Troubleshooting

The IFS team is here to help you with any powder or application issues you may have, Below are some of the more common issues that can crop up from time - hopefully this will help! If you want to talk to an IFS technical expert, just give us a call and we'll arrange for one of technical team to get back to you, or email us at technical@ifscoatings.com.

Powder defects?

Lumpy powder - could be caused by:

High Humidity - keep the product away from humid environments. Humid environments can cause the powder to stick together and become lumpy.

High temperature - if the product reaches a temperature above 1000F or 380C, the powder then begins to get lumpy. The desired temperature is 800F or 270C or less for storing.

Contamination - could be caused by:

  • Make sure the powder box is always closed when not in use, contaminations float in the air.
  • Make sure everything that the powder touches prior and during use have been correctly cleaned to keep from contaminating the powder.
  • If running an assembly line do not directly switch from a dark powder to a light powder or a textured to a smooth finishes due to increased chance of contamination.
  • If too late and the powder continues having random speckles of different colors or incorrect splotches of finishes, the powder is contaminated and needs to be disposed of correctly.
  • If contaminated in multiple unopened boxes please contact your powder provider.

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Application issues

Application difficulties come in all shapes and sizes

Gun problems - could be caused by:

Grounding

  • Check to make sure everything is grounded correctly.
  • Consult your equipment manufacturer for further instruction if the problem consistently occurs.

KV Settings (gun voltage)

  • Consult your equipment manufacturer for recommended KV Settings for the type of part being coated.

 Gun nozzles

  • Consult your equipment manufacturer for recommended gun nozzle for current part you are spraying.

Inconsistent powder flow - could be caused by:

Hose obstruction

  • Make sure the hose is supplying constant air flow and there is nothing constructing the path. Example: Kinks or something within the hose.

Lumpy powder

  • High Humidity 
  • Keep the product away from humid environments. Humid environments can cause the powder to stick together and become lumpy. 
  • High temperature. 
  • If the product reaches a temperature above 1000F or 380C, the powder then begins to get lumpy. The desired temperature is 800F or 270C or less for storing. 

Incorrect air pressure - consult your equipment manufacturer for recommended air pressure.

Hose obstruction

  • Make sure the hose is supplying constant air flow and there is nothing constructing the path. Example: Kinks or something within the hose.

Product spraying issues - could be caused by:

Poor charging

  • Check to see if everything is correctly grounded.
  • When grounding a recoat product, make sure to clean the coating off allowing a secure ground connection.
  • Consult your equipment manufacturer for proper grounding techniques

Air pressure - consult your equipment manufacturer for recommended air pressure.

Hose obstruction

  • Make sure the hose is supplying constant air flow and there is nothing constructing the path. Example: Kinks or something within the hose.

KV settings (gun voltage) - consult your equipment manufacturer for recommended KV Settings for the type of part being coated.

Spraying issues - could be caused by:

Incorrect air pressure - consult your equipment manufacturer for recommended air pressure.

Hose obstruction

  • Make sure the hose is supplying constant air flow and there is nothing constructing the path. Example: Kinks or something within the hose. 

KV settings (gun voltage)

  • Consult your equipment manufacturer for recommended KV Settings for the type of part being coated.

Spray distance

  • Recommended spray distance is approximately 10-14 inches away from your product, distance may change depending on your equipment. 
  • Please consult with your equipment manufacturer for their recommended distance

Oven issues - could cause/be caused by:

Foaming at the surface

  • This is usually caused when the products are in the oven too long (decrease oven time) or the temperature is to high (lower oven Temperature). 
  • Mainly seen when working with IR Ovens (Infra Red Ovens). 

Is it low cure or regular cure powder?

  • Check the product code, the second letter in the product code declares if it is a Low Cure or Regular Cure 
  • R = Regular Cure 
    • For example: SRSF 31002 –This is a Regular Cure Product
  • L = Low Cure 
    • For example: PLSF 60229 –This is a Low Cure Product 

 Average low cure times

  • 340F for 10 Minutes
  • NOTE: This means part temperature needs to be at 340F for 10 minutes, not in a oven for 10 minutes

Average regular cure times

  • 400F for 10 Minutes
  • *NOTE: This means part temperature needs to be at 400F for 10 minutes, not in a oven for 10 minutes

Powder delivery system - issues could be caused by

If you're using a hopper:

Is it inconsistent powder flow? It could be caused by:

Hose obstruction - Make sure the hose is supplying constant air flow and there is nothing constructing the path. Example: Kinks or something within the hose.

