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Ask Joe Powder.
Exhibitions and Conferences in June and July 2010
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India Powder Coating
3, Lalaram Nagar, Indore, 452001 MP India
Phone 91 731 2492291
emails: firstname.lastname@example.org , email@example.com , firstname.lastname@example.org
Manufacturer of Powder for Coating Purpose
An ISO 9001 Company
B 49, STICE, MUSALGOAN , TAL. SINNER,
DIST. NASHIK (M.S.),TELE-FAX : 02551-240475
Mobile :09922 028787
E mail : email@example.com
It was interesting to meet Prakash, from Radiant Microfine Abrasives Pvt Ltd and Vivek Samadhia from Paramount Powders Pvt Ltd.
Situated in Jaipur, Rajasthan. Radiant has recently entered powder manufacturing. Paramount manufactures powder coatings in Gurgaon Haryana
Prakasah and Vivek briefed about the company's manufacturing facilities and marketing policies
|Zinc-Aluminium Flake Coating|
Water reducible Non-Electrolytically
applied Zinc-Aluminium Flake Coating:
Contributed by Kalyan Dhakane and Digamber Dhake
What Coating thickness is applied?
Generally, the coating thickness ranges from 5-15 microns. The corrosion resistance can be achieved over 1000 hours by ASTM B117 in Salt Spray test; The results of corrosion depends up on the shape and geometry of the parts.
Water Soluble Polymet™ Coating Technology
Premium products Inc., USA has developed water based coating for threaded hardware and metal parts in Automotive and engineering construction and it offers direct cost saving by not using solvents compare to other solvent based products. These water based coatings are environmental friendly, Low VOC, HAP free, Hazardous (declarable by ELV) substances free and best suitable for tough climatic/weather conditions.
|Ask Joe Powder (New)|
"Ask Joe Powder"
"Ask Joe Powder" is a question and answer column authored by Kevin Biller of the Powder Coating Research Group. Mr. Biller has over 30 years experience formulating and manufacturing powder coatings. He welcomes your questions regarding powder coating technology. Please write to: firstname.lastname@example.org
The Powder Coating Research Group
4419 Brookpark Road
Cleveland, OH 44134
Dear Joe Powder:
Please send me the answer for this example:
The powder coating costs 130 Rs./kg, and the coating thickness is 70 to 80 microns in this situation. How can I calculate cost per square meter for powder coating including labour, gas and all things, and what is the standard cost per square meter for powder coating painting to quote any company?
Dear Kishor Palhade,
In order to make this calculation you must know the specific gravity of the powder coating. I can make an assumption to illustrate how to make the calculation. Please assume that the specific gravity is 1.6 and the average coating thickness is 75 microns.
A. 1.6 g / cm3 x 75 microns = 120 g – micron / cm3
B. Then divide 1000 by the answer in “A”. (1000 converts microns and centimeters to meters and grams to kilograms.) Therefore: 1000 divided by 120 = 8.33 m2 / Kg.
This of course assumes 100% transfer efficiency. If you are spraying the powder without reclamation and reuse, you can assume 60% transfer efficiency. This provides coverage of 5.0 square meters per kilogram.
Your cost per square meter at 130 Rs/ kg will be 26 Rs per square meter. This is only the material cost.
To factor in the labour, gas and other manufacturing overheard you should first determine how many square meters can be coated with one man hour. (This will vary based on the parts coated.) Then calculate the cost of one man hour (wages, company paid taxes, company paid benefits, uniforms, meals, etc). To calculate gas expense it is best to use a meter on your oven and measure how much gas is used during a typical shift. Then divide this usage by the amount of product (in square meters) that was processed. You can then calculate the gas usage per square meter of product. Next account for all of your manufacturing overhead costs such as electricity to run your finishing line, water used, maintenance of your process, depreciation of your equipment, etc.
As for a standard cost, there really isn’t one. So much depends upon the quality requirements of the job. For a simple product with low quality demands you do not have to charge as much as for one that requires careful cleaning, masking, coating
thickness control and cleanliness. All of these activities must be factored into the final estimate and cost of the job.
Lastly and most important is to factor in your profit on the hard work and valuable service that you provide your customer.
I hope that this helps and please let me know if you have any further questions.
aka Kevin Biller
Hi Mr. Joe Powder!!
I have a question, we have a Powder Process here in our facility, and we use a PPG Epoxy, and it doesn’t pass an accelerated exposure test. Question is, this kind of Powder does or doesn’t pass the QUV test?
Because we are having troubles with our customers.
Thanks for your time.
Buenos Dios Tito,
Thank you for the question, this is a good one. The QUV test simulates the exposure a coating will experience in a high intensity UV environment. The wavelengths are close but not identical to the sun. It is a decent comparative test for similar formulations. Epoxies will not last long in a QUV chamber without fading and chalking. Similarly a hybrid powder coating which also contains epoxy resin will not resist degradation in the QUV cabinet.
Powder coatings that have good to excellent QUV performance are based on the following chemistries: aliphatic polyurethanes, polyester TGIC, polyester HAA, acrylic and fluoropolymer. Pigmentation also has a strong influence on UV resistance. Mixed metal oxides have the best performance.
If you need more guidance please let me know.
