A Introduction To The Powder Coating Process For The .
The World Leader inPowder Coating SystemsThe What, Why & How of Powder CoatingA Introduction to the Powder Coating Processfor the Medium Density Fiberboard Industry
Powder Coating of MediumDensity FiberboardThe use of powder coatings asa finish for wood substrateshas been a topic of discussionfor several years, but only recently have powder materialsbeen available to the marketplace. New breakthroughs inpowder chemistries have led tothe emergence of a new finishing option for manufacturers ofMedium Density Fiberboard(MDF) products.operational costs, and environmental friendliness.or awkward handling is required.Designs Without Limits: Until now users have had twochoices: design around thelimitations of laminates or paythe price for liquid paint coatings.Over the past decade, powdercoating has been increasinglyaccepted as the preferred finishing process for the metalfinishing industry. Based onthe technology available today,powder coatings appear to bethe coating material of the future for the wood industry.The reasons for this conversioncan be attributed to three major forces:One Step Finishing Process:Gone are the days of sanding,priming and sealing for paint–and the gluing and edge band-Specifically, manufacturers ofproducts using MDF canapply a“laminatelike” finishto complexwoodshapes.Productsthat are traditionallycoated withvinyl, melamine, paperlaminates,or other organic finishing processmay findpowder coatings as anPowder Coating of a MDF Cabinet Doorattractivealternative. When used withing of laminates. Additionally,MDF, powder coatings providevolatile solvents traditionallya seamless finish to curvilinearrequired by both are elimishapes, rounded or ogee edges,nated.concave and convex surfaces,cabinet doors, drawers, andSimple to Handle, Verticalmultiple sides simultaneously.Orientation: Just hang thework from an overhead conPowder coating advantagesveyor, then coat all sides of thetranslate into several benefitspiece at once. No drying timeregarding coating performance,Economy - the high cost ofenergy, labor and materialsrequire a more cost-effectiveand less wasteful process.Excellence – consumers,and other end-users, are demanding newer designs andappearances, higher qualityand durable finishes.Ecology – progressivelymore stringent regulationsare being aggressively enforced in an effort to controlair pollution and hazardouswaste disposal. This in turngoes back to economy.But the move to a to totallynew technology can still beconfusing. This brochure isdesigned to make your evaluation easier, providing both explanations and justification tohelp determine the right solution for you. So let’s start atthe beginning to work throughthe questions.
Resins Plus Pigments and AdditivesPowder Coatingthe part, using an electrostaticspray process, the part passesthrough an oven, melting thecoating into a smooth film onthe surface of the part.“Powder coating” is a one stepfinishing process. The powderis a dry coating and, instead ofbeing dissolved or suspended ina liquid medium, such as solPowder Formulationvent or water, is applied in agranular form. The material isfiner than ground pepper butThere are two distinct types ofcoarser than flour, and applied powder, thermoset and thermodirectly to the surface beingplastic. The thermoset powderscoated. Powder is purchased in are reacted, which means thatthe ready-to-use form, but isin the curing process there is amanufactured to meet yourmolecular change. This changespecifications. Blending various is the result of a chemicalcomponents(binders, resigns,pigments, fillers andadditives) and putting them through aprocess that incorporates extruding,grinding, and a pulverizing processpowder coatings arecreated. Upon beingextruded, this homogeneous mass iscooled and brokeninto small chips,Example of the Electrostatic Processwhich are then pulverized into thesmaller powder particles. Each “cross linking”, so that, oncecured, the coating will not reparticle contains within it thenecessary components to allow melt. Epoxies, acrylics andforming of the finished coating. most hybrids are examples ofthermal set powders, making upAfter the powder is applied toover 90 percent of the currentpowders used in the metal finishing market. Thermoplasticpowders do not “cross link”when cured but simply meltand flow over the surface of thepart. The film hardens on cooling, but if it is reheated, it willre-melt. Vinyl, nylon andfluorocarbon are examples ofthermoplastic powders. However, for the engineered woodindustry, thermoset powdersare used to obtain the desiredperformance