How to Powder Coat MDF
Office furniture ready for powder coating at Climate circa 2004
MDF boards entering the cure oven after powder coating
Point of sale displays powder coated all six sides in a custom red for Target retail chain in Australia
Powder coating MDF – why and how?
If you know powder coatings, you know it is designed for protecting and decorating metals, like aluminium and steel. Back in the late 90’s the industry started experimenting with powder coating other materials like MDF for furniture and kitchen cabinetry. While the early days of the technology development didn’t exactly go to plan, the time since has been used to perfect the process.
Why powder coat MDF in the first place? Initially the idea was to offer a more sustainable alternative to solvent based paints and PVC foils for furniture and cabinetry made from MDF. Providing a highly durable, attractive furniture product without the environmental impact. While that’s still true, the limitations of powder on MDF meant the technology didn’t get much of a foothold in the market. Today however, the technology challenges are largely solved and breadth of finishes possible continues to evolve. Which means powder can play a part in improving the manufacturing industries sustainability footprint by lowering carbon emissions, improving air quality, reducing waste, minimising water use and using materials that can be recycled or re-used.
Powder coating MDF process. The process relies on low cure powder formulations that melt, flow and cure as fast as possible to minimise edge cracking, dehydration and off-gassing of the MDF. These powders are available from a range of producers that claim 130c for 3-5 minutes to 140-160c for 5-7 minutes, when cured in an infra-red oven. Powders that cure when exposed to UV light are also available and reduce the cure temperate window to as low as 100c but they require the addition of UV lamps to get the job done.
The electrostatic application of the powder utilises the moisture in the board (ideally 4-8%) to attract the charged powder. Like in metal coating, the substrate needs to be cleanly grounded. The board is lightly pre-heated to around 60c, which helps draw the moisture to the surface and then the powder is applied. Managing film thickness and consistency, particularly on the edges of the MDF, is key to avoid blistering during cure, thick edges and appearance inconsistency. This can be controlled with the use of counter electrodes in the coating booth, positioned opposite the powder applicators, they help prevent a buildup of powder on the edges by drawing excess powder spray away from the part.
The melt, flow and cure the powder is best achieved with infra-red, which is an effective and efficient heating technology. The right wavelength of IR will ensure optimal absorption by the coating and less by the substrate, minimising the impact of high temperatures on the MDF while maximising cure. Ensuring a consistent and even heat profile of the MDF by placement of the IR heaters and reflection of the IR is also key to consistency. IR can be electric or gas powered depending on the degree of surface temperature control required, access to natural gas and energy costs.
Climate Surfaces has been coating MDF for 25 years, not without its challenges. Back in 2004 we pioneered and patented a two-coat process to address some of the shortcomings of the technology. These days the business powder coats MDF panels on a large format horizontal powder coating line. The panels are cut then have an edge tape applied to the edges, just like a joiner or shopfitter would do when working with low pressure melamine panels. Because powder can be produced in any colour for a small minimum order quantity compared to laminates and the colour doesn’t change over time, has meant we’ve supplied a leading NZ supermarket for over a decade. Always the same colour and quality, no colour deletions.
There is a smattering of powder applicators and OEMs around the world that have purpose built coating lines for kitchen cabinetry, furniture or anything where powder can play a part in finishing MDF. Each company has carved out a niche for powder, sometimes on other substrates like plywood or plasterboard. There is still some way to go before powder can rival the incumbent technologies of paint, laminates and foils but it is moving in the right direction in terms of finish options and production formats that can reduce costs.
What’s next for powder coating MDF? Covestro, a leading resin producer for powder coatings, has developed a process called ImFuse®, which combines a fast curing, low bake powder with a hot press curing technique. This enables smooth and high gloss finishes, as well as designs to be imprinted into the coating, giving it a visible structure that can replicate other materials like wood. Powder is also a great base to digital printing onto with any image or design. The end result can replicate other materials or add unique finishes.
Powder coating technology on non-metallic substrates like MDF will continue to find its way into the market as long as there are companies willing to innovate with a very sustainable coating technology. The world needs a dry and efficient coating technology to ensure materials look great and last longer with less impact on the planet and people.
Climateline – an ideal durable lining for wet areas
Wet area and hig
h hygiene wall lining solution made 100% in NZ, that won’t break the budget. Climateline® is a suitable alternative to other pre-finished panels that will save you money, while still delivering the performance required from a factory coated panel product.
✅NZ made Gib® plasterboard with a Climate® powder coated surface
✅Rated Group 1-s reaction to fire so it’s ideal for commercial interiors
✅Moisture & abrasion resistant powder coated surface
✅Now with BioCote® to reduce mould, fungi growth & surface stains
✅Certified Global Greentag
✅Bright white, off-white, matte black, grey + custom colours
✅Standard panel sizes in standard and wet area grade boards
Ecotile – matte black fine texture plasterboard tile
Ecotile™ – NZ made plasterboard ceiling tiles featuring a durable powder coated surface for use in suspended ceiling systems.
The matte fine texture powder coated surface provides a consistent and durable finish where a black finish looks great.
