Powder Coating - the finish that protects your Delmade every day
Aug 31, 2023 Posted by Brittany Cunningham
All Delmade equipment is manufactured in Tasmania and finished by Powder Coating which involves a three-process treatment, abrasive blasting, zinc undercoat and coloured topcoat. Our facilities are world-class and state of the art. To ensure quality is maintained a strict quality control process is in place. This procedure includes temperature control, data logging for oven temperature, material thickness tests and visual checks before it leaves the factory.
The Facility
The finishing process for our Delmade equipment takes place in our purpose-built Finishing Factory located adjacent to our Fabrication Factory. Run by a skilled team including blasters and applicators. The 504 m2 facility built by local construction firm Bison houses an Industrial Oven and two Powder Bays, a dust extractor, a large Blasting Room complete with a garnet reclamation unit and an underfloor conveyor plus other critical equipment including powder guns, a paint booth, compressors and a gas burner.
The industrial batching oven by Garnic Technologies is the centrepiece of the operation. The oven set up features two powder rooms that directly feed into the oven using a roof railing system capable of handling in excess of 5 Tonne per zone. This setup is designed for optimal efficiency allowing for three batches to process at any one time. The batching oven is in a controlled fully sealed environment which allows it to reach heat in excess of 200°C without affecting the outside environment. The oven is also built wide and high to accommodate large and uniquely shaped equipment ideal for large products like the Delmade Offset Discs and Rut Fillers.
The facility also houses a Garnet Blasting Room. The inside chamber is fully sealed and fresh air is delivered through a dust collection and ventilation system which keeps dust levels low and clear the room of dust after blasting is finished. The underfloor reclamation conveyor takes care of used garnet ensuring that the facility is environmentally friendly.
The Process
Achieving a quality Powder Coat finish involves a three-step process and at each step certain checks and balances must be undertaken to ensure quality standards are maintained. Delmade prides itself on the quality of the finish on our equipment in fact that is why we are proud to offer powder coating as a service under a branded offering Tas Powder Coating!
Step 1: Abrasive Blasting
📷 Photo1: www.blastone.com.au
Abrasive blasting removes the surface rust and mill scale from the steel providing a clean surface in preparation for the primer and then topcoat.
Delmade uses a mesh garnet which is ideal for sandblasting new steel. The garnet is a pinkish colour and is formed from naturally occurring minerals that are safe to use and handle. Typically the sandblasting plant running at full capacity (2 persons) would consume 500kg of garnet per hour which will provide roughly 40m2 to 50m2 of prepared surface area.
After sandblasting, metals are extremely porous and must be stored in a controlled environment where they are not exposed to moisture or the oils that can be found on human skin. The metal will be treated as soon as possible with a Zinc undercoat for corrosion prevention.
Step 2: Priming
A zinc powder protects the metal by improving corrosion resistance. The powder primer known as "Zincshield® is a zinc-rich epoxy modified thermosetting powder primer designed to inhibit rust and subsequent adhesion loss on ferrous metals"2. The primer features "improved corrosion resistance and durability, film integrity, no solvents or emissions and provides a sacrificial layer increasing service life"3. After applying the primer it is recommended that the topcoat is applied within 12 hours.
Step 3: Topcoat
The colour topcoat is applied electrostatically and then cured under heat. This results in a dense finish that is more durable than conventional painting.
OptiFlex® Pro manual guns are used to apply the colour topcoat. These units feature a built-in hopper and distribute the enamel powder with ease. The guns have a complex arrangement of nozzles and settings to allow for a quality application even on the most challenging of items. Featuring a power clean for fast colour changes the guns allow our operators to switch between colours without the risk of colour mixing and can be set to flat spray, round spray and angle spray depending on the job at hand.
In the Paddock
After the topcoat has been applied and cured the items pass through quality control where they are measured against various AUS (Australian Standards) for blasting profile, the thickness of the powder coat and visual quality, completed items are then sent back to the Fabrication Factory for final assembly and pre-delivery checks, from there they are shipped to farms across Australia ready for a life shaping the land!
The team at Delmade would be happy to answer questions you may have please call 1800 335 623.
Credits to the following references