The World Leader In Powder Coating Systems

3y ago
30 Views
2 Downloads
854.87 KB
10 Pages
Last View : 22d ago
Last Download : 2m ago
Upload by : Samir Mcswain
Transcription

The World Leader inPowder Coating SystemsThe What, Why & How of Powder CoatingA practical approach to powder coating justification

The What, Why and How of Powder CoatingA Practical Approach to Powder Coating JustificationWhat is powder coating, whyshould I consider using it, and howwill it work in my operation arequestions that every finisherneeds to be asking today. Briefly,these questions can be answeredas follows: 1) powder is a dry,clean finish that gives a highlydurable coating, 2) in the long run,powder will save you money, and3) a powder coating system canbe designed to meetjust about anyrequirement youroperation may have.The purpose of thisbooklet is to explainquickly and simply howpowder coating deliversthese highly desirablesolutions to manyfinishing problems, andto provide you with aP o w derpractical, worksheetV o ltageapproach, to help youdecide if moving topowder is the right move for you.Over the past decade powdercoating has been increasinglyaccepted as the preferred finishingprocess for the future. Thereasons for this conversion fromwet to dry can be attributed tothree major forces: economy —the high cost of energy andmaterials require a more costeffective and less wastefulprocess; excellence —consumers, and other end users,are demanding higher quality andmore durable finishes; andecology — progressively morestringent regulations are beingaggressively enforced in an effortto control air pollution andhazardous waste disposal. Whichin turn goes back to economy.The cost of complying with theRegulations and the disposal oftoxic and flammable waste areconstantly rising.IMany companies have found thatit is less expensive to convert topowder than to bring their wetsystems into compliance!With strong financial argumentsproviding the necessary stimulus,therefore, powder coatingtechnology has evolved quickly.The quality and variety ofpowders available have grown asWhat is Powder Coating?Powder is a dry coating. Insteadof being dissolved or suspendedin a liquid medium, such assolvent or water, powder isapplied in a granular form. Thismaterial is finer than groundpepper but coarser than flour,and is applied directly to thesurface to be coated.The powder is createdby blending thevarious components(binders, resins,pigments, fillers andadditives) andprocessing themthrough an extruderinto a continuousmass. This homogenous mass iscooled and brokeninto small chips, whichare then ground intothe powder. Each powderparticle contains within it thenecessary components forreforming into the finishedcoating. After the powder isapplied to the part, typically usingan electrostatic spray process,the part passes through an ovenand cures, melting into a smoothfilm on the surface of the part.ChargedParticlesM axim u m voltage atthe tip o f the electro d eApplicatorE lectros tatic W r apan increasing number ofcompanies get involved with itsproduction; and the technologyfor spraying the powder,collecting it and reusing it, isconstantly improving transferefficiencies and materialutilization, and reducing colorchange times. Early perceptionsthat powder was too difficult tocontrol, too costly to install, tootime consuming for color change,or did not provide enough choiceof color are largely obsoletetoday.But the move to a totally newtechnology can still be confusing.This brochure is designed tomake your decision easier,providing both explanations andjustifications to help determinethe right solution for you. So let'sstart at the beginning and workthrough the questions.Powder FormulationThere are two distinct types ofpowder, Thermoset andThermoplastic. The Thermosetpowders are reactive, whichmeans that under cure conditionsthere is a chemical "crosslinking",so that, once cured, the coatingwill not remelt. Epoxies, acrylicsand most hybrids are examplesof Thermoset powders, makingup over 90% of the currentpowder market.Page 1

