Physics Always Wins

How we got coil-coating down to a science.

Working alongside world-class product engineers and machinists everyday provides a routine humbling reminder of what’s really calling the shots. The undefeated, politically neutral and often frustrating Laws of Physics. 

The laws of physics are what prevent a balloon from popping on a bed of nails. Or why my son’s hand shocks me after he gets off a slide on the playground. 

They’re also why our powder-coated metal outperforms and outlasts conventionally painted metal. 

We have science on our side. 

Where liquid paint creates an additive layer, leading to corrosion vulnerabilities and application limitations, our approach differs at the molecular level. Using fluidized polyesters, epoxy, teflon and other hybrid materials, powder coatings are electrostatically charged, and applied across the totality of a moving sheet before being cured. 

Our curing agents don’t just protect the newly applied coating, they facilitate the cross-linking of the resin molecules themselves, creating a formidable three-dimensional network within the coating itself. 

The difference? Superior chemical resistance, durability and overall performance. 

Want to see it in action? Get in touch to learn more.

For the fellow systems nerds such as myself, here’s a more detailed overview of how it works: 

Entry End Section

In the PowderCoil® Continuous Coil Coating Line (CCCL), coils are carefully unwound, feeding into a system designed for seamless throughput. Engineered for precision, this process handles up to 25 tons while maintaining efficiency and consistency. Every parameter, from material flow to tension control, is calibrated to ensure high-quality coatings at scale.

Cleaning and Pre-treatment

Before a coating can adhere, the metal must be prepared at a molecular level.

Each strip passes through a multi-stage cleaning and pretreatment process that removes contaminants and optimizes the surface for bonding. Etching, using Trivalent Chrome and Chrome-Free treatments, enhances adhesion while aligning with PowderCoil®’s commitment to sustainability.

Traditional liquid coatings require primers to improve adhesion and corrosion resistance. PowderCoil® coatings eliminate that step, achieving a single-pass powder finish with enhanced durability and weathering resistance.

At the core of the process are PowderJet® applicators, which electrostatically apply a uniform layer of powder across the pre-treated metal strip. These systems handle a variety of coating materials, including polyester, polyvinylidene fluoride (PVDF), and plastisol, adjusting parameters like airflow, temperature, humidity, and pressure for precise application.

The flexibility of PowderJets®, whether in vertical or horizontal configurations, allows for seamless integration into different production environments. 

Curing

Once coated, the strip enters the curing oven, where controlled heat triggers the chemical reaction that solidifies the coating.

The process follows a staged approach:

1. Initial heating melts and levels the powder.

2. Peak Metal Temperature (PMT) stage initiates cross-linking, strengthening the coating.

3. Controlled cooling stabilizes the finish and ensures long-term durability.

PowderCoil® fine-tuned curing techniques to work with shorter ovens while maintaining optimal performance at varying line speeds. Darker primers absorb heat efficiently, while lighter colors require specialized chemistry adjustments to ensure full curing.

As coating technology evolves, Infrared (IR) and UV curing methods offer new efficiencies and expanded material compatibility—an area where PowderCoil® is already investing.

Exit End

After curing, the coated strip is rapidly cooled to set the finish and prepare it for further processing.

PowderCoil® optimized quench misters to fine-tune cooling, ensuring coatings maintain their structural integrity. These techniques can be adapted to future CCCL developments for even greater efficiency.

For applications requiring additional functionality or visual enhancements, extra coating layers can be applied. The modular design of PowderJets® allows for seamless expansion, making it possible to add protective or decorative finishes without disrupting throughput.

Once the process is complete, the finished strip is recoiled, ready for storage, transport, or final manufacturing. We work closely with OEMs and logistics partners to tailor specifications for both entry and exit ends, ensuring smooth integration into downstream production.

From start to finish, every step is engineered for precision, durability, and efficiency.

Because why paint steel when you can fundamentally transform it into something new altogether? 

Does physics hold the secrets to the next transformative breakthrough in coil coating? Of course. We’re busy uncovering them as we speak. 

Science is finding the truth and developing new ways to put it to work. So if you need us, we’ll be in the lab.