Prepainted metal is coated with a coil coating process, coating a continuous sheet of metal with a highly efficient process that improves quality and provides many additional benefits.
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Metal coated with coil coating applications may include many surface options in addition to aesthetic paint or finishes. UV resistant, corrosion resistant, weatherproof, and antibacterial coatings are just some of the metal coatings applied with a coil coating process. Prepainted metals by coil coating with state-of-the-art coatings chemistry deliver unique properties not available with post-painted, traditional methods.
Manufacturers who outsource metal finishes to coil coaters realize many benefits over performing these post-painting processes in-house. The most recognizable benefits of prepainted metal include improvements to product quality and cost savings for the manufacturer:
Product and Quality Improvements:1) Improved coating quality and uniformity &#; coil coating sheets of metal provides a more uniform coating application with edge-to-edge coverage on a flat surface that has been consistently prepped and pretreated. Tight coil coating controls maintain this uniform application consistently, which is mandatory for consistent high quality finished products.
2) Two-sided coverage &#; coil coated metals are typically covered on both sides of the metal as opposed to post-painting applications which usually is sprayed or applied only on one side.
3) Improved corrosion resistance &#; with a more uniform and two-sided coverage, metal products are better protected against corrosion with no chance of missed spots that can occur when post-painting on product seams or bends. Once rust begins in an obscure or out-of-sight area, it can be difficult to control and cause product quality issues.
4) Improved mar resistance &#; prepainted metals are protected with improved durability and can easily be moved, stored, and shipped without harming the surface. Coil coated metals retain a more flawless surface over post-painted metal for a beautiful surface coating on finished products.
5) Meets complex forming demands &#; prepainted metals retain excellent resistance to markings by retaining high hardness and durability while still retaining the needed flexibility for complex forming. Many coil coated metals are expected to last a minimum of 50 years with resistance to weather, corrosion, color fading, chemical alterations, dirt, wear, and tear.
Processing and Cost Saving Improvements:Manufacturers that outsource their metal sheet finishings to coil coaters realize many processing and cost saving improvements by freeing up valuable resources. Here are some of the most significant benefits of using prepainted metal:
6) Save on capital equipment &#; coil coating machinery with shipping, placement and installation is costly and requires maintenance along with possible equipment upgrades. Installing coil coating equipment is not a one and done, it is an ongoing process fine-tuned for precise coating and laminating applications.
7) Eliminates the need for a post painting station &#; setting up a coil coating process or even a post painting station can take up a lot of space, capacity that could be used for other manufacturing applications.
8) Improves cycle times &#; prepainted metal eliminates dry times for post painting processes, which can cause massive bottlenecks with painting, drying, and curing, taking space and delaying assembly. Improving processing times and reducing bottlenecks in the process significantly improves cycle times and overall productivity.
9) Staff can focus on core operations &#; utilizing the expertise of a coil coating specialist allows the manufacturer to focus on core operations and eliminates the need to train staff on post-painting processes. Leaders can focus on nurturing customers and growing business opportunities with a simplified supply chain.
10) Reduces risk of environmental contamination &#; proper use, storage and disposal is required of coatings, paints, and industrial adhesives. Companies must maintain compliance to all regulations enforced by the Environmental Protection Agency (EPA) or face costly fines for improper disposal or spills.
The durability and technical capabilities of prepainted metals outlast and outperform post-painted metals with no comparison. You can learn more about manufacturing with prepainted metals from the National Coil Coating Association (NCCA), and contact UNICHEM for all your metal coating needs. Prepainted metals are the material of choice for a wide range of industries and applications, such as vehicles, buildings, equipment, and appliances due to the many benefits to product quality and cost saving efficiencies.
Universal Chemicals & Coatings, Inc., UNICHEM, has been providing coating and adhesive solutions to the coil coating industry for more than 50 years. We have been a market technology leader in industrial coatings, adhesives and paints offering high-quality and customized solutions. Contact us to learn how to improve your prepainted metal coating process and realize maximum benefit with coil coating metal solutions.
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Design with Pre-paint in Mind Even if manufacturers don&#;t plan to begin production using pre-painted metal, they can evolve to pre-paint production by planning for it during the design phase. Below are recommended steps for a team approach to the design process:
Broaden The Design Team: Invite engineers, chemists, marketing, sourcing and supply management, coaters and manufacturing to join discussions during the design process. Emphasize innovation and problem solving to create a seamless transition from design through manufacturing to the end user.
Establish Coating Objectives: Pre-paint can reduce or eliminate an &#;orange peel&#; finish because it offers excellent flow properties. Setting coatings objectives on the front end of the project will help guide the design process.
Explore Ways to Differentiate: A unique appearance for products can be achieved through innovations in color and texture. A manufacturer&#;s coating partner can help weigh the pros and cons of various options. Rather than handing the coater a chip to color match once the design process is complete, ask them to share trends in the marketplace, in colors and finishes and from other industries. They can help balance design, performance, functionality and cost when recommending coatings options.
Establish Vision During Initial Design Phase: Review drawings early with attention toward finish options such as color, texture and gloss. Typically the initial design phase is comprised of several planning meetings with the end vision becoming clearer as meetings progress.
Prepare Lab Display Panels: The team can explore coating options by having the coatings partner prepare lab display panels with various coatings to review.
Plan for Form and Function: The team will want to ensure the coating meets the requirements of both form and function to avoid issues in the launch phase. This will involve weighing the pros and cons of various coating types to meet aesthetics, flexibility, durability and other performance objectives.
Apply Lean Six Sigma to Production Process: The team should assess the entire coating production process to achieve efficiency, from sourcing raw materials to Lean manufacturing. Production lines may need only minor tweaking to accommodate pre-paint or more major production changes that the coatings partner can help implement.
Manufacturers in many industries continue to discover the benefits that can be achieved from pre-painted metal to differentiate their products while improving speed to market. Pre-paint opportunities abound in multiple industries. Through a strong and early design partnership with the coating manufacturer, applicator and substrate supplier, many benefits can be realized. Through the team-design approach, all involved members of the immediate supply chain have a voice and can actively contribute to the success probability offered by a pre-paint process model.
Pre-Paint Design Guidelines
When designing for metal coatings, consider the following:
Substrate Type: The general performance characteristics of the selected substrate will help guide coating selection, including surface topography, yield, tensile and elongation (YTE).
Pretreatment Designation: Determine whether the application requires Restriction of Hazardous Substances (RoHS) compliance.
Durability versus Formability: Understand the specifics around minimum durability requirements such as scratch-resistance and hardness with the knowledge that these characteristics will likely require a compromise with general pre-paint flexibility. Design for pre-paint with as generous-as-possible bend radii to allow for maximum factory formability.
Finish requirements: Appliance &#;industry standard&#; pre-paint finish applications are generally comprised of a &#;primer&#; application and a &#;finish coat&#; application.
Fold Design: Avoid exposed edges on final part design, allowing for an engineered fold to &#;hide&#; cut edges.
Multiple Design Finishes: A large range of finish colors and effects are available in pre-paint coatings, as well as multiple gloss levels.
Mechanical Post-Embossing: For finished part applications that require a mechanical post-emboss, recognize and design for additional finished thickness. Mechanical embossing also can lend structural rigidity to an end-use part.
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