Thermoplastic powders do not"crosslink" when cured, but simplymelt and flow over the surface ofthe part. The film hardens oncooling, but if it is reheated it willremelt. Vinyls, nylons andfluorocarbons are examples ofthermoplastic powders.Enamel powder is a specializedformulation used in applicationsthat previously used liquidporcelain enamel. It utilizes glassin its formulation and is cured, orfired, at a very high heat. Theresult is a finish that is particularlyresistant to heat, scratching andharsh chemicals, and is typicallyused in appliances, such aswashers, dryers, ovens andranges.How is the Powder Applied?The application process involvesapplying a charge to the drypowder particles and sprayingthem onto a grounded substrate.The substrate, or part, is typicallygrounded through the conveyor orhanger holding the part. Thepowder, once attracted to thepart, is then held on the surfaceuntil it is melted and cured into asmooth coating film in the bakeoven. The spray process takesplace inside a booth designed tocontain the oversprayed powderand makes it possible tocollect the overspray andultimately reclaim it forreuse.the powder to "wrap" around thepiece, coating the back side.The oversprayed powder,suspended in the air containedinside the powder booth, is thenpassed through a separationprocess that permits the powderparticles to be retrieved from theair. The clean air is fed back tothe work environment, eliminatingthe need for air make-up. Thereclaimed powder is mixed with aproportionate amount of fresh,virgin powder for reuse achievingconsistent results and up to 98%material utilization.How Will Powder CoatingBenefit My Operation?Reviewing the potential benefitsof powder coating will give you anincentive to proceed with thequest for the best finish for youroperation. So let's look at thethree "E's" of powder coating inmore detail.Economy1. Material utilization is muchhigher with powder, making yourmaterial costs much lower. 92%to 98% of your powder may beapplied to the parts you arefinishing versus an average of60% with an electrostatic liquidsystem (the other 40% is wasteand must be disposed of!)2. Since most of the material isused on the part, there is verylittle waste. And powder is notconsidered hazardous waste, sothe cost of disposal is minimalcompared to the high cost of toxicwaste disposal.3. Air used to exhaust thepowder spray booth is returneddirectly to the plant, eliminatingheating and cooling costs for themake-up air required when air isvented outside the plant.4. Air loss from the curing oven isminimized as there is only a verysmall amount of volatile substance that must be exhausted.The cost of maintaining oventemperatures is thereforeminimized also.5. Powder is simpler to spray, soless skilled labor is needed,training is easily done and lesserrors are made in coating. All ofwhich saves scrap, labor and,ultimately, operating costs.6. Most powders require noprimer, providing more savings intime and materials.The powder is fedpneumatically out of thepowder container orhopper, into the powderapplicator, or gun. As thepowder exits the gun, a lowamperage, high voltagecharge is applied to thepowder particles, causingthem to be attracted to thegrounded work piece. Thisattraction may even causePage 2I

Excellence1. The cured powder finish is lesssusceptible to damage than aliquid finish. There is less needfor repair work on the finisheditem, and packaging is lesselaborate, saving time and coston rework and packaging.2. Epoxy, acrylic and hybridpowders provide excellentadhesion and hardness forimproved resistance to chipping,abrasion, corrosion, andchemicals; and it's flexible enoughto be formed without cracking.Application Equipment3. Polyester powders provideadditional advantages inultraviolet and weatheringresistance.EcologyPowder is the overwhelmingpreference of the EPA,eliminating:1. Solvent fumes and VOCs fromspray booth and oven exhauststhat pollute the air.2. Potentially toxic sludge andwater that can contaminate theearth and must be disposed of ashazardous waste.How Will a Powder SystemWork in My Operation?Powder systems are available inall degrees of technicalsophistication, and can bedesigned to meet a wide range ofrequirements for performance,cost and space constraints.From a basic manual, one gunoperation with a batch booth, to ahighly complex multi gun, totallyautomated configuration, thereare guns, booths and otherperipherals for all occasions.IThe guns are all essentiallysimilar in their function ofspraying the powder. Each gunhas a control unit that regulatesthe voltage being generated andthe rate at which the powder isdelivered from the hopper. Areasto review when selecting theapplication equipment are theefficiency of the charge, theconsistency of the powder flow,and the accuracy with which bothcan be adjusted to provide theright level of performance. Oncethe optimal settings have beenestablished, it is important thatthey can be repeated systematically each time they are used.be considered when making theselection.Booths and RecoveryTherefore, prior to starting yoursearch for the perfect powdersystem, you should have a clearpicture of what you need andwhat factors are important to youroperation. If you expect tochange powders frequently, thena fast color change time will behigh on the list of necessaryfeatures; if, however, you do longruns using the same powderthroughout, then a highly efficientreclaim system will be morecritical. If the parts are all thesame then automatic guns maybe cost effective, but if they areintricate structures that aredifficult to coat, manual operatorsmay make more sense.Powder booths are also basicallysimilar, but use two distinct typesof recovery equipment, cartridgefilters or a cyclone separator.Each style is particularly suitablefor a different type of application.To select the appropriate systemyou should consider theproduction batch size, thenumber of colors or differenttypes of powder being used, andthe frequency with which they arechanged. The finished quality ofthe desired coating should alsoNow that we have covered thebasics you should have a betteridea of what powder is all about.On the following pages are somework sheets that will show youjust how powder can deliversavings to your operating costs.After working through them, youmay be surprised at how quickly apowder system may pay foritself — and it will keep you incompliance, no matter how muchmore stringent the regulationsbecome!Page 3

