We specialize in the application of industrial coatings for a wide range of industries and products, from automotive and military to manufacturing and food processing. One popular choice is powder coating, producing a durable, high-quality finish, especially on metal items.
Read our complete guide to discover how powder coating can be a viable option for your items. We can apply functional industrial-grade powder coating to your products so they last longer and look great.
What Is Powder Coating?
Powder coating creates a durable and attractive finish for metal parts. The multi-step process uses a specially made powder that combines resins, pigments, and fillers.
Metal parts are then electrostatically charged while the powder is applied before heading to a large industrial-strength oven to cure at a precise temperature and length of time.
The result is a finish that can add years to the longevity of products in many environments. Powder coating also has advantages over other types of industrial coatings.
Benefits of Powder Coating vs. Traditional Industrial Paint
When choosing how to protect your metal items, two common selections come from powder coating vs. traditional industry pain. Powder coating wins out on several fronts.
Durability
Powder coating outperforms traditional industrial paint when it comes to durability, environmental impact, and cost efficiency. This advanced finishing process creates a harder, more resilient surface. Powder coating is ideal for items exposed to heavy wear or harsh conditions.
Unlike traditional industrial paint, which often chips or peels, powder coating forms a seamless layer that resists scratches, corrosion, and fading. Outdoor furniture, automotive parts, and industrial equipment retain their appearance and integrity far longer when powder coated.
Sustainability & Eco-Friendliness
Environmental considerations further set powder coating apart. Traditional liquid industrial paints frequently release volatile organic compounds (VOCs), harming air quality and endangering worker health.
Powder coating eliminates VOCs entirely, offering a safer and more eco-friendly solution. Additionally, the powder application process reduces waste. Technicians recover and reuse over-sprayed powder, which contrasts sharply with the significant waste generated by liquid paint overspray.
Cost-Effectiveness
From a financial perspective, powder coating lowers long-term costs. Its superior durability reduces the need for touch-ups or replacements. Moreover, the curing process requires less drying time, streamlining production schedules, and putting your products to market faster versus industrial paints. The process is more efficient, and it enhances your products.
Aesthetics
Aesthetic flexibility also gives powder coating an edge. Traditional industrial paints may struggle to achieve uniform finishes on complex shapes. However, powder coating adheres evenly and in every possible crevice, creating smooth, consistent surfaces.
Available in a wide range of colors, textures, and finishes, powder coating allows customization to suit various needs, from sleek modern looks to rugged, rustic, or industrial designs. The creative options are nearly limitless.
Types of Powder Coating
Powder coating comes in multiple types, each tailored to specific applications and performance requirements. Manufacturers commonly use thermoplastic and thermoset powders, which differ in composition and behavior under heat. Our team can help you select the most suitable coating for durability, appearance, and functionality.
Thermoset Powder Coating
Thermoset powder coatings dominate the market, and rightfully so due to their chemical resilience and cost-effectiveness. Many of the powder coating products are thermoset varieties.
Curing under heat triggers a chemical reaction, creating a permanent, cross-linked bond. This structure provides superior resistance against scratches, chipping, and chemical exposure.
Popular thermoset options include epoxy, polyester, and polyurethane powders. Epoxy coatings deliver exceptional corrosion protection, making them ideal for indoor or industrial applications. Polyester coatings, in contrast, shine in outdoor environments with their excellent UV resistance, maintaining vibrant colors and finishes over time.
Thermoplastic Powder Coating
Thermoplastic powder coatings, while less common, offer unique advantages in certain scenarios. These powders melt and re-solidify without undergoing a chemical change, making them more malleable and easier to rework. They adhere strongly to metal surfaces, providing robust protection against impact and abrasion. Industries often choose thermoplastics, like nylon and polyvinyl chloride (PVC), for applications requiring flexibility, such as wire coatings or automotive parts.
Specialty Powder Coating
Specialty powders also enhance the range of available options. We can formulate powder coatings that resist high temperatures and extreme heat, such as the outside of colorful bakeware. Anti-microbial powders inhibit bacterial growth on medical or food-processing equipment.
