Finishing metal parts and other surfaces can be challenging, and although painting is commonly used it has many drawbacks. It is imprecise and there are high chances of runoff. Powder coating cuts on your finishing cost and labor as you only require to apply a single coat.It eliminates most of the problems and is environmentally friendly.
If you are looking to start a powder coating business, it is essential that you are familiar with how the system works. This allows for enhanced safety and component performance. Read on for some fundamentals of this finishing process.
Powder Coating System: What Is It?
All steps of the powder coating process require different components. The stages are:
Pretreatment - Any dirt or foreign objects on a surface can negatively affect the quality of your coating. For this reason, always ensure you prepare the part beforehand. Pretreatment equipment comes in handy in cleaning the debris and old paint so you can achieve a perfect finish. The most common pretreatment methods are chemical cleaning and abrasive blasting.
Application - You require several pieces of equipment for this step. The feeder gun ensures a steady supply of the coating substance to the gun, which then sprays charged particles on the surface of your parts. Additionally, spillage is likely to occur during application. This is where the powder coating booth comes in. It prevents the overspray from other areas of the facility. Curing - The curing temperature is a crucial aspect of the drying process. It reduces the risk of overbaking which can affect the quality and durability of the finish. Curing is done in an oven for a set duration. Curing ovens can either be traditional or advanced depending on the complexity of your powder coating project.
Batch Powder Coating Systems vs. Conveyor Powder Coating Systems
Each type of powder coating system has unique advantages. It is essential that you are familiar with the convenience of each system as you determine their suitability for your application. For instance, the conveyor system is commonly used for powder coating large bulks of products because of its faster finishing rate.
The batch system is used for single client powder coats or small-scale production. If you are working on a project that requires keen attention to details, or complex parts like hidden spots, and tiny pieces the batch system is an ideal choice.
How Do I Choose Powder Coating Systems?
You should carefully choose your powder coating systems if you want to achieve top quality finishes. Some factors you should evaluate are:
Suppliers
There are several ways to determine the suitability of a supplier. Seek information on their reputation in the industry so you know whether they are trustworthy. Additionally, the higher their experience, the better. A supplier with a variety of powder coating equipment allows you more flexibility during selection.
Ensure you select a supplier who provides top quality powder coating systems so you get value for your money. Good customer support is important as it enhances communication between clients and the company.
Safety and Compliance
Like with any other industrial process, some risks might arise during powder coating. Following safety regulations minimizes these risks and ensures enhanced efficiency. There are no shortcuts when it comes to powder coating system compliance.
The protocols set by regulating bodies are meant to protect people in the facility. For this reason, operators should have a clear understanding of any compliance requirements at every step of the finishing process. Examples of some safety measures are:
●Protective gear like goggles and gloves should always be available in your facility
●Ensure adequate ventilation to reduce harmful fumes.
●Exercise proper storage of hazardous materials
●Comply with waste disposal regulations
●Keep up with on any dynamics in the workplace safety regulations
Quality Assurance
Powder coating system operators are always looking to achieve excellent outcomes and consistency. Regular inspections, efficient systems and intensive employee training are some ways they can achieve these goals.
Also, record keeping is a great way to keep tabs with any potential hazards of the powder coating process. Understanding different quality assurance aspects enables the operator to achieve exceptional results.
Conclusion
Powder coating is a complex process. Nevertheless, with the right equipment and information, you can indulge in your DIY projects or provide products more effortlessly. We hope our basic guide on powder coating systems helps you navigate your upcoming project.
The quality of your system determines the efficiency of the finishing process so ensure you work with a reliable supplier.
At Ramseier Koatings, we are ready to provide you with assistance on any of your powder coating system queries, and high-performance spraying equipment.
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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