CDLPL WORK INSTRUCTION REV. NO.

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DOC CODE: DOC. TITLE: POWDER COATING DATE01.08.2019
PSP7.5.1WI(2) REF. TO LEVEL II DOC. CODE: PSP7.5.1 PAGE: 1 OF 9

1. Hazards:

a) Dust explosion and fire hazards

b) Electrical hazards

c) Exposure to hazardous materials

2. Safety control:

a) Handling of Powder Coatings:

 Avoid excessive skin exposure.

 Wear proper respiratory equipment.
 Wear proper clothing and eyewear.

b) Fire Risk:

 Maintain a safe concentration of powder in air- outside the explosion (flamability) limits.
 Eliminate any sources of ignition
 Maintain a good ground on everything in the powder coating system.
 Maintain a good ground throughout the racks.

c) Pretreatment Chemicals:

 Avoid skin contact.

 Wear recommended safety clothing
 Maintain good ventilation.

d) High Temperature Environments:

1. Limit access
2. Never open washer or oven during operation.
3. Disconnect power before entering.
4. Use good lighting when entering
5. Wear a hard hat in areas where it is neccessary to stop.
6. Know the hazards inside the equipment.
 CDLPL WORK INSTRUCTION REV. NO.: 0
DOC CODE: DOC. TITLE: POWDER COATING DATE01.08.2019
PSP7.5.1WI(2) REF. TO LEVEL II DOC. CODE: PSP7.5.1 PAGE: 2 OF 9

3. Prestart requirements:

Equipments Coating booth

Powder curing oven
Pre-treatment tanks
Conveyor trolley system
Materials Ridoline 1352 BA
Rustokem 2A
Kemkote210
Kem passivate 2

4. Work Instructions :

6.1 Powder coating system:

1. The ‘pretreated’ articles are jigged and loaded onto the continuously moving overhead conveyor.

2. As the conveyor moves the articles through the coating booth, they are coated on all sides by manual
spray guns.

3. The conveyor then carries the articles into the tunnel oven (or in a semi-automated version, the articles
are offloaded for off-line curing).

4. In the oven, at a skin temperature of 180-220C, in 10-15 minutes, the powder melts, polymerizes, fuses
and cures into the tough uniform and consistent powder coat that has high aesthetic value.

5. At the end of the curing schedule, the article moves out of the oven (or the trolley is rolled out of the
oven) and allowed to cool down through a cool-off zone.

6. The articles are then removed off the conveyor and taken out of the paint-shop.
 CDLPL WORK INSTRUCTION REV. NO.: 0
DOC CODE: DOC. TITLE: POWDER COATING DATE01.08.2019
PSP7.5.1WI(2) REF. TO LEVEL II DOC. CODE: PSP7.5.1 PAGE: 3 OF 9

6.2 Pre- treatment system:

6.2.1 Surface cleaning

PHOSPHATING: The conventional seven-tank Hot Zinc Phosphating system is used in CDEL for all MS ,HR
and CR parts .
The following are the different steps involved in the process:-

1. Alkali degreasing
 Tank:…………………………………… Mild steel

 Capacity: …………………………………..7000 L

Chemicals used:
 Ridoline 1352 BA: Water …………………… 1:20
 Appearance: ……………………………...Powder form
 Operating temp:………………………. 60°C

 Duration: ………………………………….10-12 Min

Operating parameter:
1) Do degreasing only after 60°C Temperature is attained.
2) Air agitation should be done during processing
3) In every shift remove the top layer of oil before starting the work

*Oxide films & rust stains are dissolved in acid.

*The tank is lined with FRP to avoid corrosion of the tank

2. Cold swilling

Tank: …………………………………………..Mild steel

Capacity: …………………………………….7000 L

Cold swilling medium: ………………..Static water

Operating temp: …………………………Room temp.

Duration: …………………………………….2-3 times

Operating parameters:
1) No oil should remain on the surface
2) The oil film and water should flow off smoothly like a sheet . it should not break into glass
bead type bubbles.
*continuous air agitation is provided for effective cleaning.

3. Hot phosphating / De rusting

Tank: ………………………………………….Mild steel

 CDLPL WORK INSTRUCTION REV. NO.: 0
DOC CODE: DOC. TITLE: POWDER COATING DATE01.08.2019
PSP7.5.1WI(2) REF. TO LEVEL II DOC. CODE: PSP7.5.1 PAGE: 4 OF 9

Capacity: ……………………………………7000 L

Chemicals used:

Rustokem 2A: Water …………...1:4

Accelerators (Sodium nitrite, an oxidising agent)

Operating temp:……………………….Room temperature

Duration:……………………………………10 - 12 mts.
*Iron dissolves in phosphate solution & hydrogen is evolved due to chemical reaction & adheres to the metal
surface. Sodium nitrite reacts with hydrogen & forms water.
*The tank is lined with stainless steel

4. Cold swilling

Tank: …………………………………………..Mild steel

Capacity: …………………………………….7000 L

Cold swilling medium:………………… static water

Operating temp: ………………………….Room temp.

Duration: …………………………………… .2-3 times

*continuous air agitation is provided for effective cleaning.

5. Water rinse
Tank: …………………………………………..Mild steel

Capacity: …………………………………….7000 L

Cold swilling medium:………………… static water

Operating temp: ………………………….Room temp.

Duration: …………………………………… .2-3 times

*Thoroughly rinse the part to prevent acid carry over.

6. Phosphating
Tank: …………………………………………….Mild steel

Capacity: ………………………………………7000 L

Chemicals used: Kemkote 210

Ratio :
a) For 100 ltr water –Add 5 liters of chemical
b) Add 50gm accelerator powder every shift starting
Appearance:………………………………..White color liquid
Operating temp: ……………………………55 – 60°C

Duration: ………………………………………5 min .

