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2 Powder Application
2.1 Poor fluidization
2.2 Sintering in the powder hoses
2.3 Powder drizzles off the work piece
2.4 Poor wrap
2.5 Clumping in the hopper
2.6 Poor penetration into recesses
2.7 Film thickness too high
2.8 Film thickness too low
2.9 Film thickness varies

3 Surface Defects
3.1 Powder puffs on the work piece
3.2 Craters
3.3 Pin holes
3.4 Picture framing effect
3.5 Contaminations
3.6 Blisters
3.7 Dripping
3.8 Orange peel
3.9 Insufficient drying of the substrate

4 Surface variations in the powder film

4.1 Color deviations
4.2 Clouding
4.3 Poor coverage
4.4 Loss of gloss, yellowing, discolorations

5 Mechanical and Chenical Deficiencies

5.1 Poor mechanical properties and chemical resistance
5.2 Oily surface
5.3 Poor adhesion
5.4 Poor rub resistance

6 Special characteristics of application involving reclaim

6.1 Contamination of powder surface (additional to section 3.5)
6.2 Poor processing properties (additional to section 2.1 and 2.6)
6.3 Continuous discolorations

7 Special characteristics of application of metallic powder coatings

7.1 Color deviation from color chart of product sample 7.3 Color deviations during coating
7.2 Graying of the surface 7.4 Clouding
2. Powder Application

2.1 Poor Fluidization

Problem:
Powder is supposed to flow like water in the fluid container (boil). Poor fluidization is recognizable in a slow and non-continuous transportation of
the powder coating from the fluid container to the guns. No homogenous powder cloud is achieved.
Possible causes Corrections, testing, procedures
Fluidizing air too low or too high Change pressure
Use larger hose diameter

Fluidizing plate defective Exchange plate

Fluidizing plate clogged Clean plate

Oil remnants in compressed air Check filter in front of coating booth

Powder too fine (reclaim), high over spray ratio Add virgin powder, change powder

Powder in carton very hard or lumpy Strain

Do not set fluidizing plate to continuous operation

Excessive temperatures in the coating system Correct condition

Provide circulation
Cool
Reconstruct
2.2 Clogging of the powder feed hoses
Problem:
Deposits (agglomerates) form in the powder feed hoses, which sporadically are freed by delivery air and appear as powder puffs on the work
pieces. After curing these powder puffs appear as faulty surface elevations.
Possible causes Corrections, testing, procedures
Feed air pressure too high/too low Reduce/increase pressure

Delivery air moist or oil in pressurized air Check in-line filters and moisture traps

Inappropriate hose mounting Establish appropriate hose mounting, no kinks

Particle size distribution of powder coating too fine Note appropriate particle size
Optimise virgin powder plus reclaim ratio

Venturi nozzle worn Exchange nozzle

Feed hose diameter wrong Adjust hose diameter to appropriate powder flow

Feed hose too long Minimize feed hose length

Inappropriate hose material Exchange hose type, use appropriate type (silicone, polyurethane,
Teflon)
2.3 Powder does not adhere to substrate
Problem:
The powder coating, which should electrostatically adhere to the substrate, falls off–no relevant coating thickness can be achieved.
Possible causes Corrections, testing, procedures
Insufficient grounding Test contacts and transport mechanism (especially booth) and
hooks (< 1 MO). Insulation from lubricants and residues in
transport
Voltage too low or no voltage Gun, test high voltage, cable and cable lead

Not enough charging Increase voltage, reduce powder flow

Wrong particle size distribution If reclaim is involved add virgin powder

Contact powder manufacturer

Chain does not run smooth, vibration too strong Check conveyor system

Film build too high Check geometry of part

Reduce powder flow

Insufficient wetting Check pretreatment

Airspeed blow of air too high Optimise controls

Too much powder output Reduce air flow and/or powder flow

Gun distance to part too close, blast off effect Adjust distance

Unsuitable geometry of the part If possible change geometry or hanging position

2.4 Poor Wrapping
Problem:
With one-sided gun positioning only minimal film thickness can be achieved on opposite side.
Possible causes Corrections, testing, procedures
Powder flow too low or too high Optimise system parameters, adjust air flow

