Order organisation

One batch - one application equipment

If the components are installed directly next to each other, we recommend determining the amount of powder required for coating the entire job, allowing for a certain reserve and coating the entire job with one finished batch. This minimises colour and effect differences when coating the entire application.

Experience has shown that Application with devices from different manufacturers (due to different characteristic curves of the high-voltage generators) produces different results in terms of shade and effect formation.

Electrostatic parameters such as the level of the set high voltage, the setting of the current limiter (µA), the use of ion-leakage rings and the processing of effect powder coatings with opposite polarity (tribo coating: positive polarity, corona coating: negative polarity) significantly influence the shade and effect formation.

The coating booth is another influencing factor. In contrast to steel booths, plastic and glass booths prevent the flow of electrostatic charge through insulating booth walls. This results in different coating results in terms of shade and effect formation.

Avoid processing the same job on different types of booths. When processing a specific commission, no changes may be made to the processing or application parameters on the coating plants. Once system data or application parameters have been determined to be optimal, they must be documented and strictly adhered to. This procedure and parameter settings must also be adhered to when coating subsequent orders.

We strongly recommend the production of limit samples to check that they match the ordered shade (incoming inspection!) and to monitor the shade and effect throughout production. A check for any deviation from the tolerance limits must be carried out under suitable lighting conditions before delivery of coated parts (outgoing inspection).

If coatings on different systems cannot be avoided, or if the geometry places high demands on the application process, we strongly recommend the use of effect powder coatings from the IGP-Effectives® series.

Reclaiming

In powder systems with cyclone recycling systems, the finest powder grains and effect particles are not separated in the cyclone and are continuously removed from the powder. This removal results in a shift in the ratio of effect particles to the base colour. In order to completely rule out colour changes due to effect losses during coating, pearl mica products can only be processed in pure loss mode without reclaiming.

In the case of automatic coating with a corresponding batch size, a certain amount of reclaimed powder can be added depending on the categorisation of the shade. Please refer to the table at the end of the document. In this case, we recommend creating limit samples before the start of production and using them throughout production to check the shade and effect. If there is a deviation in shade and effect, the proportion of fresh powder should be increased accordingly.

It is recommended to feed part of the powder through the reclaiming process before coating begins in order to use a stable mixture of fresh and reclaimed powder during the coating of the first object.

If very high demands are placed on the stability of the effect image or if a high proportion of overspray is to be expected due to the geometry of the components, we recommend the use of IGP-Effectives®. The special production of this powder type enables the use of up to 90% reclaimed powder.

Mounting the parts

The mounting of the workpieces must be determined before coating (horizontal or vertical). The distances between the coating objects within the hanger as well as the distances between the hangers should be as small and even as possible. If the distances between the hangers are large, it is advisable to switch the guns on and off automatically via a parts detection system. It is also important to ensure that similar workpieces are always coated together.

Earthing

When processing coating powders with pearl mica effect, particular care must be taken to ensure sufficient earthing. This measure contributes significantly to a uniform consistency of the shade and effect formation.