Why is Prepainted Steel Coil For Commercial Appliances Better?

Coil coating technology is increasingly recognized for its efficiency and environmental benefit. Prepainted metal not only streamlines the manufacturing process but also provides cost savings, making it a favorable option for manufacturers. As companies seek to improve their production methods, the advantages of prepainted steel coil for commercial appliances become even more significant.

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Historically, manufacturing was burdened by the need to treat and paint raw steel and other metals within their facilities, leading to increased operational costs and environmental concerns. The advent of coil coating in the 1960s revolutionized this process by allowing large coils of metal to be prepainted before reaching the manufacturing plant. Initial adoption was prevalent, especially in the Venetian blind industry, and it has since expanded across numerous sectors.

Today, the coil coating industry produces over 800 million tons of steel and aluminum annually in North America alone. Major players like GE, Whirlpool, Trane, Mercedes Benz, Nordyne, and Steelcase have integrated coil coated metals into their products, highlighting the widespread benefits and applications across diverse industries.

Key sectors utilizing prepainted metal include building products (metal roofs, wall panels, garage doors), office furniture (desks, cubical dividers, cabinets), appliances (refrigerators, dishwashers, etc.), heating and air-conditioning components, commercial appliances, vending machines, foodservice equipment, beverage cans, automotive parts, and much more. The trend towards prepainted metal grows yearly as new applications emerge.

The Coil Coating Process

Coil coating stands out as an advanced and eco-friendly method for metal treatment. It involves unrolling large metal coils (including a variety of metals such as cold-rolled steel, galvanized steel, aluminum, etc.), which are then cleaned, treated, primed, coated, oven cured, and rewound for shipments. This continuous process ensures high efficiency and consistent quality.

Available coatings are diverse, including polyesters, epoxies, acrylics, and more. Continuous advancements in coating technologies lead to improved product quality as new industry-specific solutions are regularly developed and tested throughout the coating process.

Superior Quality Control

The prepainting process is optimized to deliver consistent and high-quality coatings. Specialized equipment ensures coatings are applied evenly, meeting stringent product specifications and yielding uniform color, texture, thickness, and performance across finished products.

To maintain top quality standards, multiple control tests occur throughout the coil coating process. Tests are conducted on the metal substrate, viscosity, color, gloss, and various paint physical performances before and during the coating application. Post-production, thorough inspections for corrosion resistance, heat tolerance, and other performance traits guarantee superior durability.

Parts prefinished with prepainted metal often outperform those that are post-painted. The flat pre-cleaned surface allows for better primer adhesion, increased corrosion protection, and generally superior durability. Additionally, various primers and coatings can be applied according to specific industry needs that enhance performance.

Case in Point

Trane, Inc., renowned for its commercial air handlers, illustrates the benefits of switching from traditional painting methods to coil coating technology. By implementing prepainted metal systems at their Cullen, LA facility, Trane has noted significant gains in productivity and profitability, along with enhanced strength and appearance in their products.

The introduction of a new prepainted fastener system has streamlined production by eliminating the need for pre-punched holes. Post-conversion, Trane reported notable consistency in joint strength and overall product finish. Similarly, many appliance manufacturers also benefit from employing prepainted metal combined with matched fasteners, further streamlining their production lines.

Numerous Benefits

The advantages of utilizing prepainted metals are vast. They contribute to a more efficient manufacturing process, substantial cost savings, and a more sustainable operational footprint.

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SIDEBAR: 5 Misconceptions about Coil Coating

Despite the longstanding success of prepainted metal processes, some misconceptions remain.

1. Myth: Outsourcing your painting operations would be an added cost.

Fact:

Manufacturers frequently face increasing expenses related to in-house paint shops due to stringent regulations and operational overhead. Outsourcing can relieve some of these economic burdens.

It's advisable to form a prepaint conversion team to assess production processes and the feasibility of adopting prepainted solutions. After thorough analysis and a cost justification study, companies can validate the economic value of conversion.

2. Myth: Prepainted metal cannot be formed.

Fact:

Contrary to popular belief, prepainted metal can be formed while maintaining surface integrity, often outperforming post-painted results.

3. Myth: Prepainted metal with cut-edge doesn’t weather well.

Fact:

Field research indicates prepainted cut-edge surfaces demonstrate superior weathering and corrosion resistance when compared to traditional post-paint methods.

4. Myth: Coil coated metal cannot be joined without aesthetic issues.

Fact:

Modern advances allow prepainted metal to be joined with minimal aesthetic drawbacks through various methods, ensuring a flawless finish.

