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Poor Process Balance: The Overlooked Powder Coating Problem

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For all powder coaters, especially larger industrial powder coating operations, the most expensive problems are not always caused by bad powder, poor equipment, or careless employees. Instead, their coating line’s effectiveness may be getting clobbered by something less obvious. Whether using a batch or conveyorized powder coating system, the real issue in many facilities is process imbalance. The pretreatment system, dry-off oven, powder booth, application equipment, conveyor/cart movement, and curing oven may all function individually at what seems like an acceptable level, but they may not function well when viewed as a coordinated production system.

That distinction matters because small issues throughout the coating process become roadblocks to profitability once they pile up. A successful powder coating operation is more than just a group of machines and operators. It should be a controlled manufacturing process. When one phase of the process is poorly maintained, log-jammed/undersized, improperly adjusted, or out of sync with the rest of the process, the entire operation suffers. The results usually show up as slow throughput, excess labor, wasted powder, substantial rework, inconsistent film thickness, poor adhesion, unusually long cure windows, or operators making constant adjustments to compensate for system-level problems.

Bart Roegner, CEO of Reliant Finishing Systems, observes, “A fair amount of our business comes from companies that already know powder coating, but still can’t get their finishing line to produce the results they need. Sometimes the problem is obvious. A worn-out multi-stage washer. An oven that was never built for the current workload. A line that has been pushed past what it can reasonably do. Other times, it is not one big failure. It is ten smaller failures stacked on top of each other until the whole system starts failing. Those are the jobs we like. We can step back and look at the coating operation as a system. We are not buried in the day-to-day frustration. We are not worn down by the same recurring problems. We can see the line clearly, identify what is actually driving the failures, and apply experience the customer may not have internally. That is one of Reliant’s real strengths: we solve system-level finishing problems without overcomplicating things.”

Let’s move through the finishing process step-by-step to identify potential areas of concern, starting with parts prep. The vast majority of finish defects are caused by improper parts preparation. Pretreatment should always be evaluated as a component of the full coating process, even if it takes place elsewhere (such as when parts are blasted off-site before being coating). A well-designed pretreatment process removes soils, improves surface condition, and supports adhesion and corrosion resistance. However, if parts leave pretreatment with blasting debris, trapped moisture, chemical residue, or inconsistent surface preparation, the other equipment in the process can’t fix these problems. That’s why it is critical to routinely review chemical concentration, rinse quality, water condition, nozzle performance, dwell time, and dry-off effectiveness for chemical pretreatment systems, and blast nozzle wear, compressed air quality, and blasting media choices when mechanical surface preparation is required.

Once pretreatment performance has been reviewed, including the performance of the dry-off oven if one is in use, the next step is to consider the powder coating booth and what takes place inside it. There’s a lot that can go wrong without giving immediate warnings. 

As an example, coating inefficiencies aren’t always glaringly obvious. First-pass transfer efficiency is one of the most important metrics you can measure. In a larger industrial setting, even a modest improvement can have a major financial impact. If a plant applies hundreds of pounds of powder per week, improving transfer efficiency by only 10% can reduce powder waste, coating time, filter maintenance, reclaim handling, and cleanup time. Better transfer efficiency also tends to improve consistency because operators aren’t fighting the system to get adequate coverage.

Grounding is a related issue that deserves regular attention. Poor grounding reduces powder attraction and makes it harder to coat quickly and efficiently. Hooks, racks, carts, conveyor components, and other contact points should be inspected periodically for powder build-up. A part that appears to be grounded because it’s hanging from grounded equipment may still have a poor ground path if the contact surfaces are insulated by coating residue. In addition to clean contact points for parts, it’s not uncommon for supplemental grounding to be necessary for achieving optimal results. This is often done using copper grounding rods and heavy gauge grounding straps at the booth. In all coating operations, especially ones that routinely see a large volume of parts traffic, grounding should be treated as a high-value maintenance item, not a one-time setup detail.

Parts orientation and hanging schemes are also important. Some coaters, especially fabrication job shops and powder coating service providers, process a wide mix of parts. Inconsistent loading patterns can create inconsistent results. If parts are hung too close together, airflow and powder cloud movement may be restricted. If parts are oriented poorly, painters may have to over-apply powder to reach hidden surfaces or reposition carts by hand to gain access. Better organized racking and spacing can improve finish quality without changing the powder or the equipment.

Another common issue is poor airflow balance in the powder booth. Industrial powder booths must capture overspray effectively, but excessive airflow can pull charged powder away from the parts before it has a chance to adhere. This is most common in undersized booths, where the displacement caused by the load leads to excessive air velocity around the part. The same thing can happen if a portion of the load is too close to the exhaust filter surface. When these issues occur, first-pass transfer efficiency drops. The booth interior may look fairly clean, and the exhaust system may appear to be working well, but the company is spending more on powder, filters, and labor than necessary.

At the other extreme, some booths have inadequate airflow, often due to clogged filters. In fact, poor filter maintenance is probably the number one cause of powder booth performance issues. Insufficient airflow can cause the powder cloud to hang in the air around the part after an appropriate amount of powder has already coated the surface. The painters must deal with decreased visibility, which can lead to errors. The powder overspray eventually falls to the floor in the workspace without being moved towards the exhaust. The painters end up dealing with a heavy film of powder underfoot, which can be a safety issue, plus the wheels on rolling racks get soiled with powder build-up more quickly. This situation necessitates increased booth cleaning labor and can also lead to incidental cross-contamination issues when changing between powders during the workday.

Similarly, airflow issues inside the curing oven can limit productivity. A powder curing oven needs adequate, evenly distributed heated air across the entire work envelope. If airflow is weak, uneven, or blocked by poor part spacing, some areas of the load may reach cure temperature much later than others. Operators may respond by increasing dwell time or raising the setpoint. That may help the worst-case part cure properly, but it can also increase fuel consumption, slow production, and risk overbaking lighter or thinner parts. If heavy parts and light parts are mixed without considering cure response, some parts may be under-cured while others are exposed to unnecessary heat.

Even with ovens that are designed with a substantial work envelope where temperatures are relatively uniform and airflow is appropriate, poor hanging practices can lead to problems. This is most commonly found in batch coating situations where managers are pushing for maximum throughput or employees haven’t been properly trained. Operators end up racking parts well outside the oven manufacturer’s designated curing envelope. This happens by jamming parts against the discharge points of the oven’s heat system or hanging them too close to the floor or doors. The parts end up being blasted by hot air that hasn’t had a chance to normalize across the curing zone or located in an area inside the oven that will never have adequate curing performance.

A Reliant gas-fueled convection powder curing oven

As mentioned earlier, finishing operations should evaluate powder coating performance as a complete process instead of troubleshooting each defect in isolation. For example, adhesion failure may be blamed on the powder or the curing routine, but the root cause could be poor pretreatment. Surface defects like orange peel may be blamed on the gun settings, but the real problem may be that the parts are too hot coming out of the drying oven, taking too long to get to temp in the curing oven, or you’re dealing with excessive film build caused by repeated touch-up. Color inconsistency, particularly with whites and light colors, may be blamed on the supplier, while the actual cause may be inconsistent cure temperature or contaminated reclaim powder.

Bart Roegner adds, “A useful starting point is to measure the entire coating process in practical terms. You may find that easier and more useful than trying to drill down on the technical aspects right away. It’s rare that you can fix everything all at once, so after you get an objective look at the big picture, you can prioritize your efforts.” 

Typical questions might include:

How many different parts are coated in a typical day/week/month and what size are they? 

What is the target film thickness and what’s currently being achieved?

How many pounds of powder are purchased versus how many pounds are actually deposited on saleable parts? Has this shifted when changing powder vendors or using different products?

How often are parts recoated or touched up? Are the types of failures recorded and tallied?

How many operators are needed at each stage of the process to get maximum productivity? How many do we have now?

How much time is lost each day/week/month waiting on pretreatment, drying, booth availability, or oven capacity? Is there a log showing what phases of the process caused delays?

How much time is lost each day/week/month due to unplanned equipment downtime? Is there a log of what appliances were down and why?

Getting answers to these questions can reveal whether the current coating operation is an effective production asset or an ongoing fight against bottlenecks, waste, and defects. If these answers aren’t immediately available, a good first step (if you’re not dealing with an emergency due to powder coating issues at your facility) would be to put systems in place so you can get the information you need to make objective decisions.

The best powder coating systems are designed around the work being processed. Part size, material thickness, production volume, coating specification, available labor, floor space, handling method, and future growth plans all affect equipment selection. A booth, oven, washer, or conveyor that looks adequate on paper may not deliver the desired output if the full operating pattern is not considered.

This is where experienced system design matters. Reliant Finishing Systems works with manufacturers, fabricators, and coating operations that need practical, dependable powder coating equipment built around real production requirements. For industrial coating operations of all sizes, the goal should not be to simply to buy an adequately sized equipment package. The goal should be to create a balanced coating process that maximizes throughput, reduces waste, supports consistent quality, and gives the company room to grow.

A well-balanced powder coating operation does not depend on constant operator correction by experienced, highly skilled employees. It gives even inexperienced, moderately skilled operators the right conditions to succeed. Airflow, heat, grounding, pretreatment, part movement, and application technique all work together. When those elements are properly matched, the result is lower operating cost, better finish quality, fewer rejects, and a more profitable coating department.

Want to talk with an expert about your coating operation? Give Reliant Finishing Systems a call at (256) 355-9000 or click HERE. Check out our website at www.reliantfinishingsystems.com.

LINE 2

When to Stop Repairing an Existing Powder Coating Line

If you manage a powder finishing line, you’ll eventually have to consider replacing your aging powder coating equipment. 

You’ll be faced with choosing between spending a significant amount of money or continuing with repairs and workarounds to keep the equipment functioning. From a business perspective, there’s one main question:

Is the powder coating line still a cost-effective production asset? 

Sometimes, the answer isn’t clear-cut. Let’s look at key indicators that it may be time to stop repairing and move towards replacement.

Also, check out our Repair or Replace Checklist to evaluate your specific situation.

