what is powder coating

Powder Coating Systems – How Does Powder Coating Work?

Here at TD Finishing, we are proud to be one of the country’s leading suppliers of powder coating equipment for sale. If your business would like to invest in such facilities, you may be looking to have those all important questions answered, to begin with. For example; ‘what is the powder coating process?’ and ‘what is a powder coating system? and how does powder coating works?‘ As highly experienced experts in powder coating systems, we’ll be able to answer all of these questions and more. Therefore, when the time is right to invest in a powder coating line, you will know exactly what to look for.

What Is Powder Coating And How Does It Work?

Powder coating is a finishing process that you apply to metal surfaces. A powder coated surface will be more resistant against corrosion, scratches, wear and tear, chipping, and fading. Especially compared to a surface that doesn’t have this advanced protective finish. It consists of a flowing, fluidised powder that is baked in a coating oven. The powder then flows as a liquid. Then, it cools to form a hard and durable finish. TD Finishing powder coating equipment is used to paint everything – from bicycles to car parts and domestic boilers to Architectural aluminium. There are usually three stages to the powder coating application.

Stage 1

The first stage involves preparing a surface for powder coating. This can be done in several ways, depending on the final finish requirements. The two most common ways are hand wiping with cleaner and shot-blasting followed by a full online pre-treatment plant. Our Pre-treatment plants work in one of two ways, an online spray for conveyorised plant or an automated dip tank with gantry system. The system will allow you to load the basket with longer or higher quantities of material. The powder coating pre-treatment cleans and prepares the surface of the substrate. It allows for good, reliable adhesion of the powder coating. TD Finishing can assist you with working out the correct pre-treatment regime for your business. This stage is followed by the use of a powder coating drying oven.

Stage 2

Once dried and cooled, the second stage involves the careful application of the powder coating. Electrostatically charged on leaving the gun, the positive (+ve) coating is attracted to the grounded substrate material. It is then held in place by the electric force. The application equipment ensures sufficient charge of the particle, as well as field strength. This prevents the powder bouncing off or falling from the substrate before curing. For fluidised beds, or fusion bonded epoxy coatings, the product needs heating during the drying stage. This is for the purpose of melting the powder into a green-cured state before moving to stage three.

Stage 3

Finally, once the substrate is fully coated, the product needs heating in the oven to the required temperature. The product then dwells until the powder has finished flowing across the surface. The times and temperatures will vary depending on certain factors. These factors include the powder, thickness or gauge of material and product weight. But, typically around 180-200 degrees for 15-30 minutes is sufficient. At this part of the process, it is vital to ensure the oven’s temperature is enough to cure all the products evenly. td have many years’ experience in powder coating equipment. We understand the importance of air movement within the oven whilst simultaneously balancing the flow. Therefore, avoiding any significant disturbance of the powder prior to jelling.  

Powder Coating Equipment for Sale

We have decades of experience as powder coating equipment manufacturers. TD Finishing supply online conveyorised powder coating systems, manual & monorail conveyors, power & free systems, standalone box ovens. We also supply infrared ovens for simple one-dimensional products, or as a pre-gel system. This prevents cross contamination during a colour change. In addition to the above, we supply equipment for wet spray systems too. No matter what type of plant you are looking for, we’ll work hard to find you the perfect solution for your requirements.

Contact us Today

For more information on our powder coating systems for sale, head to our website today. Or, call 0121 520 8884 to speak to a member of our helpful and friendly team. We’ve invested in some of the worlds best powder coating equipment so everything we deliver is top quality.

If you enjoyed reading this blog about how powder coating works, you may also like to read our previous article on powder coating plants.

Powder Coating Plant Manufacturer Partners With Welbilt

TD Finishing are a leading powder coating plant manufacturer in the UK. We specialise in the design and installation of custom finishing systems and offer our services globally as well as the UK. We recently partnered with Welbilt, an award-winning global manufacturer of professional catering equipment. They manufacture a range of top brands, making them leaders in their industry for over eight decades.

Unless you are in the industry their name may not be familiar. But, it is very likely that you have seen one of their Merrychef branded speed ovens in a high street coffee shop. The Merrychef range is manufactured at the state-of-the-art Sheffield site. Additionally, it is supplied globally to many household name coffee shops and restaurants. 2021 saw major investments in the Sheffield factory, with a range of new machinery and equipment. The largest project was the installation of a complete TD Finishing powder coating facility.