Insufficient grounding Use clean hooks, test transfer resistance (< 1 MO), check diameter
of hooks

Temperature of the part too high after dry-off oven or pre-heating Allow adequate time for cooling (less than 40 °C /104 °F]

Supplemental air flow is too high or too low Adjust air speed and powder cloud

Unsuitable particle size distribution Consult powder manufacturer

Gun voltage too high Adjust voltage to suit part geometry

Gun voltage too high Adjust voltage to suit part geometry

Insufficient charging of the powder - gun defective Adjust high voltage; Consult equipment and powder manufacturer

Insufficient charging of the powder - gun defective Adjust high voltage; Consult equipment and powder manufacturer

Poor or wrong positioning of the parts Adjust hanging configuration

2.5 Powder lumping in the hopper
Problem:
Coal shaped lumping in the powder coating in powder box
Possible causes Corrections, testing, procedures
Inappropriate storage (temperature too low/too high, in excess of Strain before use, use fresh powder
shelf life)

Box feeding Avoid continuous vibratory operation

Transport too slow or too warm Strain powder before use, consult powder manufacturer

2.6 Poor penetration into recesses

Problem:
Despite the physical conditions (faraday cage), it is possible to achieve a minimum coating thickness in the corners. With poor penetration
procedures penetration depth is very limited. Extreme film thickness variations are noticeable
Possible causes Corrections, testing, procedures
Feed supplemental or tribo air too high Change of lower pressure

Air speed too high Adjust equipment controls

Powder flow too high Adjust equipment controls to suit part

Not enough powder flow Adjust/optimise equipment parameters

Inappropriate application, unsuitable nozzle Utilize flat spray nozzle or deflector; Adjust nozzle
Insufficient charging of powder, defective gun Adjust voltage (increase, test)
Contact equipment manufacturer

Voltage too high Adjust/reduce voltage

Faraday cage effect due to electric field Use tribo equipment and powder; Reduce voltage

Insufficient grounding Use clean hooks, test transfer resistance

Powder spray too wide Use different gun nozzle of deflector

Unsuitable particle size distribution Optimise through testing; Contact powder manufacturer

Distance from gun to part is too big or too small Increase or decrease distance

2.7 Film Thickness too high

Problem:
Powder coat layer shows uneven surface prior to curing, after curing shows orange peel, wavy flow, or pinholes
Possible causes Corrections, testing, procedures
Parts are too hot coming from dry-off oven Allow longer cooling time (less than 40 [°C] / 104 [°F]) for parts

Preheat temperature too high Lower preheat temperature or allow for cooling (less than 40 [°C]
/ 104 [°F])

Powder flow too high Lower powder feed

Coating time too long Lower coating time

Unfavorable geometry of parts Change hanging or gun configuration

Gun-to-part distance too close Increase gun-to-part distance

2.8 Film thickness too low

Problem:
Substrate shows through and powder coat has grainy flow
Possible causes Corrections, testing, procedures
Insufficient charging of powder Test and adjust voltage

Inappropriate particle size distribution/percentage of overspray too Continuous and even introduction of virgin powder to reclaim
high powder
Patio adjusted to actual consumption Optimise particle size
distribution through testing
Powder flow too low Increase powder flow

Powder delivery hose too long Shorten hose; Change hose diameter; Change injector

Fluid characteristics of powder not optimal Check fluidization (see 2.1 poor fluidization)

Residence time of parts in front of gun too short Slow down line speed of conveyor; Increase number of passes of
gun in front of part Add more guns Suction of reclaim system too
high Lower suction capacity
Suction of reclaim system too high Lower suction capacity

Booth draft too strong to allow powder cloud to deposit on its own Change system configuration
Consult with booth supplier
Slow down line speed
Changed powder supply due to powder deposits in the transport Cleaning of the transport system components, coordinate feed and
system, injectors, hose and nozzle atomized air, check fluidization

