India's Powder Manufacturing capacity

Many of our subscribers be surprised to see a tabular analysis instead of a regular pie chart which appeared regularly at this space in this month every year.

There has been a change in policy matters of some of the major powder manufacturers around the nation to  not to disclose the powder production figures.  Also many of the medium sized powder manufacturers are extremely reluctant to give away their production figures. The reason for this iron curtain policy is unknown. This has made our analysis a bit difficult, and the pie chart meaningless. In the absence of production figures of some major companies  we have decided to tabulate these figures alphabetically.

With the data we collected during the past few months, it seems that the total production of powder coatings in India has climbed up to 39,000 tons. This is 5000 tons more than last years figure of 34000 tons.

Parallel to this data collection we had been running an opinion poll on our website for our viewers estimate of the size of the Indian Market. The poll  results show the shown in the adjacent graph. 35% of the voters have voted for a figure of 45000 tons.  

The Toppers
Despite of all this confusion, the Indian Powder coating Industry appears to be dominated by Polycoat Powders Ltd. It Produced 5400 tons of powder last year. Polycoat Powders Ltd., is an associate company of M/s. Kansai Nerolac Paints Ltd., occupying the No.1 position in the powder coating segment in India. Polycoat Powders Ltd. is an ISO-9001 certified company and is engaged in the manufacture of Thermosetting Powder Coatings since 1984. The powders are manufactured in technical collaboration with Kansai Paints - Japan which is among the top 10 Coating companies in the world. The manufacturing facilities for Powder Coating are at Lote Parshuram in Ratnagiri district, Maharashtra & at Bawal,Haryana.

This seems to be followed by Marpol Pvt Ltd producing 4940 tons. Marpol is one of the leading manufacturers of Powder Coatings in India. It offers over 1300 shades of powders in a range of chemistries, finishes and gloss levels, for almost any type of interior or exterior application.

Commenting on the analysis Venugopal,VP-Marketing. Marpol said, In the OEM segment of the consumer durable &appliances, Polycoat holds the leadership while Marpol is the undisputed leader in the Job coating market. Its is now understood that the powder coating industry has two distinct leaders in two distinct battle grounds."

Let's now talk about production figures from some of the manufacturers the manufacturers. This is given below in an alphabetical order.

 

Bijoy Mukherjee informed us on phone that Berger Paints India Ltd produced 3600 tons of powder during the last year. Ashok Sharma the vice president is also a regular visitor to our website.

Sunil of Bharat Coatings informed us from Haryana "Our company produced 200 tons of powder during the last It. We also have dealers in Gujarat Himachal and a few other states. I am the only person handling my business, I am just 26 years old and I started powder production three years back. The growth rate has been in double digits.  I found your website while searching  Google about three months back for powder coating .  Your site is the only website in India where I find all the information powder coating." Sunil suggested to update the city wise job coaters list on  our website.

Deepak Muley of Color Coat,  Pune informs a figure of 150 tons . "It was 60 tons last year. we target it to 250 tons. Since we are a expert team with 25 years of experience, we manufacture best quality powder." , he said

Mega Chadha from Icon Powders informed in her email "We have three lines of production with a capacity of 100kgs, 150kgs and
250kgs. With a monthly production capacity of 120 tons on 8 hours single shift basis. For our last Fiscal year 2006-07 we produced 550 tons."

Deepak Madan from Kripton Powder Paints P. Ltd informed us a figure of 1460 tons, Maharani Paints (I) Pvt Ltd produced 2160 tons of powder in 2006-07, informed RK Bhatia

AK Tripathi of Paramount said "Your website is often used by some of the companies for their own commercial use".  He suggested "You must avoid that. The information provided by sponsors and advertisers sometime merges with the information provided by your website, and gives an incorrect impression as if its your website's information. This gives a negative impact on your credibility. Also the annual powder production analysis you do is often misleading . Certain manufacturers provide exaggerated figures to raise there position in your chart."  He further confirmed "We produced 1700 tons last year. Our OEM and other market ratio now will be around 40:60 approx."

