Powder Coated Timber in the Construction Industry

​Powder Coated Timber in the Construction Industry

Powder Coated Timber in the Construction Industry
Powder Coated Timber Case Study

“Having the world leading industrial IR process heating guys on board from the outset was an inspired choice on our part. Their in-depth knowledge and experience was key in enabling the Climate Coating Ltd concept to become a reality”

Kyle True (MD Climate Coating Ltd [climatesurfaces.com])


“Having the world leading industrial IR process heating guys on board from the outset was an inspired choice on our part. Their in-depth knowledge and experience was key in enabling the Climate Coating Ltd concept to become a reality” Kyle True (MD Climate Coating Ltd [climatesurfaces.com])
https://catalyticovens.com/heraeus-assists-metsa-improve-output-quality-reduce-operating-costs

How Gas Catalytic IR technology from Heraeus has enabled a unique breakthrough in the construction industry

Powder Coated Timber Case Study. It is often said that brilliant ideas are 1% inspiration and 99% perspiration. Jeff Stewart, co-founder of Climate Coating Ltd, found his 1% whilst watching a large wooden wall being painted single handed by a weary decorator. If it were a steel section wall, Jeff would have powder coated it, so why not try powder coating timber to see if it worked? Then the 99% perspiration kicked in and Jeff joined up with Kyle True from the timber industry, and the rest, together with ground breaking technology from Heraeus (formerly Vulcan Catalytic Systems) is history.

Substrate Heat ​Sensitivity

One of the primary problems with powder coating a timber substrate is its heat sensitivity. The time required to cure powder in a conventional hot air oven (20 – 30 minutes) would cause significant damage to the timber. The creative solution was to use Gas Catalytic IR. The IR waves are easily absorbed by the powder which will now cure (7 – 10 minutes), without overheating the substrate. The result is a patented process that is having a big impact in the construction industry. As the world population continues to increase, the need for sustainable, low waste, energy efficient commercial and residential buildings has become a necessity. The founders of Climate Coating Ltd. in New Zealand have pioneered and patented innovative methods of creating powder coated surfaces on plywood, MDF and plasterboard. The majority of these products can be fitted without any further finishing requirements and are available pre-cut to size and in many colors. They include:

  • Pre-coated plasterboard for walls and ceilings
  • Decorative MDF board for commercial fit-out
  • Moisture resistant exterior grade plywood
  • Pre-primed exterior finishes that do not need to be finished for up to 3 months

​So how do Climate Coating Ltd.’s products contribute to the drive for sustainability? The answer is multi layered and is evidenced not just by the product itself and its place in the market, but also by the innovative, energy efficient method of manufacture.


Product Advantages

The advantages of pre-finished products themselves are self-evident. By creating pre-finished and pre-sized materials that are commonly found in every type of construction, the reduced need for wet trades (brick laying, plastering and painting) has a significant impact on building lead time. Delays due to weather, material supply and waste are all but eliminated. Consider the number of half used tins of paint and wasted bags of plaster that are commonly seen on building sites! The products are also ideal for the pre-fabricated building industry.
Manufacturing Advantages

Dig down deeper, and further very significant advantages can be discovered. As Climate Coating Ltd pre-finish the board materials in a purpose built factory, the efficiencies of having a precisely controlled process means that waste is virtually eliminated and a consistent level of quality control is achieved which far surpasses that which can be accomplished “on site”. One of the vital elements of the production system is the use of Gas Catalytic IR ovens to efficiently cure the applied powder on the chosen substrate. The system, designed in conjunction with world leaders Heraeus (formerly Vulcan Catalytic Systems) has proven to be a wise choice. The systems produced by Heraeus have proven to be the most controllable, energy efficient powder coat curing solutions available today. The powder curing system details are as follows:

  • Two coat system
  • 2 PLC controlled Gas Catalytic ovens (2 section preheat and 5 section main cure)
  • 3000m2 per hour output
  • Space saving design has small footprint
  • Programmable to control the heat output horizontally and vertically through the oven
  • Perfect cure obtained by using only the exact amount of required Infra-Red.

