Reason

• 1 Unfavorable storage conditions (High heat/humidity)
• 2 Storage has exceeded the shelf life of powder

Solution

• 1-1- Sift the powder using a 200–300 micron sieve to break up any lumps.
• 1-2- Check optimal powder storage conditions in the technical data sheet
• 1-3- Store the powder at temperatures less than 25°C
• 2-1- Use a fresh batch of powder

Reason

• 1 Air Pressure is too low or too high
• 2 Powder settled at the hopper bottom (old powder or poor storage conditions)
• 3 Oil or moisture in the compressed air
• 4 Powder is moist or is too fine
• 5 Air channels of the flow plate are clogged

Solution

• 1-1- Control and adjust the air pressure
• 1-2- Replace the hose or use a hose with a larger diameter
• 1-3- Check the air filtration system (filter, pipes and air) and make sure hoses or filters are not clogged
• 2-1- Stir the powder or sift it using a 200–300 micron sieve
• 2-2- Check the optimal powder storage conditions in Technical Data Sheet
• 2-3- Store the powder at temperatures less than 25°C
• 2-4- Use a fresh batch of powder
• 3-1- Check the air for oil & moisture (Filters and Moisture Traps in the air system)
• 4-1- Increase virgin powder or change the powder
• 4-2- Check the optimal powder storage conditions in Technical Data Sheet
• 5-1- Empty the hopper, clean the pores of the fluidizing plate and if necessary replace the fluidizing plate

Reason

• 1 The hopper air pressure is high
• 2 The powder quantity is more than 3/4 of hopper capacity
• 3 The recycled to virgin powder ratio is more than recommended

Solution

• 1-1- Reduce powder quantity to 3/4 of the hopper capacity
• 2-1- Reduce the hopper inlet air pressure
• 3-1- Add virgin powder to the hopper and always limit reclaimed powder up to 20%

Reason

• 1 Inappropriate hose material
• 2 Moisture or oil in the compressed air
• 3 The air injector components are worn
• 4 The feed hose is too long or has the wrong diameter
• 5 Air pressure is too low or too high compared to the powder quantity
• 6 Inappropriate hose mounting

Solution

• 1-1- Replace the hose with appropriate type (silicone, polyurethane etc.)
• 2-1- Check the air for oil & moisture (Filters and Moisture Traps in the air system)
• 3-1- Replace the nozzle
• 4-1- Adjust the length and the diameter of the hose appropriate to the powder flow
• 5-1- Reduce or increase the pressure according to the powder quantity
• 6-1- Mount hoses properly to prevent kinking

Reason

• 1 The gun or powder system is chocked with fine powder particles (recycled powder content is high)

Solution

• 1-1- Reduce the reclaimed powder and/or increase virgin powder quantity
• 1-2- Clean the spray gun regularly and more frequently
• 1-3- Sift the reclaimed powder before using

Reason

• 1 Unnecessary excessive opening of the paint booth doors
• 2 Clogged filters inside the paint booth
• 3 Excessive powder from the spray gun (more than standard)

Solution

• 1-1- Keep the spray booth doors closed
• 1-2- Switch and adjust the inlet and outlet openings based on the size of parts being painted
• 2-1- Increase spray booth ventilator suction
• 2-2- Clean the filters and replace them if required
• 3-1- Reduce the number of guns or decrease the powder from the gun

Reason

• 1 Air velocity is too high causing the powder to disperse
• 2 Distance between the gun and the part is inadequate or improper painting technique
• 3 Powder feed is too high or too low
• 4 Poor or weak grounding
• 5 Spraying gun voltage is too low or too high
• 6 Improper spray Equipment
• 7 Powder is too fine

Solution

• 1-1- Decrease the air pressure of the spray gun
• 2-1- Adjust the distance between the spraying gun and the part (approximately 6 to 8 inches)
• 3-1- Adjust the amount of powder from the spray gun
• 4-1- Check and secure the ground (up to 1 megaohm)
• 5-1- Adjust voltage to have appropriate coverage in corners and to avoid repelling
• 6-1- Change the spraying nozzle type to a smaller or flat nozzle
• 7-1- Increase the virgin powder or decrease reclaimed powder

Reason

• 1 High film thickness
• 2 Powder is wet
• 3 Powder is contaminated with other materials
• 4 Part surface is too rough
• 5 Voltage is too high
• 6 Changes in the process of powder manufacturing