A Glossary of Common Powder Coating TermsBack Ionization: An excessivebuild up of charged powderparticles which may limit furtherpowder being deposited on thesubstrate. The electrical chargeon the surface layer may bereversed, repelling additionalpowder.Bulk Density: Mass per unit ofvolume in powder form includingthe air trapped between particles.Cartridge Filter: A cylindricalfilter unit used to separateoversprayed powder from air forrecovery and reuse.Corona Charge: The process ofinducing a static electric charge onpowder particles by passing thepowder through an electrostaticfield generated by a high voltagedevice.Faraday Cage Effect: Acondition that may exist on asubstrate due to its geometricconfiguration that may inhibit theelectrostatic deposition of powderparticles at a specific localizedarea.Film Formation: The forming ofa continuous film by meltingpowder particles and fusing themtogether by the application ofenergy.Fluidizing: The process ofsuspending the powder in acontinuous stream of air giving it"fluid" characteristics. Used tofacilitate transfer of the powderto the application device.Fusion: The melting and flow ofindividual powder particles whenheated to form a continuous film.Cure Schedule: The time/temperature relationship requiredto properly fuse a powder coating.Grounding: The electricalgrounding of the item to becoated.Cyclone: A type of recovery unitusing a centrifugal process toseparate oversprayed powderparticles from an air flow.Impact Fusion: The combiningof powder particles to form asolid mass during the deliveryand application process.Delivery: The process of movingthe powder through theapplication equipment to the endproduct.Lower Explosive Limit (LEL):The lower point for a range ofconcentrations of organicparticles suspended in air whichcan be ignited by a sufficientenergy source.Edge Coverage: A powder'sability to flow over, build andadhere to sharp corners, anglesand edges.Electrostatic Spray Technique:A deposition method of sprayingand charging powder so that it isdeposited on a groundedsubstrate. (See Corona chargingand Tribo charging.)Page 4Micron/Mils: Common unit ofmeasurement of coatingthickness. 25.4µ (microns ormicrometers) 1 mil (onethousandth of an inch)Particle Size: Average diameterof an individual, irregular powderparticle.Recovery: The process ofremoving non-deposited powderfrom the air prior to reclaiming itfor reuse.Spray Booth: A speciallydesigned enclosure in whichpowders are introduced,contained and recovered duringthe coating process.Surface Appearance: Generallyrefers to the smoothness andgloss of powder coating films andthe presence and degree ofsurface defects.System Utilization or SystemEfficiency: The combinedefficiencies of each component inthe powder coating systemresulting in total material usagecompared to the amount ofmaterial entered into the system.Transfer Efficiency: The ratioof the powder deposited on theworkpiece compared to theamount of powder sprayedduring a fixed time period.Tribo Charging: Process ofcreating a static electrical chargeon powder particles by creatingfriction between them and anonconductive material.Virgin Powder: Powder that hasnot been previously sprayed asopposed to reclaimed powder.Wrap: A characteristic ofelectrostatic application for thepowder to seek out and adhereto parts of the substrate not indirect line of sight of the deliverypoint.I

Finishing Line ComponentsComponentsLiquid PaintPowder3-5 Stage3-5 StageIron/Zinc PhosphateIron/Zinc PhosphateChromic or PhosphoricCompoundChromic or PhosphoricCompoundDry-off OvenYesYes-may be combined withBake OvenCool-offYesYes2 Automatic1 Manual1 Automatic1 Manual (or Combination)YesNo20 mins/300oF15 mins/360oFYesNo560 ft.375 ft.Air Make-Up RequiredYesNoPaint Mix RoomYesNoMinimum Once/DayMinimum Once/Day10 mins.2 mins.Major Cleaning(Except Color Change)Minimum Once/WeekMinimum Once/WeekAverage Cleaning Time(Except Color Change)2 Hours1 HourPower Spray WasherSubstrate CoatingPassivatingSpray BoothsFlash-off TunnelAverage Bake Oven Time/TemperatureSolvent ExhaustConveyorPaint Circulating orRoutine MaintenanceAverage Maintenance Time/GunFilm Thickness1111Imilmilmilmil 0.001 inches0.0025 cm0.025 mm25.4 microns1111micronmicronmicronmicron 0.0000394 inches0.0394 mils0.0001 cm0.001 mmPage 5