Key Product Points

  • Sustainable, no VOC’s produced in manufacture
  • Extremely high level of quality control that is unachievable “on site”
  • On site wet trades eliminated
  • Ideal for pre-fabricated buildings

Key Gas Catalytic IR powder curing points

  • Measurable and consistent process
  • Highly controllable (PLC) and adaptable
  • High quality finish
  • Energy efficient process
  • Small footprint
How Gas Catalytic IR technology from Heraeus has enabled a unique breakthrough in the construction industry

Powder Coated Timber It is often said that brilliant ideas are 1% inspiration and 99% perspiration. Jeff Stewart, co-founder of Climate Coating Ltd, found his 1% whilst watching a large wooden wall being painted single handed by a weary decorator. If it were a steel section wall, Jeff would have powder coated it, so why not try powder coating timber to see if it worked? Then the 99% perspiration kicked in and Jeff joined up with Kyle True from the timber industry, and the rest, together with ground breaking technology from Heraeus (formerly Vulcan Catalytic Systems) is history. One of the primary problems with powder coating a timber substrate is its heat sensitivity. The time required to cure powder in a conventional hot air oven (20 – 30 minutes) would cause significant damage to the timber. The creative solution was to use Gas Catalytic IR. The IR waves are easily absorbed by the powder which will now cure (7 – 10 minutes), without overheating the substrate. The result is a patented process that is having a big impact in the construction industry. As the world population continues to increase, the need for sustainable, low waste, energy efficient commercial and residential buildings has become a necessity. The founders of Climate Coating Ltd. in New Zealand have pioneered and patented innovative methods of creating powder coated surfaces on plywood, MDF and plasterboard. The majority of these products can be fitted without any further finishing requirements and are available pre-cut to size and in many colours. They include:

Pre coated plasterboard for walls and ceilings
Decorative MDF board for commercial fit-out
Moisture resistant exterior grade plywood
Pre primed exterior finishes that do not need to be finished for up to 3 months

So how do Climate Coating Ltd.’s products contribute to the drive for sustainability? The answer is multi layered and is evidenced not just by the product itself and its place in the market, but also by the innovative, energy efficient method of manufacture.
Product Advantages

The advantages of pre-finished products themselves are self-evident. By creating pre-finished and pre-sized materials that are commonly found in every type of construction, the reduced need for wet trades (brick laying, plastering and painting) has a significant impact on building lead time. Delays due to weather, material supply and waste are all but eliminated. Consider the number of half used tins of paint and wasted bags of plaster that are commonly seen on building sites! The products are also ideal for the pre-fabricated building industry.
Manufacturing Advantages

Dig down deeper, and further very significant advantages can be discovered. As Climate Coating Ltd pre-finish the board materials in a purpose built factory, the efficiencies of having a precisely controlled process means that waste is virtually eliminated and a consistent level of quality control is achieved which far surpasses that which can be accomplished “on site”. One of the vital elements of the production system is the use of Gas Catalytic IR ovens to efficiently cure the applied powder on the chosen substrate. The system, designed in conjunction with world leaders Heraeus (formerly Vulcan Catalytic Systems) has proven to be a wise choice. The systems produced by Heraeus have proven to be the most controllable, energy efficient powder coat curing solutions available today. The powder curing system details are as follows:

Two coat system
2 PLC controlled Gas Catalytic ovens (2 section preheat and 5 section main cure)
3000m2 per hour output
Space saving design has small footprint
Programmable to control the heat output horizontally and vertically through the oven
Perfect cure obtained by using only the exact amount of required Infra-Red.

