How Glazore Coating Work

Every batch runs through a 7-tank pre-treatment line, completing the full cleaning cycle in roughly 25 minutes:

• Cleaner Bath (8-10 min): Etches the aluminium surface and removes grease and oil residues.
• DM Water Wash (2 Tanks, 4-5 min): Neutralises the section using demineralised water (0-10 TDS) for consistent surface quality.
• Chromatising Bath (8-10 min): Forms a chemical conversion layer that strengthens powder adhesion and extends coating life.
• Final DM Water Rinse (3 Tanks): Neutralises the section fully before it moves to drying.

Aluminium profiles are earthed at zero potential while powder particles are given a high negative charge (60kV-100kV) inside the spray gun. The charged powder is drawn to the grounded profile, much like a magnet, and wraps evenly across the front, sides, and back of the section.

• Hanging & Jigging: Profiles are hung vertically (never flat) on copper hooks or stainless steel jigs for consistent earthing, with a minimum 150mm gap between profiles to prevent the Faraday cage effect in corners.
• Booth Entry: Profiles move through the automatic powder booth via overhead conveyor, inside a non-conductive stainless steel booth designed for clean overspray recovery.
• Automatic Gun Application: Four automatic reciprocating guns apply powder from both sides of the booth, with two manual guns used for touch-ups and complex corners. Guns move in sync with a conveyor speed of 0.8-1.2 m/min.
• Inside the Gun: Powder is fluidised with air in the hopper, charged at the nozzle electrode, sprayed at 1.5-3 bar air pressure, and deposited onto the profile through electrostatic attraction.

Curing is the controlled heating of the coated profile so powder particles melt, flow, gel, and cross-link into a hard, weather-resistant film. Because aluminium conducts heat roughly 3x faster than steel and can lose its temper above 220°C, curing is precisely calibrated: metal temperature of 180°C-200°C for 10-15 minutes, inside an oven held at 200°C-220°C air temperature.

• Conveyorised Tunnel Oven: A 22-metre tunnel with three zones: Heat-Up (rapid rise to 180°C), Soak/Cure (10-15 min hold at 180°C-200°C), and Cooling (temperature reduction before unloading).
• Melting Stage (~120°C-150°C): Powder liquefies and takes on a shiny, wet appearance.
• Flow / Gel Stage (~150°C-180°C): Melted powder levels into a smooth film. This stage determines surface finish and prevents orange peel.
• Cross-Linking / Cure (180°C-200°C, 10 min): The chemical reaction that hardens the powder into a durable polymer film. Timing is measured from the moment the metal itself reaches 180°C.
• Exit & Cooling: Profiles cool in open air for 5-7 minutes (or with forced-air blowers) and are not handled until metal temperature drops below 40°C.

Every batch is verified in our in-house quality control lab against recognised industry standards before it moves to packing:

• Cross-Hatch Adhesion (ASTM D3359 / ISO 2409): verifies bond strength via lattice-cut and tape-pull testing.
• Impact Resistance (ASTM D2794): confirms the coating resists cracking or de-bonding under sudden impact.
• Mandrel Bend / Flexibility (ASTM D522 / ISO 1519): checks for embrittlement or over-curing by bending coated sections over a rod.
• Film Thickness (ISO 2360): micron-gauge measurement to confirm consistent dry film build.
• Boil / Hot-Water Adhesion Test: evaluates pre-treatment quality and wet adhesion by testing resistance to boiling water.

• Cooling & Inspection: Profiles are unloaded onto felt-covered inspection tables and checked under bright light for dust, orange peel, thin coating, or scratches.
• Protective Taping: Premium orders receive a low-tack, self-adhesive LDPE protective film (60-80 micron) on visible faces, applied via automatic film applicator.
• Bundling: Profiles are bundled in sets of 4, 6, or 8 depending on size, with standard bundle weights of 25-35 kg for safe handling.