Equipment Reliability Is No Longer Predictable

It’s easy to measure if the time between breakdowns is getting shorter, or if the total amount of unplanned downtime is increasing.

A powder coating line should not experience frequent unscheduled stoppages due to finish quality issues or problems with the pretreatment equipment, booths, guns, ovens, conveyor, or controls.

If production is being interrupted and maintenance is becoming reactive and corrective rather than scheduled and preventative, the finishing department is in “failure management” mode.

Maintenance Costs Match Or Exceed A Practical Replacement Threshold

The best decision-making tool is a comparison of the coating system’s replacement cost with annual repair and unscheduled maintenance spending.

A common benchmark used in industrial equipment evaluation is:

If annual repair and unscheduled maintenance expenses total at least 8%–12% of system replacement cost, replacement should be seriously considered.

When calculating current maintenance and repair expenses, you need to not only include unplanned parts purchases, but also expenses like contracted repair services, in-house labor costs due to repairs, and downtime-related overtime needed to maintain your production schedule. You should also figure in revenue you lost due to downtime/reduced capacity.

Repeated replacement of the same components (burners, fans, pumps, safety devices, etc.) is another strong indicator that the system may be beyond the point of conventional maintenance.

Spare Parts & Controls Are Becoming Obsolete

A decision point is reached when OEM components aren’t readily available. Maintenance personnel encounter this when they can no longer easily source replacements for parts like temperature controllers, PLCS, HMIs, and burner management components, or when proprietary controls software is no longer supported. 

This can happen when the equipment manufacturer goes out of business, terminates a product line, or discontinues support. 

Once a control system or major component becomes obsolete, failures can force costly emergency retrofits or become unplanned engineering projects, which increase downtime.

Declining Oven Efficiency Has Become Costly

Older ovens can develop inefficiencies due to insulation breakdown, degraded door seals, structural sagging/panel warping, or compromised airflow. They can also suffer inefficiencies due to components that are outdated or not functioning properly.

Failing oven components can cause rising gas consumption, longer heat-up times, ignition failures, and more frequent safety alarms.

If the oven begins to require a higher setpoint temperature or longer dwell time to achieve the same part temperature that could previously be reached using a lower setpoint or shorter dwell time, the oven is losing thermal performance. It may no longer be capable of heating efficiently or retaining heat energy effectively.

A modern oven with properly engineered airflow, adequate recirculation, an effective insulation package, and accurate burner control can reduce fuel consumption while improving throughput and cure consistency.

Booth Performance Or Overspray Capture Is Faltering

Older booths may still function, but they can fail to maintain proper airflow and powder containment.

Common symptoms of aging booths include reduced or unstable airflow, noteworthy powder accumulation in booth corners, filter housings, or fan enclosures, declining reclaim efficiency, and excessive powder escape into the shop environment.

These issues create direct cost impacts through increased powder usage, higher filter consumption rates, and expanded housekeeping labor. As with other appliances, some booth repairs may require little more than replacing basic parts (or filters) and doing some in-depth cleaning, but it’s important to acknowledge how all these minor repairs and maintenance tasks contribute to the coating line’s overall “repair or replace” landscape.

With booths, there’s also an increased risk of combustible airborne dust hazards. Authorities can initiate unexpected shut-downs to address safety issues related to booth performance.

Pretreatment Is No Longer Fully Effective

If the pretreatment system doesn’t work well, the entire finishing process is compromised, regardless of booth and oven performance.

Changing your pretreatment chemistries can make your existing system unable to generate acceptable results. If the system isn’t properly designed for the chemistries currently being used—whether your pretreatment routine is manual (spray wand) or automated (multi-stage washer)—you’re inviting warranty nightmares once the finished products are in use.

If your chemicals, line speed, or pretreatment standards change, you can also end up with an insufficient number of stages or inadequate stage length to achieve proper cleaning/rinsing/sealing at the required line speed.

Other common problems include poor spray coverage due to clogged or damaged nozzles, inadequate pump output, damaged headers or risers, poor agitation, inadequate tank heating or inconsistent temperature control, and vapor migration into the shop environment due to exhaust issues.

When pretreatment issues lead to recurring adhesion failures, corrosion failures, or rework due to cosmetic issues, replacement is often more economical than attempting to modify a system that cannot operate properly with current chemistries or meet current performance requirements.

Conveyor Performance Becomes Inconsistent

If you’re using rolling racks or a manual conveyor, throughput issues may point to manpower problems. However, if your system uses a powered conveyor, aging conveyor components can cause throughput issues and related headaches. 

Frequent chain replacement, binding, drive failures, or other wear-related issues can indicate your conveyor is becoming unreliable. Changes to product sizes or hanging schemes can also lead to overloading. Because constant process coating lines rely on accurate control of the pace at which parts move through the various appliances, hiccups with the conveyor can cause issues throughout the line that potentially generate extensive rework.

Most conveyorized lines are integrated with appliances that have been built to specific dimensions and performance characteristics. Some conveyors are even attached to the appliance structures. Because these engineered systems are typically delivered as turn-key solutions, replacing or upgrading the conveyor may necessitate replacing other appliances or the entire line.

Effective Process Control & Repeatability Are No Longer Achievable

A finishing department that relies on older equipment because it can still “coat parts” may no longer be able to consistently achieve professional quality finishes. 

Outdated controls, poor maintenance practices, and aging components can create finishing equipment control issues that impact repeatability. If operators must compensate manually by slowing line speed, extending dwell time, increasing powder output, adjusting oven setpoints, or increasing inspection and touch-up labor, the system is no longer adequately process-controlled. Instead, it is being operated using tribal knowledge, which can be wildly inefficient and makes the business vulnerable to personnel issues.

Safety and Code Compliance Risks Are Increasing

Older powder coating lines may not meet current requirements for NFPA compliance, combustion safety, workspace environmental concerns, or combustible dust control.

Liabilities include poor safety interlock design or maintenance (burner running without airflow verification or booth capable of operating without meeting basic airflow requirement), inadequate explosion venting, and increased powder buildup or migration outside of the booth.

It’s also common for maintenance personnel to jump out tripped safeties on older equipment in order to temporarily regain equipment functionality rather than resolve the root problem. This can lead to disastrous consequences. A serious safety event (flash fire, dust ignition, or burner malfunction) can easily cost more than the capital expense of equipment replacement.

If the system is generating concerns from audits, insurance inspections, or internal plant safety personnel, repairs may not be sufficient. In many cases, full compliance requires major system redesign, not component replacement.

The ROI-Based Conclusion

A powder coating line should be evaluated like any other production asset: by considering throughput capacity, uptime, operating cost, safety risk, and ability to meet quality requirements.

If your equipment is causing recurring downtime, inconsistent coating quality, or increased compliance concerns, it’s a capital planning problem. The best-performing coaters replace equipment proactively, before failure forces a rushed purchase or leads to extended downtime.

When planned correctly, a new batch or conveyorized powder coating system typically delivers ROI through:

  • Higher Overall Equipment Effectiveness (OEE)
  • Reduced labor and rework
  • Improved coating consistency
  • Lower powder waste and reduced filter costs
  • Reduced gas and electrical consumption
  • Improved compliance and reduced safety exposure

If you have questions about your existing line, want to schedule a free on-site evaluation, or just need a rough estimate for CapEx budgeting, give Reliant Finishing Systems a call at (256) 355-9000 and talk with our team of experts.

Oven

Powder Curing Oven Comparison Guide for Professionals

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Considering new powder coating equipment for your business? When you’re getting quotes, make sure you’re comparing apples to apples, especially when it comes to the powder curing oven! This easy-to-understand guide from Reliant Finishing Systems helps you quickly evaluate the features that can make or break your success.

Key Features—Start by evaluating the quality of the oven’s design & components

Does the oven have a fully modular design?

Ovens that have a fully modular design, like those built by Reliant Finishing Systems, can easily be expanded in size in the future with no field welding required. Many entry-level products from oven “catalog websites” aren’t truly modular in design and can be expensive or impossible to expand in the future. The same applies to many powder curing ovens offered by higher-end oven companies, because the number of custom components and/or the amount of welding involved makes expansion costly and impractical.

Can heat units or exhaust systems be relocated in the field if there is an unforeseen issue with oven placement?

 Sometimes things don’t go as planned while you’re setting up a new coating operation. A couple oven manufacturers, including Reliant, have ovens designed so the exhaust and heat system can be placed in multiple locations during assembly without modifying the equipment or compromising the oven’s performance. With other brands of ovens, the layout can be expensive or impossible to reconfigure.

What burner does the oven use?

Make sure the oven has a brand-name burner from an established burner manufacturer such as Power Flame or Maxon. These burners are more expensive, but they ensure that your oven’s heat system will be safe to operate. By selecting one of these burners, you’ll also have easy access to repair and maintenance parts. You should check to confirm that the burner model being used has been tested and certified for oven use (this is indicated by an ETL or UL listing decal that has been applied to the burner by the manufacturer). Reliant Finishing Systems uses specially configured Power Flame burners that have been approved for oven use and proven on thousands of ovens across the U.S. and Canada.

What motors does the oven use?

Avoid ovens that use no-name motors because these can lead to troubleshooting and replacement issues in the future if you have a problem with your oven. Reliant, and some other manufacturers of high-quality powder curing ovens, integrate energy efficient and dependable Baldor heavy duty motors for both their heat systems and exhausts. As with other premium components, these may cost more but are a smart investment.

Does the oven body ship assembled?

Although a few companies tout the benefits of shipping pre-assembled ovens, most oven manufacturers provide their products unassembled to prevent shipping damage and allow for installation in hard-to-reach spots. This approach makes the oven much easier to unload and avoids situations where customers find it impossible to install their new equipment due to the layout of their shops.

 Where is the exhaust located?

 Reliant mounts their oven exhaust to the floor, so it removes only the coolest air in the oven–reducing heating costs. Some other companies mount the exhaust on the oven roof, drawing out the hottest air and wasting heat energy.

Where is the heater located?