Plugged transport system due to foreign materials (e.g. fibers, Commit to cleaning cycles and regular maintenance
cleaning residues)

Inappropriate hanging of parts Check and adjust hanging configuration

Insufficient grounding Use clean hooks

Avoid thin hooks (note voltage loss)
Check transfer resistance if system
Processing of non Tribo powders in Tribo systems Use Tribo powder

Low level of powder in fluid hopper Replenish powder

Check minimum indicator

Particle size too fine due to circulation in system Increase virgin to reclaim ratio

Too much overspray in booth due to cleaning cycles Regular transport of overspray from booth to reclaim system

Intermittent back pulse of filter too long, sudden shift of powder Keep back pulse of compressed air short (e.g. 20 seconds)
particle size (too fine)

Insulation of base coat too strong Reduce voltage for second coat and lower powder flow
Use tribo powder coatings

Gun-to-part distance too high Reduce distance

Powder hose causes friction charge of opposite polarity to charge Change hose material or ground hose
generated in gun
2.9 Film build varies
Problem:
Substrate shows through and powder coat has grainy flow. Or powder coat shows uneven surface prior to curing – orange peel after curing, wavy
flow, pinholes. These appearances vary on the surface of the work piece.
Possible causes Corrections, testing, procedures
Wrong positioning of guns in an automated system Empirical determination of proper gun positioning. Optimise
interval curve of automatic guns. Check conveyor/lift speed

Inappropriate insulation of base coat Adjustment of hanging or gun configuration

Additional grounding

No continuous, even introduction of virgin powder to reclaim Assure proper functioning of recovery system Adjust virgin to
powder based on actual consumption reclaim ratio

Sliding of powder film (in an improperly fused condition) due to Inspect conveyor and chain
conveyor vibration Test grounding/charging

Flapping/swinging of the work pieces Adjust hanging configuration

Test fastening method

Uneven powder transport Test powder transporting devices for clogging due to foreign
particles or plugs
Test for air pressure variations
Unfavorable geometry of parts (Faraday Cage) Change hanging configuration or gun positioning
Use flat spray nozzles

Geometry of parts varies greatly Optimise device and gun adjustments to suit work piece

Excessive manual touch-up Adjust automatic guns or possible pre-coat

Uneven manual touch-up If possible pre-coat

Train personnel
3 Surface Defects

3.1 Powder puffs on the work piece

Problem:
Powder puffs are powder clusters that in an improperly fused condition are visible as powder hills in the powder film. After curing these powder
puffs appear as disturbing elevations on the surface.
Possible causes Corrections, testing, procedures
Poor fluidization See section 2.1 (poor fluidization)

Powder hose too long or diameter too large Change hose diameter
Shorten hose
Change configuration
Powder too fine (reclaim) Add virgin powder

Uneven transport Test air pressure

Check for pressure variations

Clogging of the feed hoses Note hose path, see section 2.2. (clogging of the powder feed
hoses)

Powder falls off booth ceiling Adjust/increase frequency of booth cleaning intervals

Powder falls off hanging devices Remove/ reduce powder coat layer, check grounding

Powder build-up on deflector plate Check atomised air

Powder falls off work piece Test grounding

Check diameter of hoses

Catch nozzle worn Change nozzle

Air pressure variations in powder supply system Adjust air pressure

Level in powder supply container varies greatly Reduce distance between minimum and minimum level

Gun nozzle defective Check nozzle, replace

Powder moist Use dry powder; Check for condensation (temperature difference
from powder storage area to coating area), Check air filter and
moisture traps in compressed air system
3.2 Craters
Problem:
Defect – blank area in the powder coat, which extends all the way to the substrate (diameter up to 2 mm)
Possible causes Corrections, testing, procedures
Insufficient pretreatment (e.g. oil and grease residues) Test pretreatment if necessary, contact pretreatment supplier

