What Is Powder Coating? The Details You Need To Know

Feature image for what is powder coating

The powder coating market continues to grow significantly due to benefits such as durability and versatility of this surface finishing method. Key industries that widely rely on it include automotive, architecture, home appliances, and garden products. 

Characterized by the electrostatic application of coating and culminating in curing, this surface finishing technique provides speed, durability, eco-friendliness, and versatility. 

When done by a reputable company such as ProleanTech, powder coating is one of the best methods for facades, car parts, industrial machinery, and many other products. 

The options include thermoplastics, thermosets, and UV curable powder coatings. Details for these and more about the powder coating method will be shared in this comprehensive guide.

Let’s read on.

What Is Powder Coating? A Cost-Effective, Durable, and Time-Tested Solution  

Before looking at the powder coating definition and other intricacies of the process, let’s have some background. This technology is slightly over 80 years old, having started in the form of flame spraying in the 1940s. It developed progressively over the years to today’s version that incorporates advanced powder chemistries. 

The best powder coating companies are always improving their methods to go in tandem with the dynamic industry. Some have labs where processes are developed and tested. ProleanTech is always ready to adopt new powder coating approaches to deliver the best outcomes to clients. 

Today’s types of powder coating are exciting, providing different color and finish options. To experience the high-quality powder coating service at ProleanTech, call us and ask for a quote today. 

How Does Powder Coating Work—And Why Is It a Perfect Choice for Your Business

The powder coating process

As indicated in the image above, the charge is the main element in the surface adherence and durability of powder coating. The best way to define powder coating is to relate the process to metals and magnets. 

Like metal objects being attracted to a magnet, grounded surfaces offer a settling place for charged powder particles as they emerge from the electrostatic spray gun. 

By adhering to the substrate, the charged particles from the gun create a flawless uniform coat. If the charge intensity is high, the adherence force will also be strong, and vice versa. 

Grounding is also critical in the powder coating procedure. It has to be good, otherwise, the adherence will not be adequate. The powder coating procedure is effective when grounding is done correctly because it also reduces waste of particles. 

In the end, we have a durable coating that protects a part from scratches and other damage. Powder coating colors are long-lasting, so they will retain their visual appeal for years. Most importantly, it enhances the corrosion resistance of parts. 

Powder coating in numerous colors

Key Ingredients of Powder Coating and Their Impact on Quality & Cost

What makes the powder coating so effective? That’s an important question to ask because you can then know areas to focus on. Apart from the spray gun and the spraying procedure, the contents of the coating matter.

We are talking about components like resin, curing agents, additives, and extenders. What is the importance of these contents in the coating?

• Resins With A Mixture Of Functions

Resins are crucial components of powder coating, enhancing quality through weather resistance and durability, and cost through enhanced powder recovery. 

First, they are adhesives, meaning they ensure the firm adherence of pigments to the substrate. 

Resins are also essential for the viscosity required in powder coating. Viscosity is necessary for the free-flow and distribution of the coat. It helps prevent the formation of lumps on the substrate. 

The curing effect of resins is equally important in powder coating projects. Resins are markedly different from conventional liquid resins that need powerful agents. The curing process is characterized by the formation of a cross-linked structure that enhances coating durability and hardness. 

• Curing Agents Promote Durability

Curing agents are necessary for enhanced mechanical strength, chemical resistance, and faster processing. 

Curing agent for powder coating

There are different types of curing agents, each with its unique capability. For example, primid curing agents are ideal for polyester-containing coatings while dicyandiamide versions work best if the coating contains epoxies. 

• Additives To Make The Coating Even More Reliable

Additives not only provide corrosion resistance and UV resistance but also minimize formulation costs and reduce material waste, among other benefits. 

They are available in different versions and serve different functions. A notable additive is benzoin, which reduces melt viscosity and surface tension. Other additives include CERAFLOUR 920, GARAMITE-7305, and BYK 356. 

