Powder coating for industrial products

Powder coatings enable first-class coatings for a wide range of surfaces. Important success factors in industrial powder coating are an excellent look and feel of the coating layer, long durability, high economic efficiency of the process and sustainable use of resources. Powder coating offers a wide range of colors and surface effects.

WAGNER offers highly efficient standard products and customized solutions. From products for manual coating to complex systems for automatic powder coating. Standardized or customized to your application. Our products and systems offer versatile application possibilities, fast color change if required, and efficient process technology for feeding, applying and powder recovery.

Powder coating

Whether manual or automatic coating. From entry-level solutions for small quantities to fully automatic complete systems.

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Product categories in powder coating

Gesamtanlagen

Complete systems

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Foerdern Aufbereiten

Feeding & preparing

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Applizieren2

Applying

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Rueckgewinnen

Recovering

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WICOS neu

Controlling

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Digitalisierung 2

Digitalization

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General Maintenance Manager at Atlas Eletrodomésticos

 

With WAGNER's enamel powder coating booth, we finally have the production capacity we need, and we achieve reliable, high-quality coating results.

Renato Antônio Reis

General Maintenance Manager at Atlas Eletrodomésticos

Process in industrial powder coating

The powder coating process is divided into the steps of pre-treatment of the workpiece, application of the powder coating and drying (curing). For large quantities or in series production, the use of automatic production lines is suitable - with varying degrees of automation depending on requirements. For small quantities, manual coating (e.g. PEM-X1 CG Corona cup gun) is suitable. For automatic production lines, all processes must be coordinated to achieve the desired production output. Often measured with coated area per hour or hangers per hour. Our WAGNER specialists provide profitable support with their knowledge as early as the planning discussions.

Surface coating step by step

  1. Pre-treatment: The condition of the surface is decisive for the quality of the coating. The aim of pre-treatment is a clean and grease-free workpiece to which the coating layer adheres well. Depending on the workpiece, sandblasting or chemical preparation is necessary. Here, sandblasting and flushing work with grease-dissolving agents. If high corrosion resistance is required, a basic wet chemical corrosion protection is applied before powder coating.
     
  2. Application: The prerequisite for powder coating is an electrically conductive substrate. Therefore, metals are ideally suited. However, wood can also be powder coated, as the moisture in the wood creates sufficient conductivity for the process. If plastics are to be powder coated, they must first be made conductive in the surface by a conductive coating. Compared to direct liquid coating, this is often uneconomical. During coating, the workpiece is electrically grounded and the powder is charged. There are two different processes for charging. With Corona charging, the powder is actively charged by a high-voltage cascade built into the powder gun. In the Tribo process, this takes place through the friction of the powder coating on friction bodies in the gun. Today, Corona charging is predominantly used. Adjustment of the charge to the coating and the ambient conditions is very flexible. For example, for thick or thin layers, in relation to the temperature and humidity conditions during processing, structural effects, gloss effects, abrasion resistance or sealing behavior of the finished coating layer. Tribo charging is used when the requirement profile is a very smooth surface or for workpieces with large and narrow recesses. Basically, both processes are used as manual or automatic powder coating.
     
  3. Cross-linking and drying (curing): At the end of powder application, the coating layer is still in powder form. Since powder is essentially a composite of plastic and color pigments, it melts when heated to temperatures of 160 to 200 degrees Celsius. Curing takes place through the hardeners contained in the composite. In technical jargon, this is referred to as curing. There are also powders that melt at lower temperatures, e.g. at 130-140 degrees Celsius. These are referred to as low-temperature powders. These powders are very sensitive to higher ambient temperatures and must be cooled during the entire process chain. This means also during production, transport and storage, e.g. at 25 degrees Celsius. The decisive factor here is the benefit, i.e. the cost-effectiveness of the energy savings during curing versus the additional costs for the required cold chain.

Application areas of industrial powder coating

The WAGNER product range covers the entire technology bandwidth: from individual components for manual coating to highly automated complete systems. Powder coating is suitable for conductive materials due to the electrostatic process. For example, metals such as stainless steel and aluminum, pre-treated wood and MDF or heat-resistant materials such as glass and ceramics.

Typical applications:

Application examples for powder coating

WAGNER offers solutions for various industries and requirements.

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Advantages of industrial powder coating

  • High wear resistance of the paint layer
  • Wide range of color shades and surface structures
  • Environmentally friendly process without solvents in production and application
  • Nearly 100% use of the paint with minimal loss percentage
  • Low expenditure for safety engineering
  • Short training period for system operators and coaters
  • Easy color change with minimal paint loss
  • From manual coating up to fully automatic industrial complete systems

Product recommendations for industrial powder coating

powder system e-line with pxe front

E-Line with PXE

The E-Line complete system as an entry-level solution for automatic powder coating: fast color change, process reliability and an outstanding coating.

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ips coating center front

IPS coating center

Powder preparation, feeding, dosing and color change are accommodated in a closed and fully automated system, that enables decisive improvements in powder coating.

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manual gun pem-x1 from the side

Manual gun PEM-X1

With only 490 g, the PEM-X1 is a lightweight, while also being very robust at the same time. In combination with its ergonomic design it enables fatigue-free working.

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tablet with coatify platform

COATIFY

Greater transparency for higher productivity: COATIFY is a web-based Internet of Things platform which allows the intelligent visualization of coating systems.

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powder manual unit sprint airfluid xe from front

SPRINT Airfluid XE

The clear arrangement of operating elements and the fast recipe adjustment in the EPG SPRINT XE control unit allow easy handling for the daily work.

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display with wicos software

WICOS

WICOS, the integrated control and operating system from WAGNER, simplifies complex coating tasks. More effectively and efficiently than ever before.

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Frequently asked questions about powder coating

Electrostatic powder coating is suitable for all conductive materials. Moisture in wood also creates sufficient conductivity for powder coating. With plastics, on the other hand, it is necessary to first apply a conductive coating for powder coating.

Industrial powder coating comprises three sub-processes. First, the pre-treatment of the workpieces to obtain optimum coating results. This is followed by the actual application and finally the curing of the coating layer.

Depending on the requirements (coating quality, durability, structure of the surface, etc.), the appropriate surface technology must be selected. In general, most materials can be powder coated and liquid coated.

In contrast to liquid coating, the color pigments in this surface finish are in a powdery state. Powder coating works with electrostatics. The powder is drawn to the gun by means of a vacuum. The electrostatic charge causes the powder coating to adhere to the workpiece. By heating, it is melted and finally hardens.