Textured powders, which differ from ordinary powder coating that often leaves a smooth finish, create finishes that hide imperfections or offer slip resistance, expanding the aesthetic and functional possibilities. We could also create a matte finish or clear coat if needed to meet your requirements.
Other Benefits of Powder Coating
Aside from the durability and advantages over traditional industrial paints we already mentioned, powder coating has many distinct benefits.
Customizability
Customizability makes powder coating popular. Technicians can achieve a wide variety of colors, textures, and finishes, including gloss, matte, and metallic effects. Advanced formulations even allow for specialty coatings, such as those with resistance to UV radiation or high temperatures.
Adaptability
Although powder coating works mostly for metals, the application can be effective for plastics and wood (although this is more complicated). Its wide range of applications and uses make powder coating a popular industrial coating.
Common Uses for Powder Coating
Powder coating serves diverse industries while providing a wide range of applications and long-lasting protection against the elements.
Automotive & Heavy Equipment
The automotive industry relies heavily on powder coating for parts and components exposed to harsh conditions, extreme temperatures, and off-roading. Rims, frames, and suspension systems benefit from powder coating’s exceptional resistance to corrosion, scratches, and wear. Powder coating also enhances the aesthetic appeal of vehicle parts with custom colors and finishes, offering a sleek and modern look.
When you think of automotive parts, the same is true for heavy equipment in the field, such as front-loaders, cranes, derricks, earth-movers, and all kinds of industrial equipment that works outdoors.
Home Decorating
Outdoor furniture manufacturers favor powder coating for its ability to withstand UV exposure, moisture, and temperature fluctuations. Chairs, tables, and decorative metalwork maintain their vibrant colors and structural integrity, even after years of use in all types of weather conditions.
Industrial
Industrial equipment and machinery also depend on powder coating for protection against heavy wear and exposure to chemicals. Manufacturers coat parts like conveyor belts, storage tanks, and tools to improve durability and extend their service life. The process ensures that equipment operates efficiently and retains its performance over time, lowering replacement costs, downtime, and maintenance issues.
Home Appliances
Appliances represent another major application for powder coating. Washing machines, refrigerators, and ovens benefit from finishes that resist stains, rust, and scratches. Powder coating not only protects these items but also enhances their appearance with smooth, uniform finishes in a variety of colors. From modern looks to retro and vintage vibes, dough mixers, toasters, and countertop appliances can all look fantastic.
Architectural & Electronics
Specialized uses for powder coating include architectural elements, such as window frames, railings, and fencing, where weather resistance proves crucial. In electronics, powder coating protects sensitive components while offering an insulating barrier. Even medical and food industries utilize antimicrobial powder coatings to maintain hygiene on equipment and surfaces.
The Powder Coating Process
Powder coating generally follows a three-step process once the particulars are sorted out, such as understanding the substrate (iron, aluminum, titanium) as well as the type of powder coating to apply (thermoset or thermoplastic).
Surface Preparation
Preparation for powder coating begins with surface cleaning. Technicians remove contaminants like dirt, grease, and rust using methods such as sandblasting, chemical washes, or phosphate treatments. Cleaning the metal surface makes sure the powder adheres properly and creates a smooth, uniform finish.
Application of the Powder
Next, technicians apply the powder using an electrostatic spray gun. This tool charges the powder particles, allowing them to adhere evenly to the item’s surface. The electrostatic charge attracts the powder particles to the metal surface. This means the specially mixed powder can adhere to complex shapes, edges, and recesses.
Curing
Once coated, the powder-coated items move into a curing oven. Heat melts the powder, causing it to flow into a seamless layer. For thermoset powders, the heat also triggers a chemical reaction, forming cross-linked bonds that harden the coating permanently. This curing process typically takes between 10 and 30 minutes, depending on the item’s size, temperature of the oven, and the powder used.
After curing, the item cools, completing the process. The resulting finish may feature a high gloss, matte, metallic, or textured appearance.
Rely on Professional Powder Coating Services
Coating Systems, located in Greater Cincinnati, Ohio, can increase the durability of your objects with powder coating. Talk to us about your needs by calling 503-367-5600 or contacting us online.