Typical Material Cost ComparisonLow Solids PaintHigh Solids PaintCost: 12.00 per gal (mixed)Solids Content: 35% (mixed)Efficiency: 50% (E.S. Air Spray)Coverage per mil thickness:.50x.35x1,600* 280 sq.ft./galCost: 17.00 per gal. (mixed)Solids Content: 55% (mixed)Efficiency: 80% (Hi Speed Bell)Coverage per mil thickness:.80x.55x1,600* 704 sq.ft./galApplied cost per mil thickness: 12.00 0.0428 per sq.ft.280Applied cost per mil thickness 17.00 0.024 per sq.ft.704PowderCost 3.00 per lb.Specific Gravity: 1.4Volume Solids: .99%Utilization: 98%Coverage per mil thickness:.98x193**x.99 134 sq.ft. per lb.SG 1.4Applied cost per mil thickness: 3.00 0.0223 per sq.ft.134* 1,600 sq.ft. per gallon of paint @ 1 mil thickness with 100% efficiency and 100% solids is industry standard.** 193 sq.ft. per pound of powder @ 1 mil thickness with 100% efficiency and 100% solids is industry standard.Clean-Up and Waste Disposal Comparative WorksheetVariablesPaintPowder52 per year (typical)12 per year (typical)2 (minimum)2 (typical)C. Hourly rate plus fringe D. Hours required8 hours (typical)2 hours (typical)52x2x x8 /yr.12x2x x2 /yr. /bblNot applicableG. Waste volume per year bbl per yearNot applicableH. Disposal cost per year:FxG /yrx /yrNot applicable A. Clean-up frequencyB. Number of operatorsE. Clean-up cost per year:AxBxCxE /yr.F. Disposal costTotal Clean-up and WasteDisposal Costs per Year:E H Page 6I

Alternate Material Cost WorksheetMaterial cost is usually the largest single operating cost of any production finishing operation. This worksheetis designed to compare applied material costs. Applied cost is a function of the cost and solids content of thecoating material as it is actually applied, material utilization efficiency (recognizing that liquid paint oversprayis lost forever), and the thickness of the applied coating.Waterborne PaintSolvent PaintPowder /gallon /gallon /pound%%98%Not applicableNot applicableD. Additive (solvent or water) cost /gallon /gallonNot applicableE. Percent of additive (solvent orwater) per gallon of mixedpaint*%%Not applicable /gallon /gallonNot applicable%%%milsmilsmils%%%(1600xGxI)/H or1600xGxIH mils(1600xGxI)/H or1600xGxIH mils(193xBxI)/(CxH) or193xBxI(CxH) milsA. Coating costB. Percent volume solids (asreceived)C. Specific GravityF. Cost of usable coating (assprayed) (DxE) [A x(1-E)]G. Volume solids, usable coatingB(1-E)H. Dry film thicknessI. System utilization efficiencyJ. Coverage, sq.ft./gallon1600xxmils sq.ft./gal1600xxmils193xxmilsx sq.ft./gal sq.ft./lb.K. Applied cost, /sq.ft.(F/J) or/(F/J) or/(A/J) or/ / sq.ft. / sq.ft. / sq.ft.* Suppliers recommended reduction ratio P:SWhere P gallons of fully body paint andS gallons of solventIPage 7