characteristics.Application To WoodA product is cut to the desiredshape from a sheet of MDF.This process may include routing or profiling the surfaces andedges. Once the desired shapeis achieved, some board preparation may be required. Thismay include but not limited tolight sanding of the surfacesand edges. In order to ensuredefect free finishes, removal ofany wood fibers by use of compressed air blow-off or a vacuum process isimportant. Oncecleaned the product must be arranged on a fixture (or hanger)that allows fortransportation toand from the ovens and coatingbooth. At thispoint the productis transported toan oven that preheats the productto a predetermined temperature. This baseline temperature specification isprovided by the powder supplierand then adjusted to matchwith your finishing systemequipment performance and
S ta g e 8 – U n lo a dS ta g e 1L o a d /B lo w o ffS ta g e 5T ra v e lS ta g e 3T ra v e lS ta g e 4 - P o w d e rS ta g e 2 – P re h e a tS ta g e 6 – C u reS ta g e 7 – C o o lExample System Layout for Powder Coating of Wood Productsproduction needs. Once theproduct reaches this temperature, it is quickly transported itto the coating booth. Once inthe powder coating booth, thespray guns atomize the powderand electrostatically charge thepowder particles, while directingthem towards the product. Theheat that is “soaked” into thewood is used to assist in building the film thickness requiredfor coating performance. Oncecoated the product is thentransported to a curing oven,where the final heating step isperformed. The powder thathas been applied is now held onthe surface until it is completelymelted and cured into a smoothcontinuous coating. The finalstep is to allow the product tocool down to a temperature thatallows workers to physicallytouch the parts and ready themfor assembly or package themfor shipping.The two most important aspectsof this process are :1) Accurately and uniformlyThe application process involvesheating the wood to the preapplying an electrostatic chargedetermined temperature,to the powder particles as they2) Arrangement and manipulaare sprayed from an applicatortion of the spray guns in or(or spray gun). A typical powderder to achieve the correctcoating system for metal reliesfilm thickness and coverage.on a conductive substrate tocomplete the coating process,however, wood is considered toOperational Benefitsbe non-conductive and thereforeshould not work in this applicaReviewing the potential benefitstion. Nonetheless, engineeredof powder coating will give youwood does have some inherentan incentive to proceed with theconductivity that allows for alimited amount of powder to be quest for the best finish for yourelectrostatically applied to MDF. operation. So let’s look at theFurthermore, to achieve the film three “E’s” of powder coating inmore detail.thickness levels required forcoating performance, heat mustEconomybe added to the wood prior to With powder coatings beingcoating. This “pre-heat” alongapplied in a one step procwith the electrostatic attractioness, the amount of energydeveloped by the spray guns,and labor consumed to proallows the wood to be coatedduce one unit can be lessevenly and uniformly.than traditional liquid finishing and laminating process. Since the powder coat-Electrostatic Spray
ing process uses a vertical orientation on anoverhead line arrangement, productionthroughput can be increase as well. Especiallycompared to vinyl membrane press operations. ring, scratching and abrasion. Specifically for thewood industry powder coatings offer greater designflexibility. Curvilinear design capability allows product designers to develop exciting new shapes and edgeprofiles. With powder coatings, the issue of edges iseliminated and now products can be produced with“Seamless Edges".Material utilization ishigh with powder, potentially bringing your material cost much lower. Asmuch as 98% of the powder you buy will be utilized. Compare this to aconventional liquid system with an material lossof 60—80% or a vinylmembrane press operation with material wasteof 10-40%.EcologyPowder is the overwhelmingpreference by the EPA, dramatically reducing:Since most material is usedon the part, there is littlewaste to be disposed of. Inaddition, powder is not considered hazardous waste, so disposal cost is minimalcompared to toxic waste disposal.Air used to exhaust thepowder spray booth is returned directly to the plant,eliminating heating andcooling cost for the makeupair required when the air isvented outside the plant.Air loss from the curingoven is minimized, as thereis only a very small