Powder Coating Systems

Powder coating is a dry finishing process that uses electrostatic charge or heat to apply powder onto metal surfaces. At Raman Udyog, we offer a complete range of powder coating systems for different production needs — from small workshops to high-volume factories.

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electro

Electrostatic Powder Coating System

Electrostatic Powder Coating System

The Electrostatic Powder Coating System is the most commonly used system in industrial coating today. It works on the principle of electrostatic attraction, where powder particles are electrically charged and sprayed toward a grounded metal surface. The charged particles stick to the object due to electrostatic forces and are then cured in an oven to form a durable, even coating.

A corona discharge spray gun generates high-voltage (up to 100 kV), charging the powder as it exits the nozzle. A properly grounded workpiece attracts the powder, which adheres uniformly. This process ensures high transfer efficiency, minimal overspray, and consistent finish — even on complex geometries.

Sheet metal component manufacturers requiring 60–120 µm decorative or protective finishes
Automotive Tier 2 suppliers coating brackets, fasteners, and support plates
OEM electrical enclosure fabricators seeking uniform 80–100 µm epoxy/polyester finishes
Appliance part vendors needing high-efficiency spray systems with fast color change
General job coaters using hybrid powders on complex flat-to-moderate parts

Component	Description
Electrostatic Spray Gun	High-voltage gun with interchangeable nozzles (flat, round, deflector)
Gun Control Unit	Digital/analog controller (0–100 kV, adjustable current limiter)
Powder Feed Hopper	10–25 kg capacity, stainless steel or powder-coated MS with fluidization
Powder Injector	Venturi-based, feeds powder through hose with compressed air
Powder Hose	Conductive hose, anti-static, 5–10 meters length
Grounding Cable	Copper wire with heavy-duty clamp, 3–5 meters
Air Regulator with Moisture Trap	Maintains constant powder delivery pressure; prevents clogging
Power Supply	Input: 220V AC, Output: DC to gun controller
Optional: Reciprocator	Programmable vertical gun movement (in automatic setups)
Optional: Multi-Gun Setup	For high-volume lines or complex geometries

Specification	Details
Input Voltage	220–240 V AC, 50/60 Hz (single phase)
Gun Output Voltage	0–100 kV DC (adjustable, digitally controlled)
Current Output (Gun)	0–100 µA with current limiter for safety
Powder Flow Rate	100–600 grams/min (adjustable via injector air pressure)
Air Consumption	200–400 L/min @ 4–6 bar (depends on injector design)
Max Working Air Pressure	6–7 bar (recommended: regulated to 4.5–5 bar)
Transfer Efficiency	85–92% with proper grounding and booth recovery
Gun Weight	500–650 grams (with cable and nozzle assembly)
Powder Hopper Capacity	10–25 kg (standard); larger hoppers on request
Gun Control Modes	Constant Voltage, Constant Current, Corona Mode (selectable)
Nozzle Types	Flat, conical, deflector disc, fan spray
System Compliance	CE / ISO 14915 / RoHS compliant materials

CRCA enclosures (1–2 mm) – sprayed with polyester-epoxy hybrid @ 90 µm thickness
Automotive battery supports – coated for corrosion, thickness control ±10 µm
Sheet steel electrical panels – need smooth finish, RAL color matching
Cable tray fittings – electrostatically coated before assembly
Appliance back covers (refrigerators) – polyester finish, no primer required
Switchgear box internals – epoxy coat with insulation resistance >10⁹ ohm
Industrial lockers & cabinets – coated using high-flow flat nozzles
Solar junction boxes – UV-stable polyester finish with 1000+ hr salt spray
Aluminum furniture frames – coated with TGIC-free polyester @ 75 µm
Mild steel trolleys (3 mm sheet) – impact and abrasion-resistant coating

fluid

Fluidized Bed Powder Coating System

The Fluidized Bed Powder Coating System is a dipping process where preheated parts are immersed into a tank of fluidized powder. The system uses compressed air to suspend fine powder particles, creating a “fluid-like” state inside the bed. When a preheated metal component is dipped into the bed, powder particles instantly melt and bond to its surface, forming a uniform, thick coating.

Unlike spray systems, this method delivers exceptionally even coverage, especially for flat or rod-like parts. It is also ideal for parts requiring corrosion resistance or electrical insulation, making it popular in agriculture, electrical, and heavy industry.

