vibrating screen is selected, which can achieve high precision, high mesh screening, low energy consumption and high efficiency.
DDF3 high-power powder pump can operate friendly under high powder concentration and low air flow rate powder supply conditions. It can operate stably in harsh hot and humid environments for a long time. DDF3 high-power powder pump can adapt to different types of powders and maintain a soft, smooth and stable powder conveying effect. DDF3 high-power powder pump is user-friendly and easy to operate. It will not spit powder under different conveying distances and powder types. The sturdy structure can meet the high-pressure cleaning requirements required for fast color change systems.
BV-1 high-power powder pump for powder recovery is used to recover powder from the recovery system to the powder supply system. The powder delivery capacity is more than 7kg/min
Powder can be directly supplied to the powder supply system from the powder box. The bottom bracket of the powder box is equipped with a vibrator, so no "holes" will be formed during the powder suction process, ensuring the continuity of powder suction.
The powder is directly supplied from the ton bag to the powder supply system, and the ton bag is placed on a mobile trolley with a vibrator. Equipped with multiple sets of high-efficiency and high-power powder suction devices to meet the requirements of large powder consumption. The automatic lifting device and the special powder hopper design make the powder bag have less residual powder
Based on more than 30 years of successful experience in designing rapid color change systems, the unique MPC closed-loop powder supply center can provide efficient rapid color change capabilities. The MPC closed-loop powder supply center can be upgraded to the rapid color change capability of an existing powder spraying system alone or integrated with a complete powder spraying system (including spray booth, powder recovery system, spray gun and elevator, etc.).
Whether the user is adding new spraying equipment or upgrading and modifying the existing spraying equipment, the PMC system that must be configured in the process of realizing digital control technology includes DDF powder pump, new powder supply device, powder supply barrel, high-efficiency powder screen and control cabinet.
It consists of a vibrating screen and a powder barrel. The recovered powder passes through the buffer of the vibrating screen, to the screen, and then to the powder barrel after screening. The powder barrel then supplies the powder to the spray gun system.
The spray gun is fixed on AutoFlex100, which can move up and down, forward and backward, left and right, and rotate up and down. It can memorize the spray angle and position of the workpiece and realize automatic groove spraying. It adopts the latest digital positioning system and PLC control to ensure stable and reliable lifting. The main control touch screen can display the lifting speed and program multiple working programs. It can also be controlled by an independent touch screen/tablet or mobile phone. The operating system software is user-friendly through simple graphics and Chinese and English analysis.
To meet the requirements of workpiece shape, line speed, coating and output, our HDR6P lifter achieves the best results with unique functions. The HDR6P lifter is equipped with a precision programmable electric servo motor, adopts the latest digital positioning system and PLC control, ensures the long-term repeat accuracy of the spray gun during automatic spraying, and the lifting action is smooth and reliable. The main control touch screen of the equipment can display the lifting distance and speed, and can be programmed into more than 255 working programs. The operating system software uses simple graphics with Chinese or English explanations, which is user-friendly.
To meet the requirements of workpiece shape, line speed, coating and output, we provide the SR series of lifters, which can achieve the best effect required by customers with its different features. The SR series programmable electric lifter has a stylish appearance and precision manufacturing. It can ensure the long-term repeat accuracy required by the spray gun during automatic spraying. It adopts the latest digital positioning system and PLC control to ensure smooth and reliable lifting action. The lifting distance and lifting speed can be displayed on the main control touch screen of the equipment, and more than 255 working programs can be programmed. It can be controlled by independent touch screen and/or manual buttons. The operating system software uses simple graphics with Chinese or English explanations to make it more user-friendly. SR series short-range programmable lifter-suitable for vertical cloth gun automatic spraying online, with a travel distance range of 100-400 mm.
To meet the requirements of workpiece shape, line speed, coating and output, we provide the ER and HDR series of lifters to achieve the best results required by customers with their different features. The ER/HDR series programmable electric lifters are stylish and precision-made. They can ensure the long-term repeat accuracy required by the spray gun during automatic spraying. The latest digital positioning system and PLC control are used to ensure smooth and reliable lifting and lowering. The lifting distance and lifting speed can be displayed on the main control touch screen of the equipment, and more than 255 working programs can be programmed. Independent touch screen and/or manual button control are optional. The operating system software uses simple graphics with Chinese or English explanations to make it more user-friendly. ER series long-range programmable lifters - suitable for use with up to 6 automatic spray guns. HDR5P series heavy-duty long-range programmable lifters - suitable for use with up to 9 automatic spray guns.
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