Welbilt Bringing Powder Coating In House

David McHugh, UK Operations Systems Manager, discusses the project and the reasons for bringing powder coating in house:

“Powder coating has always been a process that we have contracted out in the past and something that we had never considered bringing in house until recently. We continuously assess our processes, and it became clear that growing demand was making painting a bottle neck within our manufacture, increases in transport costs and external labour brought the decision to start painting in house forward.

We are also being asked more regularly for different colours to suit our customers’ own branding, the ability to manage this internally will open up many more opportunities for us.”

Early Stages With TD Finishing Providing Expert Advice

“As we began the early stages of the project it became apparent that TD Finishing had the knowledge and experience to help. We were looking for a partner that could not only develop a plant concept but also provide comprehensive project management and advice from the beginning.

The space we had available within the factory was also limited. So, we knew that we would need an experienced team to ensure that we got a system that could give us the throughput we needed but also the quality finish that is expected by our customers.”

Evolution And Innovation

“The Welbilt philosophy centres around evolution and innovation. With this in mind we wanted to make sure that the plant we were going to install would last us for many years to come, both in build quality and technology. This led us to look at the most efficient and up to date equipment.”

High Quality Powder Coating Equipment

“Once we had a system layout and specification, we went out to see some equipment in operation. As engineers and experienced manufacturers it became apparent very quickly that the quality and design of the TD Finishing equipment was second to none, much like our own products.

We also saw the latest TD Connect PLC control system. This was a must for us as the data collection functions assist us with our internal quality monitoring. From there the decision was an easy one and we awarded the contract to TD.”

Complete Powder Coating Plant Up And Running

“We have now been running the plant for a few months, gradually moving the powder coating from external suppliers to allow us to fully understand the process.  The project has gone very well from start to finish. We have skilled operators managing the system and the results have been excellent. We are seeing improvements in overall finish quality. As well as a massive reduction in rejects, turnaround times and stock levels have also reduced significantly as we don’t have transport restrictions or the need to store large ranges of finished product.

We reached full production on the paint line in December 2021 with all outsourced powder coating coming to an end.  This is a great achievement for us and a project that we hope to replicate at other sites globally.”

TD Finishing – Powder Coating Plant Manufacturer – Get In Touch

Are you interested in installing a custom powder coating finishing system into your facility? Get in touch today. Our helpful and friendly team of experts will be happy to help you with any questions you have. From order placement to design, manufacture, installation, and commissioning, we offer full project management on all custom finishing systems.

Furthermore, if you enjoyed reading this blog, why not take a look at: Finishing Plant Replacement | TD Finishings

powder coating facilities -fusion bonded epoxy coating machine

Fusion Bonded Epoxy Powder Coating Facilities 

Looking for powder coat equipment? Epoxy powder coating facilities is just one example of the many different industrial powder coating equipment we can install on your site. TD Finishing often get asked to support a client with their specialist coating needs. They are usually looking for powder coating equipment for sale, and we are always proud to help. Several of our recent UK equipment installations have included a fusion bonded epoxy (FBE) UK powder coating machine. Fusion Bonded Epoxy coating is a protective coating of thermoset polymer, typically applied between 250 to 500µm.

Fusion Bonded Epoxy Coating

Whilst not a new technology, vast improvements have been made in this type of coating, since its introduction in the 1960’s. Thicker than a standard powder coating, this finish provides high chemical and abrasion resistance. It is a premium choice where performance of coating is key. As leading powder coating equipment manufacturers, we want to guarantee an optimal coating is achieved. Therefore, TD Finishing has developed many specialist powder coating systems for sale. These systems have ensured consistent, high-quality production output.

How Does Fusion Bonding Epoxy Work?

In a typical FBE system, the material substrate is heated to between 180-250°C. When the coating is applied, the high temperature causes the resin and hardener to react with heat, flow into a liquid and then harden. This is caused by a process of chemical cross-linking, known as fusion bonding. The product is then post cured in a second oven, running between 180 and 200°C.

For the FBE coating process, first the substrate is cleaned and prepared in the spray or dip pre-treatment system. It is then placed into a combined drying and preheat oven. This oven is used to raise the product temperature to the powders exacting requirements. Once pre-heated to the desired temperature, the component passes to the application area. This can take the form of an automated system, manual spray booth or where required, a fluidised bed dip tank. The pre-heat temperature, cooling rates and transfer times between these two stages, along with the powder application, are critical to achieving a high-quality FBE finish.