Ajit Gupta from Rapid Coat said "Our Production and sales figure for 2006-07 were 2000 tons of epoxy -polyester and 750 tons of plastic powder."


Kuldeep Verma of Sharp Coating in Faridabad confirmed a figure of 420 tons. From Titan Paints and Chemicals Ltd Manmoham Samantra informed to produce 990 tons while Sambhiaya of Trident in his telephonic talks said " We made around 120 tons. Our presence is basically in South India

Jayesh Ponda from  Vijay Enterprises  informed "We did 775 tons last year. Most of our supplies are through distributor".


To get an estimate of the total figure we had to add an estimated value of the rest of the manufacturers  which totals up to  39,000 tons. We have arrived this figure by adding:

a. Production  figures officially declared by the manufacturers.
b. For the companies from which the data was not available, we assumed it being the same as last year.
c. For those who have given us no clue, we have depended on third party sources.
 
Mukul Bhore of DOW chemical mentioned earlier that approximately 10,000 tons of  epoxy was used last year for producing the powder coatings . DOWs contribution is about 10 percent. "We are aiming it to be 50 %" he said.  He suggested that India Powder Coating should try to collect further details of the powder consumption like the amount of powder used for refrigerators washing machines air conditioners etc. The will give a correct growth pattern.

He further suggested that data about the Pipe Coating market, which is about 10 percent of the epoxy market. should also be incorporated in the analysis.

There is always a bigger fish
Ms Zhuminnan and Ms Liu Zexi from Asia Coat informed in her email, "In China, our figure is 510,000 ton in 2005 and we are doing statistic works about 2006 now".  This figure is about 15 times more than the Indian Production. Further more some of the Chinese white goods giants produce their own powder. Our sources indicate, Haier, China,  a producer of household appliances make about 7,000 tons of powder per year for there own use. This is more that India's No 1 Powder Manufacturer.

Moderator: We thank all those who helped to compile these details. We will continue to conduct similar surveys and share the results with you. Your suggestions and  support are most welcome. While we have used our best efforts in collecting and preparing the information  we do not assume, any liability for any loss or damage caused by errors or omissions, whether such errors or omissions resulted from negligence, accident or other causes. The subscribers may use their own discretion while using the information.


Site update
On the request of Mayur Chem Distributors Pvt Ltd from Kolkota we have added a new page to our directories. The Powder Coating Suppliers page.
Almost all the powder manufacturers have a dealer network present in most of he major cities. This is the link which connects the powder user to the powder manufacturer.  We invite all the powder dealers to promote there business through our new  page. Please visit www.ipconweb.com/listing.htm for other promotion options

 

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Infomercial from Vijay Enterprises Pvt. Ltd Vijay Enterprises Pvt. Ltd. Vijay Enterprises is a leading manufacture of powder coating materials (PCM) in India. VIJAY COAT today stands as a Reliable source of High Quality and Durable Powder Coating materials at very reasonable prices. Vijay's PCM find extensive application for industrial and other demanding applications. Vijay enterprises was incorporated in 1995 with a view to supplying quality PCMs to Indian industry. Vijay's manufacturing set up is equipped with best machines from M/s Buss AG Switzerland who are world's largest manufacturer of Powder Coating Machines. Vijay has now established itself and earned a name for its quality supplies and prompt delivery at very economic prices. VIJAY has multi-locational production facilities near Ahmedabad in western India and at Silvassa in the U T of Dadra & Nagar Haveli, 200 Kms off Mumbai. This makes it a competitive source of PCMs to all customers.  Vijay Enterprises Pvt. Ltd. Admin. Office : 103, Gita Bhavan, 1st Floor, Opp. Vijay Transport, Narol Char Rasta, AHMEDABAD 382 405. GUJARAT. INDIA. Telephone: +91-79-2532 9057, 25329374,Fax: +91-79-2535 9481 Email: jayesh@icenet.net web: vijay-powdercoat.com

Asian Paints to set up mega plant in Haryana
India's leading paint manufacturer Asian Paints has received a green signal to set up a mega paint plant in Haryana's Rohtak district.

