Industrial Powder Coating Services

Industrial Powder Coating Services
Benefits of Our Powder Coating Services
Corrosion Performance Standards
Wire Products That Can Be Powder Coated
Industries Served
Powder Coating Services by Madsen Steel Wire

Bronson powder coating facility — 100,000 sq. ft. powder coating facility in Bronson, MI

Industrial powder coating is the process of applying a liquid-free pigment to a substrate in a high-volume, large-scale setting. During this process, a layer of fine, colored particles and polymer resin is applied to a metal component and then cured until it hardens. Unlike paint, powder coating is highly wear-resistant and environmentally friendly.

Madsen Steel Wire offers industrial powder coating services for a multitude of wire products in a wide variety of industries. We can create durable and attractive wire components that match your branding and performance requirements.

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The industrial powder coating process involves three basic steps:

Pre-treatment: Clean surfaces are a necessity for obtaining a high-quality coating. During the pre-treatment step, we employ a 5-stage washing process, and special cleaning solutions, coatings, or sealers may be applied to the metal’s surface to prepare it for powder application. We also offer a sand blasting option.
Powder application: After all dirt, oils, and grease are removed, the workpiece is electrically grounded and the powder coating is charged. Using an electrostatic spray gun, the electrically charged powder coating is applied to the component’s surface. The powder can be applied in a range of thicknesses depending on application goals.
Curing: The final step is to heat the workpiece in a gas convection oven until the powder coating melts and forms a smooth, even finish. To achieve this, the oven temperature must be between 350 °F and 450 °F.

Unlike with liquid coatings, powder-coated products do not need to spend long periods of time drying after applying the coating. After the workpiece has cooled, it’s ready to be packaged and shipped immediately. Our powder coating services are available in a large variety of colors, glosses, textures, and are PFAS free. In addition to offering standard products, we also develop custom coatings if your project requires it. Get in touch with our team to learn more.

Benefits of Our Powder Coating Services

Madsen Steel Wire uses a state-of-the-art 5-stage stainless steel powder coating booth that operates at maximum efficiency and facilitates quick color change. When a new color is needed, we quickly and easily pivot, without having to shut down the production line to make the switch. Since we are able to clean the booth as it is working, our customers enjoy further reduced lead times.

Additionally, our powder coating is certified PFAS free. Madsen Steel Wire is committed to taking proactive, ethical, and sustainable steps in eliminating the use of these harmful chemicals. We adhere to our long-standing principles of providing rapid, high quality powder coating services without cutting corners.

As a one-stop shop, we handle everything your project needs, with reduced turnaround times on top of our already rapid delivery. Since we are the only company handling your project, your products will be more consistent and completed quickly. We also work directly with our customers to ensure that their needs and requirements are met. Our experienced team creates attractive, high-performing powder-coated products that won't fade and can even endure abrasive conditions, extreme temperatures, and long-term salt exposure.

No matter what the end-use of your product is, powder coating delivers many advantages over liquid coating processes:

Increased coating durability

Reduced material costs

Faster turnaround times

Greater resistance to moisture, chemicals, impact, wear, corrosion, and fading

No hazardous waste materials, solvents, or carbon dioxide emissions

Powder Coat Corrosion Performance Standards

Madsen Steel Wire’s Powder Coating line adheres to the AAMA 2603 and AAMA 2604 specifications, as well as ASTM B117 specifications, offering several significant benefits:

Enhanced Corrosion Protection

Meeting AAMA 2603 and AAMA 2604 specifications ensures that our powder coating line meets industry-standard corrosion performance standards. This compliance signifies a commitment to providing a more robust and effective coating that protects products from corrosion. Our customers can have confidence that the coated items will have an extended lifespan and remain structurally sound even in challenging environments. Our process can achieve 1,000 hours of corrosion resistance performance on steel parts with the correct powder selection!

Long-lasting and Durable Finishes

Our adherence to these specifications demonstrates that our high-end pretreatment process and powder coating application are designed to create durable finishes. As a result, the coated surfaces are less likely to decay, flake, or peel over time. This durability ensures that the colors of the coated products will remain vibrant and unaffected by the elements, contributing to a longer-lasting and aesthetically pleasing appearance.

Resistance to Corrosion in Various Environments

The pretreatment process at our facility is specifically designed to treat both ferrous and nonferrous substrates while accommodating a wide range of materials and part geometries such as sheets, extrusions, castings, and tubes. This versatility, combined with compliance with ASTM B117 specifications for salt spray testing, demonstrates our powder coating's ability to resist corrosion in diverse environments. The results of the salt spray test provide tangible evidence of the coating's effectiveness in protecting against corrosion.

Quality Assurance through Standardized Testing

Adhering to ASTM B117 specifications for accelerated salt spray testing reflects our unwavering commitment to quality assurance. The standardized testing procedures outlined in ASTM B117 help ensure that our powder coating meets rigorous performance standards. This not only provides our customers with confidence in the reliability of the coating, but also serves as a benchmark for our facility's commitment to producing superior-quality, corrosion-resistant finishes. In summary, our powder coating facility meets AAMA 2603 and AAMA 2604 specifications, as well as ASTM B117 specifications, assuring our customers of superior corrosion protection, durable finishes, and reliable performance in various environments. Our adherence to industry standards and rigorous testing reflects a commitment to quality and contributes to the long-term success and satisfaction of customers relying on powder-coated products.

Wire Products That Can Be Powder Coated

Since powder-coated products are exposed to high temperatures during the curing process, they must be able to withstand heat exposure. For this reason, most of the products that are powder coated are made from metal. Everything from sheet metal stampings and aluminum castings to extrusions, structural steel, industrial components, and much more can be powder coated.

At Madsen Steel Wire, all of our products can be custom powder coated according to your project's performance requirements and color preferences. Some of the most common products we powder coat include:

Wire POP Displays
Wire Shelving
Wire Forms
Wire Mesh Grids

Wire POP Displays

Point-of-purchase displays must be attention-grabbing and attractive as well as functional. Powder coating these products in bright colors ensures you’ll stand out from the competition.
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Wire Shelving

Whether used in bakeries, hospitals, grocery stores, industrial, or laboratory environments, powder coating ensures optimal performance under wet and humid conditions. It also ensures corrosion and rust are not a concern.
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Wire Forms

We create parts for virtually any industry and application, including hooks, handles, hangers, and latches. All of these products feature improved appearance and performance after powder coating.
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Wire Mesh Grids

Wire Mesh Grids

Whether used in commercial or industrial settings, our wire