---
title: "Troubleshooting Equipment: Powder Application Issues"
description: The Second Part of Our Troubleshooting Series - Common Problems and Solutions
image: https://www.azpowder.com/hubfs/No%20Gema.jpg
---

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 Aug 15, 2024 8:51:19 AM

# Troubleshooting Equipment: Powder Application Issues

[Naomi Johnson](https://www.azpowder.com/blog/author/naomi-johnson)

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The Second Part of Our Troubleshooting Series - Common Problems and Solutions

## Troubleshooting Made Easy

Achieving a perfect finish can sometimes be tricky, even with the best equipment. In this blog, we'll categorize common powder application problems to help you quickly identify and resolve them.

Each issue is linked to a table of possible causes and solutions, making it easy to find the answers you need. Click on the specific issues to get back on track with top-quality results!

## Poor Fluidization:

Air Blowing Large Holes Through Powder Surface

| ##### **Possible Cause** | ##### **Solutions** |
| --- | --- |
| Powder level too low | - Add powder until feed hopper is filled to proper level |
| Packed or moist powder | - Manually loosen powder and fluidize with clean dry air - Check compressed air for oil/water and room for high humidity |
| Obstructed membrane | - Check bottom of feed hopper for obstructions/oil/water. |
| Powder particle size | - Maintain consistent ratio of virgin to reclaim |

Powder Blowing Out of Hopper

| Possible Cause | Solution |
| --- | --- |
| Fluidizing air pressure too high | - Reduce air pressure to fluid bed |
| Insufficient hopper ventilation | - Check hopper vent for blockage - Check vents assist for obstructions and correct air supply |
| Powder too fine | - Reduce the amount of reclaim added to virgin powder |

No Air Percolation Through To Powder Surface

| Possible Cause | Solution |
| --- | --- |
| Insufficient air pressure | - Increase air supply to fluid bed |
| Blocked membrane | - Clean membrane, remove any dirt, grease and obstructions. - Check air supply to ensure it is clean |
| Obstructed membrane | - Remove all obstructions on the membrane |
| Compacted powder on membrane | - Manually loosen powder and fluidize with clean dry air |

## Poor Powder Containment:

Inadequate Air Flow Through Spray Booth

| Possible Cause | Solution |
| --- | --- |
| Primary filter media blocked | · Clean filter system. Replace filter if necessary · Check ambient air for excessive moisture · Check filter air pulse system for correct operation   |
| Final filter blocked | · Check primary filters for powder leakage. Service or replace if necessary   |
| Use of compressed air for booth clean down | · Refer to operating manual for correct cleaning methods   |
| Improper powder gun placement/alignment | · Correct as necessary. Position guns away from booth opening · Check for proper distance from top of part to the conveyor slot opening   |
| Room air drafts causing powder to drift from booth | · Correct as necessary. Position guns away from booth opening · Check for proper distance from top of part to the conveyor slot opening   |
| Blocked airflow | · Check air volume control damper adjustments |

## Poor Spray Pattern:

Non-Symmetrical Powder Cloud

| Possible Cause | Solution |
| --- | --- |
| Worn gun parts | · Replace parts as required   |
| Impact fusion build-up | · Check gun parts as required   |
| Delivery air too low | · Check air supply. Increase air for powder feed   |
| Hoses, powder pumps or guns blocked with powder | · Clean hoses, pumps and guns   |
| Reciprocator speed too fast | · Adjust gun cycle time   |

## Poor Powder Feed:

Powder feed surging or spitting. Interrupted powder flow

| Possible Cause | Solution |
| --- | --- |
| Insufficient air pressure or volume | · Check compressed air supply. Mains air pressure should be a minimum of 80 PSI and of sufficient volume to supply the system   |
| Hoses kinked, flattened or too long | · Check all powder and air feed lines, straighten and shorten if necessary   |
| Hoses, powder pumps or suction pumps | · Clean hoses, powder pumps and gun components · Check air supply for moisture and oil contaminants · Check powder delivery and dilution air settings · Check coating area, relative humidity and temperature · Check powder delivery system for leaks check powder delivery hose size for powder flow   |
| Incorrect feed hopper fluidization | · Adjust fluidization air pressure · Check fluidization membrane for damage, oil or water contamination · Check for moisture or oil in the powder   |
| Low powder level | · Add powder to the proper level in the hopper |

