Coating Factory
Industrial coatings prevent rusting, chipping, flaking and fading of color. They can also be molded into different shapes and textures. They are available in a variety of colors and finishes.
To ensure the quality of the coating, it is essential that workers follow manufacturer’s guidelines. This will ensure that the powder coat adheres properly to the surface of the part.
Cost-Effective
The coatings industry is in a constant state of innovation, as companies strive to meet customer demands while maximizing efficiency and cost savings. These goals are achieved through a combination of processes and techniques. These techniques include investing in advanced technology, reducing waste, and using coatings that are durable and cost-effective.
Powder coating is a durable and affordable process that can protect metal and wood products from corrosion. It can also protect equipment and devices from damage by abrasions or impacts. Powder coating is also eco-friendly, as it does not require solvents or other toxic chemicals. It is also safer than other spray painting methods, which can lead to worker injury and illness. Additionally, it saves money by eliminating the need for protective gear and clothing.
A typical powder coating setup costs around $10,000 to $20,000. This includes essential equipment such as a powder coating gun and curing oven. It is a major investment, but it provides many benefits that make it worth the expense. For example, it reduces inventory holding and stockouts and improves order tracking and shipping. It also makes the overall production process more efficient.
Another way to cut down on costs is by buying powder coating from a third-party supplier. These companies can provide you with a better price based on the expected volume of orders over the year. They can even give you a discount if the expected volume is lower than expected.
Some other ways to cut down on costs are by avoiding waste and investing in efficient business practices. Companies can also invest in a quality assurance system that will help them save money by reducing the number of products that need to be reworked.
Moreover, they can improve quality by using digital tools to scan and analyze surfaces for defects. For instance, a company that produces aircraft parts can use a cross-cut tester to assess the surface’s adhesion and corrosion resistance. These systems can also save time by allowing companies to monitor the quality of their work.
For instance, AkzoNobel’s Troy facility uses a virtual reality (VR)-based training tool for its spray painters. This tool uses the VR headset to immerse the trainee in a virtual spray booth, where they can see what they are doing wrong and improve their technique. It also helps them to learn how to save paint, resulting in huge cost savings for the company.
Durable
Coatings are used for a wide range of products, from cars to medical equipment. They protect these products from the elements and provide a stylish appearance. Coatings can also help to increase the durability of a product, making it more resistant to wear and tear. This can reduce maintenance costs and improve the lifespan of a product. Coatings are made from a variety of materials, including metals and plastics. They can be applied using several methods, including spraying and thermal deposition. Coatings are also available in a wide range of colors and textures.
The coating industry is constantly striving to create more durable coatings that are environmentally friendly. One example is the development of biobased coatings that are derived from natural products. These coatings are designed to be more durable than traditional paints and offer a range of advantages, including reduced toxicity, improved performance, and increased sustainability. Another example is a new type of seaweed-based coating that can prolong the shelf life of fruits and vegetables. The coating contains protein from seaweed, cellulose from wood, and turmeric extract to keep foods fresh for days. The coating is also completely edible and washable.
Durability is a key property of all coatings, and the exact properties that determine a coating’s durability depend on the environment in which it will be used. For example, the demands for a protective coating on an oil rig will be different from those of a residential application. In both cases, high-end durability attributes such as color and gloss retention are critical.
The desire for greater durability is driving demand for powder coatings, according to Jean-Paul Moonen, global segment manager for architectural coatings at AkzoNobel. This translates into LEED points for architects, opportunities for window and door manufacturers to offer longer warranties on their products, and lower maintenance costs for building owners.
Achieving a higher level of durability requires advances in all aspects of the coating system, from raw materials to formulations and applications. These improvements include a move to low VOC resins, the development of innovative additives and pigments, and the use of digital tools for inspection and predictive maintenance.
Environmentally Friendly
Eco-friendly industrial coatings are a great way to limit the impact of manufacturing on the environment. They also offer a number of benefits, including reduced energy consumption and increased durability. In addition, they can be made from renewable resources or recycled materials, making them more environmentally friendly than traditional paints. These coatings are also available in a variety of colors, textures, and finishes. Many manufacturers have also started to promote their environmental certifications, which can help customers make informed decisions.
The world’s largest economies, the US and China, are enacting policies that support net-zero emissions in major industries like coatings. This is a major driver of the sustainable coatings market. It also opens the door for newer startups and multiple M&A opportunities in the industry.
Waterborne industrial coatings emit zero VOCs and are safer for the environment than solvent-based coatings. They are also less toxic to workers and easier to clean up. This helps reduce air pollution in cities and communities, while also reducing waste and water use. In fact, the global chemical industry has cut its VOC emissions by 80% over the last 25 years.
Powder coating is a popular method for refinishing metal products, such as metal patio furniture and doors, aluminum window frames, and wrought iron fences. It is also a favorite refinishing method for kitchen appliances and automotive parts. Its durable finish protects the surface from corrosion, abrasion, heat, and chemicals. Powder coatings are also eco-friendly, requiring no VOCs during the spraying and curing process.
The development of green, sustainable, and biodegradable coatings is a growing area of research and innovation. These coatings are more durable than their conventional counterparts and provide a better protection against corrosion, weathering, UV radiation, and abrasion. They are also more cost-effective and easy to apply.
Manufacturers of environmentally friendly coatings are finding new ways to improve their manufacturing processes and materials. One way is to promote the use of recycled plastics in their manufacturing. The use of recycled plastics in their production reduces carbon emissions and the need for fresh raw materials. Another way to improve sustainability is to explore alternative sources of raw materials, such as biomass and plant-based materials.
Time-Saving
When a company chooses to outsource powder coating, it can save time and money in many ways. For example, it can cut costs by reducing item replacement expenses. Coating metal items also helps extend the life of those items, meaning fewer repair and maintenance tasks. Additionally, it can reduce employee downtime due to item failures.
One way to maximize efficiency in the coating process is by leveraging automation and technology. This can help businesses streamline their processes, minimize waste, and improve quality control. For example, using a digital system to track coating quality can save time by reducing the need for manual inspections and minimizing rework. In addition, using a paint thickness gauge with LED light indicators can save time by making it easy to quickly and accurately measure coating thicknesses.
Coating companies can also use technology to reduce energy consumption during the manufacturing process. For instance, by using a resin that cures at a lower temperature, they can decrease energy usage in their own plants and their customers’ facilities. In addition, they can use sensors to monitor the temperature of curing tanks and other equipment. This will help them identify potential problems and take corrective action before the problem occurs, saving money.
For example, PPG has made significant efforts to reduce its energy consumption by shortening cycle times and improving its manufacturing processes. It also uses a wide range of tools to ensure that its facilities are operating efficiently, including conducting periodic energy audits and implementing best practices. This has resulted in a 10% reduction in energy consumption in the past three years.
Another way to save on coating expenses is by negotiating a volume agreement with your supplier. This can be a great way to get discounted prices and increase your profit margins. However, you should be aware that you will be risking a price break if you don’t meet the expected volumes.
Another way to save on powder coating costs is by taking advantage of financing options offered by some equipment suppliers. These options can help you avoid the upfront cost and start your business with a manageable financial commitment.