Troubleshooting Guide

Having problems on your line? Check out the common issues and ways to solve them below. If your problem isn’t there, give us a call on 940.612.0401 or email at Polychem@ifscoatings.com and we’ll do our best to assist you.

General points on applying Polychem:

  • Application variables influence the appearance of a finish to a greater degree
  • Generally, Polychem powders should be applied at a higher mil. Thickness, especially the rivet textured and lower gloss finishes.
  • Certain shades will not hide as well when the gloss is lower, especially whites, yellows, light grays and off whites.

 

Problem

Possible Cause

Solution

Back ionization

Excess film thickness

Reduce film thickness by decreasing spray time and/or powder flow air pressure.

Grounding

Confirm all your equipment is properly grounded.

Spray distance

Recommended spray distance is approximately 10-14 inches away from your product, distance may change depending on your equipment settings and part configuration.

KV settings

Improve the ground connections and/or lower the KV settings.

 

Problem

Possible Cause

Solution

Change of color (yellowing)

Overbaking

Adjust line speed

Improper oven exhaust

Check exhaust fans

Oven temperature too high

Adjust oven temperature accordingly

Gas ovens: quality of gas

Ensure coatings are suitable for gas ovens. Consult coatings manufacturer.

 

Problem

Possible Cause

Solution

Charging

Poor grounding

Check the ground and all contact areas are free of powder build-up and other insulating materials.

Voltage is too low or interrupted

Increase the voltage or check for broken electrodes.

Conveying air pressure too high

Adjust the equipment air setting to its optimum.

Wrong hose material

Consult your equipment  manufacturer for a recommended hose.

 

Problem

Possible Cause

Solution

Chipping

Cure Schedule

Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.

Film thickness

Reduce film thickness by decreasing spray time and/or air pressure.

Poor substrate

Ensure parts are properly cleaned and pre-treatment s in good working order.

 

Problem

Possible Cause

Solution

Color differentiations

Same color differs between suppliers

Purchase each color from the same supplier.

 

Problem

Possible Cause

Solution

Contamination

Overspray or dirt in the spray booth, on conveyor or hangers

Clean booth, strip hangers as required and ensure parts are properly dried before entering the booth.

 

Problem

Possible Cause

Solution

Cratering

Contamination

Make sure the gun, hopper and spray booth is completely cleaned and that the powder was stored correctly.

Contamination in air line

Ensure that the air is clean and dry. Check oil absorption unit. If there is a consistent problem, install a filter.

Pretreatment

Ensure that parts are properly cleaned and that pre-treatment is in good working order. Consult with your pre-treatment supplier for recommended pre-treatment procedures.

 

Problem

Possible Cause

Solution

Craters and starbursts when recoating

Back ionization due to inferior ground (insulation)

Avoid too high of a film thickness on the first base coat; check for clean hooks.

Recoat/topcoat with tribo/airstatic equipment is used, lower the voltage.

Too high voltage

Lower gun KV settings.

Poor grounding

Check ground from conveyor rail to part

Distance gun tip to part too close

Increase distance of gun tip to part

 

Problem

Possible Cause

Solution

Dripping

Cure temperature

Reduce oven temperature and/or time accordingly.

Film thickness is too high

Adjust equipment accordingly

 

Problem

Possible Cause

Solution

Foaming of the surface

IR-oven: temperature too high

Increase line speed, or reduce the temperature.

 

Problem

Possible Cause

Solution

Gloss deviation

Incompatibility of two powder types

Use only one batch at a time and avoid mixing.

 

Problem

Possible Cause

Solution

Gloss too high

Under cured

Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.

 

Problem

Possible Cause

Solution

Gloss too low

Contamination

Make sure the gun, hopper and spray booth is completely cleaned and that the powder was stored correctly.

Over cured

Decrease oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.

 

Problem

Possible Cause

Solution

Lack of fluidization

No fluidizing air

Check the air supply or change hose for one with larger inside diameter.

Obstructed membrane

Adjust the seating of the membrane and check for plugged pores.