Solution

• 1-1- Decrease the paint thickness
• 2-1- Sift and dry the powder and decrease the ambient temperature of the paint system
• 3-1- Clean the hopper, paint booth and hoses again
• 4-1- Modify the cleaning and surface preparation procedure of the part
• 5-1- Reduce the voltage
• 6-1- Consult with the powder manufacturer and follow their recommendations

Reason

• 1 Poor charging of powder - The spray gun voltage is unnecessarily high
• 2 The spray gun and the parts are either too close or too far (gun to part distance is more or less than recommended)
• 3 Poor or weak earth connection
• 4 Time of the part in the booth is too short
• 5 Spray Booth airflow disrupts spraying - Inappropriate air humidity in the spray booth
• 6 The parts are complex in design or are not hung properly
• 7 Parts from dry off oven are too hot
• 8 Powder delivery hose is too long or clogged with powder deposits
• 9 Foreign particles (The cloth Fibers / Dust etc.) clogging the powder transport system

Solution

• 1-1- Test and adjust the spray gun voltage
• 2-1- Adjust the distance between the gun and the part (standard distance is 6 to 8 inch)
• 3-1- Check and secure the earth connection
• 4-1- Reduce line speed, increase powder from the gun or increase the number of the guns in the spray booth
• 5-1- Test and adjust system configuration and contact the spray booth supplier if necessary
• 6-1- Change the way parts are hung
• 6-2- Increase / decrease gun to part distance
• 6-3- Change the gun setting
• 7-1- Adjust dry off oven temperature or let the parts cool for longer
• 8-1- Make sure the diameter and length of the hoses is proper and that there are no kinks
• 9-1- Cleaning and maintenance of the transport system should be regular and more frequent

Reason

• 1 Poor grounding
• 2 Voltage is too low / powder does not charge properly
• 3 Too much powder output from the gun
• 4 Powder is too fine or too coarse
• 5 Conveyor / racks have too much vibration

Solution

• 1-1- Conveyor / racks have too much vibration
• 2-1- Check the gun, cables and electrodes
• 2-2- Measure gun voltage and make sure the readings match on spraying equipment display
• 3-1- Reduce the powder and / or air flow
• 4-1- Decrease the amount of recycled powder (if applicable)
• 4-2- Contact the powder manufacturer to consult about the appropriate powder gun
• 5-1- Check the system to prevent jerks and shocks to the parts

Reason

• 1 Film thickness is too low or too high
• 2 Parts do not heat up quickly (Heat up cycle is too slow)
• 3 Voltage or air pressure is too high
• 4 Inappropriate painting technique
• 5 Contamination with other powders

Solution

• 1-1- Measure film thickness with a thickness gauge and make sure to follow recommendations of the powder paint manufacturer
• 2-1- Conduct oven profile (e.g. datapaq) and confirm the recommended cure parameters
• 2-2- Consider preheating the heavy / thick parts
• 3-1- Adjust the air pressure and voltage of the spray gun
• 4-1- Adjust gun to part distance
• 4-2- Train painter for gentle passes / strokes of powder
• 5-1- Clean booth, guns and hoses
• 5-2- Consult with the powder coating manufacturer for incompatibilities

Reason

• 1 Contamination of powder with other materials and powders of different specifications
• 2 Over or under curing
• 3 Uneven gloss due to varying thickness of the parts

Solution

• 1-1- Clean the coating booth, spraying gun and hoses properly before replacing with new powder
• 1-2- Avoid using powder coatings from multiple manufacturers in the oven at the same time
• 2-1- Follow the powder coating manufacturer recommendations
• 2-2- Adjust the oven heat or the time parts spend in the oven
• 3-1- Adjust oven temperature and the time parts spend in the oven

Reason

• 1 Film thickness is too low
• 2 Different substrates and / or colored materials
• 3 Faulty spray gun
• 4 Poor ground and / or low voltage

Solution

• 1-1- Follow the manufacturers recommendations for the film thickness range
• 2-1- Compare the same substrates
• 2-2- Consult with the powder coating manufacturer for similar hiding on all substrates
• 3-1- Contact the spray gun manufacturer
• 4-1- Check and secure the ground and increase the voltage

Reason

• 1 Oven temperature is too low
• 2 The powder is contaminated with smooth powders in the hopper
• 3 The powder has expired
• 4 Storage conditions are not favorable

Solution

• 1-1- Adjust and increase the oven temperature as per the technical data sheet
• 2-1- Clean the hopper / paint booth, and hoses of other powders
• 3-1- Check the expiration date
• 4-1- Check the storage conditions (Temp and Humidity)

