There are many industries across the world that benefit from powder coating.  The architecture/building industry, oil and gas industry, appliance and automotive industries, etc., all make use of powder coating for their products and services in one way or another. 

Appliance Powder Coating

Appliances benefit from powder coating because many household appliances deal with moisture or potentially corrosive chemicals on a daily basis.  Refrigerators can be powder coated on the front panels and side panels, which is great because they can become grimy from dirty fingers and need regular cleaning to remain shiny and new.  Without proper coatings, regular cleaning and usage of a refrigerator can have it looking old and worn before its time.  Dishwasher racks are also frequently powder coated to withstand the corrosive detergents and high temperature water required to clean and sanitize dishes.  Water heaters, washer and dryer exteriors, and air conditioner cabinets are also frequently powder coated to protect them and ensure long usage.

Automotive Industry Powder Coating

There are many aspects of the automotive industry that benefit from powder coating.  There is even a new clear top powder coat for the exterior of vehicles, and door handles, bumpers, wheel rims, etc. have been utilizing powder coating in Houston for a long time. Vehicles are subject to the environment on a daily basis, as well as gasoline, oil, and other chemicals regularly. They are also not inexpensive and need to last for years if not a decade or more without falling apart and rusting, and powder coating provides great protection.

In broad terms, there are two types of powder coating in Houston that industries use today.  These are thermoplastics and thermosets. Thermoplastic powder coating is physically bonded to the surface with the introduction of heat.  This requires batch baking that sets the powder coating by turning into liquid form.  Thermoplastic coatings are thicker and tend to be more durable than thermoset powders. Thermoplastic powders are used in a variety of industries, from the automotive industry to the appliance industry and more.  Thermoset powders are chemically bonded to the surface after they are fully cured, which makes them appropriate for use in industries where conditions are harsher, especially temperature because heat will not affect the coating.

Polyvinyl Chloride (PVC)

Polyvinyl chloride powder coating in Houston (PVC for short) is one type of thermoplastic powder. PVC requires a temperature of 400 degrees Fahrenheit to set, so if the underlying substrate is unable to withstand that high temperature, PVC will not be an appropriate coating.  Polyvinyl chloride is FDA approved for use in the food industry.  It is also acceptable to coat chain-link fencing amongst other things.

Powder coating has been around for several decades—specifically since the 1940s. For most of its history, the technology and materials used in the process are widely utilized in industrial applications that require specialized protective coatings. However, multiple fusion-bonded systems are now available to the average consumer who find simple kits for surprisingly cheap prices.  Since powder coatings are more effective at protecting surfaces than simple paint, using it for the purposes of outdoor furniture refinishing (or other hobbyist projects) can be very attractive to the DIY-minded.  However, there are several reasons why professional powder coating services are worth a little extra investment.

Whether you’re looking to powder coat something yourself or send it to a small shop that promises big results, be aware that there are many factors that can and will affect the final quality of the finish. Commercial/industrial powder coaters operate under strict regulations, work with high-end and expensive commercial equipment, and bring decades of experience with them.  A DIY home powder coating kit might claim to offer safe application, but it’s naive to overlook the many protections that professional powder coaters put into place.  Proper ventilation, respiration, and handling/disposal of the powder & media all require careful consideration.

Also, professional coaters follow surface preparation and quality control standards that far exceed the capabilities of amateurs.  The removal of rust, grease, and other contaminants ensure a clean surface for which the powder will adhere to.  Furthermore, deep anchor patterns created by these processes allow for the powder to sink further into the metal to better protect against dings, chips, and abrasions.  As you can guess, these services cannot be offered by anyone other than a professional powder coating facility.

In the pursuit of bringing hydrocarbons to market, there are many obstacles, both natural and man-made. Some of these difficulties can be circumvented, but others, like corrosion, are unavoidable. As much as oil and gas production companies would love to dodge this process altogether, it’s a natural part of chemistry and physics, and it’s not going anywhere any time soon. Over the decades, many technologies have been created to resist or prevent corrosion-damage to pipelines. These pipelines are essential to the delivery of hydrocarbons, but are susceptible to corrosion damage from the heat, moisture, and abrasives that are often present in these working conditions. One such technology used in the battle against corrosion is fusion bonded epoxy coatings (FBE).

