How It's Made
Powder Manufacture
& Application
From raw materials to finished powder, a look inside the IFS manufacturing process and the application methods used by coaters worldwide.
Process
Premix → Extrude → Grind
Bonding
In-House at IFS
Application
Electrostatic
Certification
ISO 9001:2015
Manufacturing Process
How Powder
is Made
Powder coating manufacture is a precision process. Raw materials are combined under heat and pressure, then cooled and ground to an exact particle size. Once the extruder has run, the chemistry is set and there's no going back.
Color that doesn't match after extrusion means starting over from scratch. This is why IFS invests in rigorous color management and quality control at every stage.
ISO 9001:2015 certified facilities- 01
Premix
Raw materials are precisely weighed and blended together. This dry mix, called premix, ensures all components are proportioned correctly before heat is applied.
- 02
Extrusion
The premix is fed into an extruder where controlled heat and pressure completely homogenize the blend. All ingredients are fully melted and fused, and from this point the chemistry is locked in.
- 03
Cooling & Grinding
The hot extrudate is forced through chilled rollers, rapidly cooling into thin, brittle sheets. These sheets break into chips, then are precision-ground down into the final powder particle size.
- 04
Bonding (Metallics)
Metallic and sparkle powders get an additional bonding step. Mica flakes are bonded directly onto powder particles in-house at IFS, delivering a more uniform, professional metallic finish.
Application
Application Methods
IFS manufactures the powder, and professional coaters worldwide apply it. Three main methods are used depending on the application and substrate.
-
Electrostatic / Corona
Most CommonPowder is fluidized in a hopper and pumped to a spray gun. Electrodes at the gun tip charge the powder particles, which are then attracted to the grounded part. The electrostatic bond holds the powder in place until curing.
-
Tribostatic
Friction ChargedPowder particles are charged by friction as they travel through a specially designed tube inside the gun. Requires a specific powder formulation different from corona guns, and is often used for complex geometries.
-
Fluidized Bed
Dip ApplicationA powder bed is fluidized with air so it behaves like a liquid. Pre-heated parts are dipped into the fluidized powder, which melts onto the surface on contact. Used for thick, uniform coatings on smaller parts.
Surface Preparation
Pre-Treatment
Pre-treating the substrate before applying powder is critical. Skip it and you're powder coating dirt, oil, and grease, compromising both adhesion and corrosion performance.
Why Pre-Treatment Matters
At minimum, parts must be cleaned and degreased. For architectural and exterior applications, a full chemical pre-treatment program is essential for long-term adhesion and corrosion protection.
Aluminum Advantage
Unlike liquid PVDF coatings, IFS powder coatings require no chrome-based primer on properly pre-treated aluminum. That's one less layer, less process time, and reduced environmental impact, even at AAMA 2605 performance levels.
Steel Substrates
For steel, a powder primer is recommended. Where corrosion is a concern, a zinc-rich powder primer adds an essential layer of electrochemical protection beneath the topcoat.
Full Pre-Treatment Process
Chrome or non-chrome pre-treatment options are available for aluminum, both compatible with AAMA 2605.
- 01
pH-controlled water clean that removes dirt, oil and contaminants
- 02
Chemical pre-treatment applied, with chrome or non-chrome options available
- 03
Rinse stage that removes pre-treatment residue
- 04
Dry-off oven for rapid drying before powder application
Ready to specify IFS powder?
Our technical team can advise on the right chemistry, pre-treatment, and application method for your line.