4 Advice to Choose a Automated powder coating systems

Now that you understand the selection process for a batch powder coating operation, it’s time to determine if a batch line or automated coating system is the right solution for your operation.

Please visit our website for more information on this topic.

Are you launching a large coating operation from scratch and can’t decide what type of line will work best? Have you been powder coating with batch equipment but need to increase throughput? Perhaps you’re bringing powder coating in-house to finish the products your company manufactures, but you’re not sure how to do it. The decision to install an automated finishing system is a considerable one. Before you make the investment, you need to ask yourself if an automated system is right for your company’s operation style and daily coating requirements.

You Need To Powder Coat More Items Per Day

The number one reason to move from a batch line to an automated coating system is to increase throughput. If your business needs to produce a high volume of powder coated parts on a daily or weekly basis, and these parts are somewhat similar in size, you should consider installing an automated line. Since automated coating is a continual process, you’ll almost always be able to coat more parts in a set period of time than if you coated them manually in small batches. But, many problems with throughput can be resolved with less expensive batch equipment.

If you already have a batch system in place, and your production quota is exceeding your current throughput, determine if there is a bottleneck slowing down your operation. If your bottleneck is at the cure cycle, can you add another oven (https://reliantfinishingsystems.com/powder-coating-equipment/powder-coating-ovens/) to improve your capacity? If you’re losing time loading and unloading the parts on racks, is it cost effective to add more employees or build more racks? Evaluate your current system and see if you’ve done all of the simple and affordable expansions to your current operation. Bring in a consultant if you need expert advice. Sometimes a simple fix, like adding another gun or hiring an assistant for your coater, can significantly increase your throughput. If you have already upgraded your batch system and solved all of your bottleneck and speed issues, investing in an automated line is the next logical step to increase production.

You Need To Increase Your Powder Coating Consistency

If you need stringent quality control, an automatic line provides repeatable and consistent finish quality that is tough 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 repeated automatically for each part. As long as the equipment is properly maintained, the results are ideal and consistent. If your current manual approach is too erratic because your coater is having trouble keeping up, or your customer’s finish requirements are very specific, an automatic system can provide highly consistent results when properly operated and maintained by skilled employees.

Your Parts Must Meet Stringent Coating Specifications

There are several common finishing specifications that you may be asked to meet in order to capture and retain a client’s business. Some of these finish standards require you to employ a specific pretreatment process to achieve acceptable results. Others may simply require finished parts to pass a durability test. Depending on your industry or your end-customer uses, your powder coated parts may need to meet national specifications before they can be used in the field.

One group of standards includes the AAMA (American Architectural Manufacturers Association) , , and aluminum specifications. Here is a link to a chart with a comparison of the three standards:http://www.aamanet.org/upload/file/--_Comparisons_4-6-11.pdf

Each standard requires more extensive pretreatment and powder quality processes than the lower one. For example, the specification can be passed by a manual operation, but the , and definitely the , require an automatic pretreatment process (usually of 4-5 stages or more). Dip tanks can work for specialty parts, but if you are looking at part counts of 1,000-2,000 per day, manual solutions are just not practical. Hanging parts on an automatic line is the most efficient way to prepare large quantities of them consistently. Knowing your production requirements and parts specifications makes your system decision process much simpler.

You Need To Reduce Labor Costs

Cost management is an integral part of efficient production. Reducing labor costs on a per part basis can propel a company forward. Automatic lines can almost always reduce the amount of labor required when compared to their manual counterparts, but there is a minimum of how few employees it takes to run an automatic line.

Typically in a small automatic line you will need someone to load the parts, another person to run the automatic spray booth and perform manual touch-up of problem areas, someone to inspect/unload the parts, and a finish line manager who makes sure the employees are doing a quality job and the equipment is running properly. At least one person needs to know how to adjust the pretreatment section and how to maintain the equipment so that the line remains operational. A minimum of 3-5 employees is recommended for even a small automatic line.

You Don’t Need A Great Deal Of Versatility

Automated lines are sized based on the largest, densest parts that will be coated. The pretreatment and curing processes are often calibrated to get premium results with specific parts. Shops that routinely deal with parts that are in the same general size and density range are the best suited for automated coating lines. If you have parts that are substantially different in size and density (such as 10’ long sections of 3” wide railing, heavy 15” by 15” by 20” machine parts and thin 4’ by 4’ by 4’ pre-assembled frames), an automated curing line may not be practical. Although a single automated system can be set up to accommodate all of these parts, the costs to buy and operate it may be prohibitive.