What Climate Coating Ltd say about Heraeus:

Key Product Points

Sustainable, no VOC’s produced in manufacture
Extremely high level of quality control that is unachievable “on site”
On site wet trades eliminated
Ideal for pre-fabricated buildings

Key Gas Catalytic IR powder curing points

Measurable and consistent process
Highly controllable (PLC) and adaptable
High quality finish
Energy efficient process
Small footprint

Gas Catalytic Heaters Provide Quicker and Better Finish on Boats

​Gas Catalytic Heaters Provide Quicker & Better Finish on Boats

Liquid Finish On Boats - Gas Catalytic IR Heater Case study

“​The new system allows me to complete a job in a fraction of the time and provide a top class finish for my customers.”

​Jorge Borges - Owner International Marine Composites

https://catalyticovens.com/heraeus-assists-metsa-improve-output-quality-reduce-operating-costs

Liquid Finish On Boats - Gas Catalytic IR Heater Case study. The International Marine Composites company in Bristol, Rhode Island, USA is at the center of the vibrant East Coast yachting industry. The ability to complete a wide range of boat repairs, and paint refinishing is key to the company’s success. Generally, the marine industry relies upon wet finishing systems which usually comprise a wet epoxy primer underneath a two part polyurethane finish which gives the desired hull colour. Further protection to the high gloss finish can be provided by an extra two part polyurethane clear coat.

Multipurpose boat sheds tend to be big, cold and dusty which makes high gloss finishing difficult to achieve. The cold atmosphere can cause an “orange peel” effect on the finished paint, so the generally accepted method of heating the shed is to use a hot air circulation system, prior to wet spraying. Unfortunately the air movement causes dust to become airborne which can then land on the newly painted surface. Curing of each coat can take up to 24 hours, which means that a simple paint job can take 3 – 4 days.
 Jorge Borges, owner of International Marine Composites approached Heraeus Vulcan (formerly Vulcan Catalytic Systems) for help in speeding up the complete process, and improving the finish on completed boats. Our engineers quickly determined that 30 minutes of​ Gas Catalytic Heat​​​could be used to pre-heat the boat hull prior to the wet spraying of the epoxy primer. This was then followed by a further 20 minutes of IR heat. Heaters were arranged on a movable and easily adjustable framework, which can be positioned up to 2.5m away from the boat hull. By using this method there was no unnecessary air movement and a tack free and dust free primer could be achieved and cured very quickly. Previously, the epoxy primer coat required 24 hours of cure time before it could be rubbed down. With Gas Catalytic heaters, this can take place after just 6 hours. The same process can be repeated when applying the polyurethane paint and clear coat.
 The end result is a boat hull which finish which meets proud owners expectations of a high gloss finish with no imperfections. The added advantage is that Jorge can complete a simple paint job in a day.

Key improvements by switching to Catalytic Heaters

  •   Quicker job completion
  •   Improved gloss finish
  •   Flexible system
  •   Safe to use in hazardous environment
  •   30 % operating cost saving

Energy Efficient Powder Coating System - Case Study

Energy Efficient Powder Coating Oven

Energy Efficient Powder Coating System - Case Study

Energy Efficient Powder Coating System - Case Study

“It used to take 70 minutes to cure our parts with the old convection oven. With the new Heraeus Vulcan oven, it now takes only 12 minutes! We are very satisfied with its performance!"

Mr Weikert - Company Owner

https://catalyticovens.com/heraeus-assists-metsa-improve-output-quality-reduce-operating-costs

Large Parts Curing in Record Time in Energy Efficient Powder Coating System

Working with our distributor in the Czech Republic, Surfin s.r.o, Heraeus Vulcan designed a new energy efficient powder coating system for Dikrt spol. s r.o. . The system is designed to cure powder on large agricultural parts, and the performance of the oven has exceeded expectation. Mr Weikert, the company's owner stated: "It used to take 70 minutes to cure our parts with the old convection oven. With the new Vulcan oven, it now takes only 12 minutes! We are very satisfied with its performance!"

How Did We Do It?