amountof volatile substance thatmust be exhausted. Thecost of maintaining of oventemperatures is thereforeminimized also.Powder is easier to spray, soless skilled labor is needed,training is easily done andless errors are made in coating. All of which reducesCurvilinear shapes are perfectfor powder coatingsscrap, labor, and ultimately,operating cost.No primer materials are required, providing more savings in time and materials.Excellence The cured powder finish isless susceptible to damagethan other finishes. Thereis less need for repair workon the finished item, andpackaging is less elaborate,saving time and cost on rework and packaging. Powder coatings provide excellent adhesion and hardness for approved resistanceto chipping, abrasion, andchemicals. Solvent fumes and VOCsfrom spray booth and ovenexhausts that pollute theair.One of the many unique advantages of powder coatingsis the toughness of the coating. Many users of powdercoatings have experiencedsuperior resistance to mar- Elimination of potentiallytoxic sludge and water, thatcontaminates the earth. Nohazardous waste to disposeof. The cost of complying withregulations and disposal oftoxic and flammable wasteis constantly rising. Woodmanufacturing companiesare looking for less expensive methods of applicationthat bring their currentplant operations into compliance. With strong financial arguments providingthe necessary stimulus,powder coatings are expected to evolve quickly.System OperationPowder systems are available inall degrees of technical sophistication, and can be designed tomeet a wide range of requirements for performance, costand space constraints. From a
basic manual, one gun operation with a batch booth, to ahighly complex multi-gun, totally automated configuration,there are guns, booths andother peripherals to meet allproduction requirements.The oversprayed powder, suspended in the air contained inside the powder booth, is thenpassed through a separationprocess that permits the powderparticles to be recovered fromthe air. The clean air is fedback to the work environment,Application Equipmenteliminating the need for makeupGuns used for this process are air. The recovered powder isdesigned to generate an electro- mixed with the proportionatestatic charge and apply it to the amount of fresh, virgin powderpowder particles. Eachgun has acontrol unitthat regulates thevoltage being generated and thepowder delivery ratefrom thehopper. Areas to review whenselecting applicationequipmentare the efficiency of theCut away view of a powder recovery boothcharge, theconsistency ofthe powder flow, and the accu- for reuse in the reclaim process.racy with which both can be ad- This process can provide up tojusted to provide the right level 98 percent material utilization.of performance. Applicationuniformity and repeatability are Powder booths are also similar,extremely important to achiev- but use two distinct types of reing success in a powder system. covery equipment, cartridge filTherefore, once the optimal set- ters or a cyclone separator.tings have been established it is Each style is particularly suitable for a different type of appliimportant that they can be repeated systematically each time cation. To select the appropriate system you should considerthey are used.the production batch size, thenumber of different types or colBooths and Recoveryors of powder being used andThe spray process takes placeinside a booth designed to con- the frequency they are changed.The finished quality of thetain the oversprayed powderand makes it possible to recover should also be considered whenthe overspray and ultimately re- making the recovery selection.claim for reuse.Therefore prior to starting yoursearch for the perfect powdersystem, you should have a clearpicture of what you need andwhat factors are important toyour operation. If you expect tochange powders frequently,then a fast color change timewill be hot on the list of necessary features. If, however, youdo long runs using the samepowder throughout, then ahighly efficient recovery systemwill be morecritical. Ifthe partsare all thesame, thenautomaticguns may becosteffective, butif they areintricatestructuresthat are toodifficult tocoat, then acombinationof automaticand manualspray gunsmay makemore sense.Now that we have covered thebasics you should have a betteridea what powder is all about.The following pages containmore information that will illustrate the advantages and savings produced by powder coatings. Upon review of this information you will be pleased athow quickly a powder systemwill pay for itself and add valueto your products.