The Haryana Investment Promotion Board Tuesday decided to provide 160 acres of land to Asian Paints at Rohtak's industrial model township (IMT).

The plant will come up in Chief Minister Bhupinder Singh Hooda's home district.

Financial Commissioner (Industries) P.K. Chaudhary said that the plant, on full capacity utilization, will have a turnover of Rs.46 billion (Rs.4,600 crore). The annual capacity of the plant will be 400-500 KL of paint.

He said that the plant will generate annual revenues of Rs.400 million for the state and Rs.7 billion for the central government.

The company will invest Rs.6 billion in the first phase and create 1,100 jobs.

The IMT at Rohtak is being set up on the lines of the IMT at Manesar near Gurgaon, which has attracted billions of dollars in investment from foreign and Indian investors. <more>

Asian Paints arm to sell stake in Asia Paints Queensland
Asian Paints said on Friday that Asian Paints (Q, N,C,F)* (International), Mauritius, a wholly owned subsidiary of the company, entered into a share purchase agreement for sale of its entire stake in Asia Paints (Queensland) on Jun. 14, 2007, subject to due diligence.

Further the company said that above share purchase agreement is subject to requisite approvals as may be necessary. <more>.


PPG announces new appointment for refinish business
The automotive refinish business of PPG Industries has appointed Lee Smith as director of strategic growth and acquisitions for PPG Automotive Refinish, North America, with effect from 1 June.

Smith has served as director of PPG Refinish Canada since 2002. Brian Roberson, senior account manager for PPG Aerospace, will succeed Smith in Canada.

In his new position, Smith will be responsible for developing growth strategies to meet short- and long-term profit and growth objectives. Smith will relocate to the North American headquarters for PPG Automotive Refinish in Strongsville, Ohio.

Headquartered in Pennsylvania, US, PPG supplies automotive original and refinish coatings, flat glass, automotive original and replacement glass, continuous-strand fibreglass and chlor-alkali and speciality chemicals. The company has around 30,000 employees and 125 manufacturing facilities and equity affiliates in more than 20 countries.

Recently, Asian PPG, an equal joint venture between PPG Industries and Asian Paints, acquired ICI India's automotive refinish business for US$12m, to support the growth of its automotive refinish business in India.

Berger Paints ties up with Cartoon Network
KOLKATA: Berger Paints India has tied up with Cartoon Network, a Time Warner company, to get a slice of the Rs. 5,000-crore kids' product market.

Berger on Wednesday launched a do-it-yourself kit, which would allow kids to paint their walls with toon characters like Tom and Jerry. The product, called Berger Kidz, can be used on existing walls or freshly painted ones and can also be painted with professional help. Abhijit Roy, Senior General Manager (Marketing), Berger Paints, said a paint product would be distributed through non-paint channels like malls, toy shops and kids gift stores. "We expect this to play a big role in the promotion of this niche product,'' he said here at a press meet.

P. K. Sengupta, Senior Vice President (Retail), said the company, which was now the number two in the Rs. 6,500-crore organised paints market, had been having kids as part of its target audience. It recently launched a product called `Galaxy,' which helped create glittering stars and moons on the ceiling. The product, Mr. Roy said, was doing well. The toon paint was the second offering, which promised high margins.

Jotun Continues to Grow
Last year’s strong growth has continued the first four months of 2007, and Morten Fon, President and CEO of Jotun, is satisfied with the effects of the organic growth strategy.
By Rapeepat Jumnongjit

Jotun's sales this interim period (1 January – 30 April) totalled NOK 2,872 million, up NOK 420 million compared to the same period in 2006, while operating profit increased from NOK 223 million to NOK 294 million. Group profit before tax came to NOK 301 million, a 37 percent increase over the 2006 figure of NOK 220 million.

