Powder Coating (Cap: 1666.667 sq.mt./Day)

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)