The other consideration that may make an automated system impractical is if your company does not operate in a fairly consistent way from day to day. Specifically, if jobs are frequently being leap-frogged in line ahead of other work or your operating hours vary widely from day to day. It takes a while to get an automated system up and running, and it takes longer than batch equipment to shut down at the end of the day. Shuffling parts around, changing set-ups and re-starting the line can quickly offset the benefits that make an automatic line effective. Automated powder coating lines get the best results when they are used in a consistent and routine manner.

Comparing the Benefits Of An Automated Finishing System Versus A Batch System

If you can satisfy your production and cost requirements with a batch system, you are better served with the flexibility and lower cost of a well-made batch system. However, if your production quotas or part specifications require it, an automated line may be the obvious solution. We always recommend that you have a clear understanding of your production goals before making a system purchase.

If you’re still debating whether you need an automated powder coating system, here’s a summary of  the benefits and drawbacks of an automated line, as compared to a batch system.

Automated Finishing System Benefits:

1. More parts per shift
2. Repeatable finish quality
3. Better pretreatment options
4. Reduced labor per part
5. Efficient use of labor due to constant process
6. Lower powder cost per part  (especially if reclaiming powder)
7. A single automated line is more energy efficiency than multiple batch appliances
8. Consistent, high-end finishes are possible with a quality system

Automated Finishing System Drawbacks:

1. Less flexibility: Parts have to be hung on line in a specific way. Parts are also limited to a certain height, length or width. Changes to any aspect of the coating process can cause costly downtime.
2. Substantial cost increase: The capital equipment cost is significant greater, usually 3-5 times that of a comparable batch system
3. Color changes are more difficult: Reclaim booths are usually for just one color unless you buy a cyclonic or equivalent type powder recovery system. Even then, changing colors is not easy in a reclaim operation. A spray-to-waste booth positioned in line immediately after a reclaim booth is not uncommon, but this increases the total equipment cost as well as the footprint of the installed equipment.
4. Increased training expense: Automatic equipment requires better educated, well-trained employees to operate it. Employee retention is important after they have been trained because of potential downtime when dealing with new hires.
5. Increased maintenance: Automatic lines must be vigorously maintained or they won’t function correctly. Poor maintenance practices can lead to lost production time and wasted labor waiting on the line to be fixed.
6. A problem anywhere is a problem everywhere: Unlike batch systems, where the processes are isolated, a failure in one area of an automated system causes a backlash throughout the line. If a coater has a serious problem in the powder booth of a batch line, other parts can still be prepped and cured while the problem is addressed. If there is a problem in the spray booth of an automated line, the other processes will also come to a halt as soon as the conveyor is stopped.

Careful cost analysis should be performed before deciding on an automatic finishing system. Automatic lines can be very beneficial and improve profitability but their functionality is very specific. They are simply not as versatile as manual batch systems. Pretreatment stages, amount and type of powder to be applied, curing schedules and cool down times must all be calculated before the equipment is manufactured. If you’d like to learn more about the various types of powder coating media, the common steps in chemical pretreatment, and other helpful information that must be taken into account when specifying an automated system, check out our other articles by visiting our Resources page.

Struggling to find a reliable powder coating partner that can deliver high-quality results consistently? Tired of dealing with subpar coatings, extended lead times, and unexpected costs? 

For more information, please visit ZHYAO.

You’re not alone. 

Many manufacturers face challenges when it comes to selecting the right powder coating partner. The consequences of a poor choice can be significant. Poor adhesion and uneven finishes to chipping and fading affect the quality of your powder coating. This can make or break your product’s performance and reputation in the market.

At Acme Finishing, we have been providing top-notch powder coating services to a wide range of industries for over two decades. Our team of experienced professionals has the knowledge and expertise to handle even the most complex projects with precision and care. We have invested in state-of-the-art equipment. This includes automated application systems, advanced pretreatment processes, and multiple paint lines to ensure consistent quality and efficient production. Our facility is centrally located near major transportation hubs. Allowing us to serve customers across the country with ease. We continually refine our processes and stay up-to-date with the latest industry advancements. We deliver the best possible results for our customers.

In this article, we’ll share our insights on how to choose the right powder coating service provider for your needs. We’ll explore the key factors that influence powder coating costs. These factors include coating type, part complexity, order volume, and lead time requirements. We’ll also delve into the advantages of powder coating over liquid coating, such as cost-effectiveness, environmental friendliness, and durability. 

