Investing in powder coating equipment can dramatically increase the success of a busy job shop or parts manufacturing business. Whether bringing powder coating in-house to save money or improve quality, upgrading from an older coating system, or converting from wet paint to powder coating, there are huge benefits to setting up a new industrial powder coating operation. One of the most common questions the experts at Reliant Finishing Systems get asked is how much will a powder coating system cost?
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Generally, the greater the size and automation level, the higher the system price. It isn't unusual for an automated coating line with powered conveyor to cost 3-10 times as much as a batch system that can provide similar throughput. In , a coating system for use in a production environment will likely cost over $200,000.00 but less than $2,000,000.00 installed, plus the cost of getting your building ready and connecting utilities. This assumes you're buying new equipment from an established brand name provider, not unreliable used equipment from a reseller or light-duty equipment from an unknown manufacturer or a hobbyist/home coater website. When dealing with fully automated powder coating lines for very large parts, parts that require outgassing, parts that require multiple coats, or where throughput requirements are quite high, the price can reach $10,000,000.00 or more.
That's a wide price range, and it can quickly be narrowed down based on your answers to a few questions. These answers will also help determine what type of system will produce the best results for your application. Industrial finishing systems are typically broken into three categories: batch, constant process, and hybrid.
With batch powder coating systems, parts are prepped, coated, and cured in batches. Most batch systems rely on rolling racks filled with parts and manually transported between appliances. Some batch systems utilize a floor-level towline or overhead conveyor to assist with parts movement. Almost all batch systems involve manual operations. Human operators do parts preparation, powder coating application, and parts handling.
With constant process lines, automation is more common. Chemical pretreatment is often done with a multi-stage washer instead of washing parts by hand using spray wands. Powder coating is often applied using automated guns instead of painters. Parts are transferred via powered conveyor instead of rolling carts.
With hybrid systems, parts preparation may be performed offline and then prepped parts are finished using an automated process. In other hybrid systems, parts are moved from one appliance to the next using an indexed conveyor system. The parts dwell in the various appliances for a fixed period of time before being moved in unison.
This article includes some of the questions we ask when providing an estimated budget to potential buyers, as well as information that can help you assess what type of powder coating system would work best for you.
What's the largest part you want to coat?
The first thing a powder coating equipment provider must determine while pricing your coating system is the size of the parts you'll be coating. They will need to know the size of the largest part you will be powder coating with your new system and use that to establish the base size for your equipment. If you typically coat a large number of parts that are significantly smaller than your largest parts, you may want to consider outsourcing the coating for the large parts. If an automated system seems appropriate, using a stand-alone batch system for your large parts may be less expensive than upsizing your conveyorized line to accommodate them.
For batch coating large or small parts, you'll need to figure out how many parts you can coat at one time and how large the racks (also known as rolling racks or parts carts) will need to be to reach your throughput requirements. In some cases, it may be better to use multiple smaller, easy-to-move racks instead of one or two large, cumbersome ones. With very large parts, seeing only one part per rack is common.
Once you have the measurements for your parts and the rack system you intend to use, you'll need equipment that is large enough to accommodate your throughput needs and allow equipment operators adequate room to prepare and coat the parts. With automated and/or constant process systems, the appliances are typically smaller in terms of height and width, but the ovens and pretreatment system are often longer to allow for adequate dwell times as parts travel through them.
How many parts do you need to be able to coat in a typical workday?
Just as important as part size, you need to have an accurate estimate of your throughput requirements. Knowing these two things will help you determine whether a batch coating system, constant process powder coating system, or hybrid coating system will best fit your operation.
Unless you have multiple appliances to increase productivity, with a batch system the slowest step of the powder coating process limits your throughput. Typically, this will be curing your parts after they have been coated.
After the surface of the part has reached curing temperature, the typical curing time for standard polyester powders is around 10 minutes. This is based on a curing temperature of about 400°F. Sheet metal parts of 16 gauge or thinner material will usually take around 10 minutes to reach curing temperature. This leads to a total curing process time of 20 minutes or a bit more. Heavier parts, such as a frame made from ¼' angle iron or tube stock may take about 30-40 minutes to cure. Curing heavier steel parts and castings can take 45-60 minutes or longer. Different powders will have different curing requirements, but these time estimates make a good guideline when calculating throughput.
If you need greater throughput, you can either add more ovens or increase the size of the oven. If the labor costs associated with operating multiple ovens or handling giant racks of parts exceeds your operating budget, an automated coating solution might be better.
Most manufacturers immediately prefer a conveyorized system with some level of automation, but purchasing batch equipment is almost always significantly less costly. The number one reason to select an automated coating system over a batch operation is to process more parts per hour. If your business needs to produce a large number of powder coated parts on a daily or weekly basis, and these parts are somewhat similar in size, the best solution is probably a conveyorized line with automated equipment. With this type of system, coating is usually a continual process, so you'll almost always be able to coat more parts in a set period of time than if you coated them manually in batches.
Batch powder coating systems, however, provide greater flexibility regarding parts sizing, complexity, and construction materials. Another benefit over constant process lines is that an issue in one area'such as discovering a problem with the powder being applied'won't prevent other phases of the coating process from taking place, since the parts aren't being moved along a fixed path by a conveyor.
