FOCUS ON COIL PROCESSING
The method includes cleaning and chemically pre-treating the metal surface . Before the final product is created , one or both sides of the metal are painted or coated with powders or liquids , which are then dried or bonded with plastic films . Coil coating employs processes such as cleaning ; pre-treating ; pre-priming ’ pre-painting and coating flat metal coils of steel or aluminium . The coated metal coil is subsequently supplied to equipment manufacturers to be formed into a range of ready-painted parts .
Pretreatments are often used to help provide improved corrosion resistance of the substrate , often by passivating or converting the metal surface , typically via phosphate or chromate chemistries . The type of chemical treatment varies with the type of metal being used . Additionally , pretreatment can enhance performance of the fully coated product by adding topography to the metallic surface to help facilitate the bonding between the metal and the coating .
The continuous coil-coating process provides high standards of quality assurance through coil-to-coil consistency and has significantly lower environmental emissions than batch or post-painting processes . This reduces the need for re-work and lowers non-conformance levels and associated costs . By utilising pre-painted metal in their process , manufacturers can also eliminate their paint lines which are usually the major bottleneck in their operation .
“ Although the organic coatings used in coilcoating are generally thinner than post-applied powders and films , they still give better inservice performance . So , you use less paint which minimises resource consumption and enables you to cut down or even eliminate maintenance and re-painting ,” commented ECCA ( The European Coil Coating Association ).
“ The cost of complying with environmental regulations is significantly reduced , or even eliminated . The cost of the disposal of
Image : Shutterstock . com .
Coated materials for construction .
Image : Dana Steel . hazardous waste associated with the painting operation is also eliminated . Scheduling problems and the costs associated with batchtype processing are minimised or removed altogether . Since input material is more directly related to output , the processing time is reduced and stocks are minimised ,” it added .
Coil coating market
Coated coils .
According to analyst , Grand View Research , the global coil coatings ’ market size was estimated at US $ 3.44 billion in 2023 and is projected to grow at a CAGR of 4 % from 2024 to 2030 .
“ This growth can be attributed to increased demand for these coatings from the flourishing construction industry , which includes residential and commercial sectors . Coil coatings are extensively used in roofing , cladding and insulation of buildings , infrastructure and industrial facilities ,” it said .
The global construction industry is one of the major consumers of coil coatings in the world . It accounted for more than a 40 % share of the total global demand for coil coatings in 2023 . Rapid urbanisation and industrialisation have also led to the need for construction and infrastructure development , especially in the emerging countries of Asia Pacific , Central & South America , and the Middle East .
“ Advances in coating technologies have revolutionised the applicability of coil coatings in recent years . These advances have not only enhanced the performance and durability of coil coatings but have also expanded the range of their applications across industries . One such advancement is the development of highperformance polymer coatings , which provide excellent resistance to corrosion , UV radiation and harsh weather conditions ,” continued the analyst .
Pre-painted versus post-painted metals
The benefits of using pre-painted metal over post-painted metal , according to ECCA , include :
Economic : The use of pre-painted metal enables manufacturers to increase profitability through improved process flows , waste reduction and the elimination of costly processing steps e . g . paint spraying .
Product performance : Pre-painted metals offer a range of high-quality surface finishes which are generally not available via post-painting . These finishes , coupled with their in-service performance , means that pre-painted metals offer designers and engineers a leading palette of materials .
Simplified manufacturing processes and regulatory compliance : The coil coating process is tightly controlled and operated to high standards ( in Europe , for example ). This means that fabricators do not need to deal with costly batch and post-painting processes and their associated environmental impact and cost of compliance .
Sustainability : Pre-painted metals have reduced impact across many impact categories including water consumption , terrestrial ecotoxicity and global warming compared to postpainting .
‘ Building & Construction ’ dominated the market with a revenue share of 57.7 % in 2023 . Coil coatings are also widely used in the transportation industry for a range of applications in automotive , aerospace and rail . Coil coatings are used in the automotive industry for coating metal components such as car bodies , chassis and engine parts . These coatings provide superior corrosion resistance , weatherability and aesthetic appeal to vehicles . They also contribute to improving the fuel efficiency and performance of cars , trucks and aircraft .
“ Innovation plays a crucial role in the global coil coatings market , driving the development of new products , processes and technologies . There is a growing emphasis on environmentally friendly solutions , with a focus on sustainable coating formulations including low-VOC coatings , water-based formulations and recycling programmes . This emphasis on innovation aligns with the broader industry trend towards sustainability and environmental responsibility ,” concluded Grand View Research . n
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