Merry Christmas from TCI

TCI's office and warehouse in Georgia will be closed for the holidays on Thursday, December 24 through Friday, December 25 as well as Friday, January 1 for the holidays. The Canadian office and warehouse will be closing at noon on Thursday, December 24 through Friday, January 1.

Santa Claus at TCI

Each year, without fail, Santa Claus and his reindeer travel the world to bring presents and joy to the people on his nice list. This year Santa made an early appearance at TCI and surprised elementary school children who stopped by to sing holiday songs to the TCI employees. Santa (a.k.a. Dennis Hall in Customer Service) has dressed up as Santa for many years and participates as Santa in the Americus Christmas Annual Parade.

'Tis the season for believing! Thank you Dennis for your help in making this the most wonderful time of the year!

Applying a Second Coat of Powder Coating

Sometimes, you have to apply one coat of powder over another. You can recoat with most powders, though you’ll probably face common problems of poor electrostatic attraction and poor inter-coat adhesion.

Techniques to help with the application of a second coat:

• Ensure a proper ground in your powder coating system
• Lower your gun voltage
• Preheat the part
• Clean parts thoroughly before recoating
• Slightly increase cloud density
• Increase gun to part distance

If you need to apply a second coat, it is important to make sure part preparation is consistent. As with any new coating job or procedure you do, always test the procedures thoroughly to work out application techniques and find application problems before you begin to produce the powder coated part.

Please contact us today to speak with one of our professional service technicians. We can help you with application questions or any of your powder coating needs.

The Spotlight's On...

Kenneth Bryant

Kenneth Bryant has been a dedicated and valued TCI employee for almost 19 years. During Kenny’s years at TCI, he has contributed to our success in a number of roles including: grinder operator, QC technician mixer, forklift driver, lead man in grinder department, extruder operator on the busses, lab extruder, and mighty mixer. 

Kenny’s drive for success is evident in his personal commitment to quality. Kenny says, “TCI isn’t an assembly line. Each person has a machine to operate and is responsible for their own success.” He always works to improve production and promote job safety. His “whatever it takes attitude” to exceed the expectations of our customers is another indication of his dedication to TCI.

Appreciative of his accomplishments and career highlights, Kenny especially takes pride in a few key recognitions. He received the Lead Man employee of the month award, as well as being the first person to run the grinder at the new facility. He supervised on-the-job training at South GA technical school, and is a proud member of the safety committee. 

Kenny resides in Americus, GA with his wife Addie Bryant and daughter Andrea N. Owens Jones. Outside of work, Kenny likes to spend time with his family and friends, whether it’s grilling, baking cakes and pies, dinners out, walking, or shopping with his wife.

We want to offer our sincerest thanks to Kenny for the contribution he has made to our company.

Flat/Fan Powder Coating Gun Tips: Use the Right Tool for the Job

Using the right tool for the job is no exception when it comes to powder coating.  It is difficult to powder coat a part properly with the wrong control devices. Therefore it is important to use the best-suited powder gun tips to control and direct the flow of powder as it leaves the tip of the gun.

The flat spray pattern device has gained popularity in the last 20 years. This device attaches to the gun tip and focuses the powder into a flat or fan-shaped pattern.  This aims the powder into specific areas with pinpoint accuracy. The flat spray tip also produces a higher powder velocity than the deflector tip, allowing the powder to penetrate recessed areas easier. The distance between the gun and the part along with the size of the slot in the nozzle control the size of the pattern. 

Flat spray nozzle effects on powder cloud:

• Develops flat rather than conical spry pattern
• Typically covers a smaller spray area
• Heavier build in the center of the spray pattern
• Concentrates more powder into recesses
• The higher powder velocity can blow powder off the part producing insufficient wrap.
• Less forgiving than the defector tip 

Taking time to examine your application methods and investing in pattern control devices will pay off with improved coating efficiency and product quality, saving you time and money. 

Please contact us today to speak with one of our professional service technicians. We can help you with application questions or any of your powder coating needs.

