This case study highlights our partnership with Global Marine, a leading manufacturer of marine hardware and accessories. They needed a high-performance powder coating plant to protect their products from harsh marine environments while meeting demanding quality and durability standards. We successfully designed and implemented a fully automated, high-throughput system that delivers a premium, corrosion-resistant finish on a wide range of components.
Client Overview
- Industry: Marine Hardware & Accessories.
- Product Range: High-performance components and assemblies for sailboats and powerboats.
- Market: Global (Primary distribution in North America, Europe, and Asia-Pacific).
- Objective: To install a cutting-edge, high-throughput powder coating system tailored for corrosion resistance, durability, and premium finish quality, suitable for harsh marine environments.
Project Scope
Our client, a globally recognised manufacturer of precision-engineered marine components, required a turnkey powder coating solution that could handle high volumes, ensure uniform finish quality, and provide marine-grade corrosion protection.
We designed, supplied, and commissioned in partnership with our Customer Surfaceprep UK a complete automated powder coating line, built to meet international quality standards and environmental compliance, with the flexibility to handle varying part sizes, weights, and geometries for Global Marine’s needs.
Client Testimonial
System Configuration
7-Stage Spray Pre-Treatment Line
Material: Constructed using high-grade stainless steel for longevity and chemical resistance.
Stages Include:
- Alkaline Degrease – Removes oils, machining fluids and contaminants from metal surfaces.
- Water Rinse 1 – Eliminates residues from degreasing.
- Surface Conditioner – Prepares surface microstructure for uniform coating adhesion.
- Water Rinse 2 – Removes residual conditioning agents.
- Passivation (Chromate-Free) – Non-chrome final rinse enhances corrosion resistance and coating performance.
- De-ionised Water Rinse – Ensures purity and eliminates water spotting.
- Final Rinse Seal – Seals the treated surface for maximum coating adhesion.
Benefits:
- Excellent surface preparation for aluminium and stainless steel.
- Corrosion protection exceeds 1000 hours in salt-spray testing.
- REACH and RoHS compliant.
High-Efficiency Dry-Off Oven
Fuel Type: Indirect gas-fired system with heat exchangers.
Temperature Range: 120°C – 150°C.
Design Features:
- Uniform airflow system with directional nozzles.
- Adjustable dwell time to match line speed.
- Insulated panels for thermal efficiency.
Function: Rapidly evaporates residual moisture from pre-treated parts, ensuring proper powder adhesion in subsequent stages.
WAGNER Automatic Powder Coating Booth
Technology Partner: Wagner Industrial Solutions.
System Includes:
- Fully automatic reciprocators with multiple powder guns.
- Smart control system for precise film thickness application.
- Quick Colour Change (QCC) system for batch flexibility.
- Advanced cyclone recovery and filtration for powder re-use.
Capabilities:
- Handles complex geometries with consistent coverage.
- High transfer efficiency (up to 98%) = minimal overspray.
- Real-time powder flow monitoring.
Operator Safety: Full containment design with negative pressure zones to minimize airborne particulates.
Final Cure Oven
Type: Convection, gas-fired.
Temperature Range: 180°C – 220°C.
Features:
- Zoned temperature control for energy efficiency.
- Uniform airflow for consistent cure across part sizes.
- Programmable control system with over-temp protection.
Result: Complete crosslinking of powder, delivering a durable, UV-stable, corrosion-resistant finish, meeting or exceeding AAMA 2604/2605 standards.
Overhead Conveyor System
Capacity: Up to 100 kg per hanger.
Line Speed: Adjustable (0.5 to 3 m/min).
Configuration:
- In-line loading and unloading stations.
- Buffer zones for WIP (work-in-process).
- Manual touch-up station access points.
- Integrated with pre-treatment, ovens, and coating booth for continuous operation.
Efficiency Gains:
- Reduces manual handling and damage risk.
- Supports flexible batch or continuous production.
- Easily expandable for future line extensions.
Project Outcomes & Benefits
| Benefit | Description |
|---|---|
| Corrosion Resistance | Achieved >1000 hours salt-spray performance per ASTM B117 – critical for marine-grade durability. |
| Finish Quality | Consistently smooth, uniform coating across diverse geometries with superior adhesion and colour retention. |
| Production Efficiency | 40% improvement in-line throughput over previous manual systems. |
| Sustainability | Powder coating is VOC-free and the entire system meets environmental compliance for global markets (REACH, EPA). |
| Reduced Labour | Automated systems and ergonomic design lowered labour requirements by 30%. |
| Ease of Maintenance | Modular component layout for easy servicing and downtime reduction. |
Powder Coating Plant Visual Highlights (Optional Web Integration)
- 3D layout of powder coating plant and line flow.
- Coated marine hardware (before & after).
- Wagner booth in operation.
- Control panel interface shots.
- Conveyor system & oven interiors.
Conclusion
This project demonstrates our ability to engineer, deliver, and commission high-performance automated powder coating plant customised for industry-specific demands. For marine hardware — where corrosion resistance, coating integrity, and long-term durability are critical — our system delivered unmatched reliability and performance.
Whether you’re in marine, automotive, architectural, or industrial manufacturing, we can design a solution that meets your exact production and quality goals.
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