How to run a line trial with a new powder coating.

Steps

1. Set the reference

   Keep the approved panel and the TDS at the line. Agree in advance which results decide pass or fail.

2. Clean the system

   Clean the booth, hoses, guns and recovery system to avoid contamination from the previous powder.

3. Use representative parts

   Coat parts with normal pretreatment, including difficult shapes, edges and the heaviest sections.

4. Record application settings

   Note voltage, powder output, gun distance, line speed and film thickness readings.

5. Measure the oven profile

   Run a data logger with probes on the parts to record metal temperature and time against the TDS cure schedule.

6. Test the coated parts

   Compare colour, gloss and texture with the approved panel and check cure, adhesion and impact by your usual methods.

7. Include recovered powder

   If you recycle powder, run with your normal virgin-to-recovered mix and check that appearance stays consistent.

Parameters

Cure schedule

per TDS (metal temperature and time)

Target film thickness

per TDS / your specification

Reference

Approved panel version

Records

Settings, film thickness, oven profile, test results

Common mistakes

• Trialling only flat, easy parts.
• Setting the oven by air temperature instead of measured metal temperature.
• Not cleaning the system, so the old powder contaminates the trial.
• Judging metallic or textured finishes without recovered powder in the mix.