TCI's New Association Memberships

       

TCI Powder Coatings is proud to announce two new association memberships with the American Architectural Manufacturers Association (AAMA) and The Society for Protective Coatings (SSPC). With these new association memberships, TCI has more opportunities for advanced education and training programs, keeping TCI a leader in the industry. 

Deflector Powder Coating Gun Tips: Use the Right Tool for the Job

Using the right tool for the job is no exception when it comes to powder coating.  It is difficult to powder coat a part properly with the wrong control devices. Therefore it is important to use the best-suited powder gun tips to control and direct the flow of powder as it leaves the tip of the gun.

The deflector tip is the most common pattern device.  It directs the powder flow into a round pattern.  This creates a larger powder pattern than a gun without a deflector therefore increasing the area the powder covers.  The deflector also reduces the powder velocity, which increases the electrostatic charge of the powder.

Deflector size effects on powder coating:

• Determines peak film build and uniformity
• Determines size and coverage of the cloud
• Concentrates powder along edges of pattern
• Gives a more uniform deposit with moving parts

Taking time to examine your application methods and investing in pattern control devices will pay off with improved coating efficiency and product quality, saving you time and money. 

Please contact us today to speak with one of our professional service technicians. We can help you with application questions or any of your powder coating needs.

Factors Affecting Charge for Powder Coatings

The charging characteristic of a powder is directly related to both the physical properties of the material itself and the specific processing conditions.

Factors affecting charge include:

• Composition
• Particle size
• Substrate type (conductivity)
• Substrate size              
• Line speed (time to spray)
• Humidity
• Virgin to reclaim ratio
• Gun flow rates (vol. and speed)
• Gun voltage and current (amount of charge)
• Resin type
• Particle shape
• Substrate shape (flat, frame, recess, etc.)
• Substrate temperature
• Booth airflow
• Gun to substrate distance
• Quality of ground
• Gun tip and deflectors

It is important to examine and find the best process factors to improve your bottom line, reduce overall costs, and meet performance requirements with quality and efficiency.

Please contact us today to speak with one of our professional service technicians. We can help you with application questions or any of your powder coating needs.

Optimizing Gun Pressures

The key to quality powder coating is to spray just the right amount of powder with the minimum amount of air necessary. Excessive feed air pressure and powder volume will not result in faster or better coated parts, and generally speaking, the finish, spray guns, and spray booth may be compromised as a result.

Excessive gun pressures will have a dramatic negative impact on spray quality and efficiency. 

Too much powder/flow pressure can:

• Cause excessive wear of equipment
• Create impact fusion problems
• Cause gun spitting and puffing
• Increase film thickness uniformity
• Decrease first pass transfer efficiency
• Increase amount of overspray and reclaim
• Reduce electrostatic attraction:
• Large particles can bounce off
• Particles traveling too fast for wrap
• More particles to charge
• Increased friction creating high static charge reducing the effectiveness of the corona charge

It is important to find the correct gun pressures to alleviate the listed negative impacts and to improve your bottom line, reduce overall costs, and meet performance requirements with quality and efficiency.

For more information on Optimizing Gun Pressures, read TCI's Troubleshooting Guide.

Or contact us today to speak with one of our professional service technicians. We can help you with application questions or any of your powder coating needs.

Happy Thanksgiving from TCI

From All of Us, to All of You, Happy Thanksgiving

This year has flown by, and we’re grateful for everything we’ve been able to accomplish. Though 2015 isn’t over yet, we did want to pause and say thank you to all of our clients and customers for joining our community and helping us grow.

The office will be closed November 26-27 for the holiday.

Happy Thanksgiving from our TCI family.

Press Release: TCI Powder Coatings, RPM International, Names Dave Brooks Sales Representative, Northeastern United States.

(Ellaville, GA, November 17, 2015) TCI Powder Coatings, a proud subsidiary of RPM International Inc. (NYSE: RPM) is pleased to welcome Dave Brooks. Dave brings over 25 years experience in business development in the industrial coatings market. For the past 2 years Dave was with IFS Powder Coatings. Prior to that, Brooks spent 17 years with Spraylat in sales leading up to the PPG acquisition. Before joining Spraylat, Dave was an Account Manager with Morton International.

