Powder coating is one of the most popular finishing techniques available for metal, plastics, and other materials. It is durable, cost-effective, and versatile.
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Choosing a powder coating solution over paint is often an easy decision for fabrication and manufacturing companies, but businesses must make another decision before they invest in a system. They must choose a manual or automated powder coating solution. An automated powder coating line offers many advantages for companies that need to keep pace with quick turnaround times without sacrificing quality.
Manual powder coating spray booths allow workers to manually prep, coat, dry, and cure items in batches. They work well for the occasional powder coating project, but they can’t keep up with the demands of large-scale production. Automated powder coating lines, on the other hand, act as a production line for the powder paint process. Each round of coating pulls a new batch of items into the production line to speed up the overall output time.
Benefits of an automated powder coating line include:
Automated powder coating lines use conveyor systems to transition parts from stage to stage of the automated system. Companies can choose to automate all or part of the powder coating process for better control and quality assurance. Some businesses need to manually control part of the process to accommodate customer requests. Automated systems setups can accommodate both routine production demands and improve turnaround times for special requests.
Traditional spray booths can only move a limited number of parts through the process. Automation takes the legwork out of the process for better efficiency across the board.
Powder coating offers more uniform results than paint regardless of the application method. Automated systems can offer slightly more uniform results in some cases, because each batch sits in the same position and receives the same treatment at each stage of the process. Manual powder coating activities can result in skipped steps or missed coating areas.
Many manual powder coating booths operate with a spray-to-waste system. The excess powder is not reclaimable and leads to unnecessary wastefulness. Automated powder coating lines with powder reclamation systems can almost eliminate waste from the coating process.
Automated powder coating lines may cost a little more than manual systems upfront, but they can save money over time. Companies can use automated systems to reduce the number of professionals needed to maintain powder coating output levels. Companies that save money on reclaimed powder, improved uptime, and fewer quality control issues often pass along these benefits to the customer in the form of faster turnaround times, improved performance, and improved value.
Powder coating is a great way to ensure uniformity among products and eliminate the health hazards associated with conventional painting methods. Modern businesses must consider their output needs, budget, and application to determine if an automatic powder coating line can deliver a better ROI than a small-scale manual system.
Powder coating is one of the most popular finishing techniques available for metal, plastics, and other materials. It is durable, cost-effective, and versatile.
Choosing a powder coating solution over paint is often an easy decision for fabrication and manufacturing companies, but businesses must make another decision before they invest in a system. They must choose a manual or automated powder coating solution. An automated powder coating line offers many advantages for companies that need to keep pace with quick turnaround times without sacrificing quality.
Benefits of an Automated Powder Coating Line
Manual powder coating spray booths allow workers to manually prep, coat, dry, and cure items in batches. They work well for the occasional powder coating project, but they can’t keep up with the demands of large-scale production. Automated powder coating lines, on the other hand, act as a production line for the powder paint process. Each round of coating pulls a new batch of items into the production line to speed up the overall output time.
Benefits of an automated powder coating line include:
Efficiency
Automated powder coating lines use conveyor systems to transition parts from stage to stage of the automated system. Companies can choose to automate all or part of the powder coating process for better control and quality assurance. Some businesses need to manually control part of the process to accommodate customer requests. Automated systems setups can accommodate both routine production demands and improve turnaround times for special requests.
Traditional spray booths can only move a limited number of parts through the process. Automation takes the legwork out of the process for better efficiency across the board.
Uniformity
Powder coating offers more uniform results than paint regardless of the application method. Automated systems can offer slightly more uniform results in some cases, because each batch sits in the same position and receives the same treatment at each stage of the process. Manual powder coating activities can result in skipped steps or missed coating areas.
Waste Reduction
Many manual powder coating booths operate with a spray-to-waste system. The excess powder is not reclaimable and leads to unnecessary wastefulness. Automated powder coating lines with powder reclamation systems can almost eliminate waste from the coating process.
Saving
Automated powder coating lines may cost a little more than manual systems upfront, but they can save money over time. Companies can use automated systems to reduce the number of professionals needed to maintain powder coating output levels. Companies that save money on reclaimed powder, improved uptime, and fewer quality control issues often pass along these benefits to the customer in the form of faster turnaround times, improved performance, and improved value.
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Powder coating is a great way to ensure uniformity among products and eliminate the health hazards associated with conventional painting methods. Modern businesses must consider their output needs, budget, and application to determine if an automatic powder coating line can deliver a better ROI than a small-scale manual system.
The team at Swanton Welding uses an efficient and automated powder coating line to deliver products with exceptionally durable and visually appealing coatings. The system features a 30-inch by 60-inch opening, a 120-inch load bar, and an automated conveyor line process. We can handle coating requests for products of many sizes. Contact us today at (419) 826- to learn more about our powder coating system and capabilities.