How much room do you have to dedicate to your new coating line?
As a general rule, automated systems will require significantly more floor space than other solutions. You will need accurate dimensions of the equipment you are considering to plan an effective shop layout with good workflow. Make sure you have enough room in your shop for not only the equipment, but adequate space for your conveyor or the travel path of your racks. With a batch coating operation, you will also need staging areas for parts moving into and out of your pretreatment, coating, and curing areas. With automated or hybrid systems, you will need enough conveyor to allow for loading, cool-down, and unloading areas.
Walkways, forklift lanes, emergency egress routes, and storage areas for unused racks are other factors to consider when planning your shop layout. You also need to make certain you have enough space to satisfy your local code requirements. Certain codes specify how much room you must have between appliances or between appliances and the building walls and roof. Codes vary by location, so it's wise to establish a good relationship with local code inspectors before purchasing a new finishing system.
Another consideration when determining how much room you will need is the cost of having utilities routed to your equipment. Larger systems will usually require longer, more expensive utility runs to reach the various appliances. You also need to allow for code-required valves and disconnects for utilities such as gas and electrical power, as well as the cost to provide compressed air for your blasting equipment (if required), powder guns, and the powder spray booth's pulsed air self-cleaning features. Water must be supplied to the area where you plan to perform chemical pretreatment and cleaning processes. Drains or water/chemistry capture alternatives are also important, and these can significantly impact your overall budget.
What are the quality requirements for the powder coated finish on your parts?
There are numerous finishing specifications that you may be required to meet in order to capture and retain a client's business or meet your company's own product standards. Some of these finish standards require a specific pretreatment process to achieve acceptable results. Others may require finished parts to pass a durability test. Depending on your industry or your end-customers' uses, your powder coated parts may need to meet national specifications before they can be used in the field.
Three commonly encountered quality standards for coating aluminum are AAMA (American Architectural Manufacturers Association) , , and (http://www.aamanet.org/upload/file/--_Comparisons_4-6-11.pdf). Each standard requires more extensive pretreatment and stricter powder quality processes than the last. A manual operation can pass the specification, but the , and definitely the , require an automated pretreatment process (usually of 4-5 stages or more). Dip tanks can work for specialty parts, but manual solutions are not practical if you have a high throughput rate. Using a conveyorized line with a multi-stage pretreatment system is the most efficient way to consistently prepare large quantities of parts.
If you need stringent quality control, an automated coating line provides repeatable and consistent finish quality that would be challenging to match with a manual coating operation. Automatic gun systems from companies like Wagner, Nordson, and Gema can be programmed to apply specific amounts of powder at just the right setting for best coverage. The process can be fine-tuned for each unique part and then easily repeated automatically. If the booth and guns are properly maintained, the results are consistently ideal.
Knowing the details of your finish quality requirements makes specifying your coating system much simpler. As with size and throughput, the more demanding your finish requirements are, the more expensive your powder coating system is likely to be.
What are your goals in terms of long-term labor costs?
Labor cost management is a critical component of efficient production. Reducing the labor costs associated with manufacturing can propel a company forward. Automated finishing lines can almost always reduce the amount of labor required when compared to their manual counterparts, whether batch, constant process, or hybrid in nature. In any case, a minimum number of employees is required to operate and maintain a finishing system, no matter how heavily automated it is.
With a small to midsize automated line, you will need someone to load the parts, another person to set up and keep an eye on the pretreatment system and spray booth, and perform manual touch-up of problem areas, a third person to inspect/unload the parts, and a finish line manager to keep chemical and powder orders up to date, assure the employees are doing a quality job, and make certain the equipment is running properly and being well maintained. At least one person needs to know how to adjust the pretreatment equipment, titrate the chemistry, load powders, and maintain the conveyor and finishing equipment so the line operates efficiently. Even if personnel perform multiple roles, a minimum of 3-5 employees is typically required for a basic automatic line.
You will likely need a few more workers to obtain a similar amount of throughput using batch equipment. You will need someone to load the parts, possibly a second person and third person to move loaded racks from station to station, another person or two to perform pretreatment, one or two people to coat parts, at least one person to load the oven and inspect/unload the parts, and a finish line manager. Even if personnel perform multiple roles, a minimum of 6-9 employees is usually required for a production powder coating operation that uses batch equipment.
Need Coating Advice or Help Sizing A New Powder Coating Line? We're Here for You!
In addition to designing new coating systems, and manufacturing, installing, and supporting our own powder coating and industrial painting equipment, Reliant Finishing Systems also provides a wide range of services to help you update your existing finishing system or make changes so your coating operation runs smoothly. We offer line audits, on-site troubleshooting, consulting, equipment refurbishment, and more. Call us today at (256) 355- if we can be of help.
Benefits Of Purchasing A Powder Coating Line ' Solar Home Guides
If you're in the business of manufacturing and producing metal products, you know that a crucial part of the process is finishing them with a protective coating. Powder coating is one of the most popular methods of finishing metal products, and investing in a powder coating line can offer a host of benefits. In this blog post, we'll explore the advantages of purchasing a powder coating line for your business.
