Manufacturers across industries rely on high-performance coatings to protect their products and safeguard their brand. As their products become more complex and customer expectations increase, coatings must deliver consistent performance across substrates, maintain throughput and reduce production costs.
The Challenge
Agriculture and construction equipment manufacturers face two critical challenges: keeping heavy-duty machinery looking good despite extreme use conditions and streamlining operations to control costs while meeting rising demand.
Protecting the complex parts of heavy-duty machinery from UV damage, corrosion and wear and tear is vital to keep equipment in good working condition. These machines represent significant investments and customers expect long-term value and performance.
For one leading agricultural and construction equipment manufacturer, meeting these requirements with the right coating system was a constant challenge. The company relied on a conventional but problematic powder coating system that required a long curing process, causing costly production bottlenecks and extra weekend shifts to meet demand.
What Was Needed
The manufacturer needed a new powder coating solution with significantly shorter curing times but delivered the same level of quality and resistance to damage and fading. Additionally, the system had to provide uniform coverage on all components, regardless of thickness or metal type. One of the key challenges for this industry is the range of different and complex parts assembled into a single unit as parts are often made of different metals like aluminum and steel with varying thicknesses. If a coating's processing window is too small, there's a risk of over- or under-curing, which reduces durability and protective properties.
The Solution
PPG solved this with ENVIROCRON® ULTRAX™.
Envirocron UltraX is an ultra-durable, low-cure polyester powder coating that produces a high-quality finish with excellent UV fastness. With a wide processing window, it delivers high process stability for thin- and thick-walled aluminum and steel components, with a fade-resistant, even finish.
While many low-temperature systems create performance losses, Envirocron UltraX delivers the same performance features as standard ultra-durable cure powders with very good storage stability, without compromising on durability, color protection or corrosion resistance.
The Impact
Process Improvements:
- Reduced oven curing times by 25%
- Decreased cooling times by up to 20%
- Eliminated one complete work shift
- Reduced weekend crew requirements
- Lowered heating costs per coated m²
Environmental Benefits:
- Reduced energy consumption and CO₂ emissions
- Lower stoving temperatures required (150°C to 180°C range)
- Formulated without CRM substances
- Powder can be reclaimed and resprayed
- Requires only compressed air for cleanup—no hazardous waste produced
The end result:
The manufacturer produced more parts in less time with less labor while realizing significant energy savings—all without performance losses, a common concern with most speed-cure solutions.
The Appeal of Powder
Powder is one of the fastest-growing coating platforms in the world. Several factors are driving rapid adoption, including global interest in more sustainable solutions and rising demand for fast-cure, low-bake formulas.
PPG Envirocron UltraX delivers on both fronts. Overall, powder coatings have a lower carbon footprint than traditional liquid coatings because of the improved energy and transfer efficiency and absence of solvents that emit volatile organic compounds (VOCs). Low-cure powders like Envirocron UltraX require even less energy with lower curing temperatures and shorter cure times than standard powders.
Low-temperature systems like Envirocron UltraX can streamline manufacturing processes, improve productivity while meeting important environmental objectives, and preserve finish durability, color and gloss even in extreme conditions.