Jack Bostock, TCI Vice President Sales and Marketing, expresses “We are truly excited to bring Dave onto the TCI team. Dave has an outstanding track record and reputation in the powder coatings market. Dave’s technical insight and sales professionalism will add great value to our customers.”

Dave Brooks is a graduate of Bryant University with a BS in business and currently resides Sharon, Massachusetts. Dave will cover the New England states along with NJ, PA and NY.

About TCI Powder Coatings For over 25 years, TCI has been manufacturing powder coatings and dedicating itself to developing superior thermoset powder coatings and providing unparalleled service to its customers.

About RPM RPM International Inc., a holding company, owns subsidiaries that are world leaders in specialty coatings, sealants, building materials, and related services serving both industrial and consumer markets. RPM's industrial products include roofing systems, sealants, corrosion control coatings, flooring coatings, and specialty chemicals. Industrial brands include Stonhard,Tremco, illbruck, Carboline, Flowcrete, Universal Sealants and Euco. RPM's consumer products are used by professionals and do-it-yourselfers for home maintenance and improvement and by hobbyists. Consumer brands include Zinsser, Rust-Oleum, DAP, Varathane, and Testors. Additional details can be found at www.RPMinc.com and by following RPM on Twitter at www.twitter.com/RPMintl.

Click here to read the press release on our website.

Powder Application Tips Series: Powder Atomization

In conventional powder spray systems, paint atomization occurs via high-velocity air jets, forcing powder through small air holes in the gun face caps. Air pressures used range from 40 to 80 psi.  If the atomized paint particles travel at too high or too low velocities, poor application can occur, preventing powder from adhering to the surface.

Powder Atomizer Rate: Too High

• Low film build
  
• Low transfer efficiency
• Fat edges
• Poor penetration into recesses

Powder Atomizer Rate: Too Low

• Powder spurting, surging, or puffing
• Streaking on parts
• Low wrap around

Controlling the powder atomization rate is an important step in application. If you need some additional assistance with your spray equipment and controlling powder atomization rates, feel free to contact us today and we will be more than happy to help. 

Powder Application Tips Series: Powder Flowability

Powder flowability is defined as the ease with which a powder will flow under a specified set of conditions. Some of these conditions include: the pressure on the powder, the humidity of the air around the powder, and the equipment the powder is flowing through or from. 

Powder Flow Rate or Ejector : Too High

• High impact fusion
• High venturi wear
• Low transfer efficiency
• Poor penetration into recesses – low wrap 

Powder Flow Rate or Ejector: Too Low

• Powder spurting, surging, or puffing
• Low powder film build
• Poor penetration into recesses

Controlling the powder flow rate is a critical step required to create accurate process control. Spray equipment can be complicated, so if you need some additional assistance with your spray equipment and controlling powder flow rate, feel free to contact us today and we will be more than happy to help.

For more information on application, please see or download our powder coating technical guide on our website.

Success at FABTECH 2015

TCI Powder Coatings found great success at FABTECH 2015 in CHICAGO, IL. Fabtech is North America’s largest showcase event featuring technology, equipment and industry leaders in the metal forming, fabricating, welding and finishing industries.  This year’s lineup included impressive keynote presentations, industry panel sessions, and special events throughout the four-day show.

FABTECH represents every step of the metal manufacturing process from start to finish.  It’s where new ideas, products and technology are highlighted through interactive exhibits, education, and networking.

TCI is proud to have presented alongside the best minds in manufacturing while helping attendees find tools to improve quality, productivity, and increase profit.

Visit our website for more information on TCI’s products, programs, and solutions.  

Powder Application Tips Series: Spray Gun Air Controls

Spray guns can spray most coatings or finishes currently being used for automotive refinish, industrial, architectural, and general metal applications. Spray guns carry and direct the paint from the gun to the surface.

Spray guns typically have 2-3 air controls per gun:

1. Powder regulator (flow regulator): controls the amount and velocity of powder being sprayed
2. Atomizer regulator (diffuser or sub regulator): controls the density and size of the powder cloud as well as ensuring a steady output
3. Swirl regulator (TIP regulator): delivers air directly to the gun tip, which can shape the cloud and prevent powder build up at the electrode and deflector. 

