Dawn Denby, Author at Production Systems

Powder Coating Reclamation Systems

A powder coating reclamation system is an essential component of a modern powder coating booth, engineered to capture and reuse oversprayed powder. During the coating process, not all powder adheres to the target part. Instead of being discarded, this excess material is efficiently collected, filtered, and reintroduced into the system—often blended with virgin powder—to maximize usage and minimize waste. How the Reclamation System Works Separating and Collecting Overspray Powder booths equipped for reclamation use cartridge collectors or high-efficiency filters to draw in air containing oversprayed powder. As the air passes through the filtration system, powder particles are trapped and deposited into a recovery bin. Advanced systems may incorporate cyclone separators alongside filters. These cyclones use centrifugal force to isolate heavier powder particles from the airstream before final filtration. The result is a cleaner work environment and a higher recovery rate of usable powder. Reconditioning and Reusing the Powder Collected powder is screened to remove impurities or contaminants. It is then blended with a calculated amount of fresh (virgin) powder to ensure consistent finish quality. The blended powder is returned to [...]

Dawn Denby2025-06-23T14:15:59-04:00June 23rd, 2025|Powder Booths|Comments Off

Unlock the Secret to Flawless Finishes: Transform Your Production with Our End-To-End Paint Booth Solutions!

In today's fast-paced manufacturing world, the difference between good and great often lies in the details. If you’re in the business of delivering high-quality finishes, then you know that an open-faced paint booth isn’t just a luxury—it’s a game changer! Here’s why investing in a state-of-the-art paint booth is essential for your operation: Seamless Workflow Our paint booths integrate every step of the finishing process, from preparation to application, ensuring a smooth and efficient operation that saves you time and money. Enhanced Quality Control With advanced technology and controlled environments, achieve flawless finishes every time. Say goodbye to imperfections and hello to consistency! Eco-Friendly Solutions Reduce waste and emissions while maintaining high-performance standards. Our paint booths conform to OSHA, NFPA, UFC and EPA regulations. They are designed with sustainability in mind, allowing you to meet regulatory demands without compromising quality. Customization at Its Best Tailor your paint booth to fit your specific needs. Whether it's size, features, or technology, we provide solutions that match your vision. Increased Productivity Streamline your finishing process and watch your output soar! A well-designed booth can [...]

Dawn Denby2025-06-23T13:18:27-04:00June 23rd, 2025|Spray Booths|Comments Off

Best Construction Materials For Industrial Ovens

Production Systems works with manufacturers and finishing companies to design industrial ovens that meet the specific requirements of the groups. The engineering and design team at Production Systems incorporate the proper air circulation, ventilation exhaust, air seal, combustion equipment, safety controls, temperature controls, and electrical controls that are necessary for a successful process. One of the primary factors in designing an industrial oven is the selection of the right materials. Initial considerations include the interior and exterior metals. When choosing materials for an industrial oven, temperature and corrosion are key considerations. Material Options for Industrial Oven Walls Industrial oven walls must be durable, resistant to high temperatures and corrosion, and provide effective insulation to maintain consistent temperature and energy efficiency. They also need to be designed to prevent warping and heat loss. Heavy gauge cold rolled steel is often used for structural components, including industrial equipment. Due to the cold rolling process, this steel exhibits these properties: improved hardness, resistance to deformation, and greater tensile strength. It also produces smooth, high-quality surface finish, that makes it aesthetic pleasing. Another material, [...]

Dawn Denby2025-05-12T13:30:36-04:00May 12th, 2025|Industrial Ovens|Comments Off

Space Considerations When Designing a Powder Coating System

When planning to integrate a powder coating system into a facility, carefully evaluating the space requirements is vital to creating an efficient and productive operation. Asking the right questions can help ensure a well-designed and functional layout. Key Questions to Ask What is the total amount of floor space required for the powder coating system? Ensuring adequate floor space is essential for safety and efficiency. Crowded layouts can increase the risk of accidents and create operational bottlenecks. Is there sufficient space between machines for accessibility? Providing enough clearance between machines is crucial. Operators should be able to remove parts from the line and resolve issues without difficulty. Do workers have enough room to maneuver? Workers need proper access to all sides of the parts being coated. Comfortable movement promotes efficiency and reduces fatigue. Is the conveyor space adequate for safe operation? The conveyor system must have sufficient space to move parts smoothly through the entire coating process. Can rolling racks or forklifts be used effectively? Facilities should accommodate the movement of heavy racks or forklifts, including turning radii and entry [...]

Dawn Denby2025-03-31T17:55:15-04:00March 31st, 2025|Design & Engineering|Comments Off

Industrial Finishing Systems For Military Applications

For manufacturers in the Defense Industry, every piece of equipment and every component must meet the most stringent requirements. Military equipment and parts must be reliable, durable, and precise. To ensure requirements are met, advanced industrial finishing solutions are extremely important. The most often used finishing solutions for this industry segment include metal plating, shot blasting, and paint/coatings application. Metal Plating Processes Metal plating is a process where a thin layer of one metal is deposited onto the surface of another material, to enhance its properties like corrosion resistance and hardness. Metal plating creates a protective coating on the receiving metal. Metal plating technology includes: Electroplating - uses an electric current to deposit the metal ions onto the surface Anodizing - thickens the metal's natural oxide layer Electroless plating - A chemical reaction that creates a uniform coating without using electricity Chemical film - A chromate-based coating that protects against corrosion and improves electrical conductivity Few industries demand more metal plating than the Defense Industry. Production Systems provides specialized solutions for the metal plating process, such as conveying systems and industrial ovens [...]

