Our Process
World-class coating processes with precision at every step. From surface preparation to final quality check, we ensure excellence that lasts for decades.
Powder Coating Process
A durable and environmentally friendly finishing process where dry powder is applied electrostatically and cured under heat to form a tough, protective finish.
Step-by-Step Process
Each step is carefully executed with precision equipment and expert supervision
Pre-Treatment
7-Tank Chemical Process
The foundation of a quality coating. Raw aluminium profiles pass through our advanced 7-tank pre-treatment line. Each tank performs a critical function: removing manufacturing oils, etching the surface for better adhesion, and applying chromate conversion coating for superior corrosion resistance.
Tank 1: Etching & Degreasing
Removes oils, grease & etches surface for adhesion
Tank 2: Water Rinse
Removes etching chemicals thoroughly
Tank 3: Water Rinse
Secondary rinse for complete cleaning
Tank 4: Yellow Chromatizing / Chrome Free
Applies corrosion-resistant chromate or chrome-free layer
Tank 5: DM Water Rinse
Rinse with demineralized water
Tank 6: DM Water Rinse
Final demineralized water rinse
Tank 7: Dry-Off Oven
Complete moisture removal at 100°C
Powder Application
GEMA Electrostatic Technology
Treated profiles enter our climate-controlled spray booth. Using Swiss-made GEMA electrostatic spray guns, finely ground powder particles are electrically charged and attracted to the grounded metal surface. This ensures uniform 60-80 micron coverage on aluminium surfaces.
GEMA Electrostatic Guns
High-transfer efficiency electrostatic spray guns
Powder Charging
60-100 kV electrostatic charge applied
GEMA Filtration System
Advanced filtration for clean spray environment
Transfer Efficiency
80-85% powder transfer efficiency
Thickness Control
Target: 60-80 microns (±5 microns)
Color Matching
RAL, Interpon & custom colors available
Curing
Precision Heat Treatment
Coated profiles travel through our state-of-the-art curing oven on an automated conveyor. At 180-200°C, the powder undergoes three phases: melting, flowing (leveling), and finally cross-linking into a dense, molecularly-bonded finish. This creates a coating 10x harder than liquid paint.
Phase 1: Melt
Powder particles liquefy and flow together
Phase 2: Level
Molten coating spreads uniformly across surface
Phase 3: Cross-Link
Chemical bonds form creating hard finish
Heat Distribution
Multi-zone burners ensure ±2°C uniformity
Conveyor Speed
Precisely calibrated for optimal cure time
Result
Weather-proof, UV-stable finish
Quality Inspection
Multi-Point Testing
Before packaging, every profile undergoes comprehensive quality testing by our trained inspectors. We use digital instruments to verify coating thickness, adhesion strength, surface hardness, and gloss levels. Only profiles passing all parameters are approved for dispatch.
DFT Measurement
Digital gauge: 60-80 microns required
Cross-Hatch Test
ISO 2409 adhesion classification 0-1
Gloss Meter
Verifies gloss units per specification
Pencil Hardness
Minimum 2H hardness level required
Impact Resistance
No cracking at 50 kg-cm impact
Visual Inspection
100% inspection for defects & uniformity — Colorimeter
Pre-Treatment
7-Tank Chemical Process
The foundation of a quality coating. Raw aluminium profiles pass through our advanced 7-tank pre-treatment line. Each tank performs a critical function: removing manufacturing oils, etching the surface for better adhesion, and applying chromate conversion coating for superior corrosion resistance.
View Process Details
Tank 1: Etching & Degreasing
Removes oils, grease & etches surface for adhesion
Tank 2: Water Rinse
Removes etching chemicals thoroughly
Tank 3: Water Rinse
Secondary rinse for complete cleaning
Tank 4: Yellow Chromatizing / Chrome Free
Applies corrosion-resistant chromate or chrome-free layer
Tank 5: DM Water Rinse
Rinse with demineralized water
Tank 6: DM Water Rinse
Final demineralized water rinse
Tank 7: Dry-Off Oven
Complete moisture removal at 100°C
Powder Application
GEMA Electrostatic Technology
Treated profiles enter our climate-controlled spray booth. Using Swiss-made GEMA electrostatic spray guns, finely ground powder particles are electrically charged and attracted to the grounded metal surface. This ensures uniform 60-80 micron coverage on aluminium surfaces.
View Process Details
GEMA Electrostatic Guns
High-transfer efficiency electrostatic spray guns
Powder Charging
60-100 kV electrostatic charge applied
GEMA Filtration System
Advanced filtration for clean spray environment
Transfer Efficiency
80-85% powder transfer efficiency
Thickness Control
Target: 60-80 microns (±5 microns)
Color Matching
RAL, Interpon & custom colors available
Curing
Precision Heat Treatment
Coated profiles travel through our state-of-the-art curing oven on an automated conveyor. At 180-200°C, the powder undergoes three phases: melting, flowing (leveling), and finally cross-linking into a dense, molecularly-bonded finish. This creates a coating 10x harder than liquid paint.
View Process Details
Phase 1: Melt
Powder particles liquefy and flow together
Phase 2: Level
Molten coating spreads uniformly across surface
Phase 3: Cross-Link
Chemical bonds form creating hard finish
Heat Distribution
Multi-zone burners ensure ±2°C uniformity
Conveyor Speed
Precisely calibrated for optimal cure time
Result
Weather-proof, UV-stable finish
Quality Inspection
Multi-Point Testing
Before packaging, every profile undergoes comprehensive quality testing by our trained inspectors. We use digital instruments to verify coating thickness, adhesion strength, surface hardness, and gloss levels. Only profiles passing all parameters are approved for dispatch.
View Process Details
DFT Measurement
Digital gauge: 60-80 microns required
Cross-Hatch Test
ISO 2409 adhesion classification 0-1
Gloss Meter
Verifies gloss units per specification
Pencil Hardness
Minimum 2H hardness level required
Impact Resistance
No cracking at 50 kg-cm impact
Visual Inspection
100% inspection for defects & uniformity — Colorimeter
Rigorous Testing Standards
Every batch undergoes comprehensive quality testing to ensure coating performance meets international standards
Impact Test
Measures coating flexibility and adhesion under impact
DFT Test
Dry Film Thickness verification using digital gauges
Gloss Level
Ensures consistent sheen across all finished pieces
MEK Test
Methyl Ethyl Ketone rub test for cure verification
Crosshatch Adhesion
ASTM D3359 cross-hatch tape test for coating bond strength
Shade Matching
Visual and colorimeter comparison against master sample
Hot Water Boiling Adhesion
Boiling water immersion test for adhesion integrity
Pencil Hardness
Pencil hardness testing per ASTM D3363 for scratch resistance
Conical Bend Mandrel
Flexibility test per ASTM D522 without cracking or peeling
Salt Spray Test
ASTM B117 salt fog exposure for corrosion resistance
UV Color Retention
Accelerated weathering test for color and gloss stability
Etch Rate & Chrome Weight
Pre-treatment quality verification per AAMA standards
Eco-Friendly Operations
We are deeply committed to environmental protection. Our powder coating process produces zero VOC emissions, and our state-of-the-art effluent treatment plant ensures responsible water management.
Effluent Treatment Plant
Advanced water treatment system for responsible disposal
Zero VOC Emissions
Powder coating eliminates harmful solvent emissions
Recyclable Overspray
Unused powder is collected and reused, minimizing waste
See Our Quality First-Hand
Schedule a factory visit or request samples to see our quality standards in action.