For more information on application, please see or download our powder coating technical guide on our website.

Spray equipment can be complicated, if you need some additional assistance with your spray equipment, feel free to contact us today and we will be more than happy to help. 

Powder Application Tips Series: Venturi Pump Impact Fusion

The powder pump can be referred to as an injector or venturi pump.  There is normally one pump for each gun which delivers powder from the feed hopper to the spay gun in a consistent and uniform flow.  Pumps use the venturi principle in which air is passed over the venturi throat (a smaller constricted cylindrical section) and powder is drawn up though a pick-up tube into the pump where it is then passed on to the spay gun.   

Powder pump parts are exposed to high-velocity powder streams, and therefore are prone to wear and impact fusion, especially the venturi throat. It is important to continually check this part for wear.  When the venturi throat wears, it opens in diameter, allowing air to rush through creating inconsistent powder flow and increased impact fusion.

To prevent inconsistent powder flow and impact fusion, check, clean, and replace tubes, hoses, pumps, and nozzles on a regular basis.

For more information on application, please see or download our powder coating technical guide on our website or contact us today to speak with our experienced team about how we can help you with your powder coating needs.

We’re at Fabtech 2015!

TCI is exhibiting at FABTECH 2015 in Chicago, IL today through the November 12^th. 

FABTECH provides a convenient venue where attendees can meet with world-class suppliers, see the latest industry products and developments, and find the tools to improve productivity, increase profits, and discover new solutions to all of your metal forming, fabricating, welding, and finishing needs.

If you are at the show, please stop by to visit us at Booth #S5016.  We are excited to introduce our new TruAnodize Architectural Powder Coatings, coatings with an anodized effect in 6 popular anodized colors that minimize or eliminate color variations in anodized metal.  

Powder Application Tips Series: Controlling Impact Fusion

Impact fusion is the packing or partial melting of powder particles occurring within application equipment. When powders travel through the application equipment from the feed hopper through the powder pumps, hoses, and guns, friction can occur, causing the powder to pack together in a fused or semi-fused state.

The packed powder can start out as a small obstruction that continues to grow restricting powder flow or breaks loose causing a finishing defect. Any area of the powder delivery equipment is a potential site for impact fusion, including the powder pump, the delivery hose, and the gun. Therefore impact fusion can be controlled by eliminating or minimizing friction as well as the sites for potential powder build up.

To prevent impact fusion:

• Keep powder hoses short with minimal sharp bends – reducing friction
• Clean and replace tubes, hoses, pumps, and nozzles on a regular basis
• Reduce your reclaim  - powder may be too fine causing easier fusion
• Control powder gun flow rates - excessive air pressures and powder feed rates will increase the amount of impact fusion
• Maintain a clean, moisture-free air supply

For more information on application, please see or download our powder coating technical guide on our website or contact us today to speak with our experienced team about how we can help you with your powder coating needs.

RPM and TCI Relationship: The Value of 168

TCI Powder Coatings is a subsidiary of RPM International Inc., a multi-national holding company with a broad range of subsidiaries in the coating and sealing fields.

RPM founder,
Frank C. Sullivan

RPM International Inc. owns subsidiaries that are world leaders in specialty coatings, sealants, and building materials serving both consumer and industrial markets. The corporate philosophy of RPM stems from “The Value of 168” an approach conceived by RMP founder, Frank C. Sullivan.

The figure 168 represents the total number of hours in a week. On a deeper level, it serves to remind us that we have been given gifts of both life and time, and that we need to use these gifts wisely and productively.

The Value of 168 signifies RPM’s commitment to its employees, customers, and stockholders. 

Overcoming The Faraday Cage Effect (Part 2)

Coating complex part geometries can be very challenging due to the Faraday cage effect.  However, with the proper set up, right equipment, and correct application technique, even tough Faraday cage areas can be successfully powder coated. 

