Powder coatings have become a popular finishing option for many manufacturers thanks to their durability, versatility, and eco-friendliness. However, to achieve the best results with powder coatings, organizations, whether an original equipment manufacturer (OEM) or third-party technical coatings partner, must learn the ins and outs of the process, from choosing the proper tooling to programming the automated system. In this article, we will discuss some of the key things that manufacturers and technical coatings providers, like Advanced Coatings Inc. (ACI), need to know about powder coatings when launching a brand-new powder coating operation.

Choosing the Right Tooling

One of the challenges that many manufacturers face when starting with powder coatings is choosing the right tooling. Unlike liquid coatings, powder coatings require special equipment that can handle the unique properties of the powder material. This includes spray guns, curing ovens, and racks.

For new businesses that are still figuring out their coating needs, it is important to work with a supplier who understands the nuances of powder coatings and can recommend the best equipment for a specific application.

Flexible tooling can be a good starting point, allowing the ability to experiment with different coatings and part sizes, without committing to a specific setup. However, as a business grows, it may need to invest in specialized tooling that can handle higher volumes or more complex parts.

Learning the Ins and Outs of Powder Coating

Once you have the right equipment, the next step is to learn how to use it effectively. Powder coatings involve several steps, including surface preparation, powder application, curing, and post-curing touch-ups. Each of these steps requires attention to detail and a deep understanding of the properties of the powder material.

For example, applying the powder too thick or too thin can result in uneven coverage or surface defects. Similarly, curing the powder at the wrong temperature or for too long or too short can affect the adhesion and durability of the coating.

To avoid such issues, it is important to train your operators and quality control personnel on the best practices for powder coating. This may involve developing standard operating procedures (SOPs) for each process step and providing ongoing training and support to ensure consistent results.

Programming the Automated System

For high-volume applications, an automated powder coating system can improve efficiency and consistency while reducing labor costs. However, programming the system can be challenging, especially for complex parts or surfaces. System programming involves not only determining the optimal settings for powder application and curing but also knowing when to use touch-up personnel or manual post-touch-up.

To address this, it is important to work with an experienced automation supplier who can help you design and optimize your system for your specific needs. This may involve developing custom software or integrating existing software with your system to achieve the desired results.

Ensuring Consistent Quality

Consistent quality is critical for any manufacturing process, and the powder coating process is no exception. Since ACI deployed its powder coat line, business has maintained high-quality standards with very few rejections over the past year.

To achieve consistent quality, it is important to have a robust quality control system in place. This may include regular inspections of the finished parts, testing for adhesion, hardness, and other properties, and monitoring the process variables to identify trends or deviations.

One tool that can help with quality control is statistical process control (SPC), which involves tracking and analyzing process data over time to identify patterns or anomalies. By monitoring key process variables such as powder flow rate, cure temperature, and film thickness, SPC can help identify and correct any issues before they result in quality problems.

Another important aspect of ensuring consistent quality is choosing the right powder coating materials. Different powders may have different properties, such as color stability, gloss retention, or chemical resistance. By selecting powders appropriate for a specific application and performance requirements, the durability and appearance of finished parts can be improved.

Finally, it is important to have a feedback loop in place to continuously improve processes and address any quality issues. This may involve collecting customer feedback, analyzing rejected parts to identify root causes, and making process improvements based on the data.

By focusing on consistent quality, customer satisfaction can be improved, waste reduced, and a reputation as a reliable supplier of high-quality powder coated parts can be achieved.

Expanding into New Markets

Expanding into new markets can be a significant growth opportunity for any business, and the powder coating market is no exception. To successfully enter new markets with multi-national OEMs, it is important to understand the specific needs and requirements of those customers. This may involve conducting market research, attending trade shows or industry events, and building relationships with key stakeholders in the target market. In some cases, it may require individual approvals by each of those OEMs to then provide coatings for their equipment and parts.

Another important consideration when expanding into new markets is ensuring that the powder coating process can meet the unique demands of those customers. This may involve developing new coatings or processes that can withstand harsh environments, resist corrosion or wear, and meet other performance requirements.

In addition to developing new coatings or processes, expanding into new markets may also require investments in new equipment or facilities. For example, ACI is considering an investment to expand its line to have a powder primer booth and gel oven added to the powder process to meet the needs of our target customers.

Finally, it is important to have a clear strategy for growth and expansion. This may involve setting specific goals or targets for sales growth, developing marketing campaigns to reach new customers, and building partnerships or alliances with other businesses in the target market.

By successfully expanding into new markets, powder coating businesses can unlock significant growth potential and increase their customer base and revenue streams. However, this requires careful planning, research, and execution to ensure the business is well-positioned to succeed in these new markets.