For ease of inspection and maintenance, look for a heat system that mounts to the floor and has the gas train and burner components at about chest height. If possible, avoid roof-mounted heat systems that are more challenging to adjust and service. Reliant ovens typically use floor-mounted heaters. Roof-mounted versions are available if space constraints require them, but are not recommended for most applications.

 Where is the hot air discharge plenum located?

Reliant typically uses an overhead plenum that mounts above the entire ceiling of the oven because it uses no extra floor space and provides uniform airflow to the entire oven interior. Some companies use plenums that mount to one or both sides of the oven body (or the rear) using up lots of extra floor space.

Does the oven have a floor?

Reliant offers the choice of a steel floor, an insulated floor, or no floor at all. Most batch powder coating ovens don’t have a floor or have only a basic steel floor. This is because most shops use rolling carts, so an insulated oven floor isn’t practical. If your process could benefit from an insulated floor (such as when using an overhead rail to support parts hanging from hooks), make sure the oven provider has the ability to supply the best floor solution for you.

How is the oven controlled?

Reliant offers the choice of push button control panels with digital temperature management features or more elaborate color touch screen controls (with or without integrated data logging). Some oven companies provide only touch screen controls. For many customers, these don’t offer any benefits, but they are more expensive, can be more challenging to operate, and are more difficult to service. At the other end of the market, most entry-level oven websites offer only primitive push button controls that may or may not meet applicable codes.

Oven Construction—the difference is in the details

How heavy is the insulation? (heavier is better)

Almost all powder curing ovens are insulated with mineral wool. Mineral wool is supplied to the oven manufacturers in sheets. The denser the insulation, the more effective it is. Reliant ovens are insulated with mineral wool of 6# density or greater. Some oven builders use less expensive (and less effective) insulation of 4# density or less.

How thick are the walls & roof? (thicker is better)

Reliant powder curing ovens have wall and roof panels that are 6” thick. Some other well-known oven companies have wall and roof panels that are only 5” thick.  Economy-priced ovens may have panels that are only 4” thick, and some catalog sites sell ovens with panels that are less than 4”, practically guaranteeing unnecessary heat loss and significantly increased shop temps near the oven.

How thick are the doors? (thicker is better)

It’s important that your oven’s doors are well insulated to prevent heat loss. Reliant’s standard oven doors are over 5” thick and have gasketed overlapping closure flange to minimize heat loss. Many other ovens on the market use doors that are only 4” to 5” thick, and budget ovens may have doors that are even thinner—some 3” or less. If roll-up doors are best suited for your application, look for insulated fabric doors like those provided by Reliant.

Is the door assembly self-supporting?

 Many premium oven brands, like Reliant, utilize oven doors that are self-supporting and easy to adjust. These doors don’t need casters or supports. Some inexpensive ovens rely on troublesome casters to help support the doors.

 What material is used for the oven’s panels and exterior skins?

 Reliant uses prime U.S. steel from matching lots. Other companies may use U.S. steel from random lots, non-prime steel, or imported steel. Ask what type of steel the oven builder uses and where it originated. 

How is the steel used for these panels treated?

 Reliant uses only G90 galvanized steel panels to ensure long life and corrosion resistance. Some companies use less expensive and less corrosion-resistant G60 galvanized steel or generic galvanized steel that hasn’t been treated to any set standard. You’ll also find aluminized panels or powder coated panels from some manufacturers. Many less expensive ovens have panels that have only been painted or are left untreated.

 How are the panels that make up the oven body fitted together?

It’s important that the oven panels are secured in place before the oven is used. Reliant’s panels bolt together in field, assuring the snuggest fit. Some ovens use friction fit panels that are secured with screws. Others use panels that are only held together by a friction fit method, and a few inexpensive ovens rely on self-tapping screws to fasten the panel parts together.

 Are the panels insulated in the field during installation?

 Reliant ovens are unique because the panel assemblies are shipped as separate components. The insulation is applied during installation, ensuring perfect insulation placement. Ovens that rely on pre-built panels can be less efficient because the insulation can degrade slightly and settle during transport—leaving the tops of the panels without proper insulation once installed.

 Is all the oven’s advertised interior space usable?

 With some oven brands, a portion of the advertised interior space has ductwork in the way, reducing the amount of room available for curing parts. With Reliant and most premium brands, the entire advertised space is available for use.

Are the oven doors full size, allowing straight-in access to the entire oven interior? Do the doors hinge back out of the way?

Most higher-end ovens, including those from Reliant, use doors that provide access to the entire oven interior. Some ovens, however, use doors that are inset and slightly smaller. This reduces the cost of the doors but blocks straight-in access near the walls and ceiling. Remember, a reduction in clearance of only a few inches can significantly limit how you go about loading and unloading the oven. Along the same lines, most premium ovens, like those from Reliant, include doors that swing back more than 90° and clear the front of the oven. Some less expensive ovens use doors that swing open but don’t swing back out of the way. This means you’ll have to consider the turning radius of the cart you’re using because you may have to turn the cart more abruptly to clear the doors because they stick out straight in front of the oven—slowing the loading/unloading process and reducing throughput speed.

Company Information—Who are you buying from? 

Does the salesperson work directly for the oven manufacturer or are they a distributor/rep/contractor/reseller?

Reliant (and other companies that utilize full-time employees to sell equipment) can establish closer relationships with their customers and avoid the delays and miscommunication that can happen when there are layers of middlemen between the people designing and building the equipment and the people who’ll be using it.

Is their oven manufacturing facility in the U.S.?

There are a few newer brands on the market that don’t have US-based manufacturing capabilities. This can lead to issues with repair or replacement parts, technical advice, and support after the sale.

If you’re considering buying from an oven manufacturer, have they always made their own ovens?

Companies, like Reliant, that build their own equipment will have more experience and can provide greater control over product quality, lead times, and technical support. There are a handful of companies that started building ovens in the last few years (after selling equipment made by others), but their info may lead you to believe they’ve been manufacturing for decades. Don’t be shy about asking detailed questions, like “How long have you built your own ovens and exactly how many has your company built?” For comparison, Reliant has been manufacturing since 2005 and has manufactured over 1,000 ovens specifically for professional powder coating applications.

Do they start-up and calibrate their ovens using in-house technicians?

Hands-on calibration ensures that the oven is safe to operate and has been tuned for maximum fuel-efficiency and reliability. Many batch oven providers don’t offer on-site calibration. A few provide basic start-up services but rely on contractors. Premium-brand oven companies, like Reliant Finishing Systems, offer comprehensive start-up & calibration services using in-house technicians. Reliant provides these services at no additional cost.

Does the provider offer phone support by full-time in-house technical specialists? How many full-time support people do they have to assist their powder coating equipment customers?

Once your oven is operational, it’s important that you’ve got someone to call when there’s an unexpected hiccup. Whether it’s a lightning strike knocking out your power, an employee bumping the heater with a forklift, or just a situation where you need coating or curing advice, support after the sale can make a huge difference to your profitability. Additionally, Reliant offers lifetime over-the-phone support for all Reliant equipment. Monday through Friday, our in-house service team of experts (not call center operators or useless AI “assistants”) is on standby to help troubleshoot any issues or answer questions you may have. We have a team of experienced full-time employees who are on standby to support our customers, so you won’t be left hanging when urgency is critical. Some companies offer support only for the duration of the warranty. Others offer support but only have one or two employees who are qualified to provide troubleshooting guidance. A few have no established phone support program at all or direct you to contractors who charge for their services.

How good is the warranty?

It’s an unpleasant fact that sometimes parts fail. How this impacts your bottom line depends on the quality and duration of your oven’s warranty. When you do business with a top-tier oven manufacturer like Reliant, you can feel confident that your equipment will be supported for years to come. Many entry-level oven companies offer warranties that range from as little as 30 days up to 1 year. They may or may not include free shipping for replacement parts, and some have complicated requirements where old parts must be returned, or a deposit paid before your replacement parts are shipped. Reliant Finishing Systems has one of the best warranties in the industry. We cover all oven components, including belts, for 2 full years. If you’ve got a defective part, we’ll cover ground shipment of the replacement, and we offer express shipping at a reasonable charge. Since we’re the manufacturer and not just a sales outlet, we always have a huge inventory of repair and maintenance parts in stock. Because we use brand name components, you won’t be locked into buying from us down the road once your warranty expires. Many parts can be sourced from local suppliers or companies like Grainger. Additionally, Reliant offers lifetime over the phone support for your Reliant equipment. Monday through Friday, our in house and live(not a call center) Service Team is on standby to help troubleshoot any issues or questions you may have.

Does the company offer professional installation and maintenance services?

One way to understand the support you’ll receive in the future is to assess the capabilities of the company you buy your oven from. Some premium powder coating equipment companies, like Reliant, have teams of in-house technicians who can be deployed to perform installation and service work. Others may use contractors for on-site work. Some require you to work with the distributor who sold you your oven. Many online sales sites don’t offer field support at all. When you buy a standard powder curing oven, Reliant allows you to choose whether you’d like to install the oven yourself, hire your own contractors, or use our in-house techs to assemble your oven and perform interconnection wiring. Many companies choose to have their ovens installed and serviced by our techs so they can keep their workers on-task and keep their operation rolling.

As you can see, there’s more to buying a powder curing oven for your business than just comparing prices. By asking the right questions and weighing the features and benefits that are important to your success, you may not select the least (or most) expensive alternative, but you’ll get the equipment that offers the greatest value for your company. Need advice or want to discuss your coating equipment needs without feeling pressured? Give Reliant’s experts a call at (256) 355-9000 and let us help!

System 1

The High Cost of Poor Finishing Equipment Maintenance

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Whether you operate a small coating operation, run a fabrication shop, or manage a high-volume production line, your powder coating equipment is a vital asset—and maintaining it is not just a matter of good practice, it’s a strategic necessity. This article explores the importance of regularly maintaining powder coating equipment, the risks of neglect, and how proactive maintenance can significantly improve operational efficiency, finish quality, and long-term profitability.

