Vertical Powder Coating Line
For manufacturers coating aluminium profiles at production scale
The system includes all stages from pretreatment through to curing. Every component is designed to work together as a continuous production line, not a collection of standalone machines.
Specifications
- Line Speed
- Up to 16 ft/min
- Layout
- From 115 x 23 ft
- Control
- PLC with HMI touchscreen
- Pretreatment
- 5 to 8+ stages
- Compliance
- AAMA 2605, Qualicoat, GSB
Key Features
- Power & Free conveyor at up to 5 m/min — handles high part volumes continuously
- Compact 35 x 7m layout — full automated line in a smaller building
- PLC-controlled with HMI touchscreen for parameter monitoring
- 5 to 8+ stage pretreatment — configurable for coastal and harsh environments
- Compatible with Gema, Nordson, or Wagner spray systems
- Cyclone recovery booth with up to 98% powder reuse
System Components
A complete vertical line includes the following stages, configured to your specific production requirements:
- Nano pretreatment or sandblasting — removes contaminants and prepares the surface
- Dryer — removes moisture before powder application
- Detection system — automatic shape recognition for adaptive spray control
- Plastic spray booth — with cyclone recovery achieving up to 98% powder reuse
- Automatic spray guns — reciprocator-mounted, PLC-controlled parameters
- Powder center — manages powder supply, sieving, and reclaim
- Curing oven — uniform temperature distribution for consistent finish quality
Power & Free Conveyor Automation
The line uses a Power & Free conveyor system running at up to 5 m/min. This system is particularly suitable for coating a large number of small to medium-sized parts in a short time. The conveyor handles loading, transport through each process stage, and unloading — reducing manual handling and increasing throughput.
Power & Free conveyors allow individual carriers to stop at stations (loading, spraying, inspection) while the main chain continues moving. This means different parts can spend different amounts of time at each station without slowing the line.
Drying and Curing Ovens
The ovens in this line are designed for minimal heat loss and uniform air distribution. Insulation quality directly affects energy costs and coating consistency — uneven temperature means uneven cure, which means rejects. Our ovens maintain tight temperature tolerances across the full chamber length.
Have questions about the Vertical Powder Coating Line?
Our engineering team can help you evaluate whether this is the right system for your production requirements.
Recovery Plastic Booths
The spray booth uses plastic construction for fast, thorough cleaning during color changes. Cyclone recovery separates overspray from the air stream and returns it to the powder center for reuse — recovery rates reach up to 98%. This reduces powder waste and keeps material costs low on high-volume runs.
Available in cyclone or filter recovery configurations. Steel, plastic, or hybrid booth construction depending on your color change frequency and budget.
Pretreatment for Aluminium Profiles
Pretreatment is critical for adhesion and corrosion resistance on aluminium. The standard process involves multiple chemical stages designed to remove contaminants, etch the natural oxide layer, and apply a conversion coating. The number of stages depends on your end-use environment and quality standards.
Standard 5-Stage Process
- Cleaner / Degreaser — removes dirt, oil, and grease from the extrusion process
- Rinse — removes residual cleaner
- Etch or Acid Pickling — removes the natural oxide layer, creates a uniform surface
- Rinse — removes etching byproducts
- Conversion Coating — applies a corrosion-resistant layer (chromium-free zirconium or chrome)
A final DI (deionized) water rinse is added to prevent contamination before drying.
6 to 8+ Stage Processes
For more demanding requirements — particularly in harsh or coastal environments — additional stages improve chemical deposition and long-term corrosion resistance:
- 6-stage: Additional rinsing or de-smut stage
- 7-8 stages: Reverse osmosis rinses and specialized chrome-free sealing options
Proper pretreatment helps the powder adhere firmly to the aluminium and supports long-term finishing quality in line with standards such as AAMA 2605, Qualicoat, and GSB.
Why Automation Improves Output
Manual powder coating lines require operators at every station — loading, spraying, monitoring cure. An automated vertical line replaces most of this manual labor with PLC-controlled processes. The result is higher throughput per shift, more consistent coating quality, and lower per-part cost.
- Process optimization from start — the system is designed as a complete workflow, not assembled from separate machines
- Consistent coating thickness — automatic guns with shape detection adapt to each part profile
- Reduced labor — fewer operators needed per shift
- Lower reject rate — automated temperature control and spray parameters reduce human error
Project Approach
We handle projects as turnkey installations — a single point of contact from the initial inquiry through to a running production line.
Share Your Requirements
Tell us what you are coating — part dimensions, material, target throughput, and available floor space.
We Design a Layout
Our engineering team creates a system layout and equipment recommendation tailored to your facility.
Equipment Supply & Delivery
Equipment ships from our manufacturing partners to your facility with full logistics coordination.
Installation Support
On-site commissioning support to get your line assembled, connected, and running correctly.
Operator Training
Your team learns to operate, maintain, and troubleshoot the system before we hand it over.
Applications
Ready to discuss your project?
Contact our engineering team with your requirements. We respond within 1 business day.