Specification	Details
Bed Tank Material	MS Powder Coated / SS 304 (depending on model)
Tank Sizes (L×W×H)	Standard: 600×600×500 mm to 1500×1000×600 mm
Powder Capacity	20–100 kg (depending on tank volume)
Air Pressure for Fluidizing	1.0–1.5 bar (14–21 psi) with fine control
Air Consumption	300–500 L/min depending on tank size
Coating Thickness (Typical)	200–500 microns (single dip, depending on part temperature & material)
Part Preheat Temperature	180–220°C (ideal for thermoset powders like PE, Nylon, Epoxy)
Heat Source (optional)	Infrared / Gas / Electric Preheater
Powder Wastage	<1% (no overspray)
Suitable Powder Types	PE, PP, Nylon-11, FBE, Polyester
Safety Rating	Enclosed fluidizing chamber with anti-static lining

Component	Description
Fluidizing Bed Tank	Perforated air-distribution base, powder-retaining chamber (SS/MS)
Powder Storage Chamber	Holds 20–100 kg powder, sealed top lid
Air Compressor	5–7.5 HP with moisture separator
Air Regulator + Pressure Gauge	Controls fluidization air flow (typically 1.0–1.5 bar)
Preheating Oven	Optional electric or gas oven to heat parts to 180–220°C
Optional: Agitator	Prevents powder clumping in large tanks
Optional: Dust Collector	Controls ambient dust if used in enclosed booth

Refrigerator wire shelves – 300 µm nylon coating for food-grade insulation
Dish drainers & baskets – LDPE coating on 3 mm wire mesh
Tool handles (carbon steel) – dipped in PE powder for 350 µm grip layer
Switchgear busbars (Cu/Al) – epoxy or FBE coating for dielectric isolation
HV cable supports – uniformly coated to 400 µm for creep distance
Air conditioner grilles – preheated aluminum parts dipped in polyester powder
Garden implements (shovels) – 500 µm coat over shot-blasted mild steel
Mesh fencing (GI) – coated with thermoplastic for corrosion barrier
Wire forms (hanger hooks) – PE coat eliminates scratching during use
Transformer brackets – epoxy dipped @ 200 µm for surface protection

electro fluid

Electrostatic Fluidized Bed System

The Electrostatic Fluidized Bed System is a hybrid powder coating technology that combines electrostatic charging with fluidized powder behavior to deliver a highly efficient, wrap-around coating.

In this method, powder particles are fluidized using compressed air and simultaneously charged using an embedded high-voltage grid within the bed. As components are passed over or partially immersed into the bed, the electrostatically charged particles are attracted to the grounded surface, forming a highly uniform layer — even on recessed areas and internal cavities that are hard to reach with spray guns.

Unlike conventional spray or dip systems, this approach allows for non-line-of-sight coverage and high material utilization.

Parameter	Specification
Tank Dimensions	800×800 mm to 1500×1000 mm (customizable)
Powder Holding Capacity	30–100 kg
Output Voltage (Internal Grid)	0–80 kV (Corona discharge via embedded stainless steel mesh or rods)
Fluidization Pressure	1.3–1.6 bar
Charging Efficiency	65–75% (higher on large flat surfaces)
Recommended Coating Thickness	100–350 microns (single pass)
Powder Particle Size	30–90 microns (electrostatic grade)
Powder Type	Epoxy, Hybrid, Polyethylene, FBE (thermoset & thermoplastic)
Ambient Working Temp	10–40°C, RH < 60% ideal

Component	Description
Electrostatic Fluidized Tank	Powder bed with perforated membrane base and internal HV charging grid
Corona Charging Grid	Stainless steel mesh or rods connected to 60–80 kV high-voltage source
Powder Retention Lid	Enclosed top to contain powder within chamber
Air Control System	Regulates flow and pressure to ensure stable powder fluidization
HV Power Supply	Separate control unit for safe voltage regulation and interlocking
Grounding Setup	Provides a direct connection to earth for effective powder attraction
Optional Motion Table	Mechanized part handling over the tank for uniform exposure
Safety Interlock System	Prevents operation if cover or earth is disconnected

Tubular battery trays (mild steel, 2–3 mm) – 200 µm epoxy with wrap-around coating
HV transformer coil shields – corona-free coating with surface resistivity >10¹² Ω
Motor stator shields – coated internally via overhead conveyor pass-through
Preformed ducts with multiple bends – polyester coating on all surfaces without dead zones
Aluminum light pole internals – coated to 150 µm using electrostatic bed without shadowing
HV surge arrester covers – FBE coating on composite/metal surface
Steel ventilation louvres – 3-side coverage without edge thinning
Open-section channels (150 mm depth) – uniformly coated without manual gun pass
Die-cast junction boxes (non-flat interiors) – epoxy coated without hand spray
Crossmembers with internal ribs – reach full surface without manual correction

tribo

Tribostatic Powder Coating System (No HV)

Tribostatic Powder Coating System (No HV)

The Tribostatic Powder Coating System charges powder particles using friction (triboelectric effect) rather than high-voltage corona discharge. As powder passes through a PTFE-lined spray gun, it gains a positive charge by rubbing against the walls. These charged particles are then attracted to the grounded workpiece, forming a uniform and efficient coating.