Lumpy powder caused by high humidity 

  • Keep the product away from humid environments. Humid environments can cause the powder to stick together and become lumpy. 

 Lumpy powder caused by high temperature 

  • If the product reaches a temperature above 1000F or 380C, the powder then begins to get lumpy. The desired temperature is 800F or 270C or less for storing.

Incorrect air pressure - Consult your equipment manufacturer for recommended air pressure.

If you're using a box feeder:

It could be fluidization issues caused by:

Consistently reclaimed and reused powder

  • Make sure Virgin Powder to Reclaimed Powder is 3:1 Ratio. 
  • EX: 15 Pounds Virgin Powder to 5 Pounds Reclaim Powder. 

Contamination

  • Make sure the powder box is always closed when not in use, contaminations float in the air.
  • Make sure everything that the powder touches prior and during use have been correctly cleaned to keep from contaminating the powder.
  • If running an assembly line do not directly switch from a dark powder to a light powder or a textured to a smooth finishes due to increased chance of contamination.
  • If too late and the powder continues having random speckles of different colors or incorrect splotches of finishes, the powder is contaminated and needs to be disposed of correctly.
  • If contaminated in multiple unopened boxes please contact your powder provider.

 Or it could be:

Incorrect air pressure - consult your equipment manufacturer for recommended air pressure.

Hose obstruction

  • Make sure the hose is supplying constant air flow and there is nothing constructing the path. Example: Kinks or something within the hose. 

KV settings (gun voltage) - consult your equipment manufacturer for recommended KV Settings for the type of part being coated.

Reclaim issues caused by:

Consistently reclaimed and reused powder

  • Make sure Virgin Powder to Reclaimed Powder is 3:1 Ratio. 
  • For example: 15 Pounds Virgin Powder to 5 Pounds Reclaim Powder. 

Contamination

  • Make sure the powder box is always closed when not in use, contaminations float in the air.
  • Make sure everything that the powder touches prior and during use have been correctly cleaned to keep from contaminating the powder.
  • If running an assembly line do not directly switch from a dark powder to a light powder or a textured to a smooth finishes due to increased chance of contamination.
  • If too late and the powder continues having random speckles of different colors or incorrect splotches of finishes, the powder is contaminated and needs to be disposed of correctly.
  • If contaminated in multiple unopened boxes please contact your powder provider.

 

Cured film defects

Finished good defects could be caused by:

Poor corrosion resistance - could be caused by:

Undercured powder

  • Make sure the powder is fully cured. If cracking tears a piece of the coating off and if it cracks when you bend it increase your cure times. This means the product is not fully cured.
  • If the product you are coating is larger than normal size products it will take longer for the product to reach recommended heat in order to cure correctly. 
  • Check the Product Code to see if the powder is low cure or Regular cure. 
  • Check with your powder manufacturer or local sales representative if problem continues.

Pretreatment issues - consult with your pretreatment supplier for recommended pretreatment procedures.

Back Ionization - could be caused by:

Spray distance

  • Recommended spray distance is approximately 10-14 inches away from your product, distance may change depending on your equipment. 
  • Please consult with your equipment manufacturer for their recommended distance.

KV Settings (gun voltage) - consult your equipment manufacturer for recommended KV Settings for the type of part being coated.

Film thickness problems due to inconsistent powder flow:

   Hose obstruction -make sure the hose is supplying constant air flow and there is nothing constructing the path. Example: Kinks or something within the hose. 

  Lumpy powder caused y high humidity

  • Keep the product away from humid environments. Humid environments can cause the powder to stick together and become lumpy.

 Lumpy powder caused by high temperature

  • If the product reaches a temperature above 1000F or 380C, the powder then begins to get lumpy. The desired temperature is 800F or 270C or less for storing.

Incorrect air pressure - consult your equipment manufacturer for recommended air pressure.

Grounding

  • Check to make sure everything is grounded correctly.
  • Consult your equipment manufacturer for further instruction if the problem consistently occurs.

Film chipping - could be caused by:

Film thickness being too high:

Check your KV Settings (gun voltage) - consult your equipment manufacturer for recommended KV Settings for the type of part being coated.

Check your spray distance

  • Recommended spray distance is approximately 10-14 inches away from your product, distance may change depending on your equipment. 
  • Please consult with your equipment manufacturer for their recommended distance

Check if your powder flow is inconsistent:

   Hose obstruction -make sure the hose is supplying constant air flow and there is nothing constructing the path. Example: Kinks or something within the hose. 

