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Surface contamination before coating, such as wax, silicone, oil, water, rust, welding residues, or airborne pollutants.
Using coating materials that are incompatible with the substrate or topcoat.
Dry-sprayed primer (excessive powder content and insufficient resin film formation).
Using low-quality thinners with insufficient solvency.
Coating film thickness is too thin.
Thoroughly remove all contaminants from the workpiece surface before coating.
Select the correct primer suitable for the substrate and coating system.
Apply primer properly and avoid dry spraying or rough coating films.
Use qualified, high-quality thinners.
Ensure the coating film reaches the specified thickness.
The quality of a coating process layout directly affects the efficiency and performance of the entire coating line. Even if individual equipment performs well, poor layout design can significantly reduce overall system effectiveness.
Some designs fail to consider hanger arrangements, hanger spacing, uphill and downhill sections, turning radius interference, scrap rates, equipment utilization, and peak production demand. As a result, actual output cannot achieve the intended production capacity.
To reduce costs, some designs shorten process stages excessively. Common examples include:
Insufficient transition time in pretreatment, causing chemical carry-over.
Failure to consider heating-up time during curing, resulting in incomplete curing.
Insufficient flash-off or leveling time after spraying, leading to poor coating appearance.
Inadequate cooling after curing, causing overheated workpieces during handling or subsequent coating operations.
Workpieces can be transported using various methods. Poor conveyor design can negatively affect production capacity, process operations, and loading/unloading efficiency.
For example, overhead conveyor systems require accurate calculations of load capacity, traction force, and interference clearance. Conveyor speed must also be properly matched with the entire coating system. Smooth and synchronized chain operation is essential for coating quality.
Different products require different coating equipment. Each equipment type has its own advantages and limitations.
Common mistakes include:
Using inappropriate oven insulation systems for powder coating lines.
Failing to install purification equipment for products requiring high cleanliness standards.
This is one of the most common problems in coating line projects.
Improper process parameter selection is frequently encountered in coating line design.
Typical issues include:
Selecting design parameters at the minimum acceptable limit.
Insufficient consideration of system compatibility between equipment.
Lack of scientific process calculations and relying solely on experience.
A complete coating line requires numerous supporting systems. To lower quotations, some suppliers omit essential equipment without informing the customer.
Common omissions include:
Pretreatment heating systems
Coating equipment accessories
Compressed air supply systems
Exhaust duct systems
Environmental protection equipment
Such omissions often lead to disputes during project implementation.
Energy costs continue to rise, yet some coating line designs fail to incorporate energy-saving measures.
As a result:
Production operating costs become unnecessarily high.
Users may be forced to retrofit or replace equipment after only a short period of operation.
Therefore, energy efficiency should be considered from the initial design stage to ensure long-term operational sustainability and cost-effectiveness.
