Powder coating and wet industrial painting are the two main contenders when industrial surfaces need to be coated for both durability and visual appeal. Each finish comes with its own process, strengths, and limitations. For manufacturers and engineers, understanding the differences is essential for specifying the right protective solution for a part, product, or piece of equipment.
At Coating Systems, we have 50 years of experience to help clients across industries navigate the differences between powder coating, wet painting, and other commercial coating options. Keep reading to learn more about each type of coating and which is right for your organization’s needs.
What Is Powder Coating?
Powder coating is a dry finishing process that uses finely ground particles of pigment and resin. These particles are electrostatically charged and sprayed onto a grounded component (usually metal). After application, the coated part is cured in an oven where heat “melts” the powder, causing it to flow and form a robust, uniform finish.
Benefits of Powder Coating
- Strong adherence and excellent durability
- Can be applied in a single coat, reducing process time and material use
- Emits no volatile organic compounds (VOCs)
What Is Wet Painting?
Wet painting, also called “liquid industrial coating,” relies on traditional liquid paints made from pigments, resins, additives, and a solvent. The paint is applied using spray, brush, or dip methods. As the liquid paint dries (via air or heat), the solvent evaporates, leaving behind a dried film.
Key Attributes of Wet Painting
- Classic technique suitable for a variety of substrates, including metals, plastics, and wood
- Flexibility in custom color matching and finish types
- Allows for very thin, precise layers
A Step-by-Step Guide to the Industrial Coating Application Process
The industrial coating process varies depending on a range of factors. While each type of coating follows a tried-and-true set of methods, Coating Systems also customizes our approach to meet your brand’s high standards. Here’s how these two types of industrial coatings work.
Powder Coating
- Surface Preparation: Both powder coating and wet painting require a clean, contaminant-free surface for strong adhesion.
- Spraying: The powder is sprayed through an electrostatic gun, which negatively charges the particles.
- Curing: After the powder is evenly applied, the component is placed in a curing oven. The heat causes the powder to melt, flow together, and form a strong chemical bond with the substrate.
- Result: A thick, even, and robust coating often achieved in just one application.
Performance and Durability
- Wear Resistance: Thicker coatings (0.002–0.006 inches) are possible, providing exceptional resistance to chips, scratches, moisture, chemicals, and UV.
- Long-term Protection: Ideal for exterior parts, high-impact areas, and harsh conditions.
- Flexibility: Modern powder coatings are designed to flex with the metal, reducing the risk of cracking.
Wet Painting
- Surface Preparation: Cleaning and priming as needed.
- Application: Paint sprayed or brushed on. Some sophistication is needed to avoid runs, sags, or uneven film build.
- Curing: Paint may air-dry or require oven baking, depending on the formulation.
- Multiple Layers: Typically, more than one coat is required — primer, color, and often a clear coat.
Performance and Durability
- Thin Film Precision: Enables ultra-thin coatings, which are ideal for tight-tolerance parts or applications demanding a satin-smooth finish (like automotive OEMs).
- Lower Impact Durability: More susceptible to chips, wear, and environmental degradation — though multi-layer systems can improve this.
- Color Fade: Both systems can fade in sunlight, but premium powder coatings generally offer superior resistance to chalking and fading.
Solutions That Meet Sustainability, Safety, and Compliance Standards
Powder coating and wet painting have different advantages and drawbacks when it comes to sustainability, safety, and compliance. Depending on your industry, you’ll need to have a thorough understanding of what’s needed when choosing an industrial coatings partnership. Here’s what you need to know to meet your business’s goals, avoid regulatory hassles, and ensure safety.
Powder coating is VOC-free. It contains no solvents, meaning no hazardous materials are emitted during the curing process. This makes it an eco-friendly industrial coatings choice. After spraying, unused or oversprayed powder can often be reclaimed and reused, reducing waste. One last advantage? It’s not flammable and poses no fire risk.
Wet painting is still a great option for many applications, but it does emit VOCs during application. This requires specialized ventilation and environmental controls to guarantee safety. Disposal and cleanup are also more involved processes. Spills, washing, and excess material need specific waste management strategies. Significantly more flammable, wet paint and solvent storage can also increase fire hazards in facilities.
Powder Coating vs. Wet Painting Color, Finish, and Flexibility
Powder coating is available in a large but finite range of colors and surface textures (matte, gloss, wrinkle, etc.). Custom orders are possible—however, they aren’t as rapid or flexible as with wet paint. Powder also typically delivers a more uniform finish with fewer defects.
Wet painting can be mixed or adjusted on-site for hyper-precise matching. This industrial coating option also offers more special effects and ultra-high-gloss options. Whether your company needs the stability and safety advantages of powder coating or a customizable wet painting solution that makes your product stand out, Coating Systems has you covered.
Cost and Operational Concerns and Substrate Suitability
Finalizing your decision depends on both budgetary needs and the nature of your products or pieces. Your specific needs may differ, but here’s a general look at what to expect from each type of industrial coating.
Powder Coating
- Higher Initial Setup Costs: Powder coating requires an electrical charging and curing oven. Overall, though, greater labor and material efficiencies mean better long-term economic benefits for high-volume. Powder coating’s durability also reduces lifecycle maintenance costs.
- Conductivity Required: Primarily for metals; powder coating can sometimes be used on select plastics that can withstand high oven temperatures and can be temporarily made conductive.
- Curing Constraints: Not suitable for substrates that can’t be heated to 300–450°F (150–232°C), such as most wood, rubber, or certain plastics.
Wet Painting
- Lower Startup Costs: Getting started with wet painting is relatively affordable. It also offers greater flexibility for small runs, repairs, or custom work. However, it may be more labor-intensive for large pieces or projects that require multiple coats.
- Universal Substrate Flexibility: Can be applied to virtually any material, including metal, plastic, fiberglass, or wood, thanks to air-drying or low-temperature baking options.
Final Thoughts—Which Is Right for Your Commercial Application?
Both powder coating and wet painting remain important, but knowing their differences helps select the optimal solution.
Choose powder coating for parts that demand superior durability, environmental compliance, and long-term visual appeal (ideal for metal fabrication, outdoor structures, O-rings, automotive, and machinery components).
Opt for wet painting when working with fragile substrates, needing on-site color matching, or coating parts that can’t withstand high curing temperatures.
Partner With Coating Systems for a Customized Recommendation
For more insights, connect with the Coating Systems team. We’ll provide expert guidance on your next project to help you find the perfect solution for your application.