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Powder Coating vs Painting: Analysing the Pros and the Cons

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When it comes to architectural products for residential and commercial structures, both powder coating and wet painting can be used to coat and protect your products.


But when faced with the decision between the two options, which should you choose?


We break down the pros and cons of powder coating and industrial wet painting, so you can make an informed decision.


What is Powder Coating?


If you're looking for a durable and long-lasting finish for your industrial equipment, powder coating is the way to go. This dry coating process provides a hardened, high-quality finish on metallic products. In terms of both functionality and appearance, it performs well, making it a popular choice for a wide range of applications.


Powder coating is suitable for both indoor and outdoor use, providing versatility for different environments.



What is the Process Involved in Powder Coating a Material?


The process of powder coating involves several stages: preparation, application, and curing.


During the preparation stage, the surface of the metal parts is thoroughly cleaned, rinsed, etched, blasted, and dried. This ensures that the surface is free from any contaminants that could affect the adhesion of the powder coating.


Once the surface is prepared, the powder coating is applied using an electrostatic spray deposition (ESD) method. The dry powder is then sprayed onto the product.


After the powder is applied, the metal parts are cured in a curing oven; the cure time depends on the size, shape, and thickness of the parts.



Advantages of Powder Coating


When comparing powder coating to wet painting, the benefits of utilising powder coating include its durability, corrosion resistance, and variety of finishes available.



Powder coating provides superior durability compared to traditional liquid paint.


The thick and adhesive finish of powder coating ensures that it can withstand harsh environments, heavy use, and exposure to various elements without chipping or fading. This durability makes powder coating an excellent choice for architectural products which face wear and tear.


Unlike paint, powder coating is also resistant to scratches, corrosion, and chemicals. This means that your equipment will maintain its appearance and functionality for an extended period, saving you time and money on frequent touch-ups or replacements.


Rust Resistance


Powder coatings are incredibly resistant to corrosion and damage, providing an excellent barrier against rust. Unlike wet paint, which can chip and peel over time, powder coatings adhere tightly to the surface, creating a durable and protective layer.


This means that even in harsh environments or exposure to moisture, your products will remain rust-free. Additionally, powder coatings aren't affected by cleaning agents or abrasive materials, ensuring that you can easily clean your products without worrying about damaging the finish.


Wide Range of Finishes


With powder coating, you can achieve a wide variety of finishes, allowing you to customise and enhance the appearance of your architectural pieces.


The diverse range of colours and textures that can be created through powder coating is one of its main advantages over wet painting. Powder coating involves mixing and manipulating powders beforehand, which gives you the flexibility to customise the finish to your liking.


Whether you want a smooth, glossy surface or a textured, matte look, powder coating can deliver.

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Disadvantages of Powder Coating


When it comes to the disadvantages of powder coating, there are a few key points to consider.


Certain Materials Cannot Be Powder Coated


Not all materials can be powder coated. For example, it is more difficult and oftentimes not economic to powder coat materials such as rubber and non-ferritic substances.


Powdered coating requires a conductive surface for the charged paint particles to attach to, which limits the materials it can be applied to. It also requires materials that can withstand curing at high temperatures, ruling out materials like rubber that would simply melt.


As a result, powder coatings are primarily used for metal materials like steel, stainless steel, aluminium, and brass.


Higher Upfront Cost


You'll also need to consider that the upfront cost for powder coating may be higher than traditional wet painting methods. While powder coating offers numerous advantages, it does come with a more substantial initial cost.


This is mainly due to the specialised equipment and materials required for the powder coating process. However, it's important to note that in the long-term, powder coating may prove to be more cost-effective.


Its durability ensures that you won't have to spend money on refurbishments and replacements, saving you money in the long run.


Difficult to Touch Up or Repair


You'll find it challenging to touch up or repair a powdered finish.


Unlike liquid paints, which can be easily touched up as needed, powdered coatings require a more involved process. Since the coating is applied in a dry powder form and then cured, any touch-ups or repairs would require stripping and reapplying the entire coating. This can be time-consuming and costly.


And whilst there are more cost-efficient alternatives available to spot repair damaged or worn powder coats with liquid paint, for example, it won’t provide the same level of protection or aestheticism.


What is Wet Painting?


Industrial wet painting is the traditional method of applying liquid paint to a metal product, ensuring a smooth and even finish. This process involves using a spray, pump, or pressurised vessel to deliver the wet paint evenly onto the metal surface.


While wet painting can provide excellent colour consistency and a wide range of colour options, it does have some drawbacks.

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Advantages of Wet Painting


When it comes to wet painting, there are many advantages, as explored below…


Lower Upfront Cost


Opting for wet painting is likely to save you money initially, as it requires less equipment and setup compared to powder coating.


However, this must be considered in the context of the efficiency of the application process; wet painting is far less efficient and produces substantially more material waste during transfer than powder coating.


Easier to Touch Up or Repair


It’s much simpler and far more convenient to touch up or repair paint coats than powder coats, making it the ideal choice for maintaining the pristine appearance of your products.


Unlike powder coatings, paint can be easily colour-matched, allowing for seamless touch-ups. Whether you need to fix a small scratch or cover up a larger area, wet paint provides versatility and precision. With wet paint, you can simply apply a fresh coat to the affected area, ensuring a seamless and uniform finish.


More Colour Options


Wet paint is available in a wide range of vibrant colours for all building designs and aesthetics.


With paint, you can clearly see the final dry state colour from the start of the application process, making it easier for a paint specialist to accurately mix and match paints to achieve the desired hue.


This means you have more flexibility and control over the colour options for your products.

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Disadvantages of Wet Painting


When it comes to wet painting, there are a few disadvantages to keep in mind, including reduced durability and shortened longevity compared to powder coating.


Less Durable Than Powder Coating


Although wet painting may seem like a cost-effective option, it often falls short in terms of durability compared to powder coating. When it comes to withstanding harsh conditions, powder coating proves to be the superior choice.


Wet painting may provide a satisfactory finish initially, but it tends to wear off over time, leaving the surface vulnerable to damage and corrosion.


Prone to Peeling and Chipping


Industrial painting is particularly susceptible to peeling and chipping over time, especially when exposed to frequent use and abrasive, outdoor environments in architectural applications – such as window pods and cills.


While powder coating creates a strong bond between the coating and the surface, industrial paint tends to adhere less effectively. This weaker bond makes the painted surface more vulnerable to peeling and chipping. Additionally, industrial paint can be more easily damaged by impacts or scratches, which can cause the coating to chip or flake off.


Regular maintenance and touch-ups may be required to prevent further deterioration.

Choosing Between Powder Coating and Wet Painting


When choosing between powder coating and wet painting for architectural products, consider the priorities of the project. Is your construction limited by costs, or are you looking for durable and long-lasting products?


Both options provide a highly aesthetic finish for architectural applications, so the choice comes down to project requirements such as these.


Considerations for Specific Applications


There may be specific applications where the choice between a powder coat or wet paint coat may seem obvious.


For instance, in high-rise projects where quality and durability are prioritised over cost, powder coating offers a superior solution. However, for low-volume, cost-driven projects, wet paint is a great alternative.




When it comes to powder coating vs painting, it's important to think of the specific application and its requirements.


Powder coating offers advantages such as durability and corrosion resistance.


On the other hand, industrial wet painting provides flexibility in terms of colour options and can be easily touched up or repaired.


Ultimately, the decision should be based on factors like the desired finish, budget, and the specific needs of the project, although it’s always best to consult an expert before you make a final decision.

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