In the long run, powder coating will replace its counterpart, wet paint, in more and more areas. Technically, powder coating competes with wet paint head to head. In addition, powder coating is more friendly to the environment than wet paint, for the same cost, yet powder coating also has the advantage of superior mechanical and anti-corrosive properties. Whereas wet paint is all washed up!

Another advantage of using powder coatings is the subtraction of solvents. The powder is applied without any additives. The harmful emission of V.O.C., as used in wet paint, does not occur. The environment also benefits from the electrostatic adhesion of the metal to the powder particles. This adhesion creates a smooth and even layer that covers the edges of the metal object. This eliminates sharp edges that need to be ground into shape. The powder, not attracted to the substrate is contained and reused. Wet paint overspray has to be disposed of as chemical waste.

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Why Powder Coat?
To protect steel from being affected by corrosion it may be provided with a powder coating. During this process, powder is electrostatically applied to galvanized or a black steel product. It is then cured. The very durable coating that is formed protects the underlying metal and gives the object a shiny and bright appearance.

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The Benefits of Powder Coating?
Powder coatings are applied to steel, hot dip galvanized steel and aluminum as an anti-corrosive layer. The powder is electrostatically applied to the metal. No solvents are used in this process, which means that it is far more friendly to the environment than the alternative wet paint process. Powder that is not adhered can be reused, whereas over sprayed wet paint has to be disposed of as chemical waste.

Powder coatings have outstanding mechanical properties, they are elastic and resistant to impact and wear. This makes powder coating ideal for applications in areas with a high risk of damage, such as stairwells, public areas, gates, lamp posts, etc.

The method for applying powder coating, electrostatic spraying, results in a very good coverage of edges. This sharply contrasts with the wet paint process, where the pressure of the spray gun pushes the paint off the sharp edges. During the powder coating, the powder is attracted evenly to all surfaces.

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The Powder Coating Process
 

1. Incoming Material
   Incoming materials is closely checked for suitability.
2. Attaching the Product to Transport Beams
   The material is suspended on the transport system.
3. Degreasing
   The material is alkaline cleaned and then rinsed.
4. Pickling
   In a bath with inhibited phosphoric acid, the product is pickled and then rinsed.
5. Phosphating
   An active anti-corrosive layer of zinc phosphate is applied then rinsed.
6. Passivating
   During this process, the layer of zinc phosphate is sealed with a hexavalent chromating agent of very low weight. The material is then rinsed.
7. Rinsing with Deionized Water
   The material is rinsed with e-ionized water to remove remaining metal salts, which will cause osmosis.
8. Drying
   The steel is dried in the drying oven.
9. Powder Coating
   The powder is charged to 80,000 volts and then sprayed onto the grounded steel.
10. Curing
    According to the powder suppliers' specifications, the steel is heated to a temperature between 170° and 200° C. The resin cores melt and a smooth homogenous coating is formed.
11. Final Inspection
    The products are checked by the quality inspectors. Test panels that are processed together with the main material are subjected to a number of standardized tests.
12. Packaging
    To prevent damages during shipping, the product is carefully packed prior to transport.

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