## Blocked Hose / Powder Hose:

Caused By Impact Fusion Build-Up

| Possible Cause | Solution |
| --- | --- |
| Air pressure too high | · Clean or replace worn parts in pump · Reduce powder hose length · Decrease flow rate settings on pumps   |
| Moisture in compressed air | · Check air supply filters/dryers to clean, dry oil-free compressed air   |
| Worn powder pumps or parts | · Replace all worn or damaged parts |

## Reclaim Equipment:

Contamination In Reclaim Powder

| Possible Cause | Solution |
| --- | --- |
|  Reclaim in-line sieve torn · Powder or dirt falling in spray booth from conveyors, jigs, or flight bars | · Repair sieve or replace, if necessary · Clean conveyor regularly before it enters powder booth · Strip jigs regularly   |
| Contamination from components entering booth | · Check cleaning and pre-treatment system · Ensure components are clean and dry before entering booth   |
| Contamination from plant air circulated through spray booth | · Isolate and preferable enclose spray booth area · Keep outside doors closed · Maintain positive air pressure in coating room · Do not use silicone based oils or lubricants · Do not use aerosol sprays containing oil in the booth area |

Powder Levels In Booth Are Too High

| Possible Cause | Solution |
| --- | --- |
| Bag or cartridge filters blinding | · Clean or replace bags or cartridge filters · Check spray booth humidity · Check reverse air cleaning   |
| Too large an open area in spray booth housing | · Reduce open area. Increased opening reduce booth air velocity   |
| Powder delivery rates too high | · Reduce the number of guns spraying or the amount of powder to each gun |

## Poor Charging:

Inadequate Powder Film Thickness, Poor Coverage

| Possible Cause | Solution |
| --- | --- |
| High voltage is not providing enough kV at charging electrode | · Check if high voltage is ON. Systematically check electrical continuity from the voltage source to electrode, including the cable, resistor and fuses. · Use kV meter and megohmmeter to check condition of multiplier, cable/resistor. · Clean/replace electrode insulated or damaged by powder build-up or impact fusion   |
| Poor earthing | · Checking earthing from conveyor rail through hanger to part. Contact areas must be free of powder build-up, grease and other insulators   |
| Powder delivery too high | · Reduce powder feed until material is adequately charged |
| Excessive moisture in air supply | · The charge can be dissipated by moist air, humidity must be controlled   |
| Powder too fine | · Maintain consistent ratio of virgin to reclaim 3:1 · Check particle size of virgin powder   |
| Powder delivery air too high. Powder blowing past component | · Turn down air setting or move gun position further away from component |

## Poor Penetration:

Powder Won't Coat Faraday Cage Area (Holes, Grooves, Channels, Inside Corners, Recesses)

| Possible Cause | Solution |
| --- | --- |
| Powder delivery too low | · Increase powder flow rate air setting · Replace all worn or damaged parts   |
| Poor earthing | · Check all earthing point contacts. Clean if necessary   |
| Incorrect spray pattern or nozzle | · Adjust spray pattern or select a more suitable nozzle, i.e. flat-spray, deflector or pin-point   |
| Poor gun placement | · Adjust gun position so powder cloud has a direct path to recess area   |
| Voltage too high | · Decrease voltage level   |
| Powder delivery velocity too high | · Decrease voltage level   |
| Powder delivery velocity too high | · Decrease flow rate and/or atomizing settings so powder air stream does not blow out of corners |

 

## In Conclusion

By familiarizing yourself with these potential problems and their fixes, you can maintain optimal performance and achieve high-quality finishes. However, every situation is unique, and sometimes you may encounter issues that require more tailored solutions.

Don’t hesitate to reach out to us for expert guidance and support. We are committed to helping you overcome any hurdles and ensure your powder coating process runs smoothly.

 

 

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---

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