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Efficiency and Productivity
When you invest in a powder coating line, you're investing in an efficient and productive system. A powder coating line consists of several components, including a powder coating booth, conveyor system, and curing oven. This means that the entire process from pre-treatment to coating to curing can be completed without any interruption or delay. Additionally, the use of an automated powder coating line reduces the need for manual labor, which can improve efficiency and reduce costs in the long run.
Consistency and Quality
One of the key benefits of using a powder coating line is the ability to achieve consistency and high-quality finishes. Industrial booths designed for powder coating are designed to maintain a controlled environment, allowing for optimal coating conditions. This means that the powder coating process is consistent, and the finished products have a uniform and high-quality appearance. Additionally, powder coating provides a durable and long-lasting finish, protecting your products from corrosion, UV damage, and wear and tear.
Environmental Friendliness
Another advantage of powder coating is that it's an environmentally friendly method of finishing metal products. Unlike traditional wet painting methods, powder coating doesn't require solvents, which emit harmful volatile organic compounds (VOCs) into the atmosphere. Powder coating is also a more sustainable option because the unused powder can be reclaimed and reused, reducing waste and saving costs. By investing in a powder coating line, you're not only improving your bottom line but also reducing your environmental impact.
Versatility
Powder coating is a versatile finishing option that can be used on a wide range of metal products, including aluminum, steel, and even wood. Additionally, powder coating comes in a variety of colors and finishes, allowing for customization and flexibility in design. Whether you're looking to match a specific color or create a unique finish, powder coating can deliver a range of options that can meet your needs.
Cost-Effectiveness
Investing in a powder coating line may seem like a significant expense upfront, but it can actually save you money in the long run. Powder coating is a cost-effective method of finishing metal products because it requires less material and labor than traditional wet painting methods. Additionally, the durability of powder coating means that finished products require less maintenance and touch-ups, reducing the need for re-coating and extending the life of the product. Over time, the cost savings can add up, making a powder coating line a smart investment for your business.
Conclusion
In conclusion, investing in a powder coating line can offer a wide range of benefits for your business. From improving efficiency and productivity to achieving high-quality finishes and reducing environmental impact, a powder coating line can help your business operate more efficiently, save costs, and produce better-quality products. If you're considering a powder coating line for your business, be sure to research and invest in high-quality equipment, such as a powder coating booth and curing oven, to ensure optimal results.
Five advantages of powder coating as surface treatment
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.
The advantages of coil coating
Build the refrigerator from pre-coated steel or supply the finished appliance with color and a coating afterward? Manufacturers can choose. With its products, voestalpine makes the decision easier for them with colofer® brand pre-coated steel strip ' an environmentally friendly and versatile solution.
The manufacturers of refrigerators and washing machines currently take various paths:
procure the 'plain' sheet from steel producers, then process and subsequently coat it;
or use pre-coated sheet steel to construct their appliances.
The arguments for the first production strategy are that the forming steps can cause damage to the surface and also that coated product is more expensive to purchase. On the other hand, steel strip is easier to coat than a finished appliance (such as in critical areas like folds and edges). Manufacturers receive a pre-inspected surface that is free of defects in the coating. They also save the cost of having their own coating line.
More than just versatile
voestalpine offers appliance manufacturers products with properties that are not easily achieved with their own coating lines. These include colofer® brand strip material that is pre-coated with a structure that can be felt. Engraved metal rollers apply effects to the steel strip with special printing inks; using this method, even the appearance of stainless steel and carbon can be offered. The wide-ranging basic color palette has been expanded in recent years with silver tones and bright colors.
Whether they feature bright or metallic colors or are structured ' the pre-coated material meets the high manufacturer standards with respect to formability. This is demonstrated, for example, with the porthole of washing machines: This round opening in the front wall is deep drawn during production ' stress that the color and coating layers easily withstand.
'One of the customer requirements was that we also had to successfully meet the strictest color tolerances,' recalls Franz M. Androsch. The head of voestalpine Group Research was responsible for research and development in the starting phase of production for pre-coated materials. 'For example, we had to compare our measurement instruments with those of the appliance manufacturers. Later, the fact that chrome-free materials were used gave us the advantage. With that, we were better positioned when the legislators then required this.'
What is better?
It is ultimately the skill of the sales staff that convinces manufacturers of the technical advantages of the developments of voestalpine. This is an approach that, with plenty of perseverance and knowledge, leads to success. With their capabilities, they support the manufacturers in deciding whether to buy a coated material or whether to handle this production step themselves. 'Producers of white goods have always coated (powder coated) themselves and they view themselves as specialists in this field,' says Sales Manager Gerhard Maurer. 'For this reason, enormous persuasion is required to convince internal critics before a change in technology. In the approval phase, for instance, we had an adversary with a major household appliance producer who always wanted to prove to us that our products had a higher reject rate than his powder coating line did. Until one day, when it emerged that 100 percent of our materials were inspected, while his were only sampled. With that, the spell was broken and our comprehensive entry was secured.'
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