ApplianceAir conditioners & water heatersBBQ grillsClothes washer tops & lidsDishwasher doors & racksDryer DrumsFloor cleanersFreezer liners, racks & cabinetsMicrowave ovensMixers & blendersRange hoods & panelsRefrigerator liners, shelves &casesSewing machinesAutomotiveAir conditioner componentsBattery trays & bracketsBrake disk padsCoil springs & seat framesDoor handles & cranksGlove compartment latchesInterior panelsLight truck bodiesMirror brackets & roof racksOil & air filter housingsShock absorbers & hatchbackliftersStarter & wiper motorsSteering wheels & gearsSport car louvresValve covers & fansVoltage regulator housingsWheel opening & fender moldingWheels & bumpersPage 8Building & ArchitecturalAluminum extrusionsConcrete reinforcement barsExterior building panelsHighway guard rails, poles &signsInterior partitions & shelvingOrnamental facades & railingsPrefab storage building panelsPosts, rails & fencingWindow & door screeningElectricalElectrical control housings &panelsElectrical stators & coilsElectronic cabinetsFluorescent light fixturesIgnition boxes & timersOutdoor lighting fixturesPad & pole transformersRecorders & control instrumentsSatellite dishesSwitch gears & bus barsTelephone coin boxes &apparatusTV antennasFurnitureFiling cabinetsHospital bedsLockers & benchesMetal office partitionsOffice chair basesPatio & wrought iron furnitureStore, library & warehouseshelvingTubular furnitureFabricated Metal &Miscellaneous ProductsBicycle frames & partsDoor & safe hardwareFlexible gas connectorsGym & playground equipmentHand toolsLuggage framesMetal CansMetal stamping & die cast partsOil & gas transmission pipesPlumbing & marine hardwareMail boxes & letter sortersSki poles & equipmentSwimming pool accessoriesTennis racquet framesToys & recreational equipmentFarm, Garden &Industrial MachineryCommercial Ice MakersConveyor partFarm implementsFeed storage silo componentsGarden sprayersGarden tractors & mowersIrrigation sprinklers & pipesystemsLawn spreaders & seedersLivestock gates & waterersOffice machines & computercabinetsPower saws & toolsPumps, blowers & exhaust fansSolar heating panels & equipmentTextile & printing machineryWaste treatment equipmentI

Electrostatic Spray Technique: A deposition method of spraying and charging powder so that it is deposited on a grounded substrate. (See Corona charging and Tribo charging.) A Glossary of Common Powder Coating Terms Faraday Cage Effect: A . Powder .

Related Documents:

May 02, 2018 · D. Program Evaluation ͟The organization has provided a description of the framework for how each program will be evaluated. The framework should include all the elements below: ͟The evaluation methods are cost-effective for the organization ͟Quantitative and qualitative data is being collected (at Basics tier, data collection must have begun)

Silat is a combative art of self-defense and survival rooted from Matay archipelago. It was traced at thé early of Langkasuka Kingdom (2nd century CE) till thé reign of Melaka (Malaysia) Sultanate era (13th century). Silat has now evolved to become part of social culture and tradition with thé appearance of a fine physical and spiritual .

On an exceptional basis, Member States may request UNESCO to provide thé candidates with access to thé platform so they can complète thé form by themselves. Thèse requests must be addressed to esd rize unesco. or by 15 A ril 2021 UNESCO will provide thé nomineewith accessto thé platform via their émail address.

̶The leading indicator of employee engagement is based on the quality of the relationship between employee and supervisor Empower your managers! ̶Help them understand the impact on the organization ̶Share important changes, plan options, tasks, and deadlines ̶Provide key messages and talking points ̶Prepare them to answer employee questions

Dr. Sunita Bharatwal** Dr. Pawan Garga*** Abstract Customer satisfaction is derived from thè functionalities and values, a product or Service can provide. The current study aims to segregate thè dimensions of ordine Service quality and gather insights on its impact on web shopping. The trends of purchases have

Chính Văn.- Còn đức Thế tôn thì tuệ giác cực kỳ trong sạch 8: hiện hành bất nhị 9, đạt đến vô tướng 10, đứng vào chỗ đứng của các đức Thế tôn 11, thể hiện tính bình đẳng của các Ngài, đến chỗ không còn chướng ngại 12, giáo pháp không thể khuynh đảo, tâm thức không bị cản trở, cái được

MARCH 1973/FIFTY CENTS o 1 u ar CC,, tonics INCLUDING Electronics World UNDERSTANDING NEW FM TUNER SPECS CRYSTALS FOR CB BUILD: 1;: .Á Low Cóst Digital Clock ','Thé Light.Probé *Stage Lighting for thé Amateur s. Po ROCK\ MUSIC AND NOISE POLLUTION HOW WE HEAR THE WAY WE DO TEST REPORTS: - Dynacó FM -51 . ti Whárfedale W60E Speaker System' .

Le genou de Lucy. Odile Jacob. 1999. Coppens Y. Pré-textes. L’homme préhistorique en morceaux. Eds Odile Jacob. 2011. Costentin J., Delaveau P. Café, thé, chocolat, les bons effets sur le cerveau et pour le corps. Editions Odile Jacob. 2010. Crawford M., Marsh D. The driving force : food in human evolution and the future.