Working with our distributor in the Czech Republic, Jaroslav Blazek of Surfin s.r.o., the customer was able to see an existing Heraeus Vulcan system at another location and carry out part testing. Heraeus Vulcan then designed the powder coating oven to meet the customer's requirements using SolidWorks. Heraeus Vulcan then provided Surfin s.r.o with a package that included the sheet metal design, the Heraeus Vulcan infrared heaters and the controls. To see a video on how Heraeus Vulcan designs and builds ovens, please follow the link. The system was then easily constructed at the Surfin factory, with the sheet metal parts being produced locally from the SolidWorks files. The new energy efficient powder coating system was then installed and commissioned at the customer's site within a few days.

Advantages of a Energy Efficient Powder Coating System from Heraeus Vulcan

All Heraeus Vulcan energy efficient powder coating systems operate using the principles of gas catalytic infrared heating. This type of system has an energy to effective heat conversion ratio of 85%, compared to traditional convection oven which is only 5% - 7% efficient. In practical operation this results in curing  taking a third less time in a gas catalytic infrared oven than a gas fired convection oven. This translates into significantly reduced energy bills. The flameless nature of our systems means that there is no noxious emissions such as Nitric Oxide or Nitrogen Dioxide, so Heraeus Vulcan ovens are environmentally friendly. 

Powder Coating Ovens - How To Choose

Powder Coating Ovens - How To Choose

https://catalyticovens.com/heraeus-assists-metsa-improve-output-quality-reduce-operating-costs

Powder Coating Choices

If your company is involved in powder coating products and parts, then you will either be subcontracting the work out, or will have your own in house powder coating oven. Alternatively, you may be thinking of moving from a liquid finish to a powder finish. Whatever your situation, the drive for cutting the cost of manufacturing is ever present, so this article will outline the various powder coating oven technologies available, to help you choose either a new system, or upgrade your existing facility.

Liquid or Powder Finish?


The move from liquid to powder is well established. The advantages of powder over liquid can be summarized as follows:

  • A powder coated finish is significantly tougher than a liquid finish.
  • Over spray losses for liquid finishes can be as much as 75%.
  • Around 80% of liquid finishes used in the USA are solvent based and present environmental issues.
  • Even aqueous based finishes still contain some solvents contained within the resin structure
  • The storage and transportation of liquid finishes requires the use of IBC’s (Intermediate Bulk Containers). These require special handling and storage techniques.
  • Overall, powder finishes represent a more cost effective way to getting a better finish.

Powder Coating Ovens - Available Technologies

Gas Fired Convection (batch or conveyor line)

Advantages

  • Least expensive capital cost
  • Suitable for complex geometry parts

Disadvantages

  • Inefficient
  • Expensive to run
  • Large floor space required
  • Due to long start up time, cannot be shut down during breaks in production
  • Produces noxious gases
  • High carbon footprint
  • Very large batch sizes required
  • Not particularly suited to heat sensitive substrates

Gas Radiant

Advantages

  • High heat intensity

Disadvantages

  • Expensive to run
  • Inefficient
  • Produces noxious gases
  • High carbon footprint
  • Not particularly suited to heat sensitive substrates

Gas Catalytic Infrared

Advantages

  • 50% less expensive to run
  • Short ROI (Return On Investment)
  • Improved quality and consistency of finish
  • No noxious gases produced
  • 50% smaller floor footprint
  • Highly controllable
  • Allows small batch sizes
  • Ideal for Lean Manufacturing
  • Proven on heat sensitive substrates

Disadvantages

  • Initial cost 50% higher than convection

Electric Infrared

Advantages

  • High heat intensity
  • Highly controllable


Disadvantages

  • Very high capital cost
  • Very high cost of running (4 x cost of gas per kW)

How To Choose?


Perhaps the most important factor to consider when purchasing a new powder coating oven, is the initial Return On Investment (ROI). Then, the long term cost of operation. Do your calculations carefully, talk to as many different operators of the different technologies as you can. It is vitally important to run trials of your products. Do not forget to factor in the ongoing "Total Cost of Quality". Lastly do not forget to consider the overall reduction in your Carbon Footprint.