Chemical residue, faulty pretreatment Test pretreatment, if necessary contact pretreatment supplier

Rust, white rust on parts Assure clean surface, apply recommended pretreatment, possibly
buff or sandblast (sweep) surface

Oil in feed and/or atomizing air Check in-line filters and moisture traps in air system

Silicones from chain lubricants or welding sprays Use product without silicon content, educate line operators

Incompatibility with powder coatings from other manufacturers Cleaning of coating and application equipment, contact powder
coating supplier

Out gassing from substrate Pre-heat work pieces, use OGF additive
Surrounding air contaminated Balance air flows in plant, avoid cross drafts

Work piece moist/wet Increase drying time/temperature

Note material thickness especially with anodised parts

Liquid and powder paint in same plant Definitely avoid - reconfigure plant

Body filler or other compounds not compatible Forced drying, test suitability

Base coat was cleaned with solvents Preheat work piece or avoid solvents

Blasting media decontaminates surface Do not reclaim blasting media

Back ionization effect Adjust application, use tribo if possible

Instead of rough texture effect only penetration-to metal and Insufficient coating thickness
craters visible

Instead of rough texture effect only penetration-to metal and Insufficient coating thickness
craters visible

3.3 Pin Holes

Problem:
Surface defects – development of fine pores on the surface,also leads to change in gloss level
Possible causes Corrections, testing, procedures
Moisture content of powder too high Testing through drying of powder/test storage conditions
In cold climates, watch for condensation in powder (cold storage
area to warm coating area)
Pre-reaction of powder coat Check storage parameters, storage time exceeded Consult powder
manufacturer
Trapped air Check heat up curve
Possible slow heat up curve
Modify powder coating
Film build too high Note recommendations of powder manufacturer
Minimize film thickness

Incompatible with other powder coatings Clean equipment/booth

Consult powder manufacturer (if necessary change)

With rough textures, instead of effect development only pinholes Film thickness too low (see 2.8 film thickness too low)
develop

Very porous work pieces Check for satisfactory work pieces, possible surface is too rough
from sand blasting

Out-gassing from porous work pieces (cast parts, zinc galvanized Preheat parts
material, magnesium castings, anodized materials) Modify powder coating
Cast anodized materials not scaled and dried
3.4 Picture framing effect
Problem:
Higher film build of coating on the edges of the part due to wrap, therefore uneven flow.
Possible causes Corrections, testing, procedures
Powder particles too rough/unsuitable for particular application Strain powder to optimise particle distribution
Consult powder coating manufacturer

Voltage too high Adjust voltage to suit part

Distance from gun to work piece too low Adjust/increase distance

Feed air/powder flow too high Adjust powder flow

3.5 Contaminations

Possible causes Corrections, testing, procedures

Contamination through conveyor chain or chain lubrication etc Cleaning of the equipment/check sieve for contamination or tears

Contamination of powder surface due to airborne dirt from outside Isolate booth area, clean surroundings with vacuum Avoid cross
of booth (e.g. surrounding air, floor, polishing area, blasting area drafts
Balance air flows in plant
Avoid polishing in booth and oven area
Fibers from broom and cleaning cloths Use suitable cleaning apparatus and materials

Insufficient polished welding areas, metal shavings, welding Control finishing process- repeat if necessary
drops, milling flaws Improve polishing stage and pretreatment

Contamination from equipment cleaning Vacuuming is more effective than compressed air (powder is not
airborne)

Deposits from dust and powder particles in the oven (too much Reduce air speed
convection inside, powder that doesn’t adhere, is blown onto work Install pre-gelling curing stage
pieces of different colors) Do not cure other colors at the same time in oven
Deposits of dust and powder on cured work pieces Dust free cooling zone
Avoid drafts

Dirt and color particle transfer between adjoining booths If possible reconfigure area
Enclose booths