To coat or not to coat? Rotating equipment owners know protective coatings safeguard against fouling and corrosion, but are they absolutely necessary for every application? Which conditions and/or process media should be considered for coatings? Will coating impact the performance of the equipment positively or negatively? Which coating should be used for which process media? Will coating critical components reduce the need for rotating equipment repairs and downtime? These are the questions rotating equipment owners ask when deciding whether to invest in this practice. The main reason owners look at using coatings is to prolong service life, decrease operation and maintenance costs, and increase equipment efficiency.
The Advantages of Coatings
Equipment reliability and longevity are the two biggest concerns for industrial facilities and undeniably so, as capital equipment is your largest investment. Depending on the size of the equipment and its usage, the cost of the coating and labor can be paid back in less than a year by an increase in efficiency of just a mere two percent. Other secondary benefits of using coatings are decreased electricity usage and increased performance. Rotating equipment is subjected to harsh conditions with long operational times and abrasive or corrosive process materials. Coatings help protect against the damage caused by wear-prone applications. They have been designed to be wear resistant, reduce friction, protect against caustic/acidic materials and cleaning agents, and increase line efficiencies. Coatings come in two categories – organic and inorganic. Organic coatings range from thermoset and thermoplastic polymers to elastomers. They are the most commonly used and cost effective mode of protection. Inorganic coatings are non-carbon based compounds such as glass, metals, silicones, and ceramics. Choosing one type over the other involves understanding the ease of coating application and whether the service condition is mechanical, thermal, or chemical. Inorganic coatings perform highly in abrasive and corrosive applications and last long, but tend to be more expensive than organic coatings. Check with your equipment manufacturer for coating recommendations.
The Disadvantages of Coatings
Sometimes coatings are not the best solution. Coatings work well for equipment that is stationary and that will not experience high volumes of turbulence or erosion from abrasive particles. Coatings are great short-term solutions in your anti-corrosion strategy. Once a coating has been applied, it immediately begins a degradation process that will require touch-ups, maintenance, or even a complete reapplication. Coatings can also inhibit pump performance by causing obstacles or closing off passes and ports. When these applications begin to throttle your equipment, it moves the machinery farther away from its original design point, thus reducing efficiency and service life. In high velocity services, coatings will be quickly removed and will be less cost-effective in the long run because of constant reapplications.
An Alternative to Coatings
If organic and inorganic coatings are not right for your rotating equipment’s service condition, then it may be time to check out structural composite components. There are numerous advantages to composites. First and foremost, they are corrosion and chemical resistant. With metallic equipment that has been coated, process media is able to penetrate the coating, getting underneath it, and corroding the metal components. Composites are a solid piece, so coating is not required, thus eliminating corrosion issues. They are also incredibly strong and lightweight. Lightweight materials are easier to move and equate to significant energy savings. Their high strength makes them durable and resistant to pitting and damage. Composites also have excellent elasticity. When metal components are under stress, they will dent and yield. Composites will spring back into place after the stressor is removed. Because they are non-metallic, composites are also non-conductive, making them safer in high-voltage operations.
Composites are an excellent choice for rotating equipment owners, but it requires investing in new parts and equipment. There are advantages and disadvantages to using coatings on your rotating equipment. You will have to look at several factors to determine whether using a coating is your best solution or whether to invest in structural composite components and equipment instead. Though coatings are a more short-term solution, they are a more cost-effective investment (up front) and easy to apply. If you are looking for a more permanent, long-term solution, check out structural composites. Either way, you will see immediate benefits of increased efficiency, reduced energy usage, prolonged service life, and a reduction in the need for rotating equipment repair.
Anticorrosion Coatings Pump Up Efficiency. Industrial Equipment News.
1. Optimisation of resources and processes
The powder coating process offers a high level of resource optimisation because it is a highly recyclable product. The powder coating lines are adapted for the raw material recycling, between 95 and 98% of the raw material used is recovered. Moreover, it is a surface treatment that allows the automation of the lines, and therefore a high level of optimisation of the industrial processes.
2. Ecology and Sustainability
One of the main advantages of powder coating is that its composition is solvent-free, it is a thermosetting paint that does not need any polluting thinner for its application.
3. Colour choice
Powder coatings offer a wide variety of colours and textures that are difficult to achieve with other types of paint. It is a practically unlimited range, which added to the technical possibilities of the line, allows a great performance in the alternation of these colours.
4. Product durability
Powder coated products ensure a highly durability. With regular maintenance, the powder coating can last up to 20-25 years in good condition, which is a significant difference compared to liquid painted products.
5. Application and finish quality
The application of powder coatings is simple, does not require highly skilled labour and allows a High Quality finish to be offered, which increases the production capacity and efficiency of the line.
In addition, the electrostatic power of powder coating gives a high level of homogeneity in the final result of the application on the surface, especially in parts with more complex geometries. We can not only achieve a homogeneous coating but also a high level of thickness with a single paint application.
These are some of the key points and advantages of powder coating. Coating lines that can be fully adapted to different industries and business needs.. A customised design can be made according to your company’s production requirements, ranging from manual processes to full automation of the line.
Consult our specialists for an assessment of your needs and how your coating line processes can be optimised.
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