   Lumpy powder caused by high humidity

  • Keep the product away from humid environments. Humid environments can cause the powder to stick together and become lumpy.

  Lumpy powder caused by high temperature

  • If the product reaches a temperature above 1000F or 380C, the powder then begins to get lumpy. The desired temperature is 800F or 270C or less for storing.

Incorrect air pressure - Consult your equipment manufacturer for recommended air pressure.

Gloss range issues - could be caused by:

Multiple batches?

  • Make sure that you are using the same batch when spraying.
  • If the powders are the same but have different batches, mix the two together to create less color and to finish deviation.
Overcured?
  • If the product is over cured the product may give a tint of yellow.
  • If the product is over cured the gloss may be lower than expected.
  • We recommend correcting by lowering oven temperature or time in oven as per the TDS.
  • Check with your powder manufacturer or local sales representative if problem continues.

Poor flexibility - could be caused by:

Pretreatment issues - consult with your pretreatment supplier for recommended pretreatment procedures.

Undercured powder

  • Make sure the powder is fully cured. If cracking tears a piece of the coating off and if it cracks when you bend it increase your cure times. This means the product is not fully cured.
  • If the product you are coating is larger than normal size products it will take longer for the product to reach recommended heat in order to cure correctly.
  • Check the Product Code to see if the powder is low cure or Regular cure.
  • Check with your powder manufacturer or local sales representative if problem continues.

Film thickness problems due to inconsistent powder flow:

   Hose obstruction -make sure the hose is supplying constant air flow and there is nothing constructing the path. Example: Kinks or something within the hose. 

    Lumpy powder caused by high humidity

  • Keep the product away from humid environments. Humid environments can cause the powder to stick together and become lumpy.

 Lumpy powder caused by high temperature

  • If the product reaches a temperature above 1000F or 380C, the powder then begins to get lumpy. The desired temperature is 800F or 270C or less for storing.

Incorrect air pressure - Consult your equipment manufacturer for recommended air pressure.

Cratering - could be caused by:

Pretreatment issues - consult with your pretreatment supplier for recommended pretreatment procedures.

Contamination

  • Make sure the powder box is always closed when not in use, contaminations float in the air.
  • Make sure everything that the powder touches prior and during use have been correctly cleaned to keep from contaminating the powder.
  • If running an assembly line do not directly switch from a dark powder to a light powder or a textured to a smooth finishes due to increased chance of contamination.
  • If too late and the powder continues having random speckles of different colors or incorrect splotches of finishes, the powder is contaminated and needs to be disposed of correctly.
  • If contaminated in multiple unopened boxes please contact your powder provider.

Liquid in air lines

  • Flush the water out of the lines.
  • If there is a consistent problem install a filter.

Poor pencil hardness - could be caused by:

Undercured powder

  • Make sure the powder is fully cured. If cracking tears a piece of the coating off and if it cracks when you bend it increase your cure times. This means the product is not fully cured.
  • If the product you are coating is larger than normal size products it will take longer for the product to reach recommended heat in order to cure correctly.
  • Check the Product Code to see if the powder is low cure or Regular cure.
  • Check with your powder manufacturer or local sales representative if problem continues.

Poor abrasion resistance - could be caused by:

Undercured powder

  • Make sure the powder is fully cured. If cracking tears a piece of the coating off and if it cracks when you bend it increase your cure times. This means the product is not fully cured.
  • If the product you are coating is larger than normal size products it will take longer for the product to reach recommended heat in order to cure correctly.
  • Check the Product Code to see if the powder is low cure or Regular cure.
  • Check with your powder manufacturer or local sales representative if problem continues.

Orange peel - could be caused by:

Film thickness problems due to inconsistent powder flow:

   Hose obstruction -make sure the hose is supplying constant air flow and there is nothing constructing the path. Example: Kinks or something within the hose. 

 Lumpy powder caused by high humidity

  • Keep the product away from humid environments. Humid environments can cause the powder to stick together and become lumpy.

  Lumpy powder caused by high temperature

  • If the product reaches a temperature above 1000F or 380C, the powder then begins to get lumpy. The desired temperature is 800F or 270C or less for storing.

Incorrect air pressure - Consult your equipment manufacturer for recommended air pressure.

Poor adhesion - could be caused by:

Pretreatment issues - consult with your pretreatment supplier for recommended pretreatment procedures.