Contamination from warehousing Assure orderly warehousing

Close powder bags and boxes
Separate by powder type
3.6 Blistering
Problem:
Elevations of differing size in the powder coat, no adhesion due to enclosures at the part surface
Possible causes Corrections, testing, procedures
Water on work piece Check dryer and hanging configuration

Water in scooping type of work pieces Note geometry, drying time and temperature or change hanging
configuration
Air blast work pieces
Corrosion, oil and grease residues Optimise pretreatment

Over coating Assure flawless first coat

Over coating of liquid paint Check suitability of base coat

Over coating of filler areas Dry or cure filler

Check suitability

Salt residues or chemical remnants on the work piece surface, Check pretreatment, final rinse stage, and drying of
insufficient wetting media/chemicals during transport inaction

Film thickness too high, powder accumulations, powder drizzles Check system parameters
off work piece on edges and corners Reduce film thickness

Break in zinc layer, double zinc layer, corrosion under the zinc Avoid double zinc layers
layer Ensure flawless zinc layer
3.7 Drip Developments
Problem:
Running or dripping of the gelling powder coat off the work piece
Possible causes Corrections, testing, procedures
Film thickness too high (with wire or sheet metal parts) Reduce film thickness

Powder slides to the edge Increase voltage

Check grounding

Substrate temperature is too high (from preheating or dryer), Increase cooling time (max. 40 [°C] / 104 [°F]) between dry-off
therefore film build too high oven and booth Optimise film thickness

Heat up rate too high or inappropriate Reduce heat up speed

Control oven temperature

Powder accumulation on inside corners from drizzled off powder Optimise system parameters and blast off effect.
coating

3.8 Orange peel

Problem:
Poor flow (orange peel look), short or long waviness of powder coat layer, noticeable only after curing.
Possible causes Corrections, testing, procedures
Heat up cycle of parts too slow Determine heat up curve and increase (especially with parts of
high wall thickness)

Substrate temperature exceeds the melt temperature of the Check substrate temperature (max. 40 [°C] / 104 [°F])
powder, causing excessive film build Increase cool down phase

Powder coating material too reactive Consult powder manufacturer

Shift in particle size distribution, portion of reclaimed powder too Optimise deposit results of powder guns
high Increase lift intervals
Unsuitable particle size distribution Optimise particle size distribution
Consult powder manufacturer

Film thickness too high or too low Check system parameters

Incompatibility with other powder coatings Clean booth, check compatibility

Consult powder manufacturer

Powder stored too long/pre-reacted Check storage.

If powder is too old, exchange

Voltage too high Optimise voltage

Change to low ionizing application or tribo guns

Uneven wall thickness (thick to thin) Optimise oven temperature

Back ionization effect Reduce voltage

Increase distance from work piece to gun

Textured work piece surface Optimise texture, check work piece surface

Air speed too high at oven entrance Reduce air speed (max. 0.5 [m/sec] / 1 ½ [ft./sec]), change air
flow guides

3.9 Insufficient wet out of the substrate

Problem:
Poor or no adhesion of powder coat to the parts surface, large area lifting of cured powder coat
Possible causes Corrections, testing, procedures
Gummed oils, greases or separating compounds, insoluble Check pretreatment or change, use different extrusion oils or
extrusion oils separating compounds

Pretreatment residues Final rinse de-ionized water

Encumbrance from sweaty hands or soiled gloves Do not handle pretreated parts with bare hands or soiled gloves

Displaced oils or greases in pretreatment Pretreatment

Check oil separator

Conveyor halt during pretreatment, dried on chemicals Avoid conveyor halts, possibly mist

4. Surface Variations in the Powder Coat

4.1 Color Deviations
Problem:
Continuous or suddenly appearing changes in color or effect compared to original sample part or compared to first parts coated
Possible causes Corrections, testing, procedures
Film thickness varies greatly Assure constant film thickness

Differing substrates and substrate colors (steel, aluminum, brass, Use substrates of same type for comparisons
glass)

Film thickness too thin (not covering) Apply higher film thickness (same as samples)

Not sufficient or wrong pigmentation in the formulation Consult powder coating manufacturer