Reason

• 1 Over or under curing
• 2 Varying film thickness on different areas
• 3 Improper oven exhaust
• 4 Uneven color due to varying thickness of the parts
• 5 The paint booth is not properly cleaned of the previous color causing haziness or variation in color
• 6 Powder is too old or has expired

Solution

• 1-1- Follow Powder Coating manufacturer recommendations
• 1-2- Adjust the oven heat or the time parts are in the oven
• 2-1- Apply the powder to the surface evenly and follow the manufacturers recommendations
• 3-1- Check for blockage of the exhaust
• 3-2- Make sure the oven fan is working properly
• 4-1- Adjust oven the temperature and the time parts are in the oven
• 5-1- Clean the booth thoroughly before changing or adding new colors
• 6-1- Use a fresh batch of powder

Reason

• 1 The paint booth is not properly cleaned of the previous color and the contents are incompatible
• 2 Poor washing that left oil contaminants on the workpiece
• 3 Moisture or oil in the compressed air
• 4 Moisture on the work piece
• 5 Parts are rusty
• 6 Surrounding air is contaminated
• 7 Silicone from the lubricants or sprays
• 8 The part is porous and outgassing
• 9 In rough textures, pinholes appear instead of the rolling texture

Solution

• 1-1- Clean the paint booth properly before painting and with every color change
• 2-1- Test the washing system and make necessary adjustments (contact supplier)
• 3-1- Check the air system for oil and moisture. Replace filters regularly
• 4-1- Increase the dry off oven temperature or the time parts are in the dry off oven
• 5-1- Make sure the parts do not have rust before painting
• 5-2- Store the parts inside the shop unless painted
• 5-3- Use mechanical pretreatments like sandblasting or buffing
• 6-1- Avoid using powder coatings from multiple manufacturers at the same time
• 6-2- Prevent cross air drafts
• 7-1- Use silicone free lubricants
• 8-1- Preheat and outgas the parts before painting
• 8-2- Use outgas forgiving products
• 9-1- Increase the film thickness (3.5 - 4.5 mils). Consult the powder manufacturer

Reason

• 1 Contaminants from the oven, booth or conveyor system
• 2 Air pressure or voltage is too low
• 3 The feed hose is too long or the diameter is wrong
• 4 Oil and moisture in the compressed air

Solution

• 1-1- Check your cleaning procedure and clean more frequently
• 1-2- Check the paint line for dust contamination and burnout of furnace insulation etc.
• 3-1- Adjust the air pressure and voltage of the spray gun
• 4-1- Use the appropriate length and diameter for the hose
• 5-1- Check the air and oil filters and assure regular replacement

Reason

• 1 Film thickness is too high
• 2 Undercuring
• 3 Inadequate or Incompatible cleaning or pretreatment

Solution

• 1-1- Lower the powder or reduce the number of guns to adjust the film thickness to 2.5 to 3.5 mils for smooth and 3.5 to 4.5 mils for textured finishes
• 2-1- Follow manufacturer's recommendation. May need to run the oven profile to determine suitable baking schedule based on the substrate and parts thickness
• 3-1- Test the washing system and make necessary adjustments (contact supplier)

Reason

• 1 Inadequate washing and / or poor surface preparation
• 2 Very high film thickness
• 3 Parts are rusty
• 4 Lack of adhesion between two coats (primer & topcoat for example)

Solution

• 1-1- Test the washing system and make necessary adjustments (contact supplier)
• 2-1- Adjust the paint thickness based on Manufacturer Standard
• 3-1- Make sure the parts do not have rust before painting
• 3-2- Store the parts inside the shop unless painted
• 3-3- Use mechanical pretreatment like sandblasting or buffing
• 4-1- Half bake first coat, apply the second coat and then fully bake afterwards
• 4-2- For heavy parts, preheat the parts and apply both coats back to back and then put in the oven for a final bake

Reason

• 1 Film thickness is too high
• 2 Substrate temperature is too high (causing a high film build)
• 3 Powder paint moves to the edges
• 4 Inappropriate curing conditions (Heat-up rate is too high)
• 5 Powder falls and accumulates at the bottom of the part

Solution

• 1-1- Decrease the powder output from the gun to reduce film thickness
• 2-1- Increase cooling time between dry off and paint booth, Adjust the film thickness as necessary
• 3-1- Check and secure the ground and/or decrease the voltage
• 4-1- Adjust the heat up speed. Check the oven and adjust the temperature
• 5-1- Check and secure proper grounding