Tips for Implementing a Maintenance Program:

  • Establish relationships with equipment manufacturers to establish proper service intervals and get support. Use equipment only as the manufacturers intended.

Click HERE to see a sample oven maintenance guide.

  • Work with suppliers of powder, blasting media, and pretreatment chemicals to establish “best practices” and ensure proper use of expendables.
  • Train both operators and finish line managers on basic daily upkeep procedures.
  • Develop a written preventative maintenance schedule—and enforce it!
  • Keep detailed records of inspections, repairs, and replacements.
  • Maintain a supply of filters and common maintenance & repair parts to prevent delays.
  • Conduct regular audits of system performance and safety compliance. Consider having annual line audits performed by a third party. 
  • Use only properly skilled service personnel, like Reliant’s factory-authorized technicians, to deal with serious problems.

By treating equipment maintenance as a core operational priority, successful businesses position themselves for long-term success in the competitive powder coating, fabrication, and manufacturing markets.

Maximize Equipment Lifespan

A properly designed professional coating system isn’t cheap. One of the fundamental reasons to maintain powder coating equipment is to protect your investment. A well-maintained system can operate efficiently for many years, often decades. Some of Reliant Finishing Systems’ customers have equipment that’s been in operation since 2005, our first year in business. Whether it’s your pretreatment or blasting equipment, powder booths, spray guns, conveyor, or drying and curing ovens, every component has a limited lifespan that can be extended with proper care.

Just like vehicles or other industrial machinery, powder coating systems are subject to wear and tear. Accumulated powder buildup, clogged filters, poorly adjusted burners, contaminated chemistry tanks, debris-covered motors, damaged controls, and warn nozzles can all retard your system’s performance and accelerate the deterioration of your equipment. Regular maintenance—including cleaning, inspection, and timely replacement of parts—helps ensure that your equipment stays in peak working condition and avoids premature failure.

Lower Total Cost of Ownership

Some business owners hesitate to invest in aggressive maintenance because it seems like an added expense. In reality, it’s an investment that pays for itself many times over. The total cost of ownership for any type of industrial equipment includes not only the initial purchase price, but also the operational costs, repair costs, and expense of downtime.

Neglected equipment tends to break down more often, require more repairs, and operate less efficiently. In contrast, well-maintained systems are less likely to fail, use fewer resources, and deliver more consistent results. Over time, the cost savings from fewer emergency repairs, less unplanned downtime, greater energy efficiency, and fewer finish defects more than justify the cost of proper upkeep.

Reduce Downtime and Production Interruptions

Unexpected equipment breakdowns can be catastrophic in a production environment. Clogged washer nozzles, a damaged spray gun, or a malfunctioning oven can bring an entire coating line to a halt, causing costly delays and missed deadlines. In industries where turnaround time is critical, even a few hours of unscheduled downtime can cost thousands of dollars in lost productivity and overtime labor.

Routine maintenance helps prevent these types of disruptions. By identifying and addressing minor issues before they evolve into major problems, companies can schedule necessary repairs during planned downtimes rather than reacting to emergencies. This minimizes operational interruptions and keeps production schedules on track.

Postponing routine maintenance is a top cause of unscheduled downtime for both batch and constant process finishing processes.

Maintain Consistent Product Quality

Consistency is the key when it comes to finish quality. Whether they’re buying a finished product or powder coating services, customers expect finishes that are unblemished, uniform, and durable. Poorly maintained powder coating equipment can compromise finish quality in several ways.

For example, an improperly calibrated powder gun or worn tip can lead to uneven film thickness or poor coverage, while a dirty booth or clogged filters can result in finish contamination from old powder or airborne debris. Decreased booth airflow can result in missed coverage by operators due to poor visibility resulting from inadequate overspray dissipation. Temperature fluctuations in an oven due to faulty sensors or damage to insulated panels can cause improper curing, leading to poor durability, gloss issues, or discoloration of lighter colored finishes.

Maintaining your powder coating equipment ensures that it performs to the manufacturers’ specifications, delivering the consistent quality your customers require and reducing costly rework situations or rejected parts.

Improve Efficiency and Reduce Material Waste

Powder coating operations rely on efficiency to maintain profitability. This is especially true in high-volume production environments. Equipment that is not functioning optimally tends to consume more powder, blasting media or pretreatment chemistry, fuel, and electricity, which directly affects your bottom line.

As an example, a poorly maintained powder recovery system can fail to capture overspray effectively, increasing powder waste. A dirty, improperly adjusted, or misaligned spray gun may require more passes to achieve coverage, consuming more time and materials. Similarly, damaged ovens that allow heat loss and ovens with incorrectly adjusted burners will require more energy to maintain curing temperatures.

Routine maintenance keeps all components functioning efficiently, reducing waste, conserving resources, and increasing throughput.

Comply with Environmental and Safety Standards

Powder coating is considered more environmentally friendly than traditional liquid paint systems, largely due to low VOC emissions and the ability to reclaim powder overspray. However, this advantage can be compromised if equipment isn’t properly adjusted and maintained.

Overspray accumulation, clogged or damaged exhaust filters, and leaky powder delivery systems can lead to powder escaping into the air, potentially violating local environmental regulations, contaminating nearby machinery, and putting worker health at risk. Overheating ovens, careless blasting or chemical pretreatment practices, damaged electrical components, and malfunctioning safety devices also pose serious safety hazards.

Properly maintaining your equipment helps ensure that your operation complies with OSHA regulations, environmental standards, and insurance safety requirements. It protects your employees, your other equipment, and your business from the consequences of non-compliance.

Support Scalability and Business Growth

As your business grows and your production volume increases, the demand on your powder coating equipment will also rise. If your equipment is already operating at reduced capacity or demonstrating inconsistent performance due to poor maintenance, scaling your operations becomes significantly more difficult and financially risky.

By taking an aggressive approach to coating equipment maintenance, you guarantee that your finishing department is ready to meet increased demand without sacrificing quality or unreasonably extending delivery times. Proactive maintenance practices also allow you to better forecast production capabilities and plan for expansions or upgrades.

Enhance Your Business Valuation and Resale Value

For companies thinking long-term, whether preparing for a sale, merger, or expansion, properly maintained equipment holds higher resale value and contributes positively to the company’s overall valuation. Potential buyers or investors look favorably on operations that have well-documented maintenance procedures and equipment in good working condition.

Conversely, neglected equipment can be a red flag that signals operational inefficiency, future capital expenditure needs, poor management practices, or an undesirable company culture.

Don’t Ignore Maintenance

Maintaining your powder coating line isn’t just about avoiding breakdowns—it’s about protecting your investment, ensuring product quality, and keeping your business running efficiently and profitably. In a competitive market where reputation and consistent performance matters, regular maintenance is one of the smartest strategies a company can implement.

Whether you’re a small job shop or a large-scale manufacturer, integrating a robust maintenance schedule into your operational plan isn’t just prudent, it’s essential to long-term success. You’ll not only extend the life of your equipment, you’ll also build a more resilient, efficient, and profitable business.

Reliant Can Help

If you want to talk to an expert about your existing finishing equipment, need technical support, or have questions about acquiring new coating equipment, Reliant is here to help! Give us a call at (256) 355-9000 and we’ll be glad to assist you.

CART UNIT

How Manufacturers, Fabricators & Coaters Can Thrive in 2025

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After weeks of rapid policy shifts, the majority of the U.S.’s new reciprocal tariffs have been paused, but some remain in force. If you’re in the manufacturing, fabrication, industrial painting, or powder coating business, your inbox has likely been flooded with “the sky is falling” alerts, and the current pause is the perfect time to get up to speed on the situation and make an effective plan.

We’ll break down which materials and countries are affected, how manufacturing and finishing operations—especially powder coating shops—might feel the pressure, and practical steps you can take to mitigate these changes and thrive as a business. This article is based on information that was current as of May 12, 2025, after it was announced that a temporary trade deal had been made with China.

The Tariff Landscape: What You Need to Know

While the tariff scene is evolving and subject to change, manufacturers and coaters need to understand which materials and imports are being targeted so they can prepare adequately. Here’s a breakdown of major developments impacting finishing, fabrication, and general manufacturing:

Steel Products

Steel tariffs—first enacted in 2018—were expanded in March of this year. The 25% base rate remains, but fewer exemptions and tighter loophole enforcement for things like trans-shipping make this round of tariffs potentially more disruptive. Since steel tubing, bars, rods, and flat-rolled products are commonly used in fabricated parts that are later coated, price hikes could ripple across the entire steel materials supply chain.

Aluminum Products

Aluminum tariffs, increased from 10% to 25%, now cover a broader range of products, including cans and sheets. This change hits fab shops and manufacturers that rely on pre-formed aluminum parts or extrusions. While Canada and Mexico are mostly exempt under the USMCA, imports from other major sources like China and Germany will be more expensive.

Machinery and Tools from China

A broad 145% tariff on all Chinese imports became effective on April 9, 2025. Then, on May 12, 2025, it was announced that a trade deal had been struck that would temporarily reduce the tariff to 30% for 90 days. If increased tariffs reappear, it will have massive implications for manufacturers considering imported machinery, paint or powder coating booths, industrial ovens, conveyors, control systems, or parts. As an example, there has been a recent influx of inexpensive Chinese automated finishing systems that mimic finishing lines from established US and European brands. Some US companies were willing to risk the long lead times and lack of support to save money. A substantial tariff drastically reduces the appeal of these systems by decreasing the cost difference. It may also put past purchasers of Chinese products at a disadvantage since repair and maintenance parts may no longer be within budget. Less costly equipment sourced from China, such as shop tools, will also be impacted, so this potential change demands attention from almost every US manufacturing business.

Universal Import Duty

This blanket 10% tariff affects ALL goods entering the U.S., with few exceptions. For powder coating operations that source chemicals and supplies (e.g., degreasers, pretreatment agents, or powders) internationally, this means higher input costs—regardless of supplier country.

Who’s Feeling the Pressure?