“We are satisfied with the growth that we have seen so far in 2007, and we expect profitability in 2007 to exceed the level of 2006”, says President and CEO Morten Fon.
Jotun Powder Coatings

The division has global segment responsibility for the powder coatings. The product portfolio caters for the architectural, functional and industrial market segments to both protect metal surfaces from corrosion and add colour and style to their appearance.

The market situation for Jotun Powder Coatings is generally good. Both sales and profit before tax grew during the first four months of the year compared to the same period in 2006. Jotun Powder Coatings has achieved high sales in markets like India, Malaysia, Indonesia and Vietnam. Margins are tight in some markets because of high raw material prices, but in general, the division’s profit has improved over this interim period.<more>

Jotun Promotes Safety And Environmental Awareness On World Environment Day
6/14/2007
Belle Chasse, LA - Jotun, a leading producer and supplier of paints, coatings and powder coatings, furthers its commitment to workplace safety and ecological preservation by celebrating World Environment Day with three competitions aimed at promoting environmental and safety awareness among employees and their families. The only paint manufacturer which is a member of the Emirates Green Building Council, Jotun’s ecological initiatives include a comprehensive recycling program which has enabled it to avoid toxic leaks into the environment and reuse 9.6 million liters of its waste water and 63,000 liters of its waste solvents last year.

The company awarded the winners of the ‘Poster’, ‘Slogan’ and ‘Locate & Control the Hazard’ competitions during its World Environment Day celebration yesterday, which was boosted by the presence of Mr. Redha Salman, Head of Environment Protection and Safety Section of Dubai Municipality. In addition to taking part in various activities, employees and their families also had the opportunity to view the winning entries, which were on display during the event.

Entries to the three contests were pre-judged and winners were declared at the awarding ceremony. The poster competition was open only to school-age children of employees, who had to highlight conservation of natural resources, his/her role in pollution prevention and control and global environmental issues with their choice of media, which were supplied by Jotun. Aimed at raising safety awareness, the Locate & Control the Hazard competition required participants to identify the hazard in the work area, create and implement a corrective action plan and highlight the positive results. <more>
 
Defence firm gives warships ‘green’ coat of paint
Comment Warships might be the last thing you'd expect heralded as environmentally friendly, but defence firm BAE Systems is claiming exactly that.

Changing the way they have painted the Type 45 anti-air warfare destroyer, Govan-based BAE Systems have saved tens of thousands of pounds and enough paint to cover 12 football pitches.

Solvent-based paint has been replaced by a powder-coating process for component parts of the ship, cutting down the amount of solvents emitted into the atmosphere.

At the same time, water and epoxy-based paints are being used instead of solvent based ones for other parts of the ship, leading to greater levels of recycling. This has cut the levels of landfill waste they produce by 326 tonnes a year.

As a result of the changes, BAE Systems are saving 12,600 litres of paint in the Type 45 programme alone and have reduced emissions by 10 tonnes a year. Their efforts have earned them Business Commitment to the Environment UK Best Practice Award.

"This new method not only saves us time and money but is also more environmentally-friendly, which is a huge bonus," said Fred Stephenson, BAE Systems surface fleet solutions outfit manager. He added: "The days of workers using a tin of paint and brush are long gone." <more>

Akzo to buy North American wood coating producer.
Chemcraft Holdings, a producer of industrial wood coatings based in Winston-Salem, NC, USA, will be sold to Akzo Nobel. The transaction is anticipated to be completed in 3Q 2007. Chemcraft has around 500 employees and nine production units located in Brazil, Canada and the USA. In 2006, the company posted revenue of $145 M. Chemcraft will be integrated into Akzo's Industrial Finishes unit based in Louisville, KY, USA. For its coatings division, Akzo has just expanded capacity by 150,000 gallons/y and added around 11,000 sq ft of manufacturing space at its automotive refinish unit in Pontiac, MI, USA. Akzo also recently opened its fifth Chinese powder coatings unit in Chengdu. The company seeks to boost its sales from China to $1 bn by 2010.