Unlike traditional electrostatic systems, no high-voltage power supply is required, making this system safer for operators, easier to maintain, and ideal in flammable or restricted areas. Tribostatic systems also minimize back-ionization and orange peel effects, leading to smoother finishes, especially on smaller or simpler components.

Parameter	Specification
Powder Charging Method	Triboelectric (Friction-based)
HV Requirement	None
Typical Coating Thickness	60–100 µm
Powder Particle Size	20–60 microns (tribo-compatible only)
Transfer Efficiency	60–80% (can vary based on gun design and part geometry)
Air Requirement	4–6 bar clean, dry compressed air
Gun Material	PTFE or other tribo-compatible liners
Powder Compatibility	Tribo-grade epoxy/polyester powders (free-flowing, minimal additives)
Control Method	Manual or PLC-based flow and air regulation
Recommended Temperature	20–30°C, low humidity for best charge retention

Component	Description
Tribostatic Powder Spray Gun	Specially lined gun for friction-based charging, no HV cable required
Manual/Auto Control Panel	Controls for air, flow rate, and gun purge
Powder Feed Unit	Hopper with fluidization base for powder movement
Grounding Cables	Essential for attraction of charged particles
Compressed Air Lines	Supply atomization and conveying air to gun
Powder Hose & Fittings	Antistatic tubing to reduce loss of charge
Spray Booth (Manual or Automatic)	Optional enclosure with extraction and recovery

Fire extinguisher brackets (bent MS, 3 mm) – 80 µm polyester coating
Wall-mounted electrical boxes (CRCA) – thin 70 µm coat using venturi-fed tribo gun
Steel chair frames (tube, 1.5” dia) – powder flow-controlled matte finish
Cylinder holders & clamps – powder-coated without need for gun voltage control
Mild steel mesh panels – uniform coating with no back ionization
Welded accessories for racks – tribo charge ensures wrap-around on spot welds
Utility trays (formed steel) – minimal powder bounce back during spraying
Lighting back plates (aluminum) – fine coat for decorative purpose
Wall brackets & support arms – even finish without powder layering
Indoor switchboard accessories – clean edge finish with no corona marks

Comparison Matrix – Powder Coating Systems

Feature / System	Electrostatic Spray	Fluidized Bed	Electrostatic Fluidized Bed	Tribostatic Spray
Coating Method	Spray with HV gun	Dip into fluidized powder	Powder fluidization + HV grid	Spray with tribo-charged gun
Voltage Requirement	0–100 kV (gun)	None	0–80 kV (embedded grid)	None (tribo only)
Part Complexity Handling	Moderate	Simple shapes	High – internal & hidden areas	Moderate – flat/tube parts
Coating Thickness (typical)	60–120 µm	250–500 µm	100–350 µm	60–100 µm
Transfer Efficiency	70–90%	~100%	80–90%	60–80%
Powder Types Supported	Epoxy, Polyester, Hybrid	Nylon, PE, Epoxy, FBE	Epoxy, Polyester, FBE	Tribo-compatible only
Equipment Complexity	Medium	Low	Medium–High	Low
Color Change Time	Fast (modular hopper)	Slow (manual clean)	Moderate	Fast (manual swap)
Best For	Versatile mass production	Thick, protective coatings	Coating complex/recessed parts	Simple operations, HV-restricted zones
Air Requirement	4–6 bar dry air	1.2–1.5 bar	1.3–1.6 bar	4–6 bar

Decision Guide – Which System Should You Choose?

If You Want To…	Recommended System
Coat thin/medium sheet metal with decorative finishes	Electrostatic Spray System
Apply thick, protective coatings in one go	Fluidized Bed System
Coat complex parts with internal bends or hidden surfaces	Electrostatic Fluidized Bed
Operate in HV-restricted or low-maintenance environments	Tribostatic Spray System
Quickly change colors or switch between jobs	Electrostatic or Tribostatic
Eliminate powder loss completely	Fluidized Bed
Maintain simple, dip-based workflow with no spray gun	Fluidized Bed
Use FBE or dielectric coatings on electrical parts	Fluidized or Electrostatic FB
Handle jobs with frequent operator change (skill agnostic)	Tribostatic
Automate the process over conveyor/robotics	Electrostatic or Electrostatic FB