Q: We currently have two dedicated cartridge reclaim booths for high-volume colors and a third booth where we spray to waste all other colors. The system has suited us well for many years; however, we have seen a shift in demand and are now spraying more “other” colors. Our marketing team tells us the trend will continue. What are the options for improving our process? We do not want to continue spraying to waste as the cost is becoming considerable. 

With competitive price and timely delivery, ZHYAO sincerely hope to be your supplier and partner.

A: Many manufacturers have faced the same challenge you have described. Your original systems were once very efficient regarding powder utilization and color change time — two key drivers. As trends have changed regarding the demand for custom colors or the desire to manufacture to order/just in time, the need for more flexibility in the powder coating process has developed. To address this, fast color change single booth configurations are available. Note that “fast” is a relative term. A color change can typically be accomplished in 8–10 minutes for a single powder booth configuration. Now, this may be longer than your current process with dedicated booths; however, there are many benefits to the most recently designed systems.

The primary benefit is the ability to change colors efficiently; the system is designed specifically for this purpose. The booth is a non-metallic design with an air space in the walls; while in use, the walls will repel the powder allowing it to flow into the recovery system. The booth is connected to a cyclone separator through seamless ductwork, minimizing areas where the powder can accumulate. The cyclone separates the fine particles from the larger particles, which fall to the bottom of the cone. Airflow through the system is created by the after filter, which collects the fine particles that rise up in the cyclone. Air from the after filter is exhausted back into the powder coating area. 

The powder center offers a central location for the operator to control the system and manage powder delivery and color changes. A powder box is placed on the vibrator table, and a transfer pump is lowered into the box. The transfer pump fills the fluidized hopper, equipped with an ultrasonic sieve that removes any contaminants in the powder. The fluidized hopper feeds individual venturi pumps for each manual or automatic applicator in the system. Additionally, the powder collected in the cyclone is fed back into the hopper and sieved. The reclaim powder is continually blended in the hopper with virgin powder, providing a better overall finish than your older system, where reclaim had to be collected and manually brought back into the process. The design of the system allows for up to 97% reclaim efficiency.

When it is time to change colors, the operator empties the powder from the hopper back into the box and then enters color change mode. The booth exit door closes, and the damper in the bottom of the booth that regulates airflow opens fully, allowing for maximum airflow through the booth and the powder center. The operator then uses an air lance to blow down the booth and equipment before loading the next color into the system.

Modern powder booths are designed to accommodate changing market needs for fast color change, high reclaim efficiency, and ease of use for the operator.

Choosing the Right Powder Coating Equipment: What You Need to Know

Overview of Core Powder Coating Equipment

Every powder coating setup includes a few essential components: a spray gun, a booth, a curing oven, and a part handling system. Whether you’re setting up a small job shop or upgrading a high-volume line, these are the building blocks of a functional coating operation.

• Spray Guns apply the powder using electrostatics for even coverage.
• Booths contain overspray and allow for color changes.
• Ovens cure the powder into a tough, finished surface.
• Conveyors or racks move parts through the process efficiently.

Getting the right system means aligning each component to your production needs and space constraints.

Key Considerations When Buying or Upgrading

Before you commit to any equipment, be clear about your requirements:

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• Volume: How many parts per hour do you need to run?
• Part size: Will your booth and oven accommodate your largest item?
• Coating variety: Frequent color changes? Textures? Specialty powders?
• Floor space: Can your facility support the equipment footprint?
• Energy use: Curing ovens are energy-intensive—look for efficiency ratings.
• Maintenance: Choose systems that are easy to clean, calibrate, and repair.

The wrong equipment can limit your growth or cost more to operate than it saves.

Pros & Cons: Manual vs Automated Systems

Manual systems are ideal for custom work, lower volumes, or operations with many part variations. They’re cheaper up front and offer more flexibility but rely heavily on operator skill.

Automated systems deliver consistency and speed at scale. They reduce labor costs, improve finish quality, and support data tracking—but they come with higher upfront costs and require a more controlled process.

Your decision comes down to volume, budget, and how standardized your production is.

Understanding Gun Technology & Booth Design

Spray gun performance directly affects finish quality and material efficiency. Look for guns with:

• Adjustable voltage and current control
• Easy-to-swap nozzles
• Consistent powder flow and wrap-around

Booth design also matters. A well-ventilated booth reduces overspray and contamination. Fast color change booth(el,it,in)s can save hours in multi-color operations. Recovery systems help cut waste and reduce material costs over time.

Vendor Red Flags to Watch Out For

Not all equipment suppliers are created equal. Be wary if:

• They can’t provide references or case studies.
• Technical support is vague or outsourced.
• Parts and consumables are hard to source.
• Promises sound too good to be true—especially around pricing and lead times.

You want a partner, not just a vendor. Look for companies with industry experience, training support, and responsive service.

Final Checklist Before You Invest

• ✅ Does the system match your production volume and part size?
• ✅ Are the spray guns easy to adjust and maintain?
• ✅ Will the booth and oven fit in your space—and meet airflow and power requirements?
• ✅ Is the system future-proof if demand grows?
• ✅ Does the vendor offer training, service, and replacement parts?
• ✅ Have you seen the equipment in use or talked to existing customers?

Do your homework. A good setup pays off for years—a bad one holds you back.