{"id":11863,"date":"2021-06-11T06:05:34","date_gmt":"2021-06-11T12:05:34","guid":{"rendered":"https:\/\/www.ulprospector.com\/knowledge\/?p=11863"},"modified":"2024-06-26T08:47:33","modified_gmt":"2024-06-26T14:47:33","slug":"pc-the-remarkable-technology-of-coil-coating","status":"publish","type":"post","link":"https:\/\/ulprospector.ul.com\/11863\/pc-the-remarkable-technology-of-coil-coating\/","title":{"rendered":"The Remarkable Technology of Coil Coating"},"content":{"rendered":"<p><img loading=\"lazy\" decoding=\"async\" class=\"alignright size-full wp-image-11891\" src=\"https:\/\/ulprospector.ul.com\/media\/2021\/06\/coilcoating03-600x400-1.png\" alt=\"coil coating\" width=\"600\" height=\"400\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2021\/06\/coilcoating03-600x400-1.png 600w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2021\/06\/coilcoating03-600x400-1-300x200.png 300w\" sizes=\"(max-width: 600px) 100vw, 600px\" \/>The <a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings\/Formulation\/search?k=Coil%20Coatings&amp;st=31&amp;utm_source=KnowledgeCenter&amp;utm_medium=article&amp;utm_campaign=2021pc&amp;utm_term=coilcoatings\" target=\"_blank\" rel=\"noopener\">coil coating<\/a> process (see Diagram 1) provides a way to rapidly apply a variety of paints in a uniform, controlled, continuous and quality fashion at line speeds varying from 100 to 700 feet per minute with the paint being cured in 15-45 seconds to achieve a Peak Metal Temperature of 390 to 480\u00b0F depending on the paint and metal thickness. In the coil coating process, the metal coil is first unwound, cleaned and pre-treated, one or more layers of paint are applied on a flat continuous sheet, heat cured, cooled and rewound for shipment. At the fabricator, it is then cut to the desired size and formed into its finished shape.<\/p>\n<p>Since the metal is first painted and then formed into a part, coil coatings are frequently referred to as pre-paint. Pre-paint refers to the process of painting metal before fabrication rather than painting a formed article. \u00a0The coated product must not only be able to be cured quickly, it must also be flexible and resistant to pressure mottling as coated coils can weigh several tons.<\/p>\n<h3>Primary coil coated metal substrates include:<\/h3>\n<ul>\n<li>Steel\n<ul>\n<li>Cold rolled and hot rolled steel<\/li>\n<li>Galvanized steel (zinc coated steel \u2014 hot dip and electrogalvanized)<\/li>\n<li>Galfan (~95% zinc and 5% aluminum coated steel)<\/li>\n<li>Galvalume (43.5% zinc, 55% aluminum-with 1.5% silicon coated steel)<\/li>\n<\/ul>\n<\/li>\n<li>Aluminum<\/li>\n<\/ul>\n<p>Compared to most other application methods, coil coating is nearly 100% efficient from a paint usage standpoint. As opposed to a spray-applied coating, a coil-coated product offers uniform film thickness rather than the thicker films on edges, corners and bends that are more typical of spray-applied coatings.<\/p>\n<h3>Benefits of coil coating:<\/h3>\n<ul>\n<li>Consistent quality<\/li>\n<li>High speed<\/li>\n<li>Nearly 100% efficient, therefore lower cost<\/li>\n<li>High quality<\/li>\n<li>Lower environmental impact<\/li>\n<li>Wide range of metal types<\/li>\n<li>A wide variety of coating types available<\/li>\n<li>Flexibility<\/li>\n<\/ul>\n<figure id=\"attachment_2865\" class=\"thumbnail wp-caption aligncenter\" style=\"width: 498px\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-2865\" src=\"https:\/\/ulprospector.ul.com\/media\/2015\/08\/coil2.png\" alt=\"Diagram I \u2013 Typical Coil Coating Line\" width=\"498\" height=\"260\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2015\/08\/coil2.png 498w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2015\/08\/coil2-300x157.png 300w\" sizes=\"(max-width: 498px) 100vw, 498px\" \/><figcaption class=\"caption wp-caption-text\">Diagram I \u2013 Typical Coil Coating Line<\/figcaption><\/figure>\n<p>Topcoats are applied by reverse roll coat in which the applicator roll travels in the reverse direction of the strip and thus provides a smoother film with fewer defects. <a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings\/search?k=primer&amp;st=31&amp;utm_source=KnowledgeCenter&amp;utm_medium=article&amp;utm_campaign=2021pc&amp;utm_term=coilcoatings\" target=\"_blank\" rel=\"noopener\">Primers<\/a>\u00a0and backers are normally applied by direct roll coating. Some lines also apply coil coatings using an extruder or via a solid block of paint with a softening point such that it can be applied smoothly when heated.