Color deviations due to curing technique or oven atmosphere Use suitable powder coatings
(example: direct fired gas oven, IR oven), use of room air for Control oven
burner! Use outside air supply for burner
Over curing of powder coating (especially with organic pigments) Observe curing parameters of powder manufacturer

Differing curing parameters with same parts Observe powder manufacturers curing parameters
Differing curing parameters with greatly varying parts (different Observe curing parameters of powder manufacturers and adjust to
wall thickness) wall thickness

Several powder manufacturers/suppliers Use powder coatings from the same manufacturer or check the
compatibility

Varying film thickness with over coating Assure even film thickness

Bleeding of first coat with over coating Check suitability of first coat when over coating

During over coating extensive color deviations from first coat Avoid over coating of strongly deviating colors

Uneven pretreatment of parts Assure more even pretreatment of parts

Mesmerism, color deviations with differing light sources Judge work pieces in daylight (not direct sunlight)
Use day light cabinet

Rough texture too pronounced Use suitable powder coat

Powder transport directly from the powder box Use fluid container

4.2 Cloud Formation

Problem:
Uneven light to dark or matte to glossy effect of the coating on the work pieces
Possible causes Corrections, testing, procedures
Gun distance from part too great or small Test distance

Reciprocator operation parameters inappropriate for line speed Adjust lift speed to chain speed
and part configuration
Uneven powder transport line speed and part configuration Introduce sufficient virgin powder
Test for deviations in air pressure

Manual touch-up If possible pre-coat

Uneven charging Test application

Uneven grounding of parts Test grounding

Strongly varying film thickness (especially with matte finishes) Optimise film thickness

Separation of matte finish powders in reclaim system, uneven Assure consistent powder quality Adhere to the recommended
parts of virgin and reclaim powder percentage of virgin and reclaim powder

4.3 Poor Coverage

Possible causes Corrections, testing, procedures
Film thickness to low Assure appropriate film thickness, especially with critical colors
(example: red, orange, yellow)

Film thickness varies greatly from part to part Optimise system parameters

Reciprocator operation parameters inappropriate for line speed Adjust lift speed to chain speed
and part configuration

Differing materials and material colors (steel, aluminum, brass, Use same materials for comparison
glass)

Differing surfaces and reflections (polished, blasted, chromate) Use same surfaces for comparison

Mechanical treatment shows through (example: polishing) Use finer grain materials for polishing
4.4 Loss of Gloss Yellowing, Discolorations
Problem:
Difference between suggested gloss level and color and the gloss level and color of the original sample or parts coated at the beginning of the job
Possible causes Corrections, testing, procedures
Cure parameters of manufacturer were not observed Optimize curing parameters
Adhere to powder manufacturers suggestions

Oil, soluble materials in oven Do not use oil or soluble materials in oven area

Incompatibility with other powders, poor flow Clean system

Distribute incompatible powders to other booths

Film thickness to high or too low Optimize job parameters

Powder coating is not temperature stable Use temperature stable powder coatings
Consult powder manufacturer

Over curing in oven Adjust oven temperature and speed to parts being coated
Lower temperature during conveyor halts

Incompatibility of powder coating in the oven Do not use powder coatings from different manufacturers at the
same time in one oven

Direct fired ovens and IR ovens Adjust powder coating to oven parameters
Adjust oven temperature to powder coating

Powder coating pre-cured or too old Check warehouse parameters

Use fresh powder coatings

Unsuitable cleaning agents for example prior to silk screening Check suitability of cleaning agents for powder coat, pre-testing
necessary

Separation of 2 component matte powders Check reclaim system for uneven suctioning of over spray
Uneven gloss level due to different wall thickness of work piece Lower oven temperature
Increase duration time
Re-construct system
Components of the powder formula migrate to the surface causing Discuss possible changes with powder supplier and consider
haze and lower gloss trade-off between performance parameters and better stability
Optimize oven parameters Re-construct system
Binder in powder coating poorly dispersed Consult powder manufacturer

