Poor fluidization in powder hopper (The powder is supposed to flow like water in the flu

container (boil). Poor fluidization is recognizable in the slow and non-continuous transportation of the po
coating from the fluid container to the guns. No homogenous powder cloud is achieved)

Possible Causes

Powder level too low

Fluidizing air low or too high

Oil remnants in compressed air

Compact or damp powder

Oil remnants in compressed air

Fluidizing plate chugged / defective

Clogging of the powder feed houses (Deposits (agglomerates) form in the powder feed ho
which sporadically are freed by delivery air and appear as powder puffs on the workpieces. After curing
powder puffs appear as faulty surface elevations.)

Possible Causes

Feed air pressure too high/too low

Delivery of air moist or oil in pressurized air

The material choice of hoses

Worn venture or pump

Too fine powder

Feed hose too long

Poor Attraction of the Powder to the Component

ossible Causes

Incorrect Voltage at the gun

Insufficient Grounding
Excessive build-up of cured powder coating

Worn venture or pump

Too much powder out put

Gun distance to part too close, blast effect

Gun air pressure too high

Film build too high

Insufficient wetting

Poor Wrapping (With one-sided gun positioning, only minimal film thickness can be achieved on the opposit
Possible Cause
Powder flow too low or too high
Insufficient grounding
Supplemental air flow is too high or too low
Gun voltage too high
Insufficient charging of the powder
Poor or wrong positioning of the parts
wder hopper (The powder is supposed to flow like water in the fluid
recognizable in the slow and non-continuous transportation of the powder
ntainer to the guns. No homogenous powder cloud is achieved)

Explanation

Add powder to the normal level

Change pressure use larger hose diameter

Check the filter in front of the coating booth

1. Manually loosen powder in hopper

2. Check compressed air for quality

Check the filter in front of the coating booth

Clean plate or exchange the plate

eed houses (Deposits (agglomerates) form in the powder feed hoses,

very air and appear as powder puffs on the workpieces. After curing these
er puffs appear as faulty surface elevations.)

Explanation

Reduce/increase pressure

Check in-line filters and moisture traps

Check hoses for material quality

Replace worn parts

Decrease amount of reclaim to hopper Optimize virgin powder

plus reclaim ration

Minimize feed hose length

action of the Powder to the Component

 Explanation

Check voltage, clean or replace the gun

Clean grounding points and hangers
Clean hanger

Replace worn parts

Reduce air flow/powder flow

Adjust the distance

Reduce forward air pressure

Reduce powder flow

Check pre-treatment

gun positioning, only minimal film thickness can be achieved on the opposite side.

Explanation
Optimize system parameters, adjust air flow
Use clean hooks
Adjust air speed and powder cloud
Adjust voltage to suit parts
Adjust high voltage; consult powder manufacturer
Adjust hanging configuration
 Poor Penetration into Recesses

Possible Causes

Too low powder delivery

Airspeed too high

Poor grounding

Insufficient charging of powder/defective

Incorrect spray pattern/spray to wide

Too high voltage

Poor gun placement

Powder too fine

Appearance looks uneven and broken before curing

Possible Causes

Back ionization

Powder dusting out of hoper

Possible Causes

Too high air pressure

Too fine powder

Orange peel in powder coating problems and solutions

Possible Causes

Heat up cycle of parts too slow

Substrate temperature exceeds the melt temperature of

the powder, causing

Powder coating material too reactive

Film thickness too high or too low

Incompatibility with other powder

Voltage too high

Textured work piece surface

Unsuitable particle size distribution

Color difference
ossible causes
Film thickness varies greatly
Differing substrates and substrate color
Film thickness too him
Not sufficient or wrong pigmentation in the formulation
Over curing of powder coating (especially with organic
pigments

Varying film thickness with over coating

Color deviation due to curing technique or oven

atmosphere
netration into Recesses

Explanation

Increase powder flow

Adjust equipment controls

Adjust equipment controls to suit the parts

Check and improved grounding

Adjust voltage, contact equipment

Try different spray nozzle

Reduce voltage so that surface closest to the gun

does not repel powder

Adjust gun position to enter directly into the recessed

area

Reduce ration to reclaim to the hopper, contact

powder manufacturer

uneven and broken before curing

Explanation

1. Reduce voltage 2. Check if grounding points are

clean 3. Reduce deposition rate and film thickness 4.
Ensure no moisture is entering the system 5. Move
the gun further away from the component

r dusting out of hoper

Explanation

Reduce air pressure to fluid bed

 1. Decrease amount of reclaiming ho hopper 2.
Check ration of virgin powder

er coating problems and solutions

Explanation

Determine heat up curve and increase

Check substrate temperature, increase cool down

phase

Consult powder manufacturer

Check system parameters

Clean booth, check compatibility

Optimize voltage
Optimize texture, check work piece surface
Optimize particle size distribution consult
manufacturer

Explanation
Assure constant film thickness
Use substrates of same type for comparisons
Apply higher film thickness
Consult powder coating manufacturer

Observe curing parameters of powder manufacturer

Assure even film thickness

Use suitable powder coating, control oven use

outside air supply for burner