Industrial powder coating is a cornerstone of modern manufacturing, offering superior protection, aesthetics, and efficiency for metal parts across countless industries.
Coating Systems, Inc. has over 40 years of experience in the industry. Whether you’re a facility manager, engineer, or just curious, we’ll answer all your questions. Keep reading our guide to learn more.
1. What Is Industrial Powder Coating?
Industrial powder coating is a finishing process for industrial parts. Dry, finely ground particles are electrostatically charged and sprayed onto metal surfaces. Once coated, the parts are baked in a specialized oven, causing the powder to melt, flow, and cure into a tough, uniform layer.
Unlike traditional liquid paint, powder coating contains no solvents, making it an environmentally friendly and highly durable option. If the material can hold an electrostatic charge, then powder coating is the right solution.
As an alternative to spraying, powder coating can also be dipped in a fluidized bed. This allows the powder to coat and bond to the object. While both are effective, one might be better than the other depending on the product. Our experts will help you understand which method is right for you.
2. Why Choose Powder Coating Over Liquid Paint?
Powder coating has a number of advantages over industrial painting. Let’s explore how.
Durability
The cured coating is thicker and more resistant to chipping, scratching, and corrosion. Thermal bonding during the curing process makes the industrial powder coating incredibly tough.
Environmental Safety
Powder coatings emit no volatile organic compounds (VOCs) and are non-flammable, reducing health and fire risk.
Efficiency
Faster production cycles, reduced waste, and lower energy consumption make powder coating a cost-effective option.
Aesthetic Versatility
Available in hundreds of colors and finishes, including matte, gloss, metallic, and textured options.
Immediate Use
Parts are ready for service as soon as they cool, eliminating the need for lengthy drying times.
3. How Does the Powder Coating Process Work?
To achieve the best quality in industrial powder coating, we follow a very specific process. These steps ensure a flawless finish every time.
Cleaning and Surface Preparation
All surfaces must be free of oil, grease, dirt, rust, and old coatings. Methods include chemical washes, sandblasting, hand sanding, or burn-off ovens for stubborn contaminants. Additionally, some parts may undergo chemical treatments (like phosphating or chromate conversion). This helps increase corrosion resistance and adhesion.
Applying the Industrial Powder Coating
Electrostatic spraying is the most commonly used method. It uses a spray gun to apply an electrostatic charge to powder particles. These particles are then attracted to the grounded metal part, forming an even coating.
Fluidized beds are another option. For some parts, especially those with complex shapes, preheated items are dipped into a bed of fluidized powder. The powder then melts and adheres on contact.
Curing
The coated parts are baked in an oven at temperatures typically between 350°F and 450°F. The powder melts, flows, and chemically reacts to form a hard, protective finish.
Inspection and Quality Control
Finished parts are inspected for uniformity, thickness, and adhesion before being shipped or installed. At Coating Systems, we take this step seriously. We complete everything in-house, allowing us to guarantee exceptional quality for our customers.
4. What Types of Industrial Powder Coating Are Available?
Powder coatings come in various chemistries. The right one for you depends on the specific application.
Type | Key Features & Benefits | Common Uses |
Polyester | Good flexibility, impact & chemical resistance, UV stable up to 3 years | General industry, outdoor items |
Super Durable Polyester | Enhanced color retention (5–10 years), superior humidity & corrosion resistance | Architectural, outdoor structures |
Epoxy | Outstanding chemical & corrosion resistance, best for indoor use | Machinery, indoor equipment |
Epoxy-Polyester Hybrid | Combining epoxy’s durability with polyester’s weather resistance | Appliances, consumer goods |
Urethane | Excellent chemical resistance, smooth finish, higher cost | Automotive, agricultural, fuel tanks |
Fluoropolymer | Exceptional weatherability, 20-year warranties possible, requires primer | Windows, doors, curtain walls |
Recent advancements include nanotechnology for improved hardness and self-healing properties. There are also antimicrobial and “smart” coatings that adapt to environmental changes.
5. Which Industries Utilize Industrial Powder Coatings?
The potential applications for powder coatings are nearly endless. At Coating Systems, we support a range of clients, as seen in our Customer Portfolio. Here are some industries that use this coating for both protection and appearance.
- Electrical: Busbars, cabinets, transformers, junction boxes
- HVAC: Radiators, boilers, air conditioners, furnaces
- Lawn and Garden: Wheelbarrows, patio furniture, chainsaws
- Sporting Goods: Golf clubs, bikes, ski poles, baseball bats, hunting gear
- Construction: Gutters, roofing, guardrails, light poles
- Agriculture: Tractors, silos, plows, trailers, and other farm equipment
- Consumer Appliances: Refrigerators, washers, blenders, microwaves
6. How Many Colors and Finishes Are Available?
Industrial powder coatings are available in more than 200 standard shades. You can even customize your color to match your brand and product guidelines. Finishes include matte, high-gloss, metallic, textured, and even special effects. No matter what you need, we can help you find the right fit for your functional and aesthetic needs.
7. What Materials Can Be Powder Coated?
Virtually all metals can be powder-coated, including:
- Steel (mild, stainless, and galvanized)
- Aluminum
- Brass
- Copper
- Titanium
- Magnesium
- Bronze
Specialized powders also exist for some non-metallic substrates, like plastics. However, these are less common in industrial settings.
8. How Big or Small Can Powder Coated Parts Be?
Modern industrial powder coating facilities can accommodate a wide range of part sizes. From the tiniest fasteners to massive structural beams, there’s something for every industry.
9. How Long Does the Powder Coating Process Take?
Coating and curing can take as little as a few minutes to an hour, depending on part size and complexity. Typical turnaround times are quick. Because Coating Systems accomplishes everything in-house, there are no third parties to slow down the process.
10. How Does Powder Coating Compare to Other Finishes?
Feature | Powder Coating | Wet Paint | Galvanizing |
Durability | Excellent | Moderate | High (for corrosion) |
Color Range | Extensive | Extensive | Limited |
Environmental Impact | Low (no VOCs) | High (VOCs present) | Moderate |
Finish Thickness | Thick, uniform | Thin, less uniform | Thick zinc layer |
Aesthetic Appeal | High | High | Low |
Application Flexibility | High | High | Limited by size |
Industrial powder coating is a proven solution for protecting and enhancing metal parts in demanding environments. With its unmatched durability, environmental benefits, and design flexibility, it’s trusted across industries.
Connect With Coating Systems Inc.
If you’re ready to extend the life of your equipment, we’ll help you choose the right industrial powder coating. Connect with Coating Systems Inc. today to learn more.
