Colour is only one part of a coating decision.
Some products require a coating that also responds to the substrate, oven cycle, part geometry, electrostatic application, subsequent handling or another defined production condition. Intercoat selects or adjusts formulations around these requirements. The final coating and application settings are evaluated on the customer’s parts and production line during a production trial.
Technical challenge
Particle-size distribution affects how the powder:
A distribution suited to one product geometry or coating line may perform differently on another.
Formulation approach
Intercoat adjusts the relative proportion of fine and coarse particles to suit:
The objective is not simply to make the powder finer. An excessive proportion of fine particles can create application and recovery problems of its own.
Production examples
In a welded-mesh fencing application, the adjusted particle-size distribution, charging behaviour and flow balance contributed to a 20% increase in production output. In a tyre-storage-rack application, adjustments made to improve penetration into recessed profiles contributed to a 10% increase in production output.
Technical parameters
Depending on the application, evaluation may include:
Technical challenge
During electrostatic application, the electric field directs powder towards the nearest exposed surfaces. Deep recesses and internal corners receive less material, resulting in insufficient film build and the need for corrective manual application.
Formulation approach
Intercoat adjusts:
These changes are evaluated together with:
Production examples
For welded-mesh fencing panels, the revised coating and application balance contributed to a 20% increase in production output. For tyre-storage racks, improved penetration into recessed areas contributed to a 10% increase in production output.
Result
Improved automatic coating of areas affected by the Faraday cage effect and reduced dependence on corrective manual application.
Technical challenge
The molten coating needs sufficient flow to form a continuous film around wire intersections. Excessive flow can create:
Insufficient flow can leave wire intersections poorly covered.
Formulation approach
Intercoat adjusts melt flow and particle-size distribution together with the application and curing settings.
Production example
In a welded-mesh fencing application, the adjusted balance of electrostatic penetration and melt flow contributed to a 20% increase in production output.
Application objective
More consistent coverage at wire intersections while maintaining controlled flow over the complete panel.
Technical challenge
Gas released from the substrate can pass through the molten coating and create:
The result depends on the substrate, surface preparation, coating thickness and actual curing profile.
Formulation approach
Intercoat selects or adjusts the formulation for:
Production example
In the aluminium-radiator application, the revised formulation enabled the manufacturer to remove a separate pre-heating stage while maintaining the required surface quality.
Result
One complete production operation was removed, simplifying the coating process and reducing manual intervention.
Technical challenge
Insufficient part temperature can leave the coating under-cured, affecting:
Nominal oven-air temperature alone does not demonstrate that the coating has received the required curing conditions.
Formulation approach
The formulation is selected or adjusted using:
Production example
In the expansion-vessel application, the revised formulation achieved the required cure and adhesion under the existing oven conditions and allowed the line to return to its target production rate.
Result
Required cure and adhesion restored within the existing oven process.
Technical challenge
Lower-temperature curing and a matt finish can place competing demands on the resin system. A standard formulation may achieve one requirement but fail to provide the required:
Formulation approach
Intercoat evaluated several resin systems and developed a customer-specific coating for the actual oven conditions and target matt finish.
Production example
The coating was evaluated on the customer’s parts under the available curing conditions.
Result
The formulation achieved the required combination of lower-temperature curing and matt appearance and was selected for the application.
Technical challenge
The metallic-effect particles may:
Formulation approach
The required shade is reproduced as a bonded metallic formulation in which the metallic-effect particles are attached to the powder particles.
Production example
A facade-panel manufacturer replaced a dry-blend metallic coating with a bonded formulation.
Result
The bonded formulation resolved the colour variation and striping observed with the previous dry blend.
Technical challenge
When film thickness falls towards the lower end of the specified range, insufficient hiding can allow the substrate to show through and create visible colour differences.
Formulation approach
The formulation is developed to maintain the required hiding power at the specified lower dry-film-thickness limit.
Production example
For a fire-extinguisher application, hiding power at the lower end of the specified range was treated as a key formulation requirement.
Technical context
Powder coatings naturally have a different surface profile from liquid automotive coatings. Appearance is influenced by:
Formulation approach
Intercoat adjusts the formulation and flow behaviour to provide a smoother and more controlled appearance within the practical limits of the selected powder coating technology.
Available directions
Depending on the coating series and production conditions:
Technical challenge
High surface friction can create scratches and contact marks when recently coated parts move against each other. Excessive slip, however, can make automatic stacking or positioning less stable. The required behaviour therefore depends on the subsequent production operation.
Formulation approach
The formulation is adjusted to provide a defined level of surface slip for the customer’s specific handling process.
Production example
In an early-stacking application, shelving components were placed in contact shortly after leaving the oven.
Result
The adjusted surface slip helped reduce scratches and visible contact marks.
Technical challenge
Changes intended to reduce visible colour change during overbaking can also affect surface friction. The formulation therefore needs to balance two properties that do not necessarily improve together.
Formulation approach
Intercoat assesses the actual temperature exposure and adjusts the formulation around:
Production example
A shelving manufacturer needed to limit yellowing during production pauses while retaining sufficient slip for manual handling and packing.
Result
The final formulation reduced the visible colour change to a level accepted by the customer while retaining sufficient surface slip.
Technical challenge
Surface damage can occur before the product enters service. Part-to-part contact during loading or transport can create:
Formulation approach
The formulation and curing schedule are selected with the actual handling and transport conditions in mind.
Production example
For a scaffolding application, the coating requirements combined repeated mechanical contact with a bright exterior colour.
Technical challenge
Coffee, alcohol and other liquids can affect:
Formulation approach
The coating is selected around the required liquid-resistance test and end-use conditions.
Production example
A furniture coating was reportedly tested for resistance to coffee and alcohol as part of an independent European testing programme.
Result
Publication of the result is subject to verification of the original test reports and tested formulation.
Technical challenge
Print definition and adhesion can be affected by:
Formulation approach
The coating surface is selected or adjusted for compatibility with the customer’s intended printing or marking process.
Production example
A fire-extinguisher coating needed to support clear and durable printing of operating instructions.
Application objective
Clear, repeatable marking with suitable adhesion to the coated surface.
Tell us what you make, how it is coated and what result you need. Intercoat can help connect your product requirements with suitable coating options and technical documents before a production trial.