<\/p>\n<p>Coil coating physical types include solvent borne, waterborne, powder and solid block paints.<\/p>\n<p><strong>Schematic 1 \u2013 Paint layers in a typical exterior surface<\/strong><\/p>\n<figure id=\"attachment_2867\" class=\"thumbnail wp-caption aligncenter\" style=\"width: 400px\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-2867\" src=\"https:\/\/ulprospector.ul.com\/media\/2015\/08\/coil4.png\" alt=\"\" width=\"400\" height=\"109\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2015\/08\/coil4.png 324w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2015\/08\/coil4-300x81.png 300w\" sizes=\"(max-width: 400px) 100vw, 400px\" \/><figcaption class=\"caption wp-caption-text\">Schematic I &#8211; Coil Coated Substrate<\/figcaption><\/figure>\n<p><strong>Table I \u2013 Synopsis of Coil Coating Options<\/strong><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-11892\" src=\"https:\/\/ulprospector.ul.com\/media\/2021\/06\/Synopsis-of-coil-coating-options.png\" alt=\"Synopsis of coil coating options\" width=\"515\" height=\"406\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2021\/06\/Synopsis-of-coil-coating-options.png 515w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2021\/06\/Synopsis-of-coil-coating-options-300x237.png 300w\" sizes=\"(max-width: 515px) 100vw, 515px\" \/><\/p>\n<p>The total global market size of coil coatings is in the range of $3.5 billion (USD) with <a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings\/search?k=polyester%20coatings&amp;st=31&amp;utm_source=KnowledgeCenter&amp;utm_medium=article&amp;utm_campaign=2021pc&amp;utm_term=coilcoatings\" target=\"_blank\" rel=\"noopener\">polyester coatings<\/a> making up greater than 60% of the total. The types of paint curing employed in the coil industry include thermal, infrared, induction and UV cure. By and large, the vast majority of coil coatings are cured using gas-fired ovens. Accordingly, the remaining portions of this article will focus on thermal-cured coil coatings.<\/p>\n<p>Coil primers and backers are normally applied much thinner than spray-applied liquid or\u00a0<a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings\/search?k=powder%20coatings&amp;st=31&amp;utm_source=KnowledgeCenter&amp;utm_medium=article&amp;utm_campaign=2021pc&amp;utm_term=coilcoatings\" target=\"_blank\" rel=\"noopener\">powder coatings<\/a>,\u00a0<a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings\/search?k=dip&amp;st=31&amp;utm_source=KnowledgeCenter&amp;utm_medium=article&amp;utm_campaign=2021pc&amp;utm_term=coilcoatings\" target=\"_blank\" rel=\"noopener\">dip<\/a>\u00a0or electrocoat paints. Applied primer dry film thicknesses are normally in the range of 4-6 microns, whereas topcoats are normally applied to provide a dry film thickness of 18-20 microns.<\/p>\n<p>Special consideration when formulating coil coatings include adjustments in the resin technology, crosslinking, solvent system,\u00a0<a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings\/search?k=catalyst&amp;st=31&amp;utm_source=KnowledgeCenter&amp;utm_medium=article&amp;utm_campaign=2021pc&amp;utm_term=coilcoatings\" target=\"_blank\" rel=\"noopener\">catalyst<\/a>,\u00a0<a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings\/search?k=surface%20modifiers&amp;st=31&amp;utm_source=KnowledgeCenter&amp;utm_medium=article&amp;utm_campaign=2021pc&amp;utm_term=coilcoatings\" target=\"_blank\" rel=\"noopener\">surface modifiers<\/a>\u00a0and\u00a0<a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings\/Product\/search?k=Lubricants&amp;sug=1&amp;st=31&amp;utm_source=KnowledgeCenter&amp;utm_medium=article&amp;utm_campaign=2021pc&amp;utm_term=coilcoatings\" target=\"_blank\" rel=\"noopener\">lubricants<\/a>\u00a0to accommodate proper cure, flow and leveling, and minimization of surface defects. Once cured, coil coatings can offer excellent handling, physical, chemical and environmental properties. Table II details typical materials utilized in a polyester coil coating.<\/p>\n<p><strong>Table II \u2013 Raw Materials (on Resin Solids) used in a Typical Polyester Coil Topcoat (1.2:1.0 Pigment:Binder, Dupont R960 Titanium Dioxide)<\/strong><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-11893\" src=\"https:\/\/ulprospector.ul.com\/media\/2021\/06\/Raw-Materials.png\" alt=\"Coil coating raw materials\" width=\"512\" height=\"298\" srcset=\"https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2021\/06\/Raw-Materials.png 512w, https:\/\/ulprospector.ul.com\/wp-content\/uploads\/2021\/06\/Raw-Materials-300x175.png 300w\" sizes=\"(max-width: 512px) 100vw, 512px\" \/><\/p>\n<p>In summary, coil coating technology has grown more rapidly than more conventional application technologies and is projected to grow at a rate in excess of 5% per annum due to a variety of benefits that include cost savings, versatility, environmental, performance and quality issues.