Product arrives at Abc’s Plant
Unloading occurs within our drive in bay.
Product goes through an initial quality inspected for possible irregularities caused by manufacturing or shipping. All non-conforming parts are immediately separated and brought to the attention of the customer. Product is then stored in designated areas to await scheduling.
All new products that have not been powder coated before are documented on to a visual aid form for future referral, and filed. This internal quality form records all production requirements, from colour, type of powder required, special packaging, inspection criteria, to masking needs if required. Repeat powder coated products get reunited with previously documented visual aid forms. This pertinent powder coating information travels throughout our whole system and is integral part of our quality success.
Scheduling for Coating
Scheduling is completed for customer’s delivery requirements. At this point a travelling work order is initiated and joined with all pertinent information (visual aid form) required for a quality completion of the product.
To The Line
Product is located in its designated storage area and then moved to the powder coating conveyor line loading area. Parts once again are visually inspected for irregularities, the required custom powder coating tooling and product are then loaded on to the overhead line and thus they are ready for their journey through the complete powder coating system.
Clean as a whistle
Still attached to the powder coating conveyor, the product passes through an extensive chemical cleaning system of 7 or 5 stages, depending on the substrate. Both include a final reverse osmosis rinse. This pre-treatment ensures a squeaky clean phosphated and etched substrate for powder coating. This is one of the most critical steps in high quality powder coating. After leaving the final reverse osmosis rinse the product travels through a separate powder coating dry off oven. This allows us to control the temperature to ensure properly dried parts and to prevent the overheating of difficult parts such as zinc and aluminum die castings. The parts then proceed through a cool down area to bring them back to room temperature.
POWDER MEETS METAL
After cooling down to room temperature, the pretreated product passes into our dedicated enclosed powder coating area. Here the required powder is evenly applied by one of our trained technicians or with automatic reciprocators. Over spray powder can if required be re-claimed and reused. As the parts are sprayed they once again are inspected visually for irregularities.
The product is transported through our powder coating infra-red preheat section which is used to move the powder quickly into a liquid state, this intern allows us to move large amounts of heated air in our powder coating convection bake oven to ensure we have a full even cure without removing powder from the substrate. Results a beautiful incredibly durable finish second to none.
COOL DOWN INSPECTION AND RETURN TO SENDER
The items are now allowed to cool to complete the powder coating process. Once cooled, each item is individually inspected and carefully re-packed in our customer's containers as per the visual aid instructions and sent back to our satisfied clients. While it may take as little as 2 hours for an item to pass through the entire powder coating system, normal PER JOB turnaround is approximately 5 days. Regular scheduling is available and preferred in order to significantly reduce turnaround. Pickup and delivery are also available.
Advantages of Powder coating
- Highly chip and scratch resistant
- Excellent chemical, petroleum and salt resistance
- A beautiful and uniform quality finish without paint runs
- The ability to apply a thick, even coating without drips or sags
- Premium insulating quantities, both electrical and thermal (removes cold metal feeling)
- Decorative finishes (eg. Hammertone,Antique,Sandtex, Textured) applied in one application
- Excellent fade resistance to ultraviolet light reduces fading (polyester - polyurethane)
- The ability to encapsulate products, wrap around corners and help eliminate sharp edges
- High quality one coat coverage with no primary necessary
- Can resist abuse in low and high temperature variances
- Virtually unlimited number of colours and wide variety of finishes available