5. Mechanical and Chemical Deficiencies

5.1 Poor mechanical properties and chemical resistance
Problem:
Insufficient compliance with the necessary technical properties of the powder coating (mechanical and chemical)
Possible causes Corrections, testing, procedures
Too high/too low heat up temperature or time Observed curing parameters of powder coating manufacturer

Oil, grease, extrusion oils, dust on the surface Optimize pretreatment

Insufficient pretreatment Optimize pretreatment

Incompatible pretreatment and powder coating Adjust pretreatment method

Consult chemical and powder supplier

Inappropriate powder coating Use appropriate powder coating

Consult powder manufacturer

With transparent top coats slow deterioration of the powder Over coating of interior grade powder coatings with exterior grade
coating (chalking) transparent powder coatings does not result in a UV resistant
coating system, therefore adhesion problems of the top coat
5.2 Greasy Surface
Problem:
Haze like film on the surface, which can be wiped off
Possible causes Corrections, testing, procedures
Blooming effect (white film on the powder coating surface, which Change powder coating formula
can be wiped off) Increase curing temperature

Insufficient air circulation in the oven CIncrease air circulation

Contamination on the surface because of incompatible powder Use only powder coatings from one manufacturer at the same time
coatings from different manufacturers in an oven
Consult powder manufacturer
Wrong powder coating choice Use suitable powder coatings
Consult powder manufacturer

Powder coating not sufficiently cured Observe curing parameters

5.3 Poor Adhesion

Possible causes Corrections, testing, procedures
Under or over curing of the powder coating film (for example in Observe curing parameters
IR oven)

Insufficient/inappropriate pretreatment Adjust pretreatment to job at hand

Basic material too thick or unevenly thick Observe curing parameters, use slower or faster curing powder
coatings

Scale, surface rust on the work pieces Use “fresh” work pieces or store in dry environment; mechanical
pretreatment

Oxide layer on the work pieces, white rust on zinc plating Store work pieces in dry environment or use “fresh” work pieces
Use suitable pretreatment materials
Use mechanical pretreatment (sweeping) if necessary
No adhesion on laser cut edges Treat edges mechanically (brush, polish, sweep)

Purpose and powder coating properties are not suited for each Use suitable powder coatings
other

Film thickness too high Reduce film thickness or use more flexible powder coatings

No adhesion to base coat If possible lightly polish base coat or partially edge with suitable
solvent

No adhesion to liquid base coat, electro coat or coil coating Test suitability, lightly abrade base coat

Break in zinc, conversion or primer layer Adjust pretreatment to work piece and powder coating

Double zinc layers, corrosion under zinc layer Consult with H.D.G. supplier

Transport residues on work pieces (salt, dust etc), which have not Assure flawless surfaces and protected transportation, suitable
been removed by pretreatment pretreatment

5.4 Abrasion resistance too low

Problem:
Insufficient resistance of the powder coating against abrasive media
Possible causes Corrections, testing, procedures
Insufficient curing Observe curing parameters

Packaging causes abrasion to powder coat surface Use suitable packaging/foils to wrap work pieces (tissue paper,
bubble wrap, foam, fleece)

Powder coating scratches too easily/too soft Select suitable powder coating for purpose
Consult powder manufacturer
Abrasion during further mechanical treatments (profiles) Carefully handle work piece in further manufacturing steps

Unsuitable transport containers Avoid sliding

Transport bundled and restrained on pallets or in boxes

6. Special Characteristics of Application with Reclaim

6.1 Contamination of the Powder Coating (additional to section 3.5)

Problem:
Foreign or powder particles of a different color are enclosed in powder film
Possible causes Corrections, testing, procedures
Powder remnants or dirt in coating booth, cyclone or filter Clean system
Constantly clean screen

Powder remnants in application, powder accumulation from Clean application

injector, hose or gun Check screen

Contamination of reclaim No sieve or insufficient screen

Use proper screen size (mesh size approx. 200
[ìm] / 8 [mils]) Check screen for tears or dirt
Final filter defect, powder is blown into coating area Check and repair final filter