✅NZ made Gib® plasterboard, rated Group 1-s reaction to fire
✅White, black, grey and custom colours
✅No VOC, low carbon footprint (assessment available on request)
✅Moisture & abrasion resistant surface that’s easy to wipe clean
✅Now with BioCote® built into the coating to reduce mould & fungi growth & staining
✅Certified Global Greentag – easy assessment of contributions towards NZ green building standards
✅CAC 43 & light reflectance value 94
✅Standard size plus 600x600mm made to order
Ideal for retail, hospitality, offices, aged care, medical facilities…. anywhere an economic and hygienic ceiling lining is needed. Used in commercial interiors since 2006.
Available from Comfortech nationwide.
https://www.comfortech.co.nz/our-products/ceilings/plasterboard-ceiling-systems/climateline-eco-tile/
Enhanced Hygiene Protection on your Wall Linings and Ceiling Tiles with Climate® Powder Antimicrobial Formulations
Climateline® and Ecotile™ plasterboard linings now feature BioCote® antimicrobial technology in their powder-coated surface, offering increased levels of protection against bacteria, mould, and fungi for your projects that need to meet high hygiene standards.
Climate is pleased to announce the latest development in their zero-VOC powder coating technology, with the addition of the BioCote® antimicrobial technology. This ensures greater bacterial and mould resistance for linings where hygiene is crucial including; hospitals, schools, restaurants, food processing plants, laboratories, gyms and more.
Increased resistance against bacterial growth for hygiene critical areas
BioCote® active ingredients disrupt the cellular functions of microorganisms, to prevent their survival on treated surfaces.
By incorporating BioCote® into Climate Surfaces powder coating formulas, it offers peace of mind that Climateline® and Ecotile™ products actively reduce and minimise bacteria and mould — helping to keep surfaces fresher for longer, reducing odours, and making maintenance easier in demanding environments.
Tested to reduce up to 99% of bacteria in 24 hours
Rigorous testing confirms that BioCote® technology in Climate powder coatings reduces up to 99.9% of bacteria, including Staphylococcus aureus and Escherichia coli within 24 hours.
Long-lasting surface protection from mould, odours and discolouration
In addition to the antimicrobial effect, the BioCote® additive in Climate powder coatings contributes to reduced mould growth, odours and stains that can affect a surface over time — typically caused by bacterial growth. This ensures Climateline® and Ecotile™ retain their performance and visual appeal for longer — even in areas exposed to significant moisture and robust cleaning schedules.
NZ made, Global Greentag certified, Climateline® and Ecotile™ — now with BioCote® are available nationwide from Comfortech Building Performance Solutions.
Sustainable Powder Coating for Wood and Plasterboard Substrates
Paints and coatings are a large contributor to pollution and reduced indoor air quality because they are typically water- or solvent-based products that emit Volatile Organic Compounds (VOC’s) during application, drying and clean up.
Powder coating is referred to as a 100% solid coating system, which means no solvents/water are used to carry the pigments, resigns etc. The upside is less waste with low or nil VOC’s emitted into the atmosphere. This sustainable advantage is driving the adoption of powder coating in countries like Germany, where legislation has been in place to reduce airborne pollution caused by VOC’s from paint related industries e.g. car and furniture manufacturing. BMW and Audi’s made in Germany now have a powder coat clear finish, instead of the traditional liquid based finishes.
Auckland based Climate Surfaces, after 10 years of development and operations, is a global leader in commercially powder coating non-metal substrates, such as MDF, Plywood and Plasterboard. Powder coating on these substrates provides cost, performance and aesthetic benefits as well as a more sustainable coating solution compared to liquid or PVC based coatings. PPG Industries manufacture a specialised low cure powder for Climate, which is applied electrostaically and thermally cured to the substrate in a state of art factory environment. No water or solvents are used in the process or materials and up to 95% powder utilisation is possible with any waste powder being reclaimed and reused.
Climate is poised to deliver greater advances in powder coating technology for a range of building product substrates, which will provide a more sustainable alternative without compromise on cost, performance and aesthetics.
Powdercoating a Sustainable Option for Non-metals
Powdercoating provides a sustainable option for those who need a durable finish to their interiors – and it’s no longer limited to metal surfaces. These days it can also be applied to non-metal surfaces such as plywood, MDF and plasterboard.
Large international companies, such as furniture manufacturers IKEA, are now adopting this method in order to reduce the environmental impact associated with the finishing of its furniture. Powdercoating contains no solvents, so it’s essentially a VOC-free coating.
In New Zealand, Climate Surfaces was one of the industry leaders with this method. Managing director Kyle True says it was 11 years ago that the company was involved with the creation of this coating methodology.
To manufacture this advanced finish for non-metals, Climate Surfaces has a specialist plant which uses significantly lower curing temperatures as well as infrared heat instead of convection. It’s a precise formula.
“Powdercoating is a baked-on finish so it provides an inherent durability. It’s also a more efficient way to apply coatings at a lower cost,” Kyle says.
Aesthetically, it provides a wide range of colours and finish effects which work equally well on both metal and non-metal surfaces, even when placed alongside each other.