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The Coating Factory – Industrial Coatings For a Variety of Applications

Coating Factory

Coating Factory

Coating Factory is a company that provides industrial coatings for a wide variety of applications. They are available in a multitude of colors and provide both aesthetic and protective properties.

Coatings are applied in spray booths that contain air handling systems for temperature and humidity control, as well as paint and VOC capturing equipment. The quality of atomization determines the quality of the sprayed coat.

Pretreatment

The pretreatment process is where a surface is prepped for powder coating. It cleans, removes oils and existing rust spots to make it easier for the powder paint to adhere to metal surfaces. It also makes it more likely that the paint will resist corrosion in harsh environments or extreme weather conditions.

There are several different ways to pretreat surfaces, depending on what the surface will be used for and what performance characteristics it needs to meet. For example, items that will be used in corrosive marine environments may require additional rust and corrosion resistance while indoor surfaces may need protection from UV rays and other environmental damage.

Metal parts are typically cleaned in a tunnel-type wash station, sometimes called a degreasing tunnel or rinsing tunnel, with spray nozzles that release chemicals onto the surface of the items. This is followed by a rinse using deionized or reverse osmosis water to make sure that all of the chemicals have been removed from the surface of the item. After rinsing, the item may be air or oven dried in order to eliminate any traces of water or chemistry that might prevent the powder coating from adhering.

If the metal surface has sharp edges, these might need to be smoothed in order to provide a good base for the powder coat to stick. Some manufacturers also use a blasting process to remove any existing rust or scale on the item, which is an efficient way to quickly and thoroughly clean it.

Most pretreatment systems are based on iron phosphates and have anywhere from two to six stages. The longest sequence is generally used for items that will be exposed to corrosive environments, while the shorter sequences are best suited for items that don’t need that level of durability.

Once the object is washed, a zinc phosphate coating is applied to the metal, which serves to enhance the adhesion of subsequent layers of powder paint. Instrumentation is often used to check the uniformity of the deposited coating, its crystal structure size and the chemical composition. This helps ensure that the final product will be of high quality and perform as intended.

Spray Booth

A spray booth creates a controlled environment where coating materials are applied. This is important for both the health and safety of your employees and for creating a better painting process. The spray booth can help your products dry faster and with a smoother finish. It is also against the law to operate without a proper paint booth.

A typical spray booth is a ventilated work chamber that separates the spray application of surface coatings from the surrounding workspace. Ventilating air typically enters the spray booth through an intake plenum that may be located either on the roof or in front of the enclosure. An exhaust plenum captures overspray (wasted paint that forms a dust) and solvent vapors, trapping them in the filter before they are released into the atmosphere. A fan may also help circulate the filtered air.

Paint overspray that lands on the walls of a spray booth can be airborne and can contaminate other areas of the work area. This contaminate is hard to remove by hand, so you must plan for a regular deep cleaning of your paint booth. A sprayable masking liquid such as Endura-Peel WB Bright White can protect the booth walls from overspray, making the deep clean much easier and faster.

Keeping your intake and exhaust filters clean is vital to the performance of your paint booth. Using high-efficiency filters can reduce the amount of overspray recirculation and fumes that are released into the atmosphere. Regularly replacing these filters will extend the life of your spray booth and improve the quality of your coatings.

The EPA regulates VOC (Volatile Organic Compound) emissions from spray equipment for compliance with criteria pollutant standards. Regenerative thermal oxidizers (RTO) are an effective technology to control these volatile organic compounds and meet the EPA’s emission standards for ground level ozone.

Spray booths come in a variety of sizes and features to suit your specific operation. For example, some systems include observation windows for painters to monitor the work area. Others include RollSeal doors to control contamination between bays. Some are equipped with personnel doors to allow workers quick and easy access to the spray booth.

Electrostatic Gun

If you’re looking to reduce paint waste and boost transfer efficiency, an electrostatic gun is the solution. Traditional spray guns are prone to overspray, which creates waste and serious pollution. OTSON’s electrostatic spray gun technology eliminates overspray, allowing you to make more efficient use of your paint and reduce costs.

When sprayed, a droplet of coating material is charged negatively by an electric current and is attracted to the grounding surface of the workpiece. This causes the coating to stick to the workpiece, improving the transfer efficiency and reducing overspray. It’s also possible to apply much thinner coatings with an electrostatic gun than a traditional one, which can reduce overall cost per square foot of coating.

The electrostatic gun is a powerful tool, but it requires training and careful maintenance to perform at its best. A poorly maintained gun can easily become unusable. To avoid this, lubricate the gun each day after painting. This will prevent the gun from clogging and help you keep your equipment in good working condition for longer.

Another advantage of the electrostatic spray gun is that it can be used on nongrounded items as long as they are primed with a conductive primer. This allows the gun to be used on many different types of commercial and residential projects. In addition to coating furniture, doors, windows and walls, this type of gun can also be used to spray disinfectants and sanitizers on a variety of surfaces.

The only downside of using an electrostatic gun is that it may struggle to coat deeply recessed surfaces. This is due to the Faraday cage effect, which occurs when the negatively charged paint hits a conductive object. For this reason, it’s often a good idea to spray a recessed area with an airless gun first before finishing it with an electrostatic gun. This will ensure that the paint is evenly distributed throughout the recessed area. This is especially important when spraying metal objects, such as a metal locker, that will be sprayed in an enclosed environment. This will minimize the chance of the paint leaking out and becoming a health hazard for employees.

Drying

The drying process is a critical part of the coating operation. It helps to ensure that the product is completely coated and dry before it is shipped out. It also helps to prevent any issues with the product that could occur after the coating is applied.

Different types of drying processes are used depending on the type of coating. For example, some lacquers are cured by crosslinking and do not require an oven cycle to form the film. Other coatings are cured by a combination of classic drying and catalyzed curing. Still others are cured by evaporation of solvents followed by reaction with oxygen in the air over days, weeks or even months to create the film.

The preparation treatment is a series of cleaning and treating steps that may include cleaning, rinsing, etching and blasting. These steps help to remove any residues or deposits on the surface of the substrate that can cause poor adhesion between the powder and the substrate. This helps to provide a smooth and even coating that is both decorative and functional. The finishing process for powder coating involves three stages: surface preparation, application of the coating material and heat curing. This type of finishing provides a wide range of colors, finishes, textures and patterns that are not easily achieved using liquid coating methods.