Thursday, September 24, 2015

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. 

Tuesday, September 22, 2015

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.

Monday, September 21, 2015

The Spotlight's On...

Larry Spears

Larry Spears has been a dedicated employee of TCI Powder Coatings and will be celebrating 20 years of employment this October. Larry started out on the Extruders then moved to Quality Control. In 2001, he moved into his current position as Inventory Clerk and has just recently been given a new role as Warehouse Lead Man. 

Larry really enjoys his job and working at TCI.  He says, “even though we are owned by a corporation and are one of the largest employers in town, it feels like I work for a small, family run business. Everyone cares about the products and each other. We treat each other as family.”

Although Larry was raised as an Army brat, he has settled in Ellaville for the past 21 years. Larry likes spending time with his family, wife of 14 years, daughter and granddaughter. Outside of work, Larry is an avid reader, enjoys puzzles, chess, and outdoor activities. 

Thank you Larry for your years of great service and commitment to TCI!

Thursday, September 17, 2015

Back Ionization

Back Ionization is when powder layers start being repelled from the part during application and is primarily caused when the part has reached its saturation point, which prevents any more powder from being deposited on the substrate.

Back ionization results in improper surface coating, which leads to a coating that is not suitable for corrosion protection. It also causes an “orange peel” type texture on the part, an undesirable look in most scenarios. The back ionization effect is more typical when applying a second coat on a part, but can also happen when applying first coats. Back ionization is also known as starring or starburst effect.

How to avoid back ionization:
  • Lower voltage settings
  • Optimizing distance between the gun and coating surface
  • Check the grounding.

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

Tuesday, September 15, 2015

Press Release: TCI Powder Coatings Appoints Steve R. Jones to Architectural & Building Products Segment Manager

(Ellaville, GA, September 15, 2015) TCI Powder Coatings, a proud subsidiary of RPM International Inc. (NYSE: RPM), is pleased to announce the appointment of Steve Jones to the new position of Architectural & Building Products Segment Manager.  Steve Joined TCI in 2011 and has held several different positions over the last 5 years, most recently as the Director of National Markets.  Tom Whalen, Director of Marketing and Segment Strategy, said, “Steve’s extensive experience in the coatings industry and work in the architectural and building products segment will provide us with the required leadership to become the recognized industry powder coatings leader.”

In this new role, Steve will develop and implement new strategies for the architectural and building products (ABP) segment, actively work with TCI’s regional commercial team members to maintain and grow the strategic multi-location/geographical accounts, maintain and drive approvals within the industry, develop relationships and position TCI with key architects and engineers, and be an active member in the various industry associations throughout the Americas. Steve comments, “I am very excited to start this new challenge within TCI Powder Coatings and look forward to working with the ABP team to further develop their already extensive products and services. I am fortunate to be working at such a well respected company that prides itself on world class quality products and service.”

Steve’s appointment is a sign of TCI Powder Coatings’ commitment to being a leading company in the coatings industry. TCI is confident that Steve will play a key role in providing and implementing high quality solutions for ABP customers.

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 and by following RPM on Twitter at

Click here to read the press release on our website.

Thursday, September 10, 2015

Who Says Appliances Have To Be Boring?

There are innumerable everyday uses for powder coatings, and as with everything people want choices. 

The appliance industry is another market where powder coatings are seeing fast growth.  Powder coatings provide both protective and decorative finishes for appliances offering both security and luxury. 

Appliances benefit from the decorative aspects of powder coatings on the front and side panels, as well as the protective functions of powder coatings needed for dryer drums, air conditioner cabinets, water heaters, dishwasher racks, and cavities of microwave ovens. 

Appliances are often overlooked but are an essential part of everyday life.  In this design-conscious time, customers are just as interested in aesthetics as they are in functionality.

Contact us today to speak with our experienced team about how we can help you with your powder coating needs.

Tuesday, September 8, 2015

RPM and TCI Relationship: Industrial Products

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 industrial brands are equally well recognized and regarded in the markets they serve. They are sold worldwide to contractors, distributors and directly to end-users, such as manufacturers, public institutions, and other commercial customers.

Product Categories Include:
  • Construction sealants and chemicals
  • Roofing systems
  • Flooring systems
  • Corrosion control coatings
  • Exterior insulating finishes
  • Fluorescent pigments
  • Fiberglass reinforced gratings
  • Waterproofing and concrete repair
  • Powder coatings

Market Leadership Subsidiaries

  • Tremco: No. 1 in the North American high-end institutional roofing market and No. 2 in the North American sealants market 
  • Stonhard: No. 1 global supplier of industrial, high-performance polymer flooring systems  
  • Carboline: No. 1 U.S. supplier and a leading global supplier of industrial, high-performance corrosion control coatings  
  • Day-Glo: No. 1 in the supply of daylight fluorescent color
  • Dryvit: No. 1 North American supplier of exterior insulation and finish systems
  • Mohawk: No. 1 market share position in North America for professional touch-up and repair products for furniture and cabinetry
  • Pettit: Global market leader in water-based antifouling paints for the marine industry
  • Tremco illbruck: Leading European supplier of high-performance sealants and window and door installation systems for the construction industry 

*Rankings based on market share

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

Tuesday, September 1, 2015

Honoring Deacon Edward Hicks

It is with great sadness that we inform you of the passing of Deacon Edward Hicks in July. Edward was a valued member of our team having worked for TCI for 20 years, and he will be missed.

As a Bonding Operator Supervisor at TCI, Edward was a wonderful employee who understood the meaning of the word "team." He was always more focused on the good of the company and the department than on his own benefit. He made many great contributions to TCI and helped it move forward in numerous ways. His work here will not soon be forgotten.

The deep admiration and respect Edward had from his colleagues shines through in the following words from his co-workers and friends:

“Edward was the best boss a person could ever have.  He made sure I was taken care of.  I shall miss him.  He was just Edward, a friend indeed.  He taught me a lot.”  Beverlyn Luckerson

“Edward Hicks loved his job.  He loved the people he worked with.  He truly thought of everyone here as family.  That being said, he took his job VERY seriously.  If something went wrong in his department, he took it very personal.  He felt everything that went on there, reflected on him, not just TCI. 

On a personal note, Edward was a Christian, first and foremost, and an extremely proud father to his son, Josh.  He was a true friend of mine, in every sense of the word.  He cared for others, genuinely.  He always wanted to know how others were doing, and how their children/family was.  Edward is and will continue to truly be missed.”  Kricket M. Barineau – HR/Payroll/Benefits

“Edward set an example for all of us during his time here as he clearly tried to make each day of his 20 years count.   He cared for our business, our customers, and our employees and continually sought improvements.  I am not sure what else you could ask of an employee.”  Sheldon Holloway VP – Product Development

“Best way to describe Edward……  Most loving gentle giant with a huge smile.”  Tina Bennett – Accounting/Accounts Receivable

“Edward was an employee who always put TCI first. He always tried to excel in what he was doing, and asked for the same from the employees under his supervision.  He took pride in his departments efficiency and appearance.  I do not think we will ever replace Edwards’s drive and hard work, and certainly not his personality.   Edward had a distinctive laugh and a quick smile, and would always give his time no matter what.  His presence has been and will continue to be missed.”  Chuck Pless – EHS Manager

“Edward always greeted everyone he met with a smile.  He was always in search of any extra snacks or sweet tea anyone could send his way.  He lived by the golden rule and knew that this was only a temporary stop and that by living a Christian life he was building his heavenly home.”  Wanda Burke – Production Planner

Edward Hicks was a remarkable man and everyone at TCI is better for having known him.

To read Edward’s obituary and more about his life outside of work click below.