The powder process - Introduction

There are two principal technologies that are the back-bone of the coatings industry:

1. Liquid coating technology (wet), which has been applied for more than two centuries
2. Powder coating technology (dry), which has been applied on an industrial scale for some 30 years.

The global average annual growth for powder coatings has been approximately 7-9% over the last 10 years. From country to country worldwide these figures have varied considerably. This relatively high performance has been achieved by autonomous growth on the one side and by replacing liquid coatings on the other.

When the opportunity arises for coating technology selection, there are a multitude of factors that need to be considered and judged for their importance and weight of impact. We discuss in The Powder Process:

1. Applied materials
2. Application techniques
3. Health, safety and environmental implications
4. Quality achievements
5. Economic advantages.

Although thermoplastic resins were initially employed, the thermosetting powders that were later developed and applied have opened up much wider fields of use. The accelerated application of thermosetting powder coatings have therefore been a logical development in light of the more stringent environmental requirements and the demand for more commercially attractive alternatives compared to conventional industrial liquid coatings.

There are many advantages that make the choice of applying thermosetting powder coatings so attractive to the coating company:

1. Powder is immediately ready for use
2. Less powder wastage during the application process
3. Reduced health hazard in case of exposure of operators
4. Superior cured-film properties
5. Lower capital investment costs.

Today, many of the advantages of powder coatings are no longer actively promoted as powder has secured its place within the finishing industry. Advances in powder technology have brought new opportunities, such as:

1. Low film thickness powders
2. Substrates other than metal can be coated
3. Low curing temperatures can be achieved.

Today, the selection of a powder coating is dependent upon:

1. Market demand
2. Industry requirements and standards
3. Price and finished cost.