Metal Fabrication and Finishing

Higher costs on raw or semi-finished metals mean higher base material prices. Since powder coating or painting is typically one of the final steps in the production chain, some operations may see delays and/or cost increases passed down from upstream. This could have a broad impact because everyone from small fab shops to large-scale manufacturers of metal products commonly rely on powder coating and industrial painting as a part of their production process.

Automotive and Equipment Manufacturing

Tariffs on steel, aluminum, and auto parts could mean U.S. manufacturers of vehicle frames, truck enclosures, and other components for vehicles, vehicle conversions, or heavy equipment will feel margin pressure. Finishing specialists serving this market should anticipate tighter budgets, shifting sourcing strategies, and possible production slowdowns. Established customers may choose to bring coating in-house to save money and offset increased material costs.

Construction and Infrastructure

Aluminum extrusions and steel components for building products such as railing systems, window frames, and HVAC components are key targets of current tariffs. Businesses in this sector may find themselves juggling uncertain material costs and increased competition from domestic suppliers ramping up production. On the other hand, an increase in domestic suppliers could result in more choices when sourcing critical components.

Strategies for Coaters and Manufacturers to Mitigate Tariff Impacts

Cost Reduction

Now’s the time to reassess your vendor base for everything from industrial machinery to shop supplies and small hand tools. Domestic producers are increasingly attractive, especially if you’re considering replacement or upgrades to big-ticket items like capital equipment. Established US firms that have a strong presence in your market may have more appeal than ever before. Tools like ERP systems can help you compare pricing across suppliers, streamline procurement, and avoid duplication or waste.

For powder coating operations specifically, optimizing material usage and reclaiming powder overspray more efficiently can offer serious savings. Simple steps, such as reviewing your coating thickness targets and ensuring you’re not over-applying, will become more valuable if material prices rise.

Operational Efficiency

Boosting throughput and/or reducing processing costs without compromising quality is key. This may require fresh investment in equipment, as well as more sophisticated quality control processes. Improvements might include Overall Equipment Effectiveness (OEE) tracking and the implementation of predictive maintenance tools. Minimizing unplanned downtime with fabrication equipment, automated production machinery, and finishing equipment like pretreatment washers, spray booths, and ovens can dramatically improve your margin during times of supply strain.

Smart Automation

Automation doesn’t just mean production-boosting robots or sophisticated finishing systems, it includes software-based process improvements. Barcode scanning of materials/inventory/WIP, AI-assisted workflow scheduling, and real time inventory tracking are the types of improvements that can allow your team to run leaner, faster, and with fewer errors. For larger industrial painting and powder coating operations, using automation to track parts as they go from pretreatment through cure can shave off hours of manual labor every week.

Looking Ahead: Thriving in a Tariff-Challenged Business Environment

The current pause in tariff escalation offers a temporary window to reassess sourcing, optimize processes, and invest in equipment and systems that increase productivity and improve your company’s resilience. Your reliability to your customers, as well as your profitability as a business, may end up being linked to how well you navigate tariff-related volatility. But what if you want to do more than just survive—you want to thrive? Amidst the current uncertainty lies massive opportunity. Here’s what it looks like:

Leverage the “Buy American” Momentum

No matter what your political views, an undeniable outcome of the current tariff climate is a renewed national emphasis on sourcing domestically. As imported metals and machinery become significantly more expensive, large U.S. manufacturers will be increasingly turning to local suppliers and service providers. For businesses of all sizes, this is a unique opportunity to grab market share from overseas and beat large domestic players who are slow to adapt.

To take full advantage:

  • Go all-in on your company’s domestic roots. Whether your company is nationally known or competing in a small metropolitan area, emphasize your role in the domestic supply chain by touting your predictability, proximity to customers, reduced shipping times, competitive lead times, and responsive service. These are all highly appealing in a disrupted market, particularly one where price points are subject to fluctuation.
  • Get bona fide. There’s going to be a glut of companies who rely on “flag waving” to attract buyers. Distinguish your company by doing more than just talking the talk. Refine your reference lists and don’t take aging relationships for granted. Get involved with promotional and educational organizations within your industry. Join established business advocacy groups that have been supporting US businesses for years. If applicable, attain certifications like ISO 9001 or American Welding Society (AWS) endorsements to increase your credibility with larger buyers looking to switch from offshore partners.
  • List in procurement directories. Register with platforms and databases used by governmental agencies, prime contractors, OEMs, and large manufacturers looking to source from local or regional suppliers.

Rethink Your Supply Chain—Without Sacrificing Quality

The increase in steel and aluminum tariffs has hampered some companies that relied on imported materials, but those businesses that can pivot towards domestic suppliers, can mitigate the damage.

Steps to consider:

  • Renegotiate with suppliers. Build strategic partnerships with local mills or distributors who might offer volume discounts or payment flexibility to secure a long-term relationship.
  • Cooperate with other shops. Join or form co-ops or buying groups with nearby businesses to improve purchasing power and lower raw material costs.
  • Audit material specs. Determine which domestic alternatives can be used without compromising product integrity or customer standards. This probably won’t be an issue since most businesses choose to buy imported materials and products because of lower prices, not because of higher quality.

Invest in Operational Efficiency

If you can’t effectively manage your raw material costs, the next best way to protect your margins is by improving throughput, reducing waste, and automating repetitive tasks.

  • Upgrade equipment where possible. New CNC production capabilities, added robotics, larger booths and ovens, and conveyorized finishing system upgrades can help significantly reduce labor hours.
  • Adopt ERP and OEE software. Modern enterprise resource planning (ERP) tools can help even smaller businesses forecast demand, track materials, streamline quoting, and optimize scheduling. Overall Equipment Effectiveness (OEE) tools can identify performance bottlenecks and reduce downtime for companies of all sizes.
  • Lean manufacturing. Even a basic implementation of lean principles such as 5S, standardized work, and just-in-time production can reduce scrap, improve workflow, and lift profitability.

Add Value Through Secondary Services

In an uncertain or highly competitive landscape, the more value you can offer beyond basic production work, the more attractive you become to your customers.

Popular add-ons include:

Powder coating and paint finishing. Tariffs on aluminum and pre-finished goods have driven up demand for suppliers with in-house finishing capabilities. Savvy businesses use their ability to apply unique-to-market, custom, or extremely high quality finishes as a way to differentiate themselves from competitors.

  • Assembly and packaging. Help customers reduce handling and shorten their own supply chains by shipping finished assemblies or sellable products rather than just parts.
  • Design-for-manufacturing support. Collaborate with customers earlier in the design phase to recommend cost-saving tweaks and ensure manufacturability. Technical prowess and astute project management are valuable sales features.

Target Reshoring Manufacturers and Strained Industries

As big companies begin to reshore manufacturing in response to high import costs, they’ll need nimble, capable local partners. Focus your outreach and sales efforts on industries that are actively seeking domestic supply chain partners.

Hot segments include:

  • Aerospace & Defense: Despite the recent focus on reducing government spending, there’s a huge demand for domestically-provided parts and services in support of government aerospace and defense projects. Support contracts can be lucrative and somewhat insulated from consumer market volatility. As private companies continue to expand commercial space ventures, a similar demand for domestic components is likely.
  • Agricultural equipment: With many imported components now facing a 25% tariff, U.S. ag equipment makers are looking to domestic shops for components and finishing services. There’s also a growing refurbishment industry for big agricultural equipment. 
  • Consumer goods: Brands eager to highlight “Made in the USA” credentials are on the hunt for domestic metal parts and components. It makes sense that these domestically-sourced parts will need to be painted or powder coated in the US as well. 
  • Automotive: The Big 3, Japanese companies with established US plants, and electric vehicle start-ups are all looking for their suppliers to shift away from tariff-exposed materials and parts. The same goes for aftermarket companies that provide vehicle upgrade and customization components for automotive, commercial trucking, and recreational vehicle applications.

Embrace Flexibility as a Competitive Advantage

Unlike large, capital-intensive businesses that are burdened with high overhead and long project cycles, fabricators, coating businesses, and even midsize manufacturers can change direction more quickly and use their agility to:

  • Take on short-run jobs that larger companies might decline.
  • Offer custom prototyping, rush work, or repair services for customers that require special attention or fast turnarounds.
  • Experiment with new materials, equipment, or processes that might provide an edge in a disrupted market.
  • Look outside their comfort zone to build products for new applications or find work from unexplored market segments.

Plan for the Long Game—Don’t Just Survive, Strategize

The current tariffs are partially paused but may change for better or worse at any time. Use this moment to future-proof your business.

  • Don’t ignore technology. If your business has the financial means to do it, consider investing in fresh machinery or updated software. These purchases can increase your company’s productivity no matter how the economic climate changes.
  • Build cash reserves if possible. If you’re already benefiting from higher domestic demand, save strategically to enable near-term equipment and automation purchases while building a cushion against future price volatility.
  • Diversify your customer base. Don’t become too reliant on one industry or client. Spread your risk and revenue across customers from various sectors.
  • Monitor policy changes. Stay informed about tariff updates, USMCA modifications, and proposed legislation. Being proactive about how you operate your business will give you a major competitive advantage, especially against larger, less agile competitors.

We hope you’ve found this article informative. If your business is considering modernizing, expanding, or upgrading existing finishing capabilities, or if you’re considering bringing powder coating or paint finishing in-house, the experts at Reliant Finishing Systems can help. Give us a call at (256) 355-9000.

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Why Doesn’t Reliant Finishing Systems Use Distributors?

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Why Doesn’t Reliant Finishing Systems Use Distributors?

When purchasing equipment like industrial ovens, paint booths, or powder coating systems, buyers often interact with a distributor or sales rep who works in their area. If not, they may deal with an online sales outlet instead, but this isn’t always the company that actually builds and installs the equipment.

This article outlines why Reliant chose to use a different approach to sales than most established industrial equipment manufacturers. 

The quickest explanation is that we want to give our customers the best buying experience possible, ensure they receive the right equipment at a competitive price, and provide them with outstanding support after the sale is concluded.

Reliant designs, manufactures, installs, commissions, and services the equipment we sell. This provides significant advantages to our customers in terms of support before and after the sale, and it maximizes the overall value they receive.

