Powder coating Ovens

                                                                          ANSWERS TO COMMON POWDER COATING OVEN QUESTIONS

• What Size Oven is Needed for Powder Coating?

When selecting an oven for powder coating, size is a critical factor that depends largely on the items you intend to coat. Here’s how to decide on the right dimensions:

Object Size and Capacity:  Assess Dimensions: The oven should comfortably fit the largest object you plan to coat, taking into account not just length, height, and width, but also ensuring there’s ample room around the item for air circulation.

Overestimate for Safety: It’s wise to opt for an oven slightly larger than your needs. This ensures that air can flow freely and heating is even, preventing spots or inadequate coating on larger pieces.

Components and Mechanics: Ensure your oven’s size aligns with the capacity of its heating burner, fans, and other critical parts that contribute to efficient operation.  Most “bargain” ovens are cheap for a reason – many undersize fans and burners.  Not only does this mean the parts may not fully cure and the cost to operate the oven can be up to 20 x higher per hour, but in many cases they DO NOT MEET CODE. And failure to meet code can result in MAJOR LEGAL ISSUES, up to but not limited to FINES, CANCELLATION of INSURANE POLICIES, and even the SHUTTING DOWN OF YOUR BUSINESS.

Ventilation and Insulation: Adequate space within the oven is necessary for proper insulation and ventilation, both vital for maintaining consistent and safe temperatures.  Oven walls should be 6” thick and should be packed with high temperature insulation.

Consult Professionals: When in doubt, seek advice from powder coating experts.  There are now dozens of coater’s who have been fined by their local municipalities and many have had insurance and even leases cancelled due to having powder coating equipment that is not built to code.  Build-it-yourself powder coating ovens have caused more than one person to lose their business and even their homes.  When it comes to code and compliance – PROCEED WITH CARE!

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• What air flow design is ideal for a Powder Coating Oven?

When selecting an oven for powder coating, a forced air convection oven stands out as the top choice. Here’s why it’s essential:

Consistent Heat Distribution. This oven type excels in maintaining uniform heat, which is critical for the effective curing of powder coating materials. The convection system circulates the air efficiently, eliminating hot spots and ensuring an even cure. Infrared heater ovens work, but they only cure WHAT THEY SEE. This works great for curing one particular size part – over and over. But for multiple varieties of parts, shapes, and thickness, convection is the only way to go.

• Any other design considerations I should take into account for a Powder Coating Oven?

Absolutely!  When it comes to ovens, always remember that it’s not simply about the up front price.  The cost to operate should be the MAIN consideration.  You will pay the up front cost only once – the cost to operate will come in every month’s fuel bill. 

    Joey Note:  Here’s a real-world example on this.  I recently did a consulting ROI with a large, well known manufacturer – a household name to most.  They had the opportunity to purchase a used powder coating oven for about $20,000 less than the cost of a new one.  The used oven was only 7 years old, but burner technology has come a LONG way in that period of time.  We did the math on the two burners:  The used oven burner would cost around $17 per hour to operate while the new oven burner would be closer to $5 per hour to operate.  $12 per hour  difference x 40 hours per week x 52 weeks per year equals $24,960……a first year savings of nearly $5,000 and a $25,000 per year savings every year after that.  Not to mention the fact that they new oven offers a warranty.  It was a no brainer.

• Gas or Electric? What Powder Coating Oven design is better?

If you are doing parts no larger than a motorcycle frame, electric heated ovens can often be used.  Once you get above around 96 cubic feet, natural gas or propane ovens are the only way to go.  They are much less expensive to operate at that point.  To get enough kw elements in an oven above 96 cubic feet, you are talking several hundred amps to operate.  Some of the hobby oven manufacturers are WAY undersizing the amount of elements they are putting in electric ovens in order to make a product that sells “cheaper” but the issue comes with the quality of the finish because of hot and cold spots.  Not to mention how long they take to heat up.

• How are powder coating ovens delivered and installed?

When you order a powder coating oven, it typically arrives unassembled, giving you the flexibility to tailor the installation process to your specific needs. While many businesses successfully set up these systems themselves, a considerable number opt for professional installation to ensure everything operates seamlessly from day one.

Delivery Process

• Unassembled Shipping: The ovens come in parts, making transport easier and more cost-effective. This modular approach allows for efficient delivery, regardless of your location.

Installation Options

• Professional Installation: If you prefer a quick and hassle-free setup, expert installation services are available. Installation teams, specialized in coating and curing systems, travel globally to assist.
• DIY or Third-Party Contractors: You have the option to assemble the oven using your own team or third-party services, although this might take a bit more time.

Benefits of Professional Installation

1. Speed: Professional teams usually complete the setup much faster, helping you go operational weeks earlier compared to DIY or third-party installations.
2. Expert Calibration: These installers ensure precise equipment calibration, crucial for optimal performance and longevity of your coating system.
3. Peace of Mind: With experts handling the process, you minimize risks and complications, focusing instead on ramping up production efficiently.