Undercured powder

  • Make sure the powder is fully cured. If cracking tears a piece of the coating off and if it cracks when you bend it increase your cure times. This means the product is not fully cured.
  • If the product you are coating is larger than normal size products it will take longer for the product to reach recommended heat in order to cure correctly.
  • Check the Product Code to see if the powder is low cure or Regular cure.
  • Check with your powder manufacturer or local sales representative if problem continues.

Film thickness problems due to inconsistent powder flow:

   Hose obstruction -make sure the hose is supplying constant air flow and there is nothing constructing the path. Example: Kinks or something within the hose. 

   Lumpy powder caused by high humidity

  • Keep the product away from humid environments. Humid environments can cause the powder to stick together and become lumpy.

    Lumpy powder caused by high temperature

  • If the product reaches a temperature above 1000F or 380C, the powder then begins to get lumpy. The desired temperature is 800F or 270C or less for storing.

Incorrect air pressure - Consult your equipment manufacturer for recommended air pressure.

Poor penetration - could be caused by:

Consistently reclaimed and reused powder

  • Make sure Virgin Powder to Reclaimed Powder is 3:1 Ratio. 
  • EX: 15 Pounds Virgin Powder to 5 Pounds Reclaim Powder. 

Contamination

  • Make sure the powder box is always closed when not in use, contaminations float in the air.
  • Make sure everything that the powder touches prior and during use have been correctly cleaned to keep from contaminating the powder.
  • If running an assembly line do not directly switch from a dark powder to a light powder or a textured to a smooth finishes due to increased chance of contamination.
  • If too late and the powder continues having random speckles of different colors or incorrect splotches of finishes, the powder is contaminated and needs to be disposed of correctly.
  • If contaminated in multiple unopened boxes please contact your powder provider

Poor spray distance

  • Recommended spray distance is approximately 10-14 inches away from your product, distance may change depending on your equipment. 
  • Please consult with your equipment manufacturer for their recommended distance.

Grounding

  • Check to make sure everything is grounded correctly.
  • Consult your equipment manufacturer for further instruction if the problem consistently occurs.

Check your KV Settings (gun voltage) - consult your equipment manufacturer for recommended KV Settings for the type of part being coated.

Poor impact resistance - could be caused by:

Pretreatment issues - consult with your pretreatment supplier for recommended pretreatment procedures.

Undercured powder

  • Make sure the powder is fully cured. If cracking tears a piece of the coating off and if it cracks when you bend it increase your cure times. This means the product is not fully cured.
  • If the product you are coating is larger than normal size products it will take longer for the product to reach recommended heat in order to cure correctly.
  • Check the Product Code to see if the powder is low cure or Regular cure.
  • Check with your powder manufacturer or local sales representative if problem continues.

Film thickness problems due to inconsistent powder flow:

   Hose obstruction -make sure the hose is supplying constant air flow and there is nothing constructing the path. Example: Kinks or something within the hose. 

 Lumpy powder caused by high humidity

  • Keep the product away from humid environments. Humid environments can cause the powder to stick together and become lumpy.

 Lumpy powder caused by high temperature

  • If the product reaches a temperature above 1000F or 380C, the powder then begins to get lumpy. The desired temperature is 800F or 270C or less for storing.

 Off coloring or yellowing - could be caused by:

Contamination

  • Make sure the powder box is always closed when not in use, contaminations float in the air.
  • Make sure everything that the powder touches prior and during use have been correctly cleaned to keep from contaminating the powder.
  • If running an assembly line do not directly switch from a dark powder to a light powder or a textured to a smooth finishes due to increased chance of contamination.
  • If too late and the powder continues having random speckles of different colors or incorrect splotches of finishes, the powder is contaminated and needs to be disposed of correctly.
  • If contaminated in multiple unopened boxes please contact your powder provider

Over cured powder

  • If the product is over cured the product may give a tint of yellow.
  • If the product is over cured the gloss may be lower than expected.
  • We recommend correcting by lowering oven temperature or time in oven as per the TDS.
  • Check with your powder manufacturer or local sales representative if problem continues.

Speckle - could be caused by:

Contamination

  • Make sure the powder box is always closed when not in use, contaminations float in the air.
  • Make sure everything that the powder touches prior and during use have been correctly cleaned to keep from contaminating the powder.
  • If running an assembly line do not directly switch from a dark powder to a light powder or a textured to a smooth finishes due to increased chance of contamination.
  • If too late and the powder continues having random speckles of different colors or incorrect splotches of finishes, the powder is contaminated and needs to be disposed of correctly.
  • If contaminated in multiple unopened boxes please contact your powder provider.