Lloyd's Register and International Paint join forces to support shipyards in China
Coating Flash June 04 2007
Lloyd's Register and International Paint have teamed up to offer shipyards in China step-by-step advice on how to prepare to meet the requirements of the new Performance Standard for Protective Coatings (PSPC) as the industry looks to increase vessel safety and lifecycles by preventing corrosion. This new partnership has been offering interested Chinese shipyards a free consultancy, or "gap analysis" survey, comparing their current processes for coating a ship's water ballast tanks to those that will be required under the PSPC regulations adopted late last year by IMO, the International Maritime Organization. To date, Lloyd's Register and International Paint (IP) have completed "gap analyses" for four of China's biggest private and state-owned shipyards and have agreements in place to extend this service to many other leading yards in the country. Many yards in Korea, for example, have already begun accepting PSPC-compliant contracts for new vessels. And while ships have yet to be built to the new PSPC regulations, some yard executives believe the process may add 10% to construction costs.

ICI brushes aside £7.2bn bid from Dutch rival
ICI, one of Britain's most famous industrial names, has rebuffed a takeover approach from Akzo Nobel, its Dutch rival, valuing it at £7.2bn.

The Dutch chemicals company, which owns the Crown brand of paint in Britain, is understood to have made an indicative offer of around 600p for ICI in the past few weeks. The preliminary offer was rejected by the board of ICI, led by chief executive John McAdam, as too low. Shares in ICI closed at 549p on Friday.

Akzo Nobel has long coveted ICI's very profitable paints business, Dulux

Takeover speculation has surrounded ICI for several months, helping to drive up its shares by almost 25pc since the start of the year. Akzo Nobel has long been tipped as the most likely suitor and was revealed on Saturday to have mandated Morgan Stanley, the US investment bank, to advise it. Akzo is flush with cash after selling its pharmaceutical division, Organon Biosciences, to Schering-Plough of the US earlier this year for €11bn (£7.5bn). The company has long coveted ICI's paints business, Dulux, one of the most profitable in the world with strong market shares in Britain, eastern Europe and Asia. <more>

Broken Arrow business destroyed by fire
(BROKEN ARROW, Okla.) June 4 - Fire investigators say they should know the cause of a fire that destroyed a Broken Arrow business by Tuesday.

An employee found the fire about 4:30 this evening at Broken Arrow Powder Coating, Inc. in an industrial park near Elm and Elgin.
Broken Arrow Powder Coating is a specialty paint shop specializing in lawn furniture and car paints. The business specializes in power paint coats and uses large ovens to melt the paint.

Neighbors say they saw flames coming from one of the ovens. The smoke plume could be seen from mid-town Tulsa. <more> <video>
 
Art expert puts broken eagle under careful eye
Margaret Little (left), a conservator at Winterthur, takes a look at the shattered eagle with Lorraine Dion, Middletown's Main Street program manager.
MIDDLETOWN -- An art expert Friday inspected Middletown's broken eagle, a town icon perched for nearly a century atop a World War I monument in Cochran Square that crumbled during a recent restoration attempt.

Town employees drove Margaret Little, an objects conservator at Winterthur Museum, near Wilmington, to the town's water department on Lake Street where a foreman showed her the partially reconstructed eagle and a box of pieces.

Little's prognosis: the eagle needs "an awful lot of repair," and a reconstructed statue may not fare well in the elements.

"You do have enough parts and you might be able to put it back together, but whether or not that would be able to stand what's going on in the outside atmosphere is another question," said Little.

The eagle shattered about a month ago when the town had the monument powder-coated, a process like painting that would have baked on a brilliant gold sheen.

