Problem: As KLAW Industries began manufacturing its own equipment at scale, we needed a durable, professional-quality coating process that could withstand harsh industrial environments without requiring excessive capital or labor.

Solution: After evaluating several coating methods, I selected powder coating and designed and built an industrial powder coating oven and spray booth. 

A commercial oven of the required size would have cost over $50,000 with a six-month lead time. I built ours for approximately $8,000 in three weeks, reducing upfront costs by over $42,000 and dramatically shortening the timeline.

The system was used to coat more than 100 large equipment components and remained operational throughout its service life.

Steps Taken

1) Evaluate Coating Methods - Developed a decision tree comparing coating options, from conventional spray painting to hot-dip galvanizing, based on durability, cost, labor requirements, and production needs.

2) Design and Build Powder Coating Oven - Designed and constructed a custom industrial powder coating oven sized for our large equipment, completing construction in 3 weeks for approximately $8,000.

3) Establish Coating Infrastructure - Built a powder spray booth and sourced application equipment, coating materials, and suppliers to establish an in-house coating operation.

4) Develop Operating Procedures - Created detailed standard operating procedures (SOPs) covering equipment operation, powder application, curing times, and coating quality inspections.

5) Train Team and Begin Production - Trained employees on the coating process and established quality standards, enabling the team to powder coat 100+ large equipment components in-house.