Dawn Denby2025-03-10T15:42:46-04:00March 10th, 2025|Process Enclosures & Oven Designs|Comments Off

Heavy-Duty Equipment Manufacturers Provide Exceptional Exterior Protection With Industrial Coatings

To meet the demands of harsh environments, large equipment manufacturers use powder coating to protect their products. Powder Coating offers exceptional durability, flexibility, and resistance to chemicals, corrosion, and impact. However, manufacturers must use the right powder coating products, and that means coatings that are tested and meet stringent specifications. But that’s not all, they must also apply them properly. Pretreatment To achieve the best results from a powder coated finish, the receiving surface must be thoroughly cleaned. It should be free of dust, oil, rust, old paint or other coatings. Any contaminant left on the surface will affect the powder’s adhesion and durability. Production Systems offers pretreatment systems, including sanding and grinding booths and parts washers, all designed to properly prepare the machine surface for the coating process. Production Systems also offers industrial ovens for those instances where drying is needed from a wash station or when a specific temperature needs to be met. Application For effective application of a powder coating, a powder spray gun system that’s made specifically for this finish is needed. The powder is blown [...]

Dawn Denby2025-03-10T13:58:28-04:00March 10th, 2025|Finishing Systems|Comments Off

In The Powder Coating Pretreatment Process, Various Methods May Be Needed

As mentioned in a previous post, pretreatment of parts in a powder coating process is the key to a successful finish. When parts are properly prepared, the powder coating adheres as it should and creates a long-lasting, corrosion-resistant, protective layer. One method for pretreatment is manually applying chemicals to the part. However, when throughput demands are high, an automated system will be a better solution. An automated pretreatment process consists of three to nine stages. In a simple three-step method, there’s a heat treatment step, a rinse step, and a sealant. A more complex system includes multiple heating and rinsing steps, and special sealants. Removing Hard-To-Remove Contaminants When the part has contaminants that are hard to remove, another step may be needed for cleaning parts. Blasting, also known as sandblasting or media blasting, this a mechanical cleaning method that uses high-velocity abrasive particles to clean and prepare a surface. Blasting removes contaminants, such as rust, old coatings, and minor surface defects. Blasting ensures an even surface for the coating and can also aid the adherence of the powder by creating [...]

Dawn Denby2025-01-06T12:17:17-05:00December 9th, 2024|Pretreatment & Surface Prep Booths|Comments Off

Revolutionizing Surfaces With Industrial Powder Coating Systems

Industrial powder coating ovens are large, high-capacity ovens used in the manufacturing industry to cure powder-coated finishes on metal and other materials. These ovens are typically equipped with precise temperature controls, airflow systems, and conveyor belts to ensure uniform heat distribution and thorough curing of the powder coating. Industrial powder coating ovens are essential for producing durable, high-quality finishes that resist chipping, scratching, and corrosion. These ovens are designed to handle heavy workloads and can accommodate a variety of part sizes and shapes, making them versatile and efficient tools for finishing processes. Industrial powder coating ovens are commonly utilized in a variety of industries for their efficiency, durability, and versatility. One of the main industries that heavily rely on industrial powder coating ovens is the automotive industry. Powder coating is used to provide a durable and attractive finish to automotive parts, such as bumpers, wheels, and engine components. In addition, the aerospace industry also utilizes powder coating ovens for coating materials like aircraft components and parts. Other industries, such as furniture manufacturing, appliance manufacturing, and metal fabrication also make extensive [...]

Dawn Denby2024-12-09T13:32:28-05:00December 9th, 2024|Powder Booths|Comments Off

Step 1 Of The Powder Coating Process: Pretreatment

The pretreatment stage of powder coating process, also known as parts prep, is crucial to the success of the finish. Ensuring that the parts are properly cleaned and prepared to accept the powder coating may be the most critical step. This step ensures the powder coating adheres properly, resulting in a long-lasting, corrosion-resistant, protective layer. Most defects in a powder coated part are due to inadequate pretreatment. Different materials require different pretreatment approaches and often, there are strict guidelines that need to be met. Step one in pretreating parts begins with cleaning – mostly with chemicals. The amount of cleaning required is dependent on the condition of the parts. Is the part brand new and relatively clean? Or has it been sitting on the manufacturing floor or outdoors for weeks and gotten rusty? Is there oil, grease, or welding spatter on the part that needs to be removed? Manual pretreatment cleaning methods, such as using a pump sprayer or spray wand, are common for most shops. With this set-up, an operator manually applies chemicals using specific equipment. Sometimes pretreatment with [...]

Dawn Denby2025-01-07T08:40:01-05:00November 11th, 2024|Pretreatment & Surface Prep Booths|Comments Off

Types of Spray Machines And The Latest In Technology

When it comes to spray machines, the various types are ideal for their respective application. Fan coaters are used most often for applications such as trim, siding, and molding. A fan coater is a compact machine that applies a mist of coating to a surface. Fan coaters are used for water-based and UV coatings on substrates up to 12 inches wide. Reciprocating spray machines are best for large-scale, continuous coating of flat surfaces. They use oscillating spray guns to apply the coating in overlapping waves. They provide an extremely high-quality consistent finish. The benefits of this precise method is that overspray is reduced and material waste is minimized. Reciprocating spray machines are often used to coat panel products like doors and cabinets. Rotary spray machines have rotating arms with spray guns that move in patterns to create a fine mist. The machine identifies the shape and size of the part as it passes under a scanner, and then adjusts the flow speed and rotation to provide a high-quality coating. Rotary spray machines can achieve feed speeds of more than 30 FPM and colors [...]

Dawn Denby2024-10-07T14:56:33-04:00October 7th, 2024|Spray Booths|Comments Off

About Dawn Denby