5. Myth: You can’t handle coil-coated metal without marring the surface.

Fact: Prepainted metal can be safely handled during shipping and storage, maintaining a superior surface quality compared to post-painted alternatives.

Source: NCCA


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SIDEBAR: 10 Signs a Manufacturer Should Consider Prepainted Metal

Many manufacturers contemplating the transition from in-house post-painted operations to outsourced prepainted metals frequently encounter indications that prepainted metal might be viable.

1. Rising in-house paint shop expenses. Prepainted metal may prove more financially viable if in-house painting costs are increasing due to regulatory adherence and maintenance demands.

2. The need for lower internal operating costs. Outsourced prepainted metals can result in decreased expenses in various operational areas.

3. Plant capacity must be expanded. Purchasing prepainted metal may allow greater space for other uses within a facility.

4. Quality improvements are essential. Coil coated metals minimize variability and provide superior adhesion compared to traditional coatings.

5. Downsizing/combining facilities. Outsourcing prepainted metals can yield significant savings during business restructuring.

6. Development of new product models. Incorporating prepainted metal can facilitate cost-effective designs.

7. Productivity bottlenecks. Prepainted options can alleviate assembly delays related to traditional paint processes.

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8. Time for paint line upgrades. Transitioning to prepainted steel can prevent unnecessary capital investments.

9. Implementation of outsourcing strategies. Prepainted metals offer a cost-effective solution enhancing coating durability.

10. Equipment evaluation. Significant changes in operations present opportunities for improved processes, including assessing prepainted metal.

Source: NCCA

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Prepainted Metal Coatings: Aesthetic and Functional Properties

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Prepainted metal offers not only an impeccable finish and an expansive palette of colors and designs but also various functional properties. Through advanced coating processes, prepainted coil metal becomes weatherproof, corrosion resistant, and even smog-eating. The multiple layers of state-of-the-art coatings yield durability and unique capabilities unavailable through traditional methods.

Coil coated metals undergo extensive cleaning and chemical pretreatment, followed by the application of two to four coats of specialized paint formulations. Because the metal is coated while in flat forms, exceptional uniformity is achieved across the strip and throughout the coil.

Prepainted metals have been engineered to withstand various demands over significant periods. The coatings must retain their aesthetics and functionality, combatting challenges such as color fade, chemicals, extreme temperatures, and daily wear. Ultimately, prepainted metals provide unmatched technical capabilities and extended product life compared to traditional coating techniques.

Color

Color can significantly enhance product appeal and meet consumer demands, transitioning from classic styles to contemporary trends. Prepainted metals afford manufacturers quicker access to varied color choices without hefty overhead costs. Notably, coil coaters produce options like brushed steel appearances, polished copper, and wood-like textures to captivate consumers.

Texture

The growing trend of textured products has entered diverse markets, leading to a demand for architectural designs that reflect visual depth. Textured paints can emulate the appearance of materials like brick, stone, and wood, meeting design expectations across commercial sectors.

Durable textures minimize maintenance concerns and offer impressive aesthetic qualities while meeting high-performance standards. Additionally, texturing can help disguise issues like dents or scratches over time, making it ideal for high-traffic applications.

Antimicrobial

In environments like hospitals and foodservice areas, antimicrobial coatings are increasingly vital for safeguarding health. These coatings protect against various pathogens, vital for maintaining hygiene.

Fingerprint Resistant

Modern consumers often prefer appliance finishes that resist fingerprints. The development of fingerprint-resistant coatings has received positive industry feedback, ensuring easy maintenance while enhancing product appeal.

Solar Reflective

Solar reflective coatings can optimize energy efficiency and comfort by mitigating heat absorption. Prepainted roofs featuring such coatings integrate advanced pigment technologies to combat urban heat conditions effectively.

Additionally, prepainted roofs can emulate various residential styles, offering design flexibility while contributing to sustainability. This technology promotes healthier environments through reductions in energy consumption and improved cooling efficiencies.

Anti-Graffiti

Recent advancements in coating techniques now produce anti-graffiti properties, making surfaces easier to clean and maintain in commercial settings.

Anti-Static

In high-tech facilities necessitating cleanroom standards, anti-static coatings can be crucial for operational efficiency.

Insulated Metal Panels

Prepainted IMPs allow for fundamental innovations within architectural design, promoting unique aesthetics and energy efficiency through their insulating capabilities.

Interior Applications for Coil Coatings

Prepainted metal applications similarly expand within interior construction, from walls and ceilings to cabinetry and fixtures, offering lightweight and durable solutions suited for modern design.

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