VR201.2 - IGP Coating Powder with IGP-Effectives® Process
IGP Coating Powder with IGP-Effectives® Process.
Introduction
IGP-Effectives® is an innovative finishing process. It provides exceptional application safety for effect powder coatings. Here, unlike conventional effect powder coatings, the application parameters or plant configuration only have a small influence on the coating result. Processing parameters and recovery mode cause only very slight differences in color and effect. Irrespective of the plant and the application, IGP-Effectives® generally creates a uniform coating result.
This VR 201.2 processing instruction informs users about the relevant processing characteristics of IGP-Effectives®.
IGP coating powders with effect agents are agglomerate-free and ensure problem-free, reproducible processing. IGP effect powder coatings come in five main processing categories, from 1-STAR * to 5-STAR*****. The products in the IGP-Effectives group are all classified as 5*, therefore they do not require any higher skills of the coater than processing single color powder coatings.
Fundamental Information
The principal characteristics of these effect powder coatings are their application safety, flow stability, and excellent suitability for processing in recovery mode.
Using IGP-Effectives® technology significantly reduces the otherwise very high requirements that apply to processing effect powder coatings. The user gets a product which is easy and safe to use under the standard
quality criteria in the application process. IGP-Effectives® technology is mainly used for weather-resistant façade qualities in theIGP-DURA®face 58, IGP-HWFsuperior 57 andIGP-HWFclassic 59 series (e.g.: 5807U; 5703U, 5903U). It is indicated by a “U” as the fifth character of the product key.
Project Organization
One Batch, one Application Facility
If the components are installed directly adjacent to each other, we recommend determining the required powder amount for the entire order and planning a certain reserve in order to coat the entire application with a single production batch. This guarantees absolute color and effect consistency of the coating on all objects. For subsequent orders, we recommend exclusively using powder coatings which have also been produced using IGP-Effectives® technology.
Processing
When processing IGP-Effectives® powder coating products, we recommend using corona guns with a negative polarity electrostatic charge. We recommend setting the high voltage to between 60 and 90 KV. A current limitation is not necessary.
At an electron flow of at least 2 μA, the products can also be processed using tribo pistols. Here, we recommend spraying and curing a sample before starting production. Compare this with an approved limiting sample. Depending on the electron flow (μA), deviating nuances in the lightness can occur if you use a tribo pistol.
In order to achieve a smooth, even surface, especially on large-surface objects, observe a pistol spraying distance of at least 180 mm. Further measures during the application ensure the best possible coating thickness distribution on the components, for example optimizing the movements in long-stroke operation using sinus programs or matching the pistol spacing to the stroke height in short-stroke operation.
Ideally, manual application that is necessary in semi-automatic operation should always be performed as a preliminary coat. If this is not possible due to the technical system used, manual application can also be used for the follow-up coating with IGP-Effectives® effect powder coatings. In this case, we recommend observing a spraying distance of more than 200 mm, at least for the final coating. This also applies for pure manual application.
Recovery Operation
As a basic principle,IGP-Effectives® effect powder coatings are very stable in circular processing and ideally suited to use in recovery mode.
Due to the proportion of overspray that is recoved via the separation system, a concentration of fine powder particles (fine grains) may occur when recovery by means of a filter. During the processing of IGP-Effectives® in recovery mode using a cyclone, fine powder particles (fine grain) are continually extracted from the powder coating. In both cases, the grain spectrum is altered.
In order to achieve a consistent grain spectrum during recovery mode, we recommend the continuous addition of fresh powder.
Plant Maintenance and Cleaning
To ensure the coating plant achieves reproducible coating results, the maintenance work for replacing parts subject to wear in the entire plant must be performed at the specified intervals, as recommended by the manufacturer. Various functional tests, e.g. checking the high voltage, must be carried out at regular intervals.
Suspension of the Parts
The suspension of the parts must be determined prior to coating (horizontal or vertical). The intermediate spacing between the coating objects within the hangers as well as the spaces between the hangers must be kept as small and regular as possible. If there are large distances between the hangers, it is advisable to automatically switch the guns on and off via a parts detection system. Furthermore, it must be ensured as far as possible that similar components are always coated together.
Curing
Different curing temperatures and heating speeds of the parts must be avoided. Furthermore, thick and thin-walled parts must be coated separately. Observe the recommended range of curing conditions without fail.
Earthing
Special attention must be given to sufficient earthing when processing coating powders with a pearl mica effect. This measure significantly contributes to a uniform shade and effect formation consistency.
Other Applicable Documents
Recommendations for Processing IGP-Effectives® Effect Powder Coatings
To ensure the coating plant achieves reproducible coating results, the maintenance work for replacing parts subject to wear in the entire plant must be performed at the specified intervals, as recommended by the manufacturer. Various functional tests, e.g. checking the high voltage, must be carried out at regular intervals.