Packed or moist powder

Extend fluidization with dry clean and pol free air or manually loosen powder. Sieving powder may be necessary.

 

Problem

Possible Cause

Solution

Lack of polymerization

Cure cycle too short and/or substrate temperature too low

Check cycles and substrate temperature.

 

Problem

Possible Cause

Solution

Lumps or packed powder

Improper storage – temperature or humidity too high, or shelf life expired

Screen and sieve powder prior to spraying. Consult powder supplier.

 

Problem

Possible Cause

Solution

Metallic: change in metallic appearance (areas with varied metallic appearance)

Variation in the cure cycles

Maintain the temperature at a consistent level.

Variation of the distance between powder gun and object

Maintain consistent distance while spraying.

 

Problem

Possible Cause

Solution

Metallics: no charge

Shortcut due to powder build up in the gun and hoses

Consult the equipment manufacturer and use adaptors suitable for metallic application (electrodes outside).

 

Problem

Possible Cause

Solution

Off color or yellowing

Film thickness variation

Verify that product is applied at manufacturers’ recommended film thickness. Film thickness may vary depending on the product, powder and equipment that is used.

Oven exhaust

Confirm that the exhaust system is functioning correctly.

Over cured

Decrease oven temperature and/or time, coating may begin yellowing if over cured. Verify that the object itself reaches the correct cure temperature for the correct time.

 

Problem

Possible Cause

Solution

Orange peel

Substrate heat up time

Adjust oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.

Improper storage

Make sure that the powder has been stored in the proper environment. Storage in high temperature or humidity can ruin powder.

Film thickness

Verify that product is applied at manufacturers’ recommended film thickness. Film thickness may vary depending on the product, powder and equipment that is used.

Conveyor line is interrupted variance in substrate wall

Avoid line slow or shut down optimize cure cycle.

 

Problem

Possible Cause

Solution

Outgassing

Film thickness

Verify that product is applied at manufacturers’ recommended film thickness. Film thickness may vary depending on the product, powder and equipment that is used.

Poor substrate

Porous substrates such as blasted, cast, or galvanized parts may require a pre-bake over the recommended cure schedule.

 

Problem

Possible Cause

Solution

Pinholes

Outgassing of the substrate materials

Degassing by pre-heating or use Out Gassing Forgiving (OGF) materials. Available through Polychem

Film thickness too high

Apply less coating

Powder too moist

Check air dryer

Contamination

Make sure the gun, hopper and spray booth are completely cleaned and that the powder was stored correctly.

 

Problem

Possible Cause

Solution

Plugged hoses

Conveying air pressure too high

Adjust air pressure accordingly.

Incorrect hose material

Consult equipment manufacturer for correct nozzle materials.

Moisture in air supply

Clean air supply and ensure free of oil and dirt.

Worn parts or pumps

Consult equipment manufacturer.

 

Problem

Possible Cause

Solution

Poor abrasion resistance

Under cured

Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.

 

Problem

Possible Cause

Solution

Poor adhesion

Film thickness

Verify that product is applied at manufacturers’ recommended film thickness. Film thickness may vary depending on the product, powder and equipment that is used.

Pre-treatment

Ensure parts are properly cleaned and pre-treatment is in good working order. Consult with your pre-treatment supplier for recommended pre-treatment procedures.

Under cured

Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.

 

Problem

Possible Cause

Solution

Poor corrosion resistance

Film thickness (too thin)

Verify that product is applied at manufacturers’ recommended film thickness. Film thickness may vary depending on the product, powder and equipment that is used.

Pre-treatment

Ensure parts are properly cleaned and pre-treatment is in good working order. Consult with your pre-treatment supplier for recommended pre-treatment procedures.

Under cured

Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.

 

Problem

Possible Cause

Solution

Poor flexibility

Film thickness

Verify that product is applied at manufacturers’ recommended film thickness. Film thickness may vary depending on the product, powder and equipment that is used.