The Faraday cage effect can be overcome in a number of ways:

• Making sure the part is properly grounded: ungrounded parts have more severe Faraday issue
• Control humidity in the environment: below 40% relative humidity will increase the Faraday effect
• Adjust airflow velocity to deliver the powder inside a recess but not excessively preventing powder transfer
• Adjust gun voltage to reduce the charge on the powder particle: highly charged particles are more difficult to drive into the recessed areas and are more easily attracted to the flat surfaces. 
• Change spraying angles: approach recess at an obtuse angel
• Use a slotted spray gun tip to concentrate spray: selecting a different nozzle for the gun to slow the powder velocity can be very helpful in coating recessed areas
• If all else fails, a tribo-charging (frictional charging) gun can be used to coat the most difficult Faraday areas, as they don’t have electrostatic field lines that cause the Faraday problems
• Finally, operator coating technique is very important: a well-trained operator will help ensure tough Faraday cage areas will be successfully powder coated

For more information on the Faraday cage effect, read TCI's Troubleshooting Guide.

Or contact us today to speak with one of our professional service technicians. We can help you with Faraday Cage questions or any of your powder coating needs.

What is Faraday Cage? (Part 1)

Have you ever powder coated parts with inside corners or complex geometries?  If so, it is likely that you have struggled with the Faraday cage effect. For those of you who have not, the Faraday cage is like an invisible electrical shield that prevents charged powder particles from reaching internal corners and recesses. If the powder particles cannot reach these areas, then the part will not be completely coated, which will result in poor coating performance and most likely premature corrosion.

Contributing Factors to Faraday Cage

• Edges build quickly and can back-ionize before recesses can coat
• Corona charging creates strong electric fields
• Edges offer the least amount of resistance
• Electric fields follow the paths of least resistance
• Charged particles follow with lines of force
• The less the distance the more the attraction

Look for Faraday Cage (part 2) next on - Overcoming the Faraday Cage Effect

For more information on the Faraday cage effect, read TCI's Troubleshooting Guide.

Or contact us today to speak with one of our professional service technicians. We can help you with Faraday Cage questions or any of your powder coating needs.

RPM and TCI Relationship: Consumer Brands

TCI Powder Coatings is a subsidiary of RPM International Inc., a multi-national holding company with a broad range of subsidiaries in the coating and sealing fields.

RPM’s consumer brands are primarily marketed in North America, but have a growing presence in Europe and the United Kingdom. These brands can be found on almost every garage or basement shelf in the U.S. and Canada which are sold through home improvement centers, mass merchants, hardware stores, paint stores, and craft shops.

Product Categories Include

• Small-project paints and coatings
• Primer-sealers
• Specialty paints
• Caulks and sealants
• Wood stains and finishes
• Rust-preventative paints
• Wall covering preparation and removal products

Market Leadership Subsidiaries

• Rust-Oleum: No. 1 brand recognition and market share position in the U.S. and Canada in the rust-preventative, decorative, specialty, and professional segments of the small-project paint category 
• DAP: No. 1 brand recognition and market share position in the U.S. and Canada in the caulk and sealant residential market 
• Varathane: No. 1 market position in Canada and No. 2 in the U.S. offering interior wood stains, finishes, wood repair, and maintenance products 
• Zinsser: A leader in brand recognition and market share position in the U.S. market for specialty primers and sealers and wall covering sundries

*Rankings based on market share

TCI is proud to be part of RPM’s success and its commitment to market leadership.

TCI Powder Coatings Head to Fabtech 2015

TCI is excited to exhibit at FABTECH 2015 in Chicago, IL from November 9^th – 12^th, 2015 which is anticipating 40,000 attendees and 1,500 exhibitors, and 100 conference sessions all under one roof.

FABTECH provides a convenient venue where attendees can meet with world-class suppliers, see the latest industry products and developments, and find the tools to improve productivity, increase profits and discover new solutions to all of your metal forming, fabricating, welding, and finishing needs.