• Extenders For Enhanced Surface Properties

Extenders are also called fillers. Their main functions are providing a durable layer and minimizing glossiness of the coating for a more matte appearance. They optimize cost by minimizing formulation cost. 

The Powder Coating Process: Enhancing Durability in Manufacturing & Finishing

The dry finishing process that is powder coating is intricate and follows specific steps, with the goal of promoting durability and appeal of products. 

Starting with surface preparation and continuing through other stages to curing, this process ensures excellent protection of the substrate. 

ProleanTech has a dedicated team that ensures all the steps are adhered to for superior and predictable performance of parts. 

The main steps of powder coating are highlighted below:

Surface Preparation And Treatment

The starting step of the powder coating process matters a lot. The goal is to get rid of all dirt, rust, and other contaminants from the material’s surface. Examples of surface preparation methods are degreasing and sandblasting. This step is essential because it enhances surface smoothness and coating durability. 

Powder Coating Application

The next step is powder coating application using a spray gun. This is a specialized tool that sprays the powder particles after charging them. The gun has settings for adjustments that can change the coating thickness and other elements. 

Note that the application method can be automatic or manual, but the concept is the same. 

The Curing Stage 

When the application process is complete, curing is necessary. The powder coated component is put in an oven. The function of this stage is to create a continuous film by melting the coat. 

Upon cooling, the powder coat becomes more durable. Curing is essential in powder coating because it enhances anti-fading and anti-scratching properties. 

With a professionally powder coated and cured process from ProleanTech, your parts should provide durable protection and prove to be valuable to your investment. 

Powder Coating Types: Choosing the Right Option for Your Manufacturing Needs

The main components of powder coatings are curing agents, polymer resins, and pigments. When charged, the coatings adhere to metal and create strong bonds. The possible combinations of powder coating colors and types of powder coating are limitless. 

However, there are two main types of powder coating: Thermosets and thermoplastics.  

Thermoplastics

A thermoplastic powder coating is a thick coating suitable for superior protection required outdoors. This coating is largely functional with a thickness of 300 µm or more. Apart from providing electrical insulation, the coating is highly resistant to chemical and mechanical stress. 

Since this is a synthetic coating, it can melt at high temperatures. One advantage of this property is the chance to recycle the coating if need be. Provided the heat is manageable, thermoplastics can be very durable.

Furthermore, thicker coatings can be applied without the risk of cracking. Popular applications of thermplastic powder coatings are kitchen appliances and metal components. 

Examples Of Thermoplastic Powder Coating Materials 

The ingredients of a powder can be varied to achieve different textures and appearances. This gives rise to different powder coating materials whose appeal to customers varies. 

Here are some of the most common thermoplastic materials for powder coating:

• Nylons 

A metal part with a nylon powder coat

• Polyester 
• Fluoropolymers 
• Polyolefins
• Polyvinyl Chlorides (PVC)
• Urethanes

Thermosets

Thermoset powder coatings undergo the usual application as dry powder and cured. However, this coating cannot be remelted like the thermoplastic coating. Its formation is irreversible because of the chemical cross-linking reaction that occurs. 

One challenge with thermosets is the tendency to become brittle and crack with thickness. 

Examples of thermoset powder coating materials 

As research and design advance, the list of powder coating materials continues to grow. Custom powder coating results are available thanks to this versatility. 

Here are some of the most popular thermoset powder coating materials:

• Acrylics 

Acrylic coated car rim

• Epoxies 

Epoxy coated product

• Epoxy-Polyester Hybrids
• Silicon-based Powders

Why Powder Coating? The Benefits of a Durable, Cost-Effective Finish

Powder-coated parts are highly valued because of the reliability of this surface finishing method. It is one of the most preferred surface finish options at ProleanTech, where the goal is to enhance the aesthetics and durability of materials.

Our surface finishing services are fast, efficient, and high-quality. Focusing on powder coating, parts users enjoy benefits such as durability, environmental friendliness, a polished look on parts, and cost-effectiveness. 