FBE coatings are supplied by multiple manufacturers.  Axalta is a leading provider of protective coatings throughout North America, offering an array of high-tech FBE options. Axalta Nap-Gard® 7-2500 Fusion Bonded Epoxy is one such coating, designed to provide corrosion protection in the demanding oil and gas production environment. In addition, Nap-Gard® 7-2500 is used in transporting wastewater and saltwater, each of which present their own challenges that must be addressed.

Nap-Gard® 7-2500 is designed to provide protection for both internal and external surfaces of pipeline. The protection of both surfaces is important: internal surfaces are exposed to chemically-active hydrocarbons, while outside surfaces can be exposed to high heat, high pressures, and abrasives such as salt.  The 7-2500 specification is formulated to withstand high temperatures of 107°C (225°F)—vital heat protection in the unforgiving oil and gas production environment. In addition to providing this protection for oil and gas applications, the product complies with NSF-61 specification, meaning that it’s approved for transporting potable water.

With the increase of environmental regulations making solvent-based corrosion protection expensive and complicated to apply and dispose of, protective powder coatings such as zinc-rich primers offer premium corrosion protection without harming the environment.   Zinc-rich primers are considered sacrificial coatings, a subset of protective powder coatings meant to dramatically slow down the process of corrosion if the top layer is damaged.    This makes them the perfect coating for steel in highly corrosive environments.  Zinc-rich primers are great for use in marine, tanker, or underground environments, all of which are considered immersive environments.

There are two types of zinc-rich primers: inorganic and organic.  Organic zinc-rich primers are primers that use binders such as epoxy, polyurethane, or alkyd, etc.  More commonly used for highly corrosive environments on oil rig platforms, chemical plants, and more, organic zinc-rich primers require a top-coat to be long-lasting.   

Inorganic zinc-rich primers do not require top-coats in more mild atmospheric environments and provide better galvanic protection overall.  Inorganic zinc-rich primers usually use only silicate as a binder and is applied as a powder using the blast method on “white” metal, metals that are light-colored alloys.  This is the type of zinc-rich primer Houston Powder Coaters uses.

Polyester powder coating technology has been around since the 1970s and accounts for 30-45 percent of powder coating product sales globally.  There are two main categories of polyester powder coatings used in the industry today: TGIC (an acronym for the chemical compound curing agent it uses, triglycidyl isocyanurate), and HAA.  HAA polyester powder coating uses β-hydroxyalkyl amides as its curing agent and is often called TGIC-free or Primid polyester powder coating after the brand of curative used in most HAA powder coatings.  While both categories of polyester powder coatings perform relatively similarly, there are some pros and cons that can tilt a company toward one or the other. 

TGIC coatings typically offer better chemical resistance and corrosion resistance than their TGIC-free counterpart.  The HAA curing mechanism can release water, which makes the coating slightly more water soluble than TGIC-polyester.   Because of its slight water-solubility, HAA coatings are more susceptible to acidic and alkaline chemicals.  All of this makes HAA-polyester less corrosion resistant than TGIC-polyester.  However, with different formulations, a Primid polyester coating can perform on par with TGIC. When it comes to impact and abrasion resistance, flexibility, and hardness, TGIC and TGIC-free polyester powder coatings are the same. 

For application and curing, TGIC-polyester cures at a lower temperature than HAA-polyester (roughly 290 degrees Fahrenheit and 330 degrees Fahrenheit respectively).  Many companies find HAA-polyester applies more easily and sticks to nooks and crannies better than TGIC-polyester.  Thickness of application varies greatly between the two, with TGIC-polyester coating able to reach about 10 mils (250 microns) thickness and HAA-polyester coating reaching 3.5 – 4.0 mils (90-100 microns) thickness.  When it comes to color stability, TGIC-polyester comes out ahead.  HAA-polyester can yellow in color in overbake conditions, while TGIC-polyester has very little color drift over a wide range of cure times and temperatures. 

Unlocking The Benefits Of Powder Coating Finishes

Imagine a world where your car’s paint job lasts longer, your patio furniture doesn’t chip, and your appliances maintain their sleek appearance for years. That’s the world of powder coating - a game-changing technology that has revolutionized the coating industry. In this blog post, we’ll dive into the fascinating world of powder coating, exploring its components, processes, and advantages over conventional liquid coatings. Get ready to unlock the benefits of this durable, cost-effective, and eco-friendly finishing solution.

Key Takeaways

Powder coating technology is a dry finishing technique that offers uniform finishes, enhanced durability and diverse colors.

It utilizes an electrostatic process for even coverage and has two primary materials: thermoset & thermoplastic.