The eagle apparently had been broken and soldered together years ago. Before the eagle was to be powder-coated, it was prepped in an oven, where it fell to pieces. <more>

Sherwin-Williams, Paint Makers Win Lead Suit Ruling (Update4)
June 15 (Bloomberg) -- Sherwin-Williams Co., DuPont Co. and other former makers of lead-based paint won dismissal of a suit by cities and counties in New Jersey claiming the companies' products endangered public health.

The New Jersey Supreme Court said municipal and county officials can't sue paint manufacturers for creating a public nuisance with their lead-based coverings because state law doesn't give them the right to do so. Shares of Cleveland-based Sherwin-Williams, the largest U.S. paint maker, rose 2.3 percent. Wilmington, Delaware-based DuPont rose 1.9 percent.

``It's a very unfortunate day for the lead-poisoned children in New Jersey,'' said Fidelma Fitzpatrick, a lawyer representing the cities and counties in the case. ``Children will continue to live with this poison in their homes while the companies that put it there will continue to turn their backs on the kids.'' <more>


TPR2 Introduces a Heat Insulating, Fire Extinguishing Coating for Car of Tomorrow NASCAR Applications

WATERBURY, CT - Dec 2006 - TPR2, Thermal Product Research, announces it's latest new fire safety product for professional motorsports...a FIRE EXTINGUISHING, FIRE BARRIER, FLEXIBLE WATERPROOF COATING. AFESTM (short for Automatic Fire Extinguishing System) Flexible Fireshell(TM) Coating is the first of its kind. This new product from TPR2 aggressively reacts to extinguish flame, heat and the associated smoke that is produced during a flare up.

The environmentally friendly, water based coating is designed for and can be applied to the protective wall panels being used in the new COT. It is also effective at reducing heat soak on highly other plastics and components such as fiberglass, carbon fiber and other composites used widely in professional motorsports.

Per Rick Barone, VP of Marketing for TPR2, "There are no other fire extinguishing coatings in the market like this, to our knowledge. Significant challenges needed were overcome to meet and exceed the demanding conditions professional racecars and drivers experience. The COT was a considerable challenge, overcoming water resistance, low smoke, ease of application, and weight constraints. We now have a stable of different products to protect drivers and their equipment, including this revolutionary insulating, fire extinguishing coating that will stay flexible and is waterproof. "

This revolutionary waterbased coating can be applied directly to the substrate and air dries. Besides extinguishing fires, it generates no smoke, no fumes and will reduce the spread rate of fires, the company claims.

Incorporated in 2004, Thermal Product Research was created with a purpose of creating new technology and safety products in the motorsports industry worldwide. TPR2's technology includes: insulation, anti-explosion, fire abatement, non-flammable and fire extinguishing products. TPR2's product lines also include coatings, pellets, plastics & powder technologies.

More information as well as test videos on this coating can be found at www.TPR2.com. You can send email to mail@tpr2.com or call the company direct at 203-756-8772.

Xiom Corp. Teams With New Bedford Coatings
6/13/2007
West Babylon, NY - Xiom Corp., manufacturer of the first on-site plastic powder coating spray system, has announced 50 percent ownership of a new joint venture, New Bedford Coatings LLC of New Bedford, MA. This new venture will focus on applying Xiom’s plastic protective coatings on the more than 700 sea-going fishing trawlers in the New Bedford Harbor fishing fleet. The fleet is a $2B dollar commercial enterprise. Because Xiom’s coatings are actually a hard plastic, they are more durable and weather resistant than conventional powder coating and will provide the trawlers superior protection against the elements at a fraction of previous maintenance costs.

Charlie Quinn, president of New Bedford Coatings LLC, says that “keeping protective paint coatings on the fleet is a $200M proposition each year.” It is expected that Xiom’s coatings — solvent-free plastic coatings that are applied using Xiom’s portable application systems — will go a long way in reducing that $200M annual maintenance bill. Xiom’s coatings are heavy duty tough coatings that are designed for maximum protection in difficult environments.