Chafing of carpet material in carpet systems Use suitable carpet or replace carpet
6.2 Poor Processing Characteristics (additional to section 2.1 to 2.6)
Problem:
Continuously or suddenly deteriorating application while processing parameters are unchanged
Possible causes Corrections, testing, procedures
A change in particle size distribution due to reclaim, powder too Continuously add virgin powder and ensure proper ratio of virgin
fine to reclaim powder ( max. 1:1)
Reduce over spray
Change rack configuration
Introduce reclaimed powder continuously
6.3 Continuous Shade Variations
Problem:
Continuous or sudden changes in color/shade or effect compared to sample or originally coated parts
Possible causes Corrections, testing, procedures
Separation or particle size distribution changes through reclaim Add virgin powder

Powder remnants in reclaim system Clean reclaim system

Detraction due to several booths being located next to each other Reconstruct coating area layout
Cover booth during downtime, since powder or dirt may transfer
and contaminate area
Powder transfer due to uneven air flow or performance of booths Reconstruct/reconfigure area
next to each other

With powder extraction from box feeder no even ratio of reclaim Use fluid container
and virgin powder is next to each other Ensure even ratio of virgin to reclaim powder

Addition of reclaim powder is inconsistent, virgin powder ratio is Add sufficient virgin powder Ensure consistent ratio
too high or too low
7. Special Characteristics of Application of Metallic Powders
7.1 Color shift from color chart or original sample
Possible causes Corrections, testing, procedures
Inconsistent batches Coat each job with powder from a single batch
Consult powder manufacturer

Varying application (Corona, Tribo, Corona modified with ion Use only one type of application equipment
catch) Consult with powder manufacturer

Defective application, gun short circuits Check application

Use proper application

Object related coating jobs With several applicators for one coating job, colors and systems
have to be checked against each other. Use original samples, and
warn customers of risks involved
Differing work pieces For comparison always use a single work piece with its particular
substrate color (aluminum, steel, zinc plated steel, glass, wood)

Poor grounding Check ground and contacts

Wrong RAL chart used or effect difference between RAL chart Use proper RAL chart (GL or HR), inform customer
and powder coating

7.2 “Graying” of the Surface

Problem:
Disappearance of the metallic or non-metallic effect components (drowning)
Possible causes Corrections, testing, procedures
Powder coating is tribo suitable, or metallic effect appears Use Corona gun, always conduct pre-tests
different

Varying application methods (Corona, Corona modified with ion Adjust KV setting and gun-to-part distance: the higher the KV
catcher or Tribo) and inappropriate gun settings setting, the lesser the metallic appearance; the lower the KV
setting, the more metallic effect will appear
Varying deposition of effect pigments gives rise to color/effect Use one suitable application method
changes

7.3 Color Variations during Coating

Problem:
Continuous or sudden change of color or effect from original sample or begin of coating job
Possible causes Corrections, testing, procedures
Powder extraction from box feeder Use fluid container

Powder separation Check reclaim

Spray to waste

Separation of powder in cyclone or in reclaim Read metallic Check Cyclone

application guidelines datasheet system Check reclaim

Batch change during coating job Use only one batch for each coating job

Color change between manual and automatic application Touch-up difficult to spray areas before automatic application

7.4 Cloud Formation

Problem:
Uneven light to dark effect of the coating on the work piece
Possible causes Corrections, testing, procedures
Gun distance to work piece to big or too small Check distance

Reciprocator operation parameters inappropriate Check lift and chain speed

Uneven powder transport Add sufficient virgin powder

Check compressed air for variation
Manual touch-up Position manual touch-up before automatic booth

Uneven charging (defective gun) Check application

Uneven grounding of work pieces Check grounding

Extremely varying film thickness (especially with matte coatings) Optimize film thickness

Powder extraction from box feeder Use fluidizing hopper