TCI Powder Coatings Blog

Faraday in Your Way? Problem: Everything is running smoothly when you notice that some of the powder will not penetrate a faraday cage (inside corner or complex area that acts like an electrical screen that stops charged particles).   Origin: This faraday cage may be due to the powder delivery rate being too low for an adequate amount of coverage. Solution: Increase the powder delivery rate and airflow and adjust the spray gun position to gain sufficient powder coverage. Second Origin: It’s possible that during application, the air velocity was too high, and the powder is blowing out of corners. Solution: Try adjusting and optimizing the spray gun positioning and reducing the air flow rates. Third Origin: The problem could be that the high voltage is creating a strong magnetic field, obstructing the penetration. Solution: Reduce voltage to the electrical field that is currently limiting the penetration. Fourth Origin: The part is not grounded enough for powder to penetra...

Lack of Charging and Insufficient Film Buildup (Continued) Problem: Struggling with inadequate film coverage due to poor charging? There are several reasons this could be happening. We’ve expanded on our checklist for you to figure out the true cause and solution of your charging and coverage problem   Origin: There may be excessive moisture or oil in the air supply, in the fluidized bed, and/or within the powder booth.   Solution: The humid air acts as an antistat (lessens or prevents accumulation of static electricity). Monitor and control the humidity in the booth and in the air supply.   Second Origin: Excessive moisture in the powder coating could be preventing the powder from building up efficiently.   Solution: The moisture sometimes acts as an antistat as well. Store the powder in a controlled, dry environment.   Third Origin: It’s possible that the powder coating contains higher concentrations of small-sized particles. Solution:...

Lack of Charging and Insufficient Film Buildup Problem: Struggling with inadequate film coverage due to poor charging? There are several reasons this could be happening. We’ve formed a simple list for you to figure out the true cause and solution of your charging and coverage problem. Origin: The powder delivery rate is too high, resulting in inadequately charged powder. Solution: Reduce the powder delivery rate until the powder is appropriately charged. Also, make sure the spray gun is positioned correctly. Second Origin: Voltage to the charging electrode is too low. Solution: Assess the electrical continuity throughout the electrostatic system. Clean or repair the voltage-limiting components. Third Origin: The part is not grounded enough for the film to build. Solution: Check any contact areas to ensure that there is no buildup of cured powder coating, grease, or any other insulating material that could impede the ground. Fourth Origin...

We are pleased to announce Rodney Usry’s promotion to Quality Assurance Manager! He will play a key role in our effort to ensure continuous improvement throughout our business and in becoming the premium brand in powder coatings. In his new role, Rodney will review all products manufactured for compliance with specifications, manage customer complaints, and collaborate with co-workers to conduct weekly reviews of all open compliant issues and assure proper technical and management focus on solutions. Additionally, Rodney will complete documentation of issues identified and communicate analysis and solutions to the customer, field reps, and the TCI internal team. Eventually, he will work with the Quality Director (a new position to be filled) to fully acclimate the individual to TCI processes while promoting long-term commitment to continuous improvement. Rodney is a 20-year veteran of TCI with intimate knowledge of product formulations and processes. His driven nature helps hi...

Problems with Cured Coating Cohesion Problem: Have you been noticing less than desirable cohesion when curing powder-coated parts? Little or no cohesion on a cured part can stem from multiple origins. We're here to help you fix this mishap and maintain optimal curing results. Origin: The phosphate coating weight is too low, usually due to the wrong temperature or amount of time. Solution: In order to increase the weight of the coating, increase the phosphate or accelerator concentration. If this fails to work, increase both of these concentrations. Additionally, increase the process, time, and temperature . Second Origin: Adversely, the phosphate coating weight could be too high. Solution: Reduce the concentrations, time, or temperature of the process. Third Origin: Potentially, leftover surfactants and soils remain, limiting phosphate disposition.   Solution: Adjust the cleaning and rinse stages. Be sure to orient the parts for maximum coverage, and clean and adjust th...