<\/p>\n<hr \/>\n<h2>Find the materials you need on your next project with a search on <a href=\"https:\/\/www.ulprospector.com\/en\/na\/Coatings?utm_source=KnowledgeCenter&amp;utm_medium=article&amp;utm_campaign=2021pc&amp;utm_term=coilcoatings\" target=\"_blank\" rel=\"noopener\">ULProspector.com<\/a>.\u00a0 <a href=\"https:\/\/www.ulprospector.com\/session\/new?utm_source=KnowledgeCenter&amp;utm_medium=article&amp;utm_campaign=2021pc&amp;utm_term=coilcoatings\" target=\"_blank\" rel=\"noopener\">Log in<\/a> or <a href=\"https:\/\/www.ulprospector.com\/session\/new?utm_source=KnowledgeCenter&amp;utm_medium=article&amp;utm_campaign=2021pc&amp;utm_term=coilcoatings\" target=\"_blank\" rel=\"noopener\">create your free account<\/a> today!<\/h2>\n","protected":false},"excerpt":{"rendered":"<p>The coil coating process (see Diagram 1) provides a way to rapidly apply a variety of paints in a uniform, controlled, continuous and quality fashion at line speeds varying from 100 to 700 feet per minute with the paint being &hellip; <a href=\"https:\/\/ulprospector.ul.com\/11863\/pc-the-remarkable-technology-of-coil-coating\/\">Continued<\/a><\/p>\n","protected":false},"author":12,"featured_media":11891,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"episode_type":"","audio_file":"","podmotor_file_id":"","podmotor_episode_id":"","cover_image":"","cover_image_id":"","duration":"","filesize":"","filesize_raw":"","date_recorded":"","explicit":"","block":"","itunes_episode_number":"","itunes_title":"","itunes_season_number":"","itunes_episode_type":"","footnotes":""},"categories":[16],"tags":[],"ppma_author":[1249],"class_list":{"0":"post-11863","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-paint-coatings","8":"entry"},"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Learn about the Remarkable Technology of Coil Coating<\/title>\n<meta name=\"description\" content=\"Learn how the coil coating process provides a way to rapidly apply a variety of paints in a uniform, controlled, and quality fashion.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/ulprospector.ul.com\/11863\/pc-the-remarkable-technology-of-coil-coating\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Learn about the Remarkable Technology of Coil Coating\" \/>\n<meta property=\"og:description\" content=\"Learn how the coil coating process provides a way to rapidly apply a variety of paints in a uniform, controlled, and quality fashion. 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Lewarchik, President and CEO of Chemical Dynamics, LLC, brings 40 years of paint and coatings industry expertise to his role as a contributing author with the Prospector Knowledge Center. As a contributing writer, Ron pens articles on topics relevant to formulators in the coatings industry. He also serves as a consultant for the Prospector materials search engine, advising on issues related to optimization and organization materials within the database. Ron's company, Chemical Dynamics, LLC (www.chemicaldynamics.net), is a full-service paint and coatings firm specializing in consulting and product development based in Plymouth, Michigan. Since 2004, he has provided consulting, product development, contract research, feasibility studies, failure mode analysis and more for a wide range of clients, as well as their suppliers, customers and coaters. He has also served as an Adjunct Research Professor at the Coatings Research Institute of Eastern Michigan University. As such, Ron was awarded a sub-grant from the Department of Energy to develop energy-saving coating technology for architectural applications, as well as grants from private industry to develop low energy cure, low VOC compliant coatings. He taught courses on color and application of automotive top coats, cathodic electro-coat and surface treatment. His experience includes coatings for automotive, coil, architectural, industrial and product finishing. Previously, Ron was the Vice President of Industrial Research and Technology, as well as the Global Director of Coil Coating Technology for BASF (Morton International). During his fourteen-year tenure with the company, he developed