A Glossary of Common Powder Coating TermsBack Ionization: An excessivebuild up of charged powder particles which may limit furtherpowder being deposited on thesubstrate. The electrical chargeapplied to the surface layermaybe reversed, repelling additional powderCartridge Filter: A cylindricalfilter unit used to separate oversprayed powder from air for recovery and reuse.Corona Charge: The process ofincluding a static electric chargeon powder particles by passingthe powder through an electrostatic field generated by a highvoltage device.Faraday Cage Effect: A condition that may exist on a substrate due to its geometric configuration that may inhibit theelectrostatic deposition of powder particles at a specific localized area.Out gassing: Blistering of thecoating during the curing process; caused by heat forcingvolatiles through the coating.Particle Size: Average diameterof individual, irregular powderparticle.Film Formation: The forming ofa continuous film by meltingRecovery: The process of repowder particles and fusingmoving non-deposited powderthem together by the applicafrom the air before reclaiming ittion of energy.for reuse.Fluidizing: The process of suspending the powder in a continuous stream of air giving it“fluid-like” characteristics.Used to facilitate transfer of thepowder to the spray applicationdevice.Cure Schedule: The time/Fusion: The melting and flow oftemperature relationship required to properly fuse a powder individual powder particlescoating.when heated to form a continuous film.Cyclone: A type of recovery unitGrounding: The electricalusing a centrifugal process toseparate oversprayed particlesgrounding of an item to befrom airflow.coated.Delivery: The process of moving Impact Fusion: The combiningthe powder through the applica- of powder particles to form ation equipment to the product.solid mass during the deliveryand application process.Edge Coverage: Ability of aLower Explosive Limit (LEL):powder to flow over, build andadhere to sharp corners, angles The lower point for a range ofand edges.concentrations of organic particles suspended in air which canbe ignited by sufficient energyEdge Cracking: Delaminatingor separating of MDF layers due source.to heat stress from pre-heatMicron/Mills: Common unit ofprocess.measurement of coating thickElectrostatic Spray Techness. 25.4 microns equals onemil (one thousandth of an inch)nique: A deposition method ofspraying and charging powderso that it is deposited on agrounded substrate. See coronachargingSpray Booth: Specially designed enclosure, in which powders are introduced, containedand recovered during the coating process.Surface Appearance: Generallyrefers to the smoothness andgloss of powder coating filmsand the presence and degree ofsurface defects.System Utilization Or SystemEfficiency: The combined efficiencies of each component inthe powder coating system resulting in total material usagecompared to the amount of material entered into the system.Transfer Efficiency: The ratioof the powder deposited on thework piece compared to theamount of powder sprayed during a fixed time.Virgin Powder: Powder that hasnot been previously sprayed asopposed to reclaimed powder.Wrap: Characteristics of electrostatic application for the powderto seek out and adhere to partsof the substrate not in directline of site of the delivery point.
Finishing Line Components ComparisonComponentLiquid PaintPowderSanding of surface and edgesmay be requiredSanding of surface and edgesmay be requiredNo10-20 minutes/350-375 FNon-electrostatic manual andautomatic air spray gunsElectrostatic powder manual orautomatic spray guns2 automatic or 2 manual booths1 automatic or 1 manual or acombination boothFlash-off TunnelYesNoBake Oven Time/Temperature20-30 minutes/250-300 F5-15 minutes/350-375 FSolvent ExhaustYesNoAir Make-Up RequiredYesNoPaint Room MixYesNoPaint Circulating or RoutineMaintenanceMinimum Once/DayMinimum Once/DayAverage Maintenance Time/Gun10 minutes2 minutesMajor Cleaning(Except Color Change)Minimum Once/WeekMinimum Once/WeekAverage Cleaning Time(Except Color Change)2 Hours1 HourBoard PreparationPreheat OvenSpray GunsSpray Booths