History 

Reliant was formed in 2005, but the founders had been involved with finishing equipment for many years before launching the company. Back in those days, the vast majority of finishing equipment buyers met face-to-face with distributors, sales reps, or resellers who would guide them through the purchase process. 

Reliant originally used this approach, as did our competitors like Global and Col-Met. We opted to partner with one national-level reseller and later added a handful of small regional distributors. We also built equipment that was sold by others under different brand names. Unfortunately, we observed that not dealing directly with our end-customers contributed to a less-than-ideal situation for everyone.

Once we changed our sales approach and removed the middlemen, Reliant began to grow rapidly by selling our equipment factory-direct and providing 5-star customer service straight from our main office. We also stopped working with labor sub-contractors. Instead, we hired and trained multiple installation crews so we could have greater control over the installation process and make sure our customers were exceptionally happy with the work being done. We had already started using our own specially trained employees to commission and calibrate every oven we sold. 

As we became increasingly involved with our customers, we enjoyed sharing in their successes and our repeat business skyrocketed. This, combined with our development of new products, including specialized ovens and much larger and more complex finishing systems, led to a wave of growth. 

Direct Access to Expertise

When you purchase directly from Reliant, you gain direct access to sales and technical support teams with in-depth knowledge about not only the equipment, but a wide range of finishing and thermal processing practices. If you have questions about product specifications, installation, operation, or maintenance, we’ll provide expert guidance and troubleshooting assistance. The same people you speak with on your first call will be with you through the design, production, installation, and start-up of your equipment, and they’ll continue to support you for as long as you have the equipment.

In contrast, distributors won’t have the same universal level of technical expertise and knowledge about your order. They typically act as intermediaries, relaying your questions to the manufacturer and then getting the answers sent back. This can lead to delays in getting critical information. There’s also the potential for miscommunication that can cause catastrophic results if your needs aren’t perfectly explained to the manufacturer, or your project isn’t managed with honesty and technical know-how.

Stronger Warranty & After-Sale Support

In addition to offering superior after-sale support compared to distributors, issues such as warranty claims, repairs, and replacement parts are handled more efficiently at Reliant because you are dealing directly with the source. If an issue arises, Reliant streamlines the resolution process, ensuring that your equipment remains operational with minimal disruption.

If considering between various equipment providers, we suggest that you request a list of recent customers. Explain that you don’t want a list of just the buyers where everything went right, but you want to talk to a couple who had issues like a motor failing in the first month or the control panel being damaged during delivery. Call them and ask detailed questions. Sometimes, despite the manufacturer doing everything right, there’s still a hiccup. It’s important that if something goes wrong, you’re doing business with a company that has the resources and authority to take immediate action to help you.

Transparency in Product Quality & Origin

Purchasing directly from Reliant assures transparency regarding the quality of materials, production processes, warranty, and country of origin. You can verify the construction methods, component quality, and overall durability of the equipment before making a purchase. One of the most important things a potential buyer can do is ask exactly which company or facility is building specific equipment or components, then request factory visits or video tours to confirm the facts BEFORE issuing a purchase order.

We encourage this because distributors may not always provide complete information about where or how the equipment was made, and some distributors and online sales outlets (particularly those that market to first-time buyers) avoid full transparency about who’s doing the manufacturing. They may re-brand products or components from one or more different manufacturers, making it harder for the buyer to assess product quality and understand what will happen if they need warranty coverage. 

Customization & Engineered Solutions

Engineered solutions often make sense when considering a comprehensive finishing system purchase. A custom turn-key system can lead to improved efficiency, better finish quality, and reduced operational costs in the long run. 

Reliant can customize our standard “catalog” equipment to meet your specific needs, or we can design a unique system for you from the ground up. Whether you require specific appliance dimensions, unusual airflow configurations, uncommon heating capabilities, or cutting-edge integrated automation features, our engineering team will provide equipment that aligns perfectly with your requirements.

Distributors often lack the technical expertise and direct communication channels needed to facilitate this type of project effectively. Companies that utilize distributors typically allow them to sell a limited number of standard models with a handful of customization options. If a project becomes reasonably complex, the manufacturer may cut out the distributor and designate the project as a strategic sale, essentially mimicking the Reliant approach, but with much less experience—and an angry distributor.

Faster Lead Times & Better Parts Availability

Buying directly from a manufacturer like Reliant can also result in faster lead times, but use caution. If a lead time seems too good to be true, it probably is. Do your homework and speak with plenty of references before you make a purchase decision! Some sales outlets have a reputation for downplaying lead times and then running weeks or months late with little or no warning. 

Also, be aware that distributors are sometimes vying for the same resources within their network. They rely on inventory levels and manufacturing slots that may not align with your needs. Get lead time information in writing and confirm it with the manufacturer. Remember, once the factory or warehouse releases your order, it can take additional time for the distributor to interact with the manufacturer, arrange shipping, and schedule your project for installation.

Reliant can provide real-time updates on production schedules and lead times, keeping you informed and ensuring that you get your equipment as quickly as possible. Any potential deviation from the schedule will be reported well in advance. This type of direct, cooperative relationship can be especially critical if you’re expanding existing operations or replacing old equipment, since you’ll want to coordinate delivery and installation to minimize downtime.

These benefits also extend to warranty, repair, and maintenance parts. Unlike smaller companies that keep only a limited stock of parts on hand, or distributors who may not have any inventory at all, Reliant stocks a massive inventory of parts to support the thousands of customers we’ve done business with over the past two decades. We also typically keep smaller equipment, like powder coating guns, stocked in our warehouse for immediate delivery.

Because we operate from a single facility, it’s easy for Reliant to create custom maintenance packages that include spare parts kits, additional booth filters, extra powder gun hoses or hoppers, etc. We can ship these items with the main equipment order, saving our customers time and money.

More Negotiation Power & Relationship Building

When buying from Reliant, you benefit from the fact we have more negotiating power than most distributors and small online equipment providers, especially when making bulk purchases of things like raw materials, filters, and common maintenance items. We also get more traction when planning long-term partnerships with other companies, such as burner manufacturers or pretreatment spray wand builders. This means our customers won’t be faced with last-minute parts substitutions or inferior components blamed on supply chain issues.

It also means we value our business relationships, both with our customers and our vendors. We’ve seen countless distributors and online sales outlets swap between suppliers of small ticket items, like powder guns, again and again, sometimes also bouncing from one equipment manufacturer to another while chasing “a better deal.” These decisions have typically NOT been based on what’s best for the customer.

In contrast, we feel that establishing meaningful long-term relationships with the companies that provide us with key components is crucial to our success. We also believe that it’s important to have this same type of direct, no-razzle-dazzle interaction with our customers. Rather than a “one and done” sales philosophy, we want Reliant’s customers to turn to us for future purchases, upgrades, and service needs for years to come. We work to stay informed about our customers’ experience with their equipment. We also strive to keep them up to date on new product developments. When requested, we offer thoughtful recommendations about products and processes that will best suit our customers’ needs as they grow.

Reliant offers customized equipment packages and volume discounts, extended warranties, loyalty incentives for repeat customers, and special pricing for pre-scheduled delivery of filters and maintenance parts.

Cost Savings

Perhaps we’ve saved the best for last. One of the primary advantages of buying directly from Reliant is cost savings!

Distributors add their own mark-up to the price of the equipment, often hiding some of it in the installation budget or spreading it across the entire order. In addition to working with one or more manufacturers, they also typically make deals with other companies to provide certain components that are added to the total package being sold. The appliances and components are then shipped from the various sources once the bill is paid. By purchasing directly from Reliant, you can avoid these additional shipping costs, secure a better price on your equipment, and feel confident about where everything was sourced.

Additionally, Reliant offers package discounts and financing options that aren’t usually available through distributors and online resellers. These savings can be particularly significant for small to mid-sized businesses seeking professional quality equipment but operating on tight budgets.

When is a Sales Rep a Better Choice?

While buying equipment directly from Reliant offers many advantages, there are some cases where purchasing from a local distributor or sales rep is clearly beneficial. Although we build blasting, pretreatment, and coating equipment, Reliant doesn’t sell blast media, chemicals, or powder. We strongly recommend that our customers establish relationships with vendors who operate on a local or regional basis and can help them get the best results from the expendable materials they use with their finishing equipment. These include:

  • Abrasive Media & Blasting Supplies: Many companies that sell blasting media and related supplies have representatives that can help make sure you’re using the right media for your application. This should involve occasional site visits to observe the results you are getting and suggest refinements.
  • Chemical Pretreatment: Most pretreatment chemistry suppliers provide local service, which is critical if your parts preparation routine warrants in-person support and titration assistance. You probably don’t want to buy your chemicals from the same company that sold you your equipment, especially if it is being shipped 5 gallons at a time! Instead, interview sales reps from multiple brand-name suppliers like DuBois and Chemetall to find the company that best supports your business.
  • Paint & Powder Coatings: One of the most important relationships any finishing operation needs to maintain is their connection with the companies that provide their paint and/or powder. All national-level suppliers have reps that cover specific geographic areas or market segments. Simply put, if a company won’t send someone to routinely help you with quality issues and make sure your business is using the latest and greatest paints and powders for your application, find another supplier.

A Better Way of Doing Business

Unlike distributors, regional sales reps, generic online stores, and small web-based outlets, Reliant has a proven track record, countless references from customers big and small, and the experience, agility, and business horsepower needed to guarantee a good outcome.

Reliant specializes in personalized service and practical solutions. During the sales process, we offer complete transparency, dedicated engineering and limitless equipment customization options, competitive pricing, industry-leading responsiveness, and realistic production lead times.

After the sale, we provide professional installation and start-up, excellent warranty coverage, superior technical support, fast shipment of filters and maintenance parts, and we support our customers for life. 

We’re also dedicated to constant improvement, both with our products and our business practices.

If you’d like to discuss your finishing or thermal processing requirements, the experts at Reliant Finishing Systems are ready to help! Give us a call at (256) 355-9000 and we’ll discuss your needs, provide a budgetary estimate, and promptly follow it up with a detailed plan that defines the equipment, layout, and associated costs for your project.