On April 14 th , The Architectural Segment Leader of TCI, Steve Jones, presented at the Powder Coating Technical Conference, sponsored by the Powder Coating Institute. The technical conference was held at the Georgia International Convention Center in Atlanta, Georgia from April 11 th -14 th , 2016. Jones presented a technical session called  Everything You Wanted to Know About Architectural Powder Coatings. During this session, he spoke of the best architectural coating applications, performance testing techniques, coating chemistries, and shared information on warranties. The annual Powder Coating Technical Conference gives powder coaters and end users forums to connect and communicate about technology as well as new inventions and ideas. The conference is a place for those within the industry to talk about the newest changes and developments for powder coating technology and how to improve business. More on the Powder Coating Technical Conference can ...

Adhesion Confusion Problem: You notice little or no adhesion on the cured powder coating part. Origin: The phosphate coating weight could be too low. Solution: Increase the phosphate and/or accelerator concentration, process time, and temperature. Second Origin: In contrast, the phosphate coating weight could be too high. Solution: Decrease the phosphate and/or accelerator concentration and process time. Third Origin: Surfactants and soils stuck around, limiting phosphate disposition. Solution: Adjust the cleaning and rinse stages, orient the parts for maximum exposure, clean and adjust the spray nozzles, and, as always, maintain high rinse tank water purity. Fourth Origin: There are unidentified soils that remain in the metal and/or the process. Solution: Check to make sure that all metal and process soils have been identified. For additional information on powder coatings, visit our website at tcipowder.com . Feel free to Contact us today to have som...

The Solution to Foaming Solutions   Problem: The solutions are foaming and you don’t understand why. Origin: The stage temperature is too low. Solution: Increase the stage temperature. Second Origin: The line pressures are too high. Solution: Check for plugged nozzles and adjust the pressure if necessary. Third Origin: Air is somehow being introduced. Solution: Check the water levels and pumps for any leaks. Fourth Origin: Somewhere along the line there was an improper chemical selection. Solution: In order to control excessive foaming, select foaming characteristics that match the agitation and pressure levels. For additional information on powder coatings, visit our website at tcipowder.com . Feel free to Contact us today to have someone from our experienced team answer your powder coating questions or to see how we can help you with your powder coating needs.

Rusting Powder Coating Parts Problem: You take a look at your powder coated parts and, uh-oh! They’re rusting. Origin: The phosphate coating weights are too low. Solution: Adjust the processing conditions, which includes increasing the temperature or lengthening the time. In addition, increase the phosphate and/or accelerator concentration. Second Origin: Soils and surfactants are still remaining on the parts, limiting the disposition of phosphates. Solution: First, adjust the clean and rinse stages. Check to make sure both the parts and the spray nozzles are adjusted for the maximum amount of coverage. Additionally, remember to maintain high rinse tank purity. Third Origin: Dry off is occurring between stages. Solution: Provide sufficient time for adequate drainage, but not so long that dry off occurs between stages. Reduce the temperatures and utilize the fog nozzles. Also, adjust these nozzles for maximum coverage. Fourth Origin: ...

TCI Powder Coatings is pleased to announce that Steve Brattoli has been promoted to Senior Field Service Technician.  He currently provides service to Eastern and Central Michigan, Ohio, Western Pennsylvania, Fort Wayne, Indiana, and Canada. New England states have just been added to his reach as well. As a valued asset within the TCI organization in supporting core business as well as offering his expertise in new business development and growth within his territory, Steve is expected to excel greatly in this new position. Steve has been involved in the powder coating industry for 28 years and credits his success to his past and current customers and their needs. What drives Steve the most is the ability to have a positive influence on customers and help them to improve their existing process. He believes that this ability is also a distinguishing factor of TCI Powder Coatings when compared to its competitors. Steve loves “providing the customer with hands-on training to make t...

Unwanted Powder Left on the Surface Problem: There is a powder on the surface of the phosphate-coated part. What do I do to keep this leftover powder from sticking (or not sticking ) around? Origin/ Cause: First, check and see if the parts are fully rinsed or if the rinse is contaminated. If neither of these are the primary problem, check to see if sludge is being transferred. If these three causes do not seem to be the problem, check to see if the accelerator concentration is too high. Solution: If the parts are not fully rinsed or the rinse itself is causing the contamination, orient the parts for maximum coverage. Then, clean and adjust spray nozzles for maximum coverage and maintain high rinse tank purity. If sludge is causing the problem, precipitate and filter the sludge from the cleaning stage. Lastly, if the accelerator concentration is too high, simply reduce it.   For additional information on...