innovative coil coating commercial products primarily for roofing, residential, commercial and industrial building, as well as industrial and automotive applications. He was awarded fifteen patents for new resin and coating formulas. From 1974 to 1990, Ron held positions with Desoto, Inc. and PPG Industries. He was the winner of two R&amp;D awards for coatings utilizing PVDF resins, developed the first commercial high solids automotive topcoat and was awarded 39 U.S. patents for a variety of novel technologies he developed. He holds a Masters in Physical Organic Chemistry from the University of Pittsburgh and subsequently studied Polymer Science at Carnegie Mellon University. Ron lives in Brighton, Michigan with his family. 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Lewarchik, President and CEO of Chemical Dynamics, LLC, brings 40 years of paint and coatings industry expertise to his role as a contributing author with the Prospector Knowledge Center. As a contributing writer, Ron pens articles on topics relevant to formulators in the coatings industry. He also serves as a consultant for the Prospector materials search engine, advising on issues related to optimization and organization materials within the database. Ron's company, Chemical Dynamics, LLC (www.chemicaldynamics.net), is a full-service paint and coatings firm specializing in consulting and product development based in Plymouth, Michigan. Since 2004, he has provided consulting, product development, contract research, feasibility studies, failure mode analysis and more for a wide range of clients, as well as their suppliers, customers and coaters. He has also served as an Adjunct Research Professor at the Coatings Research Institute of Eastern Michigan University. As such, Ron was awarded a sub-grant from the Department of Energy to develop energy-saving coating technology for architectural applications, as well as grants from private industry to develop low energy cure, low VOC compliant coatings. He taught courses on color and application of automotive top coats, cathodic electro-coat and surface treatment. His experience includes coatings for automotive, coil, architectural, industrial and product finishing. Previously, Ron was the Vice President of Industrial Research and Technology, as well as the Global Director of Coil Coating Technology for BASF (Morton International). During his fourteen-year tenure with the company, he developed innovative coil coating commercial products primarily for roofing, residential, commercial and industrial building, as well as industrial and automotive applications. He was awarded fifteen patents for new resin and coating formulas. From 1974 to 1990, Ron held positions with Desoto, Inc. and PPG Industries. He was the winner of two R&amp;D awards for coatings utilizing PVDF resins, developed the first commercial high solids automotive topcoat and was awarded 39 U.S. patents for a variety of novel technologies he developed. He holds a Masters in Physical Organic Chemistry from the University of Pittsburgh and subsequently studied Polymer Science at Carnegie Mellon University. Ron lives in Brighton, Michigan with his family. Contact Ron via email\u00a0or through his company\u2019s web site at www.chemicaldynamics.net to learn more about his consulting services\u2026","sameAs":["https:\/\/ulprospector.ul.com"],"url":"https:\/\/ulprospector.ul.com\/author\/ron-lewarchik\/"}]}},"authors":[{"term_id":1249,"user_id":12,"is_guest":0,"slug":"ron-lewarchik","display_name":"Ron Lewarchik","avatar_url":"https:\/\/ulprospector.ul.com\/media\/2014\/05\/Ron-Lewarchik_avatar_1399393591-96x96.png","0":null,"1":"","2":"","3":"","4":"","5":"","6":"","7":"","8":""}],"_links":{"self":[{"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/posts\/11863","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/users\/12"}],"replies":[{"embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/comments?post=11863"}],"version-history":[{"count":0,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/posts\/11863\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/media\/11891"}],"wp:attachment":[{"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/media?parent=11863"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/categories?post=11863"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/tags?post=11863"},{"taxonomy":"author","embeddable":true,"href":"https:\/\/ulprospector.ul.com\/wp-json\/wp\/v2\/ppma_author?post=11863"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}