“Bad paint”, as a cause of poor coverage, accounts for only about 10% of all cases. Everything else, most often – human error in the workplace. This can be non-compliance with painting standards, as well as improper use of appliances, equipment failure, worker fatigue and simple coincidence. No one can cancel the human factor. Even though most of the processes today are automated, only a foreman can accurately note the equipment and do proper preparation of the workplace.<\/p>\n\n\n\n
Powder paint was created to facilitate human work. Also, special attention was paid to the density and durability of the paint, which is better than other paints. One of the no less important points is the reduction of costs by the method of process automation and staff reduction. But did it play into your hands? Often we are convinced of something else. Where one will not see – others will see, but in the process of automated painting lines all the responsibility falls on the reduced number of employees. Their mistakes are just their mistakes. Therefore, any negligence can affect the production of a low-quality batch of products, or even provoke dangerous situations in the production.<\/p>\n\n\n\n
The first thing one should to keep in mind when creating an entire painting shop is labor protection and safety of workers.<\/p>\n\n\n\n
Everyone notes the environmental friendliness of powder paint. But, as in the case of any chemical, it will be useful to take care of additional protection (in the spray chamber, in the polymerization furnace until the paint hardens). After all, the same allergy, for example, no one has canceled. Workers must be provided with personal protective equipment and only start working fully equipped.<\/p>\n\n\n\n
The process of organizing the work should be clearly defined. From the moment of entering the industrial shop, to the exit from it. Workers must follow clear instructions, as they work with large metal structures and automatic conveyors.<\/p>\n\n\n\n
Everyone is convinced that dyeing is the easiest process in the production of any product. Much easier than forging and melting iron. But few people remember that the process of creating a polymer coating can also be dangerous if you do not follow all the rules. Powder still belongs to a certain category of substances in contact with which the worker must take measures for his own protection. Fire and explosion situations are possible, so first you need to think about safety and organize everything in such a way as to prevent accidents.<\/p>\n\n\n\n
So, any errors on the powder coating line have two root problems: the human factor and the technical factor. Namely – errors of workers, or malfunction of the equipment.<\/p>\n\n\n\n
If the worker is skilled, well aware of his job, safety, regulations for the creation of the coating and clearly adheres to it – no problems will harm his health. However, his responsibilities also include monitoring the condition of the equipment.<\/p>\n\n\n\n
It’s about metal fatigue. Every element of construction, every detail, equipment – all this has its own shelf life. As the equipment is in constant operation, it is subject to wear processes. Even if the equipment is made of heavy-duty materials, sooner or later it will still lose its original qualities. That is why workers must clearly check the serviceability, replace the weakened elements of the whole mechanism. Clearly note any deviations from the norm. It is advised to keep an accounting journal in the shops, in which all the nuances of the operation of the equipment will be replaced. This will allow you to track faults faster. Of course, automatic systems are equipped with introspection, but usually they can report violations in the system, rather than the breakdown of a certain area, the bending of the suspension to which the part is attached, etc.<\/p>\n\n\n\n
Despite the above causes of problems with powder paint, there are still a number of mistakes that workers make by neglecting their pickiness of certain processes.<\/p>\n\n\n\n
Often staff forget how important it is to clearly check the degree of grounding. It provides first and foremost safety for the worker. The voltage from the product and the suspension will not spread through the spray chamber and will never encounter paint loading processes. It is output through a grounding device. There are clear standards for verification. The earth resistance must not exceed 1 M\u03a9. Otherwise, an electric shock or even a fire in the workplace is possible.<\/p>\n\n\n\n
Even the highest quality paint can deteriorate in unsuitable storage conditions. It is ideal to leave it in a dry, windless and cool room. If the temperature is high, there is a possibility of partial melting and sticking of paint particles together. It is also not necessary to layer the containers with paint in several layers on top of each other, because the ones under pressure can spoil. The so-called laying effect. As a rule, such a powder is easy to restore by sieving, but it is no longer possible to be 100% sure of its quality. Humidity in warehouses is taboo. It will damage both the storage tanks and the paint itself.<\/p>\n\n\n\n
The same applies to working conditions with powder paint. It should be remembered that the paint is very vulnerable to atmospheric factors, such as humidity, temperature changes, insufficient filtration of indoor air. All these points are important on everyone at a stage of drawing paint both for safety of workers, and for creation of a covering without defects. Therefore, staff should carefully check all hoods, control the temperature and humidity in the room.<\/p>\n\n\n\n
A skilled worker must know exactly what air supply pressure needs to be set on the sprayer, how many minutes it is enough to immerse the part in solvents, how to adjust the temperature for a particular type of paint. Each batch of paint requires a special approach. Do not think that you can configure the equipment once and it will last forever. Even if you are constantly working with the same paint and product, the equipment has a tendency to weaken its actions. Again, it’s worth remembering about fatigue. Therefore control and correct adjustment!<\/p>\n\n\n\n
And the stupidest mistake is to assume that paints can be mixed. Unfortunately, powder paints do not change color as easily as liquid. We can’t change the texture or shade right away by just mixing another paint. Each of them has its own properties. Each particle of paint has its own special value. And the batch of paint is adjusted to it. Another – even the same manufacturer – may simply not match. This will cause some particles to be better electrified and melt faster than others – meaning defects are inevitable.<\/p>\n\n\n\n
How many years has a powder coating been created. And how long do we prove that there is no more functional coating than powder. Many different technologies for applying different textures and colors have already been created. And each is accompanied by clear instructions for use. Defects do not arise out of nowhere, problems do not arise by themselves. You just need to keep a close eye on the processes, keep records and be qualified in your business.<\/p>\n\n\n\n
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