POWDER COATING (CAP: 1666.667 SQ.MT./DAY)
[EIRI/EDPR/4513] J.C.: 2729INR,2729US$,2730INR,2730US$
Powder coating is a finishing process in which dry, free-flowing, thermoplastic or thermoset powder material is applied to a surface, melted, and hardened into an even coating. This finishing process is suitable for various materials, including metals, plastics, glass, and medium density fiberboard (MDF), and can provide both functional and decorative surface coatings in a wide range of colors, finishes, and textures that are not readily achievable by conventional liquid coating methods.
There are two main methods of powder coating—electrostatic spray deposition (ESD) and fluidized bed application. Either process can produce an even, hard finish which is generally more durable, cost-effective, and environmentally-friendly than a comparable liquid coating. However, while powder coatings demonstrate some advantages over liquid coatings, especially in thick or high traffic coating applications, they are not suitable for all manufacturing applications, such as for thin film or large part coatings. The requirements and specifications demanded by a particular powder coat—e.g., application environment, substrate materials, sizing, costs, turnaround times, etc.—help determine the type of coating process most suitable for use.
While each coating process has its advantages and disadvantages, this article focuses on powder coating, outlining the basics and the necessary components and mechanics of powder coating technology. Additionally, the article explores the benefits and limitations of the process and provides some of the considerations manufacturers must keep in mind when choosing a coating service provider.
Powder coating has grown in popularity over the course of the last fifty years. It has become one of the most common methods used to finish automotive and other parts. Every day, more and more people are learning about the many benefits of powder coating over traditional liquid painting. While there are some drawbacks as well, advances in technology are making powder coating a viable alternative for many applications.
COST ESTIMATION
Plant Capacity 1666.667 sq.mt./Day
Land & Building (6000 sq.mt.) Rs. 7.82 Cr
Plant & Machinery Rs. 3.00 Cr
Working Capital for 1 Month Rs. 2.36 Cr
Total Capital Investment Rs. 13.60 Cr
Rate of Return 40%
Break Even Point 49%
CONTENTS
INTRODUCTION
USES AND APPLICATION
PROPERTIES OF POWDER COATING
POWDER COATING INDUSTRY IN INDIA
VALUE OF DIFFERENT SUB-SEGMENTS OF INDUSTRIAL PAINTS IN INDIA
MAJOR POWDER COATING PRODUCERS IN INDIA
KANSAI NEROLAC
PPG ASIAN PAINTS
BERGER PAINTS
AKZO NOBEL
GLOBAL POWDER COATING MARKET
OVERVIEW OF POWDER COATING PROCESS AND EQUIPMENTS
PREPARATION STAGE
CURING STAGE
FORMULATION OF POWDER COATING
FORMULATION OF POWDER COATING (BLACK POLYESTER TGIC
POWDER COATING)
ORANGE HYBRID POWDER COATING
GREY POLYURETHANE POWDER COATING
OTHER FORMULATION OF POWDER COATING
THE ABOVE FORMULATION HAS A 1:1 STOICHIOMETRY.
THREE EXTRUDED COMPOSITIONS WERE PRODUCED.
FIVE AGGLOMERATED COMPOSITIONS WERE PRODUCED:
EXAMPLE 2
LOW FRICTION COATINGS
THIS MATERIAL WAS ADDED TO THE CLEAR POWDER COATING
SYSTEM BELOW:
FOUR COMPOSITIONS WERE TESTED.
EXAMPLE 3
INCORPORATION OF RUBBER TOUGHENERS
THREE COMPOSITIONS WERE MANUFACTURED:
WITH COMPOSITION (1) (NO RUBBER TOUGHENER):
REVERSE IMPACT
FORWARD IMPACT
EXAMPLE 4
(A) FIRST EXAMPLE
MECHANICALS
(B) SECOND EXAMPLE
ACRYLIC POWDER MANUFACTURE
A SPRAYED AND CURED PANEL HAD THE FOLLOWING
GLOSS MEASUREMENTS:
EXAMPLE 5
PRODUCTION OF SPECKLED FINISHES
EXAMPLE 6
(A) FIRST EXAMPLE
COLOUR CORRECTION
EXAMPLE 7
ABRASION-RESISTANT COATING
EXAMPLE 8
NON-SLIP POWDER COATING
EXAMPLE 9
ADDITION OF SYENEX EXTENDER (SYENEX IS A TRADE MARK)
EXAMPLE 10
TEXTURED FINISHES IN FILMS BY ADDITION OF A
THERMOPLASTIC TEXTURING AGENT
EXAMPLE 11
ADDITION OF A TRIBOCHARGING ADDITIVE
EXAMPLE 12
SURFACE SEGREGATION (STRATIFICATION)
STAGES IN MANUFACTURING POWDER COATING
WEIGHING, PREMIXING AND SIZE REDUCTION OF RAW MATERIALS
QUALITY CONTROL
EXTRUSION OF THE PREMIX
QUALITY CONTROL
MICRONISING OF THE CHIP INTO THE FINAL POWDER
QUALITY CONTROL
POST MIXING, PACKAGING AND STORAGE
SEQUENCES IN POWDER COATING
RAW MATERIAL PRE-MIXING
EXTRUSION
MILLING OR GRINDING
SIEVING
POWDER STORAGE
TECHNICAL DETAILS OF POWDER COATING MANUFACTURE
BATCHING
PREMIXING
EXTRUSION
PARTICLE SIZE REDUCTION
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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