Is there any truth to shot blast being able to “impregnate” oils in the surface of steel? I have a product that gets E-coated off site, and I want to shot blast the product versus hand cleaning, but my customer is concerned.
Your customer has reason to be concerned. Shot blasting can be a very good pretreatment process before powder coating or painting a metal surface. The issue develops if the shot blasting process is sloppy. It is imperative to have clean blasting media. If the blasting media gets contaminated, yes it will embed the surface with dirt and oil. The microscopically embedded contaminates will compromise the corrosion resistance of the finish.
This doesn't mean shot blasting can't be used as a pretreatment, it's just really important to keep the process and media extremely clean. In fact a good shot blast process is better than simple solvent cleaning because the blasting, when done correctly, provides better adhesion. This is because it creates a profile on microscopic peaks and valleys that allow the coating to 'bite" into.
Let me know if you have any other questions.
Dear Mr. Biller:
I hope you don't mind me troubling you with a question regarding the failure of the epoxy/polyester powder coat to the metal on the equipment in my office. I found your site while searching the internet for answers.
I am a dentist in Florida and am experiencing problems with the finish to my dental equipment. The equipment is 3 years old and the the paint is bubbling up and chipping off the delivery units which is that movable tray holder that the instruments sit on. I have never seen this before in the 25 years that I have been working in dental offices. The paint is covered with a protective plastic that is lightly adhesive and disposed of after each patient. The paint is wiped down with a hospital grade disinfectant wipe after every patient as well. We first starting noticing the bubbling and "corrosion" about 18 months of use.
I have had dental equipment that was over 40 years old, disinfectant with diluted bleach that never displayed this type of wear.
The manufacturer said they never experienced this phenomenon on any of their products. They used epoxy/polyester powdercoat. They insist the units were manufactured in the US according to FDA standards.
Can you think of any reason why this would happen? If you need photos I can email them to you. I sincerely appreciate any insight you can offer to this problem.
Thank you for your time and consideration,
Maria Zecca-Botwin, DMD
From what you describe there can be a couple problems that are responsible for the coating failure. Here are some of the possibilities:
1. Incorrect or poor quality powder coating - The applicator may have pulled the wrong product off the shelf (e.g. mistook one white powder for another) and applied it to the dental equipment. A standard polyester product would not have the chemical or solvent resistance that a hybrid would. A more remote possibility would be a lousy quality batch of powder coating as supplied by the powder manufacturer. This doesn't happen very often however.
2. Inadequately cured powder coating - The applicator may have applied the proper coating, but didn't bake it at high enough temperature or time to adequately harden or cure the coating. An undercured powder coating will have poor chemical resistance and could blister and lose adhesion.
3. Poorly cleaned and pretreated metal prior to powder application - This is highly probable. If the instrument parts weren't thoroughly cleaned and pretreated prior to applying powder coating, this could result in premature bubbling and adhesion failure. Adequate cleaning and pretreatment would consist of a minimum of 5 stages including an alkaline cleaner, intermediate rinses and the application of a phosphate solution. Without this the coating will not anchor to the metal substrate and will subsequently corrode and lose adhesion.
As for the FDA standards, these regulate the composition of the powder coating. Details are contained in the Code of Federal Register (CFR) 175.300. The purpose of this is to ensure nothing leaches out of the coating that could harm a human. It does not regulate the performance or durability of the coating.
Did the equipment manufacturer provide a warranty for the performance of the equipment? I would think they are responsible for the durability of the equipment including its finish. They should correct the problem or replace the equipment. It would then be up to them to pursue the powder coating applicator (if it is not them).
It would be helpful to send me pictures. I could then comment further on the mode of failure and its possible cause(s).
Please let me know how I can help you further.
Kevin Biller aka Joe Powder
Joe Powder has over 30 years experience in powder coating formulating, manufacturing and troubleshooting. If you have a question, please feel free to submit it to email@example.com
|Seminar Events Exhibitions|
Principles and Practices of Coating Formulation
Location: Ypsilanti, MI/USA
Contact: Eastern Michigan University Coatings Research Institute Jamil Baghdachi
European Coatings Conference Fire Retardant Coatings IV
Contact: Vincentz Network Matthias Janz
Phone:+49 511 9910-273
AAMA National Summer Conference
Jun 06 - 09, 2010
Chicago, IL USA
Practical Methods For Improving Efficiency And Safety Of Painting Operation
Jun 07 - 11, 2010
Contact: Oil & Colour Chemists
Phone:+44 (0)1525 372530
Improving Durability and Performance of Coatings
Jun 08 - 10, 2010
Dates: 15 June 2010 until 16 June 2010
Location: Grand Rapids, MI
Two-day Powder Coating Workshop
Jun 22 - 23, 2010 Pittsburg, PA
Asia Pacific Coatings Show 2010
23. - 24.06.2010
The Coatings Group
CCAI 2010 Annual Meeting
Jun 26 - 29, 2010
Coatings for people in general industry, sales and marketing
Jul 19 - 21, 2010
St. Louis, MO
India Powder Coating
3, Lalaram Nagar, Indore, 452001 MP India
Phone 91 731 2492291
Mobile +91 9826297112
Alternative email firstname.lastname@example.org email@example.com, firstname.lastname@example.org
While we have used our best efforts in collecting and preparing the information on this website and newsletter, 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 user may use their own discretion while using the information.