Pre-treatment

Ensure parts are properly cleaned and pre-treatment is in good working order. Consult with your pre-treatment supplier for recommended pre-treatment procedures.

Under cured

Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.

 

Problem

Possible Cause

Solution

Poor flow

Film thickness too high

Adjust equipment accordingly.

Film build too low

Increase film thickness.

Cure temperature

Adjust the temperature up/down accordingly. Check heat-up rate of oven and temperature recordings.

 

Problem

Possible Cause

Solution

Poor penetration

KV settings

Limit the micro amps, lower voltage.

Spray distance

Recommended spray distance is approximately 10-14 inches away from your product, distance may change depending on your equipment settings and part configuration.

Poor ground

Confirm that all your equipment is properly grounded.

 

Problem

Possible Cause

Solution

Poor penetration into corners and recesses

Voltage too high

Adjust gun voltage accordingly

Gun nozzle type

Select appropriate nozzle to ensure spray patter is not too wide/narrow.

Powder delivery air too high

Adjust accordingly

Faraday cage effect

Use Tribo/airstatic processed powder and spray equipment

 

Problem

Possible Cause

Solution

Poor pencil hardness

Under cured

Increase oven temperature and/or time. Make sure that the object itself reaches the correct cure temperature for the correct time.

 

Problem

Possible Cause

Solution

Poor recoatability

Too high of a film thickness is causing insulation

Recoat top coat with tribo/airstatic equipment. If E-static equipment is used, lower the voltage.

Poor grounding

Check for clean hooks.

 

Problem

Possible Cause

Solution

Powder is spitting or surging

Hose may be too long or kinked

Reduce hose length and ensure consistent air pressure.

Inconsistent powder supply

Insufficient or irregular air pressure Check for plugged pores or compacted powder in lines.

 

Problem

Possible Cause

Solution

Speckle

Contamination

Make sure the gun, hopper and spray booth is completely cleaned and that the powder was stored correctly.

 

Problem

Possible Cause

Solution

Uneven film thickness

Distance between gun and part is too close

Move the gun further away from the part.

Powder is delivered inconsistently

Adjust the equipment/air setting to its optimum.

Irregular voltage

Check the entire system (from voltage source to electrode) to ensure continuous electrical charge.

PLSF20040
PLSF50180
PLFS91169
PLFS91169
PRSF94199
SRSF10753
PLSS10754
PLFL91847
PRMF91815
PLMF91843
URWL91850
PRMF92492
PRMF91817
PRSL92476
PRFM91777
PRMF91814
PLRS92473
PRSF93612
PLMF91281
PRMS90918
PLFL92685
PRSF10729
ERFM10617
PLFF10236
PRSF93612
PRSF92880
PRRS90674
PRSL31424
PRRL10519
PRSF95885
PRRS90674
PRMF91814
PRMS92390
SRSF96612
SRSF96613
SLSL96614
SLSL96615
SLSL96616
SRSF96611
PRSL31424
PRRS90674
PRML96927
ERFM10617
PLSF 94197
PLSF94856
PLFL21454
PRSS91826
PLSF95290
PLSF95287
URSF95297
PRSF93989
PLSF93451
URSF20479
PLFL20617
PRSS93569
PRSF93989
PRSS20996
PLRS92140
PLSF93451
URSF20479
PLBF20827
PLRS93383
PLFL21072
PRMS93469
PLMF93575
PLMS91695
PLMS93176
PLMS93175
PLRS93329
PRSS93569
PLRS93383
PLMS91695
PLSF95287
PLSF94856
PLFL21072
PRSF93989
PLRF21537
PLMS91695
URWL91778
PLSS20366PT
PRFS22134
PRSL91803
PRMF91813
PRSL92478
PLHS41717
PLFL91229
PLFL43398
PLFL92611
PRSS93804
PRHS90636
PRMS90721
PRRS90687
PRFL90605
PLSS90582
PLRS90635
PLFL95588
PRFL90583
PLHS92002
PLRS91893
PLRS91894