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Considering a Manual Conveyor? Conventional Batch Coating is Better

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When specifying a new powder coating system, companies sometimes choose between a conventional batch powder coating solution or a manual conveyor-based one. By conventional batch coating, we mean using carts or rolling racks to move parts between appliances and hold parts in place while they are being coated and cured. A manual conveyor system requires an overhead rail or floor mounted track and a set of trolleys. Parts are held on hooks or carriers that are moved manually by workers, often by using a chain to pull the trolleys along the conveyor. While both approaches have their merits, conventional batch powder coating is consistently a more versatile and cost-effective option, especially for businesses with limited floor space. 

Here are the 5 key reasons why conventional batch powder coating is better than using a manual conveyor system:

1. Flexibility

One of the primary advantages of batch powder coating is its flexibility. Batch systems are designed to accommodate a wide variety of part sizes, shapes, and volumes. Whether you’re coating small, uniform components or large, irregularly shaped items, a conventional batch system can accommodate any and all parts that fit properly inside the booth and oven. In contrast, conveyor systems are typically limited by the location and configuration of the conveyor track or overhead rail (which is usually located in the center of the appliances), making it challenging to coat oversized or uniquely shaped items that may need to be positioned off-center.

For businesses that take on custom jobs or have fluctuating production volumes, batch powder coating allows for quick adjustments because different types of racks can be used. An added benefit is that projects that encounter a hiccup can be moved to the side. This isn’t possible with manual conveyor: a problem with one process impacts all the processes! As an example, let’s say the power goes out for a moment during a storm and the oven’s safety system shuts it down. With a batch system, the powder booth operator can continue to coat and simply move carts of parts to an empty spot on the shop floor once they are coated. With a conveyor system, once the space between the oven and booth is filled with parts, the coater can no longer continue working if the oven is down. Another example would be an unplanned rush job that has to go out ASAP. Until the parts that are already loaded are cleared from the conveyor, the rush job can’t get done.

We should also mention safety concerns and how they impact both cost and versatility. With conveyor systems, the parts are loaded onto hooks or carriers or some combination of both. The parts are removed once they have been processed. The same approach applies when using carts. One big difference is that the location of these operations is fixed when you use a conveyor but can be refined or changed temporarily when using carts. There’s also the issue of the travel path. Not only can parts hanging from an overhead conveyor block foot traffic or prevent forklifts and similar equipment from being able to move through the coating area, regulations or plant safety policies may require the installation of guards to protect personnel and equipment if a part falls from the conveyor. All of these factors can increase costs, reduce flexibility, and have a negative impact on productivity.

2. Lower Cost

Even without considering safety constraints, batch powder coating systems are far more affordable to purchase and install than conveyor systems. Conveyor setups require significant infrastructure, including conveyor supports and custom rails or tracks. Additionally, ovens and booths will require custom features such as cut-outs in the doors or enclosures that allow the conveyor rail to pass through. The booths and ovens are also usually larger than when using carts because there needs to be room to fit the conveyor supports. The appliances may need to be built with doors at both ends to accommodate the workflow through them. These features, plus the cost of the conveyor itself, combined with the added installation costs, can significantly increase the total acquisition budget.

This increase scales up as the system becomes more complex. If you intend to use chemical pretreatment and dry the parts before they’re coated, the cost will be even higher than if you choose a conventional batch approach. Not only will you need more conveyor, there is no convenient way to use your curing oven for drying wet parts unless you spend extra for a truly custom oven design and a much more sophisticated conveyor. In addition, the conveyor section that passes through the pretreatment system will need to be stainless steel to avoid corrosion–adding even more to the initial cost.

As we mentioned above, any breakdown in the conveyor line can halt production entirely, reducing efficiency and adding to operational costs.

In contrast, batch systems require minimal infrastructure. A basic batch setup includes a spray booth, a curing oven that can also be used to dry parts, a pretreatment spray wand, wash area or enclosure, and a powder spray gun, all of which are relatively affordable. Carts or rolling racks can be purchased or built as they are needed. There’s no customization or upgrades needed for the appliances and there’s no expense for conveyor, supports, or conveyor installation. For small and mid-sized companies or start-ups, this lower capital expenditure makes conventional batch powder coating systems a more accessible option.

3. Throughput

Batch powder coating excels in low to medium volume production scenarios, making it an ideal choice for manufacturers and coating shops that value versatility over maximum throughput. Custom fabrication shops, “job shop” coaters, and manufacturers of specialty products can all benefit from the flexibility and scalability of batch systems.

Manual conveyor systems, on the other hand, may be limited to more consistent parts profiles and their production volume is usually equal to or less than what can be attained with conventional batch coating–even though the system costs more. 

As we outline below, the likelihood of reduced throughput due to downtime is consistently greater with conveyor systems, regardless of the volume of parts being processed.

4. Maintenance & Downtime

Maintenance is a critical consideration for any coating operation, and batch systems shine in this area. Because they have few moving parts and utilize relatively simple appliances, conventional batch systems are easier and less expensive to maintain than other systems. Routine cleaning and servicing can be performed quickly, minimizing downtime. 

Conveyor systems, in contrast, are more complex and prone to mechanical issues. They must be cleaned and maintained more rigorously to avoid downtime from overspray build-up on trolleys or powder accumulation on the rail or track. A single malfunctioning trolley can shut down the entire line. Maintenance and repairs can be time-consuming and costly, leading to extended periods of downtime that can disrupt production schedules and impact profitability.

5. Scalability 

Batch powder coating systems are inherently scalable. This is especially true with booths and ovens from Reliant Finishing Systems because their modular design allows the appliances to be made longer, taller, or wider without having to scrap the entire structure. As a business grows, the appliances can be enlarged or additional equipment can be added incrementally without requiring a complete overhaul of the existing system. This makes conventional batch systems an excellent choice for companies planning for long-term growth.

Conveyor systems, on the other hand, are less adaptable. Expanding a conveyor line often involves significant capital investment and infrastructure changes, which can be a major barrier for growing businesses. Another critical consideration is floor space. The footprint of the typical batch system is almost always smaller than that of a conveyor-based system with similar capabilities. In some cases, the difference can be staggering, with a conventional batch system taking up less than half the room. For many business owners, this is reason enough to abandon plans to use a conveyor to move their parts through the coating process.

Ready to Talk Batch?

For those seeking a coating solution that prioritizes affordability, versatility, and efficiency, conventional batch powder coating systems are the clear choice over manual push/pull conveyor-based coating systems. If you’d like to discuss your coating system requirements, the experts at Reliant Finishing Systems are ready to help! Give us a call at (256) 355-9000 and we’ll talk through your needs, provide a budgetary estimate, and promptly follow it up with a detailed plan that defines the equipment, layout, and costs associated with a new powder coating system.

Wagner Hopper Guns

Free Wagner Sprint 2 Powder Coating Gun

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If you want professional quality coating results, you need a professional quality gun. That’s why we’ve partnered with Wagner to provide their newest manual powder coating gun. The Wagner Sprint 2 sets the standard for professional coating guns, providing the latest technology, exceptional ease of use, and Wagner’s outstanding customer support.

Reliant is offering a FREE Wagner Sprint 2 box-fed powder coating gun with the purchase of any booth & oven package, in addition to our usual package discount! To qualify, your order needs to be under deposit by Monday, December 30th, 2024. Click below to learn more about these great new powder guns. 

Wagner Air Flow Control (AFC) technology ensures exact powder control through a high-precision, closed control loop measurement that regulates the air volume during the coating process and produces a uniform powder cloud for premium coating results.  

Powder can be fed directly from the original container (box-fed) or out of portable stainless steel hoppers (hopper-fed). The layout of the controls makes adjusting recipes fast and intuitive. Up to 50 coating recipes can be saved, creating numerous possibilities to set parameters for your individual needs. Wagner Air Flow Control (AFC) technology ensures exact powder control. A high-precision, closed control loop measures and regulates the air volume during the coating process and produces a uniform powder cloud for premium coating results.

Using the Digital Surface Optimizer (DSO) system, up to 4 primary recipes can be easily accessed via quick selection and an additional 46 recipes can be chosen by using the rotary knob. The DSO assistance function can reduce overcharge effects. This is particularly helpful for decorative coatings on complex workpiece geometries or for challenging powder coating jobs. The DSO function provides a more homogeneous finish, especially with:

  • Complex coating situations
  • High penetration situations
  • Short spraying distances
  • Undercuts
  • Complex, easily charged powders

The PEM-X1 handgun is compact, light, and easy to use. It includes a high-performance cascade and allows for remote recipe change directly from the gun.

The Sprint 2 includes a robust swiveling arm mounted to the frame of the cart that properly secures the powder pick-up within the powder container. An integrated wiper ring ensures quick and efficient cleaning of the pick-up during color changes, saving time and reducing the costs associated with manual clean-up between colors. The quick-link injector system also provides a fast and easy solution for high-speed color changes. All the hoses can be detached simultaneously. Access to the PXS venturi nozzle with this function makes maintenance a breeze.

Reliant Finishing Systems is your source for all Wagner manual and automated gun systems, accessories, and repair and maintenance parts. For a limited time, we are offering a free Sprint 2 box-fed gun with any booth and oven package. Call one of our specialists today at (256) 355-9000 to discuss your new system.

Big Oven

Act Fast For Bonus Depreciation On Coating Equipment

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If you’re planning to purchase new powder coating or painting equipment, this is a great year to save money with tax incentives, especially if you want to take advantage of bonus depreciation benefits that are decreasing each year and will be phased out after 2026. These same savings apply to industrial ovens.

In both the U.S. and Canada, businesses can benefit from generous tax deductions that reduce their tax burden.

U.S. Tax Incentives

Section 179 Deduction

  • Deduct up to $1,220,000 of qualifying equipment purchased in 2024.
  • Applies to a variety of pretreatment, coating, and curing appliances.
  • The maximum deduction applies to total purchases up to $3,050,000.