Powder coating primers from Dulux
Dulux E-Prime powder coating Powder coating is an effective way to achieve an attractive, durable finish. With a array of colours to choose from, powder coating can take your next commercial project to a new level.
But to ensure maximum durability of the finish, a little groundwork would not go astray.

For metal surfaces such as steel and hot-dipped galvanised (HDG) steel, the first step is to prime, prior to powder coating. This will give the metal substrate additional protection, improving both the surface corrosion resistance as well as the topcoat’s final appearance.

Where the surface of the steel has been pitted due to mill scale (an oxide formed by hot rolling) or from sandblasting, priming can help to level the surface prior to a topcoat being applied.

Dulux E-Prime powder coating has been formulated to penetrate crevices and is the ideal primer for sharp profile/edges or complex metal shapes. It can be used as a sandable filler for small surface imperfections and to provide additional film thickness for improved corrosion protection.

Zincshield 2 is a zinc-rich epoxy powder coating specifically designed to inhibit rust, with strong intercoat adhesion properties. Comprising 60% zinc dust, Zincshield 2 is ideal for areas subject to high corrosion including marine and industrial environments.<more>

Akzo Nobel sets $2 bln China sales goal by 2012
AMSTERDAM, June 14 (Reuters) - Dutch chemical group Akzo Nobel NV (AKZO.AS: Quote, Profile, Research)(AKZOY.O: Quote, Profile, Research) said on Thursday it has set a target of reaching $2 billion in annual revenues in China by 2012, with 20 percent of its total revenue coming from the Asia Pacific region by then.
"China is clearly fundamental to our global strategic vision and we are fully committed to expanding our activities in what is one of the world's most important emerging markets," Akzo Nobel's Chief Executive Hans Wijers said in a statement during a trip to China by the company's top executives.
Akzo Nobel said it currently has $800 million in revenue in China. <more>


 

Advances in Emulsion Polymerization and Latex Technolgy
4.6. - 8.6. 2007
Bethlehem, PA/USA
Lehigh University Details ...

8th Asia Coatings Markets Conference 2007
4.6. - 5.6. 2007
Bangkok/Thailand
Centre for Management of Technology

FARBE+LACK WebSeminar: Lack, Modul Additive II
4.6. - 5.6. 2007
Internet
Vincentz Network

Mixing for Uniform Batches: Improving Product Quality and Productivity
5.6. - 6.6. 2007
Ypsilanti, MI/USA
Coatings Research Institute, Sandra Tanner

Asia Pacific Coatings Show 2007
6.6. - 8.6. 2007
Bangkok/Thailand
dmg world media (UK) Ltd., Jeff Montgomery

Powder Mixing Technology
11.6. - 14.6. 2007
Amsterdam/The Netherlands
The Center for Professional Advancement

European Coatings WebTutorial: The Chemistry of Polyurethane Coatings
11.6. - 12.6. 2007
Internet
Vincentz Network

FARBE+LACK WebSeminar: Lack, Modul Pigmente
11.6. - 14.6. 2007
Internet
Vincentz Network

Nanopolymers 2007
12.6. - 13.6. 2007
Berlin/Germany
Rapra Technology

European Coatings Conference: New Concepts for Anti-Corrosive Coatings
14.6. - 15.6. 2007
Berlin/Germany
Vincentz Network

Corrosion and Coatings Challenges in Industry
19.6. 2007
Boise, ID/USA
Boise State University, Dr. A. S. H. Makhouf

European Coatings WebTutorial: The Chemistry of Radiation Curing Coatings
19.6. - 20.6. 2007
Internet
Vincentz Network

COSI - 3rd Coatings Science International 2007
25.6. - 29.6. 2007
Noordwijk/The Netherlands
Eindhoven University of Technology Details ...

