INNOVATIVE AND ADVANCED PROCESSES AND EQUIPMENT, QUALITY CONTROLS, & PRE-TREATMENT SYSTEM

The quality of a powder coating is just not in the paint. If it were just about the paint, you could spray paint the part yourself. The chief benefit to using Sundial Powder Coatings is that you can be sure that the product part finish is maintained, without scratching or corrosion. We are sure that we produce the highest quality finishing because of our innovative and advanced processes, equipment and pre-treatment system.

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Car Body After Powder Coating

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PRE-PROCESS INSPECTION

All inbound parts are first placed on our overhead conveyor line and inspected for any surface anomalies including surface rust, corrosion, marks and scratches in the substrate or any other marring or damage that might have occurred during shipping or earlier processing. We also check parts for any missing hardware. Any parts found deficient will be tagged for holding until the customer can be notified to authorize further processing.

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PRETREATMENT OPTIONS

We offer customers a wide array of pretreatment options depending on their unique processing requirements and finished product specifications. A 7-stage pre-treatment wash process including a dedicated iron-phosphate coating is standard for many types of substrates followed by a DI (de-ionized water) rinse. High performance cleansers and rinse solutions offer enhanced adhesion on ferrous or non-ferrous products. Sundial also operates a 30' x 8' x 8' inhouse sandblaster, and offers non-chromate conversion and meticulous hand sanding for custom specialty work.

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INSPECTION & DRYING

After pretreatment, Sundial thoroughly inspects all parts to ensure that they have been adequately cleaned. Any retained water will have been completely removed. After inspection, parts then enter our independent dry-off oven for careful and meticulous drying. Pre-determined drying temperatures are based on the actual part density, part configuration and overhead conveyor line speed. Dry-off temperatures range from 225°F to 300° F to protect the phosphate coating integrity.

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PRE-POWDER COATING INSPECTION

Sundial performs an inspection review of all parts, materials and products prior to powder coating. Anything that might interfere with the level of finish quality is attended to before the product piece is allowed to enter the powder coating booth. All threaded areas are pre-masked as a standard procedure to ensure that these areas remain free of powder to avoid any compromising of finished product quality or performance.

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POWDER COATING BOOTH

The powder coating process integrates the very best technology and equipment available on the market. We use Nordson SureCoat powder guns for full coverage in areas that normally would be difficult to coat using conventional electrostatic systems. Three (3) experienced paint gun operators together with Quality Assurance personnel closely supervise the process to ensure that all areas are fully coated while Inspectors examine all parts prior to entering the cure oven.

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CURE OVEN

Sundial employs sophisticated data-pack temperature recorders to periodically calibrate our cure ovens throughout the year. The data-pack temperature recorders provide important information on ambient and actual metal temperatures which enables us to ensure that our powder coatings are optimally cured. The part curing schedule varies depending on the substrate being processed and ranges from 350°F to 525°F. Performance results from annual salt spray testing are also monitored.

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FINAL INSPECTION

Quality control personnel check every processed part for total consistency and uniformity. We use only reference samples acquired from and approved by our customers as standards for production item comparison. Quality Assurance personnel compare color, gloss and overall finish and report any and all deviations for immediate corrective action. In addition, coating thickness is measured for uniformity and cross-hatch adhesion tests are performed.

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PACKAGING & LABELING

Once the pre-treatment, powder coating and inspection phases are complete, the finished product is packaged, counted for accuracy and labeled for final delivery to the customer. Our Production Supervisors submit completion reports on every job and Sundial Quality Assurance personnel inspect and sign off on every job and pallet to ensure a complete finished inspection and a total quality verification.

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SILKSCREENING

Sundial Powder Coatings offers quality in-house silkscreening services backed by 17 years of experience, professionalism, expertise as well as complete and total dependability. Our silkscreening services provide a wide array of options for aesthetic branding and product identification.