By the end of this article, you’ll have a clear understanding of what to look for in a powder coating partner. You will also learn how to make an informed decision that will benefit your business. You’ll be equipped with the knowledge to ask the right questions, evaluate potential providers based on their experience, capabilities, and customer focus, and ultimately select a partner that can help you achieve your manufacturing goals with confidence.

Factors that Influence Powder Coating Costs

When budgeting for your powder coating project, it’s essential to understand the various factors that can impact pricing. 

• One of the primary considerations is the type of coating required. Standard polyester powder coatings are generally more economical than specialized formulations, such as high-temperature resistant or anti-corrosive coatings. The performance requirements of your part, including durability, UV resistance, and chemical resistance, will dictate the type of coating needed and, consequently, the cost.
• Masking and special packaging requirements can also add to the overall expense. If your part requires specific areas to be left uncoated or features intricate details that need protection during the coating process, additional labor and materials will be necessary. This may involve the use of high-temperature masking tape, custom plugs, or specialized racks to ensure proper coverage and protection.
• The substrate material and thickness of your part also play a role in pricing. Thicker or denser materials may require more powder and longer curing times to achieve the desired coating thickness and adhesion. This increased material usage and processing time can translate to higher costs. Similarly, larger parts or those with complex geometries may demand more resources. They  require attention during the coating process, impacting the final price.
• Order volume and quantity per run are other significant factors to consider. Larger orders or recurring production runs may qualify for volume discounts. The setup costs can be spread across a greater number of parts. This is where partnering with a powder coating provider with experience in your industry and the capacity to handle your specific volume requirements can be beneficial.
• Finally, the timeliness and lead time expectations for your project can influence the cost. Rush orders or tight deadlines may require additional staffing, overtime, or expedited shipping, which can incur premium fees. It’s important to communicate your timeline requirements clearly with your powder coating partner. Working together develops a realistic schedule that balances your needs with their production capabilities.

The Advantages of Powder Coating vs. Liquid Coating

When considering powder coating for your parts, it’s helpful to understand the advantages it offers compared to traditional liquid coating methods. One of the most significant benefits of powder coating is its cost-effectiveness. The application process is highly efficient, with minimal waste and overspray. Unlike liquid coatings, which often require multiple coats and longer drying times, powder coating typically achieves full coverage in a single application. This efficiency translates to lower material costs and faster production times.

Powder coating is also a more environmentally friendly option. It emits zero or near-zero volatile organic compounds (VOCs), reducing the environmental impact of the coating process. This not only benefits the planet but also creates a safer working environment for employees, Helping companies comply with increasingly stringent environmental regulations.

In terms of durability, powder coating often outperforms liquid paint. The electrostatic application process and thermal curing create a strong, cross-linked bond between the coating and the substrate. This results in a thicker, more uniform finish that is resistant to chipping, scratching, and fading. Powder coated parts can withstand harsh environments, chemicals, and UV exposure, making them ideal for both indoor and outdoor applications.

However, there are some instances where liquid coating may be preferred. For parts with extremely tight tolerances or intricate details, liquid coatings can provide a thinner, more precise finish. This is because liquid paint can flow into hard-to-reach areas and create a smooth, even surface without adding significant thickness. Some specialized high-temperature applications may also require liquid coatings. This is due to their specific formulation and curing requirements.

Customization Options and Special Requirements

One of the advantages of powder coating is the wide range of customization options available to meet your specific project needs. Custom color matching is a popular request, allowing you to achieve a precise shade that aligns with your branding or aesthetic requirements. Powder coating providers with advanced color matching capabilities can create custom formulations that meet your exact specifications, ensuring consistency across your parts.

However, it’s important to note that developing a custom color may require additional time and cost compared to using standard, off-the-shelf color options. The process involves creating a unique formula, testing for compatibility and performance, and potentially adjusting the manufacturing process to accommodate the new color. Discussing your color requirements early in the project planning stage can help your powder coating partner provide accurate lead time and cost estimates.

Unique masking and special tooling requirements can also impact your project’s timeline and budget. If your part features areas that need to remain uncoated, such as threaded holes, mounting surfaces, or electrical contact points, specialized masking techniques may be necessary. This can involve the use of high-temperature masking tape, custom plugs, or reusable silicone caps. Developing and applying these masking solutions requires additional labor and materials, which can add to the overall cost of the project.