The Durability Of Powder Coating 

Powder coating is easily one of the most durable surface finishes for metal and other materials. Its strong chemical bonds are adequate for a range of surfaces, whether in demanding industrial environments or the kitchen. 

Of course, this durability depends on several factors. The most significant ones are the specific type of coating, usage, and the surface preparation before coating. In ideal situations with no UV exposure or excessive exposure to the outdoor environment, a quality powder coating can last for two decades or more. 

An Environmentally Friendly Surface Finishing

Powder coating finishes are very eco-friendly because they are reusable. This particularly applies to thermoplastic, which is easily recyclable. Even at the application stage, the eco-friendliness of the powder coating process is evident because very minimal wastage occurs.

Apart from not requiring solvents, powder coating is free of harmful organic compounds and, hence suitable for the environment. While we still need to wear protective wear when applying this surface finishing, the risks are less serious compared to other finishes. 

The Polished Appearance Of Powder Coated Parts

Are you looking for the most polished metal parts? One of the best finishes to guarantee that is powder coating. A big plus is that polished look can last for years. The element-repelling nature of this coating means the user only needs to clean the surface to get the appearance back. 

It Is Relatively Cost-effective 

When it comes to projects of the nature of surface finishing, especially for pricey items, it is important to look at the longer term angle. The initial cost of powder coating may appear prohibitive, but the performance of the finish over time often proves worth the investment. 

Powder Coating Drawbacks That You Need to Consider Before Choosing

While the advantages of this surface finishing are wonderful and many, it is important to identify the drawbacks, and maybe address them. There are a few of them, starting with the potential for cross-contamination during recycling. 

In other words, the powder coating colors may not come out as envisaged. The good thing is that packaging the unused powder correctly can minimize this challenge. 

Control of coating thickness can also be problematic. This inadequacy can result in uneven texture. Sometimes, the coating can run and reapplying it is required. Avoid this challenge by partnering with ProleanTech for powder-coated products.  

What Is Powder Coating Popular For? Industries Where You Can Use Powder-Coated Parts. 

Given the advantages we have just highlighted, you can predict that this process is popular across industries. At ProleanTech, we have clients from aerospace, automotive, and more, who seek our high-quality powder coating services to guarantee reliable part performance for years. 

Consider the process for your parts if you deal in any of these and related industries:

Aerospace And Automotive Industries 

These industries are widely recognized users of this surface finishing technology. The durable protective qualities of the coating suit parts such as wheels, frames, and panels. This coating ensures long term maintenance of the appealing look of parts.

Powder coated aircraft engine

For the aerospace industry, powder-coated parts are highly resistant to harsh environmental conditions. The uniform surface finish enhances the performance and longevity of the parts. 

Household Items

The versatility of this surface finishing technique is evidenced by the fact that it is also applicable in consumer goods. It enhances the functionality and aesthetics of consumer goods such as washing machines and refrigerators. 

Refrigerator with powder coating 

Powder coating plastic is also popular, with components such as refrigerator handles, plastic shelves, and electrical casings featuring the finishing. 

Other Industries

The list of industries for powder-coated components is inexhaustive. Here are more relevant industries for this surface finishing service.

• Commercial furniture 

Powder coated outdoor table

• Industrial 
• Sheet metal 

Powder coated roofing sheet

• Architecture 
• Agriculture 

Powder coated farm equipment 

Ask for a quote if you want parts powder-coated from any industry. The surface finishing will maintain a sleek look for years and minimize cost in the long term. 

Conclusion 

Powder coating is one of the most effective dry finishing processes for many industries. It is on all manner of products, from household goods to industrial equipment. Durability and versatility are just some of the reasons this method is so popular. 

If you haven’t dealt with powder-coated parts and products, maybe you should. When you decide to, make sure you partner with the most reliable powder coating service provider. 

Look no further than ProleanTech. For more on our capabilities and affordable rates, call our representative today.