Finishing Sessions You Can Attend at FABTECH 2015:

C10: Conceptos Básicos de Pintura en Polvo en Español

C20: New! Powder Coating Basics

C20: Powder Coating Basics

C31: The Future of Liquid Industrial Finishing

C32: The Secrets of Purchasing a Finishing System

C42: Old vs. New! Are You Ready for a Pretreatment Change

C50: Finishing Spray Painting Workshop (session repeats as C90)

C61: Troubleshooting for E-Coat Imperfections

C62: Modernizing the Abrasive Air Blast Facility – Tech Tour

C70: Painting Over Hot Dip Galvanizing

C71: Efficient Curing with Infrared

C72: Safety Codes & Compliance: How Important Is It?

C82: Saving Costs on Your Plating Line

If you are going to be at the show, please stop by to visit us at Booth #S5016.  We are excited to introduce our new TruAnodize Architectural Powder Coatings, coatings with an anodized effect in 6 popular anodized colors that eliminate color variations in anodized metal.  

The Electrostatic Charge

The electrostatic powder coating process is a method of applying electrically-charged powder coating materials to grounded parts. Powder is held to the part by this electrostatic attraction until heat is added to flow the powder together and cure it.

There are four basic pieces of equipment that commonly make up an electrostatic powder spray coating system. They are the powder feeder, power unit, electrostatic gun, and powder booth recovery system.

To start, the powder is supplied to the spray gun from a feeder unit where the powder is circulated by compressed air into a free-flowing state. The fluidized powder is then funneled out by high velocity air and is propelled through the powder feed tubing to the spray gun.

The powder then leaves the spray gun in a diffused cloud being pushed toward the workpiece. At the front of the spray gun, a high-voltage, low-amperage power unit supplies a charging electrode, which emits a charge that is passed onto the powder particles. This causes the particles to attach themselves to the grounded workpiece.

Electrostatic attraction of powder at the substrate surface:

• Powder will retain a charge for several hours (minimally) if grounded properly. 
• As the powder contacts a grounded surface, it induces an equal and opposite charge on the surface of the substrate. 
• This occurs because like ions are repelled from the area. This reaction is called a “mirror” charge and serves to hold the powder particle in place.
• Larger particles typically have stronger charges, therefore larger particles will tend to build on top of smaller particles more directly on the surface. 

For more information like this, please see or download our powder coating technical guide on our website. 

Benefits of Using Electrostatic Spray Guns vs. Conventional Spray Guns

There are many advantages to using electrostatic spray equipment. The
main advantage is an increase in transfer efficiency. With increased transfer efficiency, material usage drops, clean-up costs decrease, and disposal costs go down. Electrostatic guns create a more uniform and even coating with a much higher finish quality. Electrostatic methods also lower solvent emissions into
the air since less coating material is needed to coat each part.

Selecting a spray gun is an important decision to make in the design of a spray system. Matching the gun to the application is of utmost importance. Failure to choose the correct equipment generally results in lower efficiencies, increased coating costs, increased emissions, and higher booth filter costs.

TCI provides expert support, troubleshooting, testing, research, audits, equipment and defect analysis, corrective action plans, and training. More importantly, we dig deep into your operation to evaluate and identify the areas where we can optimize your process and lower your overall coating costs.

Contact us today to speak with one of our professional service technicians. We can help you with spray gun selection or any of your powder coating needs.

Sandra Exum, New Process Engineer & Scott Fitzgerald, Quality Control Technical Leader Trainee

Sandra Exum, New Process Engineer

It is our pleasure to announce that Sandra Exum has joined TCI as a process engineer, effective August 3, 2015.

Sandra will be responsible for understanding the process of how paint is made, and study methods to improve production, decrease downtime, and increase profit through research, equipment monitoring and improvement, energy efficiency studies, and implementation.

Sandra is a graduate of Georgia Southwestern State University, with a Bachelor’s of Science in Chemistry.  Previously, Sandra worked for Helena Chemical Co. and Royster Clark as a chemist analyzing the active ingredients of agricultural products. 

Sandra will be a great addition to the engineering department. Please join us in welcoming Sandra to the TCI family.

Scott Fitzgerald, Quality Control Technical Leader Trainee 

We are pleased to announce Scott Fitzgerald as a new Quality Control Technical Leader Trainee.  Scott will be in training on the floor for the next 3 months.

Please join us in welcoming Scott to the company.