Nanomaterials Symposium 2007
25.6. - 27.6. 2007
Denver, CO/USA
IntertechPira

Sustainable Development in the Coatings Industry
26.6. 2007
Hampton/UK
PRA Coatings Technology Centre

Latin American Coatings Show 2007
11.7. - 12.7. 2007
Mexico City/Mexico
dmg Word Media (UK) Ltd., Jeff Montgomery

Smart Coatings
17.7. - 18.7. 2007
Baltimore, MD/USA
Intertech Pira

Environmentally Friendly Flame Retardants
18.7. - 20.7. 2007
Baltimore, MD/USA
IntertechPira

Coating Wood and Wood Composites: Designing for Durability
23.7. - 25.7. 2007
Seattle, WA/USA
FSCT

30th Annual Short Course Advances in Emulsion Polymerization and Latex Technology
6.8. - 10.8. 2007
Davos/Switzerland
Dr. F. Joseph Schork

Overall system maintenance affects worker comfort, productivity, product quality, and operating cost. The least expensive and most effective
maintenance of a coating system is a formalized planned maintenance program. Planning what will be done, who will do it, what resources
they need to do it with and committing the time and resources to the task is the correct way to keep the system running well. Fixing things
when they break is the most expensive and least effective way to operate a system.

Throughout this manual there are references to specific maintenance practices and the importance of keeping the system in good working
condition. There are often situations where systems are not properly maintained and excuses are offered; ”… we are too busy to take time
out for maintenance,“ ”… management does not supply us with parts or time for maintenance.“ In reality, there is no good reason for not
maintaining the system. When it is new it runs correctly. When it is used it will gradually deteriorate. To keep production at the best possible
level and meet quality goals requires a well designed planned maintenance program that is performed on a regular basis.
Planned maintenance starts with the development of a Standard Operating Procedure (SOP). Development of a planned maintenance SOP
involves certain steps.

Step 1: What needs to be done?
Study the process with these questions in mind;
• what components of the system need periodic cleaning?
• what components of the system need to be replaced periodically?
• what needs to be lubricated?
• what items need to be inspected?
• what items need to be tested?

Step 2: How often?
Determine how often these tasks need to be performed in order for the system to run at peak efficiency.

Step 3: How long will it take?
Determine how many man-hours are required for each task.

Step 4: Who will do it?
Select the employee(s) who is/are best suited for each task.

Step 5: What materials are needed?
List the materials that will be required for each task.

Step 6: When will it be done?
Determine when each task will be performed.

Step 7: What tools will be required to do the work?
List all of the equipment that will be necessary to conduct the maintenance plan.
With the list of what, who, when, where and how the job will be done it is possible to design a plan, schedule the activities, maintain a supply
of the materials needed and keep the system operating properly. A Standard Operating Procedure is a document that clearly defines all
aspects of a specific maintenance requirement.

• Task
• Frequency
• Supplies
• Tools
• Objectives
• Safety precautions
• Steps of the process

Like any plan, the maintenance SOP must be monitored for effectiveness and adjusted if necessary. The following list is the recommended
tasks that are typically required for a powder system and the frequency that they should be performed.

Other items may be needed in a particular system. It is important to identify the maintenance items that affect system performance and
schedule the activities for servicing them. In addition to the maintenance performed by company personnel, it is advisable to have an outside contractor come in bi-annually to inspect, clean, calibrate and adjust the mechanical components of the system. A qualified contractor can check all belts for wear, inspect and clean fan blades, dismantle, clean, inspect and adjust all burners, inspect the pumps and motors for wear, and test all of the vital safety and operating controls. This provides an additional layer of protection from emergency break-down and keeps the system operating at peak efficiency

Summary
Do not underestimate the value of good maintenance. Proper attention to the systems working components can be the difference between
failure and success of a powder coating system. Once a plan is in place and the work is performed regularly, it takes very little time
away from production and makes production time more profitable.