Typical Material Cost ComparisonLow Solids PaintHigh Solids PaintPowderCost: 12.00 per gal (mixed)Solids Content: 35% (mixed)Efficiency: 20-40%Coverage per mil thickness:30% x 35% x 1,600 168 sqft/galCost: 17.00 per gal (mixed)Solids Content: 55% (mixed)Efficiency: 20-40%Coverage per mil thickness:30% x 55% x 1,600 264 sqft/galCost: 10.00- 15.00 per poundSpecific Gravity: 1.3Volume Solids: 99%Material Utilization: 98%Coverage per mil thickness:98% x 192.3 x 99% 144 sqft/lb1.3Applied cost per mil thickness: 12.00 0.071 per sq ft168Applied cost per mil thickness: 17.00 0.064 per sq ft264Applied cost per mil thickness: 10.00 0.069 per sq ft1441600 sqft per gallon of paint at 1 mil thickness with 100% efficiency and 100% solids is industry standard192.3 sqft per pound of powder at 1 mil thickness with 100% efficiency, 1.0 specific gravity, and 100% solids isindustry standardClean-Up and Waste Disposal Cost WorksheetVariablesPaintPowderA. Clean-up Frequency50 per year (typical)12 per year (typical)B. Number of Operators2 (minimum)2 (typical)C. Hourly rate plus fringe 8 hours (typical)2 hours (typical)52 x 2 x 8 /yr12 x 2 x 2 /yr /bblNot ApplicableG Waste Volume per yearbbl per yearScrap Powder 2% min.H Disposal cost per year:F x G /yrx /yrNot Applicable D. Hours requiredE. Clean-up cost per year:AxBxCxD /yrF Disposal CostTotal Clean-Up and WasteDisposal Cost per Year:E H
Alternative Material Cost WorksheetMaterial cost is usually the largest single operating cost of any production finishing operation. Thisworksheet is designed to compare applied material cost. Applied cost is a function of the cost andsolids content of the coating material as it is actually applied, material utilization efficiency(recognizing that liquid paint overspray is lost forever), and the thickness of the applied coating.WaterbornePaintSolventPaintPowder /gal /gal /gal%%99%Not applicableNot applicableD. Additive (solvent or water)cost /gal /galNot applicableE. percent of additive (solventor water) per gallon of mixedpaint*%%Not applicable /gal /galNot applicable%%99%milsmilsmils%%%A. Coating costB. Percent volume solids (asreceived)C. Specific gravityF. Cost of usable coating (assprayed)(D x E) [A x (1-E)]G. Volume solids, usable coatingB x (1-E)H. Dry film thicknessI. System utilization efficiencyJ. Coverage, sqft/galK. Applied cost, /sqft*(1600 x G x I) / Hor1600 x G x IH mils(1600 x G x I) / H (192.3 x B x I) / (C x H)oror1600 x G x I192.3 x B x IH mils(C x H) mils1600 x xmils1600 x xmils sqft/gal sqft/gal(F / J) or/(F / J) or/(A / J) or/ /sqft /sqft /sqftSuppliers recommended reduction ratio P:SWhere P Gallons of full body paint and S Gallons of solvent192.3x xx mils sqft/lb
Performance CharacteristicsKitchen Cabinet IndustryPropertyTest MethodResultsShrinkage and Heat Resistance KCMA 9.1E of up to 1.5 unitsNo change in textureHot and Cold Check ResistanceKCMA 9.2No effectChemical ResistanceKCMA 9.3No effect under vinegar, lemon juice,orange juice, catsup, coffee, olive oil,100% proof alcohol, detergent, andmustardCrosshatch AdhesionASTM D33595BHumidity TestASTM D2247-94No change after 2,000 hoursQUVASTM G-53-88No gloss or color change through 1,000hours of exposurePencil HardnessASTM D33632H (scratch)6H (gouge)60 GlossASTM D52310 to 50 unitsNEMA LD3-3.1390 to 120 mg/100 cyclesMEK, 50 double rubsNo effectTaber Abrasion ResistanceSolvent ResistanceFurniture Industry, Office and Ready-To-AssemblePropertyTest MethodResultsBoiling WaterNEMA LD3 3.5No effectHeat AgingMPTMNo effectHoffmanMPTMPass 500-700Cleanability/StainTest MethodResultsCoffeeNema LD3 3.4No effectHousehold DetergentNema LD3 3.4No effectVM&P NaphthaNema LD3 3.4No effectTeaNema LD3 3.4No effectGrape JuiceNema LD3 3.4No effectInk Felt Pen (non perm.,black)Nema LD3 3.4No effectCritic Acid SolutionNema LD3 3.4No effectHousehold Ammonia (nonsudsing)Nema LD3 3.4No effectVegetable Cooking OilNema LD3 3.4No effectMustardNema LD3 3.4No effectCatsupNema LD3 3.4No effectPerformance Data Provided By Morton Powder Coatings for the LAMINEER Powder CoatingsSurface properties of LAMINEER Powder Coatings may vary depending on board quality and process conditions
After the powder is applied to the part, using an electrostatic spray process, the part passes through an oven, melting the coating into a smooth film on the surface of the part. Powder Formulation There are two distinct types of powder, thermoset and thermo-plastic. The
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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. 3 Crawford M., Marsh D. The driving force : food in human evolution and the future.
