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.

C&O Powder Coatings Partner With TD Finishing Again

Formed in 1985, C&O Powder Coatings are approaching their fourth decade as one of the UK’s premium powder coaters. Many things have changed since 1985 but the continual drive for improvement has remained as important as ever for C&O. This is evident with their ISO9001 accreditation and various architectural powder approvals.

C&O have always invested in the latest technology and processing equipment. For instance, 2021 has seen the installation of a new powder coating cure oven, overhead conveyor, and automatic booth at their facility in St Helens. The new line replaces two older powder coating systems and compliments the TD Finishing facility that was installed in 2017.

 

The Benefits Of Investing In A New Plant

Tom Holmes, Managing Director, explains the reason for investing in the new powder coating plant and the benefits it has brought to C&O:

Continuous improvement is a philosophy that runs throughout C&O in every department. This is what has ensured our continued success over the decades and has gained us an enviable reputation within our market for quality, service and professionalism. 2020 brought uncertainty for a lot of businesses. However, we decided to press ahead with our expansion plans with the introduction of a new coating and curing line to run alongside our existing TD Finishing plant.

 

Following an extensive study of our existing processes, we took the decision to replace our two older lines with a faster and more efficient system that could process the throughput of both lines and take the excess work from our main coating line. It became apparent very quickly that this was the correct decision. We saw increased throughput and improved quality straightaway. We have also been able to streamline our shift patterns and offer even faster turnaround to our customers.  Reductions in gas usage and powder waste have also been a big benefit that go hand-in-hand with our ongoing sustainability goals.

 

This is the second project that has seen us partner with TD Finishing in recent years. Our first oven replacement in 2017 was a great success and we found that their working practices, product quality and customer support matched how we go about our business, so when we started to look at the new project, TD was our first call. This also proved to be the correct decision as the project has been a great success.”

Powder Coating Plant Manufacturers | TD Finishing

 

To find out more about C&O visit candocoatings.co.uk

TD Finishing Powder Coating Plant Manufacturers, have been designing and manufacturing complete powder coating systems since 2002. Please visit tdfinishing.co.uk to find out more.

how much does a powder coating system cost

How Much Does A Powder Coating System Cost?

How much does a powder coating system cost? Is setting up powder coating expensive? What is the average price of a powder coating plant? What is a powder coating machine? All of these questions are incredibly popular – but difficult to answer. Powder coating equipment for sale has varying prices. At TD Finishing, we are leading powder coating equipment manufacturers. With this in mind, we offer high specification powder coating systems for sale; but at competitive prices. Prices depend on three factors:

  • Business size
  • Customer requirements
  • Production volumes

 

Pricing Up A Powder Coating System

Finding out how much a powder coating system can cost is not a simple task. However, here at TD Finishing, we will talk you through all of the most suitable options. We will equip you with everything you need to know. Then, together we can make a decision on what system will be best for your business. If you are a small start-up business you are probably looking for a budget batch-system. You can purchase these for as little as £40,000-£50,000. For a large scale business, you will be looking at around £400,000 to in excess of £600,000+. A higher continuous-production can put the cost of a facility into millions of pounds.

 

What Is Required For A Powder Coating Plant?

At the very least, you will need a powder booth, curing oven and powder coating equipment. As well as this, you will also need a form of surface preparation. Before the powder application, components can be shot-blasted, wiped clean or have a full on-line spray pre-treatment regime. It is important to invest in surface preparation too. As a result, you will have better paint adhesion.

 

Batch Production

A basic batch production system usually involves a manual clean down procedure, a powder booth with spray gun and a box oven. Sometimes a box oven is the only solution you can use for powder during. However, this depends on your product variability. This can be enhanced with a simple manual conveyor. Alternatively, you can use a more advanced cassette batch-conveyor system. A manual batch conveyor helps with reducing manual-handling, powder knock-off and space requirements. Moreover, batch production has the benefits of being small, low cost and flexible.  

 

Continuous Production

A powered conveyorised system offers many advantages over a batch system. Firstly, and most importantly, being the continuous and consistent finishing of high-volume manufactured products. Secondly, the lack of manual intervention prevents mechanical damage from handling, as well as vastly reducing rejection rates. 

The continuous conveyor reduces manual handling to loading and unloading only. A suitable powder booth means human operators, reciprocators or a mix of both can ensure full, consistent powder coverage. Whilst a curing oven, specifically designed for powder coating, ensure a full even and consistent cure across all products.

A continuous production system will typically be made up of a 3 to 5 stage pre-treatment. A drying oven, a powder booth, a curing oven and conveyor system. The pre-treatment greatly depends on the client’s requirements. It is also often as high as 9 or 10 stages. Where floor space may be limited, or a particularly hazardous chemical treatment is required, a separate dip pre-treatment plant and powder coating facility will be supplied.  

 

What Can TD Finishing Provide Your Business?

Since 2002, TD Finishing supply only the highest quality and specification equipment from start-ups to multinationals. However, regardless of your needs, all our systems are customised. 

 

Capacity

Based on your capacity requirements, be it one box oven cure per day or a 5,000mm/min conveyor system. TD Finishing have the solutions to suit. We design them around your factory layout, workflow, floor space and finishing specifications.

 

Experience

Our team of engineers have over 80 years of combined experience in the design and supply of finishing plant equipment. As a result, they have provided solutions for countless valued clients. So whether you’re in the market for a powder coating gun or an entire powder coating system, our team can help. 

 

Customer Care

Our clients return time and again for new plant, replacement of old equipment, upgrades, spares and maintenance contracts.  

 

Proven Track Record

TD Finishing has installed countless facilities around the UK, and have exported across the world. So, if you are interested in a powder coating line, or looking to upgrade or expand your existing facility, then get in touch today. Alternatively, you can head to our website for more information.

If you would like to talk about how much a powder coating system will cost you, call us on 0121 520 8884. Alternatively, email info@tdfinishing.co.uk andrew@tdfinishing.co.uk.

If you have found this blog helpful, you may wish to read our previous blog on Dip Pretreatment Plants.

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