Powder Coating Robot

Development Trends of Jerrys Intelligent Robotic Powder Coating Equipment

JERRYS ROBOT

II. Energy Advantages of Powder Coating:

(1) Excellent Environmental Friendliness

"Three wastes" pollution has become a global issue, with solvent-based coating pollution of the atmosphere drawing widespread attention from various countries. Restrictions on VOC emissions from automotive coatings are becoming increasingly stringent.

Driven by strict environmental regulations, powder coatings, like other green coatings, have been rapidly promoted and used worldwide. Traditional liquid spraying processes can reduce VOC emissions by increasing energy consumption.

In contrast, automotive body powder coating achieves zero VOC emissions, produces minimal and non-toxic waste, and does not require exhaust gas combustion chambers or other methods to treat tail gases generated during the curing process.

With the development of powder coating technology, the application fields of powder coatings will continue to expand, and their proportion in industrial coatings will also increase. Therefore, powder coatings will be one of the fastest-growing varieties in terms of production volume.

(2) Simple Process, Small Footprint, and Recyclable Coating

The space required for powder coating is typically smaller than that for traditional liquid coatings, reducing the footprint of the spray booth.

Since there are no coating defects such as sagging or bubbling that may occur during traditional liquid coating processes, powder coating operations are also easier.

Additionally, due to the electrostatic spraying method, powder coating can achieve a thickness of 40–50 μm in a single application, improving coating efficiency. Powder coatings are recyclable, and powder coating equipment is easy to maintain and clean, reducing downtime and labor requirements.

(3) Energy Savings

Powder coating requires less energy than liquid coating systems. Powder coating spray booths can maintain a closed-loop air circulation system, significantly reducing the energy consumption required for operation.

Although the curing temperature for powder coating is higher, the substantial energy savings from the spray booth offset this. Some OEMs estimate that the energy consumption of powder coating spray booths is 80% lower than that of liquid coating spray booths of the same scale.

Another major reason for energy savings is the elimination of exhaust gas treatment. It is estimated that the electricity and natural gas required for powder coating are only one-third to one-half of that for traditional liquid coating.

In 2005, Jeffery Johnson of Haden Company compared the coating equipment and production costs of powder coatings, water-based coatings, and solvent-based coating systems for automotive body primers.

It was estimated that, compared to solvent-based coating, powder coating could save €2.50 per vehicle, while compared to water-based coating, it could save €6.30. This indicates that the production cost of powder coating is 38% lower than that of water-based coating and 10% lower than that of solvent-based coating.

(4) Improved Coating Quality

Powder coatings possess excellent properties and provide high-quality protective performance, enabling them to replace one or more layers in traditional liquid coating systems.

For example, liquid coatings (base coat + clear coat) used on wheels and many exterior body parts have been replaced by powder coatings.

Additionally, powder coating can achieve appearance qualities that liquid coating cannot. Using powder coating allows manufacturers to produce unique, difficult-to-replicate colors and effects, contributing to innovation in vehicle styling design.

(5) Improved Working Environment for Operators

Workers are satisfied with using powder coatings. The system is odorless and significantly reduces the need for protective equipment. The spraying equipment is easy to use, clean, and maintain, and this ease of operation can reduce the training time for operators.