Our Process

Galvanizing deposits a layered structure of zinc onto your steel fabrication for long-lasting corrosion protection. We work closely with you and our galvanizer to ensure the design optimizes the corrosion protection and the powder coated finish. Powdertech use only one galvanizing partner – Premier Galvanizing Ltd. The European Standard EN13438 recognises that technical and logistical cooperation between the galvanizer and powder coater is key to a successful finish.

Fettling improves the surface finish by removing zinc spikes and surface roughness common to the galvanizing process. We use a variety of fettling methods to ensure a smooth surface on flat, round and intricate surfaces.  Attention to detail at this stage is the key to a successful finish in safety critical applications. Fettling plans are produced for each type of component to make sure the finish is appropriate to the application.

The most important stage in powder coating. No matter how high the quality of the final powder coating, it will not produce a long-lasting high-performance barrier on the metal surface unless that surface is thoroughly and correctly cleaned, etched, converted and rinsed.  Our pre-treatment system has been chrome-free since January 2017. Details are on our DATA SHEET.

Correct jigging makes sure that the coating powder covers all surfaces evenly and to the correct thickness, avoiding marks and bare areas.

Immediately before the application of the powder, all galvanized material is heated to force out (degas) any remaining moisture trapped within the zinc. Poor degassing results in pin-holes – tiny craters in the surface where moisture has forced its way through the paint.

Powder is sprayed onto the prepared metal surface using a “gun”. The material is earthed through metal jigs, the powder particles are positively charged as they pass through the gun. The opposite charges attract each other and the powder sticks to the metal in an even layer. For more details see our DATA SHEET.

The coated metal is transferred to a large oven and heated to approximately 200 degrees C and held there for 20 minutes. This causes the resins and pigments in the powder to flow and “cross link”, transforming the powder into a smooth surface. A temperature recorder monitors the work in the oven and thermal characteristics are computer analysed.

When the metal has cooled, the finished article is checked three times to make sure the process has been successful. The gloss of the surface is measured. The thickness of the paint film is measured and the whole surface is visually checked. Test panels of similar material are more extensively tested once per day to international standards.

Methods vary depending on customer requirements. Generally a combination of card and bubble plastic is used to make sure all material is kept separated and arrives at the customer in the same condition that it left Powdertech.

Dispatch labels record the customer name and a traceable number from which all the details of the contract can be recalled.

The laboratory has all the equipment to carry our daily tests required by EN ISO 12206, ISO 13438 and Qualicoat specifications. Thes include: Boil (permeability) test, Mandrel bend test, drilling, sawing, adhesion & Falling wight, colour, gloss & film thickness. Results are recorded on company computer network.

We also have 5 dp scales to record pre-treatment etch rates.

Pre-treatment records of all tanks charanteristics, chemical additions and temperatures are tested and recorded daily.

Effluent is tested and recorded daily.

Acetic Acid (corrosion) tests are analysed externally on a rolling monthly plan.

Guarantee contracts have all their test plates stored on site together with individual process records.