Similarly, parts with complex geometries or unique hanging requirements may necessitate the creation of custom tooling. This can include specialized racks, hooks, or fixtures that allow the part to be properly supported and oriented during the coating process. The development and fabrication of these tools can add to the project’s lead time and expense. However, they are essential for ensuring consistent coverage and preventing damage to the part.

When considering customization options, it’s crucial to work closely with your powder coating partner to understand the implications for your project. They can provide guidance on the most cost-effective and efficient solutions based on their experience and expertise. By collaborating early in the design and planning phase, you can make informed decisions that balance your specific requirements with production feasibility and budget constraints.

Qualities to Look for in a Powder Coating Partner

Selecting the right powder coating service provider is a critical decision that can impact the success of your project and the quality of your final product. When evaluating potential partners, there are several key qualities to look for that can help you make an informed choice.

• Experience and knowledge of the staff are paramount. A powder coating provider with a team of seasoned professionals who have a deep understanding of the coating process, material properties, and industry best practices can offer valuable insights and solutions for your specific needs. They can draw upon their expertise to recommend the most suitable coating options. They will also troubleshoot potential issues and optimize your part design for successful coating results.
• Advanced equipment and technology are other essential factors to consider. Powder coating providers that invest in state-of-the-art equipment, such as automated application systems, programmable curing ovens, and advanced pretreatment processes can deliver consistent quality and efficiency. These technologies help minimize human error, reduce waste, and improve throughput. Ultimately benefiting your project’s timeline and budget.
• Proper surface preparation is crucial for achieving strong adhesion and long-lasting coating performance. Look for a powder coating partner with robust pretreatment and washing capabilities. This includes multi-stage wash systems that effectively remove contaminants, such as oils, dirt, and oxides, from the part surface. A provider that places a strong emphasis on pretreatment and quality control measures can help ensure your parts are properly prepared for coating. They will perform optimally in their intended environment.
• Redundancy and flexibility in production are also important considerations. A powder coating provider with multiple paint lines and curing ovens can accommodate a wide range of part sizes, coating types, and production volumes. This redundancy allows for greater scheduling flexibility and can help prevent production bottlenecks or delays. It also provides a backup plan in case of equipment maintenance or unexpected downtime. This ensures your project stays on track.
• Inventory management and just-in-time (JIT) delivery capabilities can be valuable services for manufacturers looking to streamline their supply chain and minimize on-hand inventory. A powder coating partner that offers warehousing, kitting, and JIT delivery options can help you reduce storage costs. This will also improve cash flow and ensure that your parts arrive at your facility precisely when needed. This level of logistical support can be especially beneficial for projects with complex assemblies or tight production schedules.
• A centrally located facility with easy access to major transportation routes can simplify logistics and reduce shipping costs. Look for a powder coating provider strategically situated near highways, airports, or ports that can efficiently serve your manufacturing location. This proximity can help minimize transit times. Reduce the risk of damage during shipping and provide greater flexibility for urgent or time-sensitive deliveries.
• Industry versatility is another important factor to consider. A powder coating partner with experience serving a wide range of industries, such as automotive, aerospace, consumer products, and medical devices, can bring a wealth of knowledge.  They also bring problem-solving skills to your project. This can draw upon their diverse expertise to recommend innovative solutions and anticipate potential challenges. In addition, they will ensure that your parts meet the specific requirements and regulations of your industry.
• A commitment to customer service and project success should be a top priority. Look for a powder coating provider that treats your project as a partnership. They take the time to understand your unique needs, goals, and constraints. They should be proactive in communication, transparent about timelines and costs, and dedicated to delivering results that meet or exceed your expectations. Providers that value relationships and go above and beyond to ensure your satisfaction can be as asset for your business.

Getting Started With Acme Finishing 

Choosing the right powder coating service provider is a critical decision. This will impact the quality, durability, and cost-effectiveness of your manufactured parts. By understanding the factors that influence powder coating costs, such as coating type, part complexity, and production volume, you can develop a realistic budget. This provides appropriate expectations for your project.

At Acme Finishing, we pride ourselves on being a trusted partner for businesses seeking exceptional powder coating services. With our state-of-the-art facility, team, and dedication to success, we are equipped to handle projects of all sizes and complexities. Whether you need standard or custom coatings, specialized masking, or logistical support, we have the knowledge and resources to deliver results that exceed your expectations.

For more Automated powder coating systemsinformation, please contact us. We will provide professional answers.