Related: FBE Powder Coating Line Installation

Curing FBE In A Powder Curing Oven

Where the FBE coating is a stand-alone coating, the components are post cured following powder application. However, when an additional decorative coating is to be applied, the substrate is first allowed to cool. Then, a more conventional polyester powder coating is applied. The components are then transferred to a curing oven between 180-200°C, with a variable dwell time. This time is dependant on the substrate material thickness. 

Fusion Bonded Epoxy Powder Coating Machine

In two recently delivered fusion bonded epoxy powder coating facilities, the clients required very different products be coated, with an FBE coating. The first plant for mild steel tanks required 3-stage powder coating pretreatment equipment with Demin water rinse. As well as drying and curing ovens. The second system was utilised for the coating of large copper busbars. It involved an indexing conveyor, indexing pre-heat oven, automatic drop-section, FBE fluidised-bed dip-tank and a post-curing oven with automated pneumatically powered doors.

Power And Free Conveyor Systems

Both systems required very specific and variable control parameters, which varied across the entire product range. TD Finishing chose, in this case, to utilise power & free (P&F) conveyor systems. Power & free allows for more complicated, precision control of coating processes – as opposed to a traditional monorail conveyor. All while minimising the footprint requirements of the facility. For sheet heating and curing, the P&F system allows for the processing of 2mm to 12mm sheets, within the same system. For the busbars, it was possible to transfer the flight-bar to an automated drop section and into the fluidised bed within a very specific time limit. This ensures the products could be transported into the fluidised bed, and agitated within the specified time limits.  

Related: Conveyorised Powder Coating Systems – Power & Free

Contact Us Today

Are you looking for professional powder coating equipment? To find out more about investing in powder coating facilities for your business, head to our website today. Or, you can call 0121 520 8884 or email andrew@tdfinishing.co.uk to speak to a member of our helpful and friendly team.

If you have found this blog helpful, you may wish to read our previous blog on Powder Curing Oven Installations.

powder coating oven gas burner

Modulating Gas And Air Burners At TD Finishing

We are one of the country’s leading suppliers of powder coating plants. Therefore, we understand the importance of efficiency in heated processes. As well as, the role plant design has on optimising temperature control. Accurate temperature control is key to achieving tight tolerances in temperatures. Fully modulating systems allow much greater control over traditional “High-low” burners. All TD Finishing curing ovens and powder coating systems are supplied with modulating Gas and Air Burner. As well as, all of our drying ovens and any heated stages of the spray pre-treatment systems. 

Latest APL Technology

The drying, pre treatment systems and powder coating oven gas burner uses the latest ‘Air Pressure Lead’ (APL) monoblock gas valve technology. Changes in process heat demand are transmitted to the burner by a modulating signal. This connects to a motor speed controller which varies the speed of the burner combustion air fan. It increases or decreases the burner windbox differential air pressure. As a result, the package gas burners offer flexible, high turndown control for process heating applications. Giving minimum running consumption during production, but with high-power output available on demand. Particularly during system start-up. We can offer 24/7 timers for automated system heat up prior to manufacturing operations.

Related: Industrial Drying Oven Solutions at td finishing

Safety is a Key Feature

Safety is another key feature of our package-gas modulating burners. As such, the burners comprise of a burner windbox, combustion air fan, a compact monoblock air / gas valve gas train and burner controls. Including the combustion air fan motor speed controller, mounted within a control panel. For ease of access during use, we can supply our burners with a remote panel if you require one.
Standard control items include a burner controller ignition transformer and differential air pressure switch. Two 3-way air valves perform safety checks on the air pressure switch in both open and closed modes each time the burner fires. This allows the burners independent operation of the combustion air fan in conjunction with oven /dryer main recirculation fans.

Individual Control

On our powder coating systems, you’ll find a modular immersion tube burner. This includes a cylindrical burner assembly that can withstand typical tank heating operating environments. Alongside this, a compact monoblock gas valve train, burner controls mounted in a protective control box, exhaust damper and an exhaust fan which can be coupled to multiple burner installations all the while maintaining individual control. The burner fires through a submersed stainless steel tube designed to give optimum surface area and heat transfer through the process.

Related: Finishing Plant Replacement | td finishings

Contact Us Today For Your Curing Oven Gas Or Air Burner

Are you looking for a powder coating oven gas burner or to find out more information about our coating systems? Then head to our website today. Alternatively, you can call 0121 520 8884 to speak to a member of our helpful and friendly team.
Or, email info@tdfinishing.co.uk.  

Furthermore, if you enjoyed reading this blog you may also enjoy our previous blog on Dip Pre-treatment Systems.