 CDLPL WORK INSTRUCTION REV. NO.: 0
DOC CODE: DOC. TITLE: POWDER COATING DATE01.08.2019
PSP7.5.1WI(2) REF. TO LEVEL II DOC. CODE: PSP7.5.1 PAGE: 5 OF 9

Operating parameter:
a) Add accelerator 50gms before starting work in every shift
b) Remove bottom sludge weekly once .Store sludge separately

7. Water rinse
Tank: …………………………………………..Mild steel

Capacity: …………………………………….7000 L

Cold swilling medium:………………… static water

Operating temp: ………………………….Room temp.

Duration: …………………………………… .2-3 times

*Thoroughly rinse the part to prevent acid carry over.

8. Sealing/Passivation
Tank: …………………………………………….Mild steel

Capacity: ………………………………………7000 L

Chemicals used:
Kem passivate 2: Water…………….. …..0.025 – 0.05:1
Operating temp: ……………………………60 – 65°C

Duration: ………………………………………1-2 min .

* Phosphate coating is porous. Therefore, oil or other sealers such as Chromium tri oxide, are used to achieve
corrosion resistance
Check list after surface cleaning :

6.3 Manufacturing of powder paint

a) The dry ingredients in exact amounts are blended at high speed to create a homogeneous mixture &
heated to the resin melting temp in an extruder.

b) The extruded mixture is then cooled & rolled before being broken into small chips.

c) Powder particle The chips are milled to a very fine size ( Average diameter of powder particle varies in
between 30-50 micron) & packed.

d) Each individual contains the entire coating formulation.

6.4 Requires good quality of compressed air, free of oil & moisture.
Pressure ------------------- --4 to 5 kg/cm2
 CDLPL WORK INSTRUCTION REV. NO.: 0
DOC CODE: DOC. TITLE: POWDER COATING DATE01.08.2019
PSP7.5.1WI(2) REF. TO LEVEL II DOC. CODE: PSP7.5.1 PAGE: 6 OF 9

Max. moisture content----1.4 gm/m3

Max. oil content-----------0.1 ppm & operator

6.5 SELECTION OF GUN ATTACHMENT & RIGHT POWDER
Right powder to be chosen as per the end use of the component.

6.6 APPLICATION OF POWDER:

6.7 POWDER COATING PROCESS

I. Ensure proper earthing to the equipment.

II. Put powder into the hopper.

III. Connect the equipment to the main air supply.

IV. Switch on the power supply.

6.8 ELECTROSTATIC SPRAYING

 CDLPL WORK INSTRUCTION REV. NO.: 0
DOC CODE: DOC. TITLE: POWDER COATING DATE01.08.2019
PSP7.5.1WI(2) REF. TO LEVEL II DOC. CODE: PSP7.5.1 PAGE: 7 OF 9

I. An electrical charge is applied to the dry powder particles while the component to be painted is
electrically grounded.
II. The charged powder & grounded work piece create an electrostatic field that pulls the paint particles to
the work piece.

III. The coating deposited on the work piece retains its charge, which holds the powder to the work piece.

IV. The powder coated work piece is placed in a curing oven, where the paint particles are melted on to the
surface & the charge is dissipated.
* The gun gives +ve electrical charges on the powder particles by frictioning between them & non- conductive
material (air).

6.9 Powder spray booth

7.0 ADDITION OF FRESH POWDER:

In order to maintain a constant composition, always keep the volume of re-used powder to minimum.

To reduce variations in particle size distribution due to recycling.

7.1 CURING:

The curing process requires a certain degree of temp for a certain length of time in order to reach a full cure.
–Temp…………….180-200°C
 CDLPL WORK INSTRUCTION REV. NO.: 0
DOC CODE: DOC. TITLE: POWDER COATING DATE01.08.2019
PSP7.5.1WI(2) REF. TO LEVEL II DOC. CODE: PSP7.5.1 PAGE: 8 OF 9

–Curing time……45 minutes( CDEL-).

•The application of energy to the product to be cured can be accomplished by:-
–infrared cure ovens (direct exposure to light in the range of IR-region)

7.2 RECOVERY OF POWDER

 Powder coating booth is equipped with powder recovery cyclone and filter.

 It recovers as much as 98% of powder exhausted from the booth.

 Recovered powder is progressively re-used.

 After filter, filters fine powder of powder recovery cyclone and virtually no powder goes to atmosphere

7.3 POWDER COATING STORAGE CONDITION

Proper storage is essential as it:-

–prevents particles agglomeration

–ensures satisfactory application

7.CLEAN UP AND SHUT DOWN PROCEDURE

 Powder & air mixtures can be a fire hazard when an ignition source is introduced.

 The concentration of powder in air must be controlled to maintain a safe working.

 Any finely divided organic material, such as dust, can form an explosive mixture in air.

 Personal cleanliness should be maintained at all times (soap & water clean up to remove powder from
the skin)

 Don’t use air blast nozzles to blow off powder from the skin.

8 Emergency procedures

9 Waste management
CDLPL WORK INSTRUCTION REV. NO.: 0
DOC CODE: DOC. TITLE: POWDER COATING DATE01.08.2019
PSP7.5.1WI(2) REF. TO LEVEL II DOC. CODE: PSP7.5.1 PAGE: 9 OF 9

3.0 RECORDS
Sl. Doc. Code of Doc. Title of record Retained Mode of
No Format/ Checklist With For Disposal
1

4.0 AUTHENTICATION
PARTICULARS DESIGNATION SIGNATURE
PREPARED BY POWDER COATING I/C
REVIEWED AND DIRECTOR
APPROVED BY
ISSUE AND QMS COORDINATOR
CONTROL BY