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 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 Post: 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 Post: 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 post 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.

Power & Free Conveyorised Powder Coating Systems

Conveyorised Powder Coating Systems – Power & Free

Are you looking for a powder coating conveyor plant? TD Finishing are proud to be powder coating equipment manufacturers. Our conveyorised powder coating systems are incredibly popular. However, we have a wide variety of powder coating equipment for sale. If you require further flexibility, you may wish to invest in Power & Free. This is something that we have a vast amount of experience with. The system uses two tracks, one above the other. Power & Free allows us more flexibility with your system. The top or “power” track, contains a drive chain. This chain enables the movement of product flight bars. These are located within the lower, “Free” conveyor track.

TD Finishing have an impressive portfolio of clientele. In fact, we have provided powder coating systems to businesses all over the world. As a result, we have become a very experienced and versatile business when it comes to providing sites with powder coating solutions.

 

Conveyor Systems

By using switches and multiple drive chains, you allow production to flow around the factory space better. They also remove the rigidity of a single chain monorail conveyor. On a traditional monorail conveyor system, the product is restricted to the single path of the drive chain. With Power & Free, a product can bypass certain processes. It can deliver products to a particular area of the factory for assembly, inspection or packing. For a conveyorised powder coating line this means the product can be treated individually depending on its specific process requirements.  

 

Bespoke Solutions

In a recent Fusion Bonded Epoxy installation, the client’s product could vary in thickness by up to 10mm. Following spray pre-treatment, the drying oven was also utilised as a pre-heat. The flexibility of the Power & Free Conveyorised Powder Coating Systems means it is possible to vary the dwell time in the oven to ensure sufficient heat is transferred into the product. The variable transfer speed also gave the flexibility to deliver the product to the powder coating booth before it loses the heat required to fuse the powder primer. The variance in product gauge also needed a track system that could allow for variable cooling time before applying the topcoat powder.  

 

Overhead Conveyors

A Power & Free system is good for heavier products. This is because it makes loading and unloading operations safer. The power track delivers the flight bar to the stationary load or unload station. The operator is then free to load very heavy products. This is usually with a loading crane or integrated drop section. Once loaded, the flight bar is released back into the coating system. The stationary flight bar means the line density can be increased easily. This is ideal for lighter products. 

 

High Specifications

Our powder coating systems for sale can meet a wide range of requirements. In fact, we have lots of efficient drying and powder coating ovens available too. Products are loaded into the ovens in echelon. As a result, the amount of oven volume is minimised. This space is usually empty. You can use the ovens to pre-heat or cure paint without altering the process times the flight bar spends in the pre-treatment plant. Spray pre-treatment systems have set treatment time requirements. These can be kept consistent with Power & Free regardless of the product thickness. 

There is the option to supply TD Finishing powder coating equipment with Power & Free Conveyorised Powder Coating Systems. These systems include the Pretreatment plant, drying ovens, curing ovens, infrared oven and spray booths.  Regardless of what you choose, you can be sure that our high specification systems will not let you down.

 

TD Finishing Go The Extra Mile

Still not sure which system is best for you? TD Finishing has decades of experience when it comes to powder coating plants. We will talk you through all of the suitable solutions that we have here. Moreover, we will make sure we equip you with everything you need to know. Then, you can use this knowledge to make a well-informed decision on the right solution for you and your business. However, we will always be on hand to help you determine exactly what product will meet your needs the most. We have an established reputation, a worldwide service, and modern up-to-date systems. With this in mind, you can trust TD Finishing to fully enhance your business and the services that it has to offer. 

For more information about our powder coating plants, visit our website today. Or, you can call 0121 520 8884 and speak to a member of our helpful and friendly team. We will always go the extra mile to find you the perfect solution. If you have found this blog helpful, you may wish to read our previous blog on What is Powder Coating?