Bonus Depreciation-Section 168(k)

  • Deduct 60% of the remaining cost of equipment beyond Section 179 limits.
  • Bonus depreciation is an “act now” opportunity that will be less beneficial in 2025 and 2026, and will be phased out after 2026.

Example for 2024:

  • Equipment: A $1,500,000 turn-key finishing system
  • Section 179 Deduction: $1,220,000
  • Bonus Depreciation (60%): $168,000
  • Total First-Year Deduction: $1,410,400
  • Tax Savings (at a 21% tax rate): $291,480!

Canadian Tax Incentives

Capital Cost Allowance (CCA)

  • Deduct up to 100% of certain new equipment costs under specific conditions.
  • The Accelerated Investment Incentive allows up to three times the normal depreciation rate in the first year.

Example:

  • Equipment: A $100,000 curing oven
  • Standard Deduction: $30,000
  • Accelerated Deduction: Up to $90,000

What Else Do You Need To Know?

  • Equipment must be primarily for business use.
  • In the U.S., it is important to conclude sales transactions and place equipment in service by end-of-year deadlines to qualify for appropriate benefits.
  • Leased or financed equipment may qualify. 
  • Businesses should consult a tax advisor to ensure maximum savings.

Reliant Can Help!

With bonus depreciation phasing out, now is the time to invest in capital equipment and take advantage of a temporary situation that benefits businesses of all sizes. Call Reliant Finishing Systems at 256-355-9000 and let our specialists help you determine the best solution for your finishing or thermal processing needs.

 

Box Gun

How Do Electrostatic Powder Coating Guns Work

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Powder coating involves applying a dry, free-flowing powder composed of thermoplastic or thermoset polymers, pigments, and additives. Powder coating guns work via electrostatics. This is what enables the powder particles to adhere to the object being coated during the application process. Once applied, the powder is cured using heat, which causes it to melt. The melted powder forms a uniform, durable coating once it cools.

In an electrostatic powder coating system, the powder particles receive an electric charge as they pass through the gun. The object to be coated is grounded, meaning it has a neutral or opposite charge. As a result of the electrostatic attraction between the charged particles and the grounded surface, the powder is drawn onto the substrate.

The coating process involves 3 elements:

  1. Accessing the Powder Supply: The powder coating material is stored in a hopper (when using a hopper-fed gun) or drawn directly from the powder supplier’s box (when using a box-fed gun). The powder is transported into the gun using compressed air.

2. Charging the Powder: As the powder exits the gun, it passes through an area that gives the powder particles an electrostatic charge, typically a negative charge. This charging occurs either through a corona discharge (most common, using a high-voltage electric field) or triboelectric charging (where the particles are charged by friction as they rub against material inside the gun’s barrel).

3. Spraying the Powder: The charged powder is sprayed toward the grounded metal object, referred to as the workpiece. This is done using compressed air to generate a “powder cloud” that passes over the surface. Since the workpiece is grounded and has a positive charge in comparison, it attracts the negatively charged powder particles, which settle in place and create a uniform coating on the surface.

Powder Gun Types

There are two main types of electrostatic powder coating guns: corona and tribo. While both types work on similar principles of electrostatic attraction, they differ in how they impart the charge to the powder. Corona guns are significantly more popular for most situations.

Corona Powder Coating Guns

A corona powder coating gun operates by creating an electric field using a high-voltage power supply. Most guns use a pressurized system where the powder is mixed with air to create a fine, evenly dispersed cloud. As the powder exits the gun’s nozzle, it passes through an electric field created by an electrode at the tip of the gun. The electrode applies a high-voltage charge (typically 30,000 to 100,000 volts) to the powder particles, causing them to become negatively charged.

As the charged powder particles are propelled from the gun, they are attracted to the grounded surface of the object being coated. This attraction ensures an even distribution of powder across the surface. Because the particles carry the same charge, they repel each other, which helps prevent uneven application.

One challenge with corona guns is dealing with the Faraday cage effect. This phenomenon occurs when the powder has difficulty reaching recessed or complex surface areas due to the buildup of an electric field around the area. However, modern brand-name guns are designed to help mitigate this issue using specialized controls.

Tribo Powder Coating Guns

Instead of using an electric field, tribo guns charge the powder particles through friction. As the powder is forced through the gun, it rubs against specially designed materials inside the gun’s barrel, causing the particles to gain an electrostatic charge. This is known as the triboelectric effect.

In a perfect environment, tribo guns tend to produce a very consistent charge across the powder particles, but they are less popular because they require more precise control of materials and environmental conditions to operate effectively.

Whether using a corona or tribo gun, back ionization can occur when powder particles can’t find an adequate ground. As coating proceeds, an excess charge builds up between the powder layers until newly applied powder particles are repulsed and the film of powder that has just been applied is disrupted, causing swirls, star patterns, or small voids where little or no powder remains on the part’s surface. As with Faraday cage issues, this can be minimized by properly adjusting the gun’s control system.

Powder Gun Brands

For decades, three powder gun manufacturers have dominated the professional powder coating gun market: Wagner, Gema, and Nordson. Most US coating operations rely on guns from one or more of these companies. All three brands have excellent reputations, and their products have nearly identical capabilities. 

At the other end of the market are hobbyist guns that aren’t well suited for use in a professional environment. Inexpensive “knock-off” guns, primarily from Asian suppliers, are a recent addition to the coating world. They are purposefully made to look like professional guns, but don’t offer the performance, reliability, or availability of support. 

For years, Reliant Finishing Systems worked with Wagner, Nordson, and Gema before becoming a national-level supplier of Wagner guns. Although all three brands work well, we partnered with Wagner because of the benefits their guns offer industrial users. Wagner is a German company, noted for producing innovative, rugged, and well-engineered products. They provide excellent support and maintain a huge inventory of maintenance and repair parts. Their powder coating gun systems feature small, lightweight pistols that help cut down on operator fatigue and allow for improved access to hard-to-reach areas. They also have an unparalleled level of backward compatibility, allowing customers to keep older equipment in operation longer.

What Makes Up A Gun System?

A corona-type electrostatic powder coating gun is made up of several key components that work together to charge and apply the powder to the workpiece:

Power Source

Most guns have controls that simply plug into a standard 110-120 VAC outlet using a provided electrical cord. 

Grounding Cable

A grounding cable is a critical safety and performance component that can either be attached to the gun system or installed in the area where coating is done. This cable grounds the workpiece to ensure that the electrostatic charge of the powder is attracted to the metal surface. Proper grounding is essential for optimal powder adhesion and to prevent dangerous electrostatic build-up.

Air Supply

While not a part of the gun itself, an air compressor is required to supply compressed air to both feed the powder and aid in atomizing it as it is sprayed. It is critical that the air is cool, dry, and without contaminants.

Powder Hopper or Box

A powder gun requires a container to hold the powder coating material before it is fed into the gun. Vibration and/or the injection of fluidizing air helps ensure a steady and controlled supply of powder to the system.

Cart

Most professional coating gun systems include a cart that enables the operator to easily move the hopper or box as they coat. The cart is designed so that key components are easily accessible.

Powder Pump/Feed Mechanism

Professional powder guns use compressed air to deliver the powder from the hopper or box to the gun. The pump regulates the flow rate of powder into the gun and ultimately controls how much powder is sprayed.

High-Voltage Generator

A high-voltage system supplies the power necessary for charging the electrode. 

Control Unit

The controls include an interface that allows operators to adjust settings such as voltage, air pressure, and powder flow rate. This gives the user the ability to fine tune the coating process and obtain consistent results.

Air Flow System

There is a set of air channels that control the flow of compressed air through the gun. This airflow propels the powder and helps control the spray pattern and coating thickness.

Pistol

The body of the gun, which includes the triggering mechanism, is often referred to as a pistol. It is attached to the controls and feed system using flexible wiring and hoses. It provides a pathway for powder, air, and electrical components to work together.

Nozzle

The nozzle is the part of the gun where the powder exits and is directed toward the workpiece. The design of the nozzle affects the spray pattern and can be adjusted for different coating applications.

Electrode

The electrode is responsible for imparting an electrostatic charge to the powder particles. It uses a high-voltage generator to create an electrostatic field and charge the powder particles as they pass through the electrode area.

These components enable a powder coating gun system to uniformly charge the powder, spray it, and apply it to the target surface in an efficient manner.

What Happens Next?

Once the charged powder particles are applied to the surface, they adhere due to the electrostatic attraction. At this stage, the coating is still a dry powder and requires curing to form a durable finish. The coated object is then placed in an oven, where heat causes the powder to melt and flow into a smooth, continuous layer. The temperature and duration of curing depend on the specific powder formulation, but it typically ranges from 300 to 400°F for 10 to 30 minutes once the surface of the object being coated has reached curing temperature.

During the curing process, thermosetting powders undergo a reaction known as cross-linking, which forms strong molecular bonds. Once cured, the coating cools and hardens.

The Benefits of Electrostatic Powder Coating Guns

Electrostatic powder coating guns offer several benefits that make them a preferred tool for industrial finishing processes:

Efficiency: The electrostatic attraction between the powder particles and the substrate ensures high transfer efficiency, meaning less powder is wasted compared to traditional liquid painting methods.

Uniformity: Because the particles are charged, they are evenly distributed across the surface, leading to a consistent finish with minimal defects. Surface areas with less powder on them have a higher level of attraction, so the powder cloud naturally fills thin spots as it lands on the surface of the object.

Cost-Effectiveness: Powder coating guns are highly efficient, reducing material waste and labor costs. Additionally, in high-volume operations, overspray can potentially be collected, reconditioned, and reused.

Environmental Impact: Powder coating produces little to no VOC emissions, and excess powder can sometimes be reclaimed, contributing to reduced environmental waste.

Reliant Finishing Systems has been at the forefront of innovative solutions in metal finishing for years. As we continue to embrace the latest technologies, we invite you to explore how our cutting-edge equipment can transform your operations. Contact us today at 256-355-9000 to learn more and see how we can elevate your business.

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