For businesses with tight timelines or those stepping into large-scale operations, opting for experienced professionals can prove invaluable for a smooth and timely start.

• What temperature is required for baking Powder Coating?

The ideal temperature for baking powder coating typically falls within a range of 350°F to 400°F (175°C to 205°C). This range can vary depending on the type of powder coating material in use. Different materials might have specific temperature requirements, so always check the manufacturer’s guidelines for the best results.

Key Points to Remember:

• Manufacturer Guidelines: Adhering to the recommended curing temperature and time specified by the powder coating manufacturer is crucial. This ensures the finished product achieves both optimal performance and durability.
• Risks of Incorrect Temperatures: Baking the powder coat at too high or too low a temperature can compromise its quality. Overheating might lead to a poor finish, while underheating can result in a coating that is less durable and potentially prone to damage.

By following these guidelines and ensuring accurate temperature control, you can achieve a smooth, durable powder-coated finish.

• What are the standard features and sizes of your powder coating ovens?

Powder-X supplies hundreds of ovens of all sizes as well as large curing ovens and drying ovens for automated systems. Whether you’re looking for a standard or custom solution, our powder coating ovens offer a wide range of dimensions to suit any need.

Oven Sizes and Features

• Standard Sizes: Our walk-in ovens come in common sizes with heights up to 12′, widths up to 12′, and lengths up to 100′. These dimensions cater to most industrial needs.
• Custom Configurations: For those requiring more specialized solutions, we provide custom sizes with heights reaching 30′, widths extending to 48′, and lengths over 200′. This flexibility ensures you can find the perfect fit for your space and production demands.
• Construction Quality: Built with 6″ thick walls and roofs, our ovens are insulated with high-density mineral wool, ensuring optimal energy efficiency and temperature control.
• Fuel and Material Options: Choose from natural gas or LP gas fueled versions, constructed with aluminized, stainless, or G90 galvanized prime domestic steel.
• Modular Design: Our ovens feature a modular design, allowing for on-site reconfiguration without incurring additional costs. This adaptability is ideal for evolving production needs.
• Functional Variety: Whether you need pre-heating, drying, curing, or multi-function designs, our ovens are adaptable for use with cart track, overhead conveyor, or specialized racks.

With our extensive selection, you can enhance your powder coating process with the right oven size and type tailored to your specific requirements.”

Batch ovens are classified as a Class B appliance for the application of non-combustible materials and meet all related national codes related to National Fire Protection Association (NFPA) 33, NFPA 86, and the national fire code. However, all electrical components including but not limited to burner components, safety devices, control panel components, flame monitoring devices, and timers are all ETL or UL approved per NFPA standards. In addition, all components also carry the much more stringent C-UL listing for Canadian Standards Association (CSA) approval.

And our control panels are ALL UL listed. 

To ensure maximum safety and reliability, our powder coating ovens are equipped with an array of advanced safety features:

• Premium Controls: Installed in NEMA-rated enclosures for optimal protection.
• Gas Safety Mechanisms: Include manual gas shut-off valves, analog gas pressure gauges, and high and low pressure gas safety switches.
• Ignition Safety Systems: Equipped with ignition sensors that feature auto shut-down capabilities.
• Combustion Safeguards: Feature comprehensive flame safety systems.
• Air Management Systems: Powered combustion air supply fans, circulation fans, and exhaust fans for effective airflow.
• Air Proving Switches: Include combustion, circulation, and exhaust air proving switches.
• Temperature Monitoring: High temperature safety switches and oven air temperature sensors ensure precise control.
• Purge Timers: Both combustion and oven operation are safeguarded by purge timers.
• Mechanical Protection: Motor overload protection and fan/belt/motor guards enhance durability.
• Structural Safety: Built with explosion relief and seismic tolerant designs for added resilience.

These features collectively enhance the safety and efficiency of the ovens, aligning with our commitment to delivering state-of-the-art solutions that protect both operators and facilities.

• What customizations are available on your Powder Coating Ovens?

• Custom Frontals/Doors: Modify the design of the oven’s access points to suit your operational requirements.  Various sizes and designs, including Roll Up doors available.
• Interior Dividing Doors for Multi-Zone Curing: Create distinct curing zones within the oven to handle different processes or materials simultaneously.
• Conveyor or Cart System Integration: Seamlessly integrate the oven with your existing systems for enhanced efficiency and flow.
• Color Touchscreen Controls with Integrated Data Logging: Enjoy advanced control features that enhance usability and allow for meticulous monitoring.
• Custom Burner and Exhaust Configurations: Adjust the heating and ventilation systems to achieve optimal performance tailored to your setup.

These customization options ensure that your powder coating oven is not only a tool but a pivotal part of your production line, tailored to enhance your specific operational requirements while maintaining the highest standards of safety and efficiency.

Powder-X supplies hundreds of ovens of all sizes as well as large curing ovens and drying ovens for automated systems. Whether you’re looking for a standard or custom solution, our powder coating ovens offer a wide range of dimensions to suit any need.