Technical Support
Troubleshooting
Guide
Root causes and corrective actions for the most common powder coating application and appearance problems.
01
Back Ionization
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Excess film thickness
Reduce film thickness by decreasing spray time and/or powder flow air pressure.
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Poor equipment grounding
Confirm all equipment is properly grounded. Check every contact point from conveyor rail to part.
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Incorrect spray distance
Recommended spray distance is approximately 10–14 inches from your product. Distance may vary depending on equipment settings and part configuration.
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KV settings too high
Improve ground connections and/or lower the KV settings on the gun.
02
Color Yellowing
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Improper oven exhaust
Check exhaust fans are functioning correctly and airflow is unobstructed.
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Oven temperature too high
Adjust oven temperature accordingly. Verify the object itself reaches the correct cure temperature for the correct time without exceeding it.
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Gas oven combustion quality
Ensure coatings are suitable for gas ovens. Consult IFS, as some formulations are sensitive to combustion by-products.
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Over-curing
Decrease oven temperature and/or dwell time. Yellowing commonly results from over-cure; verify substrate temperature with a profile recorder.
03
Orange Peel Effect
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Substrate heat-up time
Adjust oven temperature and/or time so the object reaches the correct cure temperature at the correct rate. A sudden heat spike can cause orange peel before the film has levelled.
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Improper powder storage
Ensure powder has been stored in correct conditions, away from high temperature or humidity. Degraded powder will not flow and level properly.
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Film thickness outside specification
Verify product is applied at the manufacturer's recommended film thickness. Both too thin and too thick film can cause texturing.
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Conveyor line interruption
Avoid line slow-downs or shutdowns mid-cure. Optimise the cure cycle so parts move through the oven consistently.
04
Fisheyes & Craters
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Contamination in air line
Ensure compressed air is clean and dry. Check the oil absorption unit, and if contamination persists, install an inline filter upstream of the gun.
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Contaminated substrate
Ensure parts are properly cleaned and pre-treatment is in good working order. Even fingerprints or residual release agents cause cratering.
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Silicone or oil in environment
Identify and eliminate silicone sources in the spray area. Lubricants, release agents, hand creams, and neighbouring processes are common culprits.
05
Picture Framing
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Excessive voltage at edges
Reduce gun kV settings when spraying edges and corners. The Faraday effect concentrates charge at edges, causing film to build faster there.
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Gun angle too perpendicular
Angle the gun slightly away from the edge rather than spraying directly at it. Feathering the gun reduces edge concentration.
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Uneven film build
Check film thickness across the full part, particularly at edges versus flat panels. Adjust spray speed and overlap to achieve consistency throughout.
06
Poor Opacity / Color
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Film thickness too low
Increase film build. IFS powders generally require a slightly higher mil thickness than other brands, especially river-textured and low-gloss finishes.
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Inherently low-hiding shades
Whites, yellows, light grays, and off-whites are the most challenging shades. Apply at the upper end of the recommended film thickness range for these colors.
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Film thickness variation
Uneven application causes color variation across the part. Maintain consistent gun-to-part distance and uniform spray speed.
07
Adhesion Problems
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Inadequate pre-treatment
Ensure parts are properly cleaned and pre-treatment is in good working order. Consult your pre-treatment supplier for procedures appropriate to your substrate.
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Contamination on substrate
Check all contact areas, including hook contact points, are free of powder build-up, oils, and other insulating materials.
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Poor cure
Under-cured powder will have poor adhesion. Verify the substrate reaches the recommended cure temperature for the full dwell time using a temperature recording device.
08
Powder Falloff
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Poor grounding
Check the ground and ensure all contact areas are free of powder build-up and insulating materials. Poor ground is the most common cause of powder not sticking.
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Voltage too low or interrupted
Increase gun voltage or check for broken/worn electrodes.
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Conveying air pressure too high
Adjust equipment air settings to optimum. Excessive air velocity strips charge from particles before they reach the part.
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High humidity on line
High ambient humidity reduces electrostatic charge effectiveness. Improve ventilation or dehumidify the spray area.
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Lack of hopper fluidization
Check the air supply to the hopper. Inspect the membrane for obstruction. If powder is packed or moist, extend fluidization with clean dry air or manually loosen before sieving.
09
Pinholes & Outgassing
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Porous substrate
Blasted, cast, or galvanised parts may require a pre-bake above the recommended cure schedule to drive out trapped gases before powder is applied.
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Outgassing during cure
Use Out Gassing Forgiving (OGF) materials where available. Alternatively, apply a thinner first coat, partially cure, then apply the topcoat.
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Powder too moist
Check the air dryer. Moist powder releases moisture as steam during cure, creating pinholes. Store powder in a cool, dry environment.
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Contaminated gun or hopper
Ensure the gun, hopper, and spray booth are completely clean. Contamination causes localised outgassing defects.
10
Sagging
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Film thickness too high
Reduce film build by decreasing spray time and/or powder flow air pressure. Excess film slumps under gravity before it gels.
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Conveying air pressure too high
High delivery air causes localised over-build at impact points. Adjust to optimum for uniform deposition.
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Excess powder build-up
Avoid multiple slow passes over the same area. Keep the gun moving at a consistent speed and overlap pattern.
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Line interruption during cure
Avoid stopping the conveyor during cure. If a stoppage occurs in the oven, inspect parts for sagging before resuming.
11
Gloss Variation
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Inconsistent cure cycle
Verify the full cure schedule, both temperature profile and dwell time. Gloss is driven by cross-linking degree; under- or over-cure both alter final gloss.
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Film thickness inconsistency
Uneven film thickness causes uneven cross-linking density. Aim for consistent mil build across the entire surface.
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Mixing incompatible batches
Use only one batch at a time. Even same-color powders from different lots can react and cause gloss deviation.
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Contamination
Ensure the gun, hopper, and spray booth are completely clean. Foreign powder or contamination affects gloss locally.
12
Mottled / Uneven Finish
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Gun too close to part
Move the gun further away. Spraying too close creates a concentrated impact zone that disrupts the powder layer before it can level.
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Inconsistent powder delivery
Adjust equipment and air settings to optimum. Irregular powder flow, often from a blocked hose or worn pump, creates uneven deposition.
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Irregular voltage
Check the entire system from voltage source to electrode. Intermittent charge causes uneven particle adhesion and a mottled appearance.
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Inconsistent gun speed or distance
Maintain consistent gun-to-part distance and traverse speed. Variation in either directly causes film thickness variation.
Direct Support
Still Stuck?
If you're still experiencing problems after consulting the guide, our technical service team is ready to help. Call us or send an email and we'll do our best to assist you.
Technical Hotline: 940-668-1062, open Monday to Friday, Central Time.
Email Support: coatingsinfo@ifscoatings.com, and we'll respond within one business day.
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Troubleshooting Guide PDF
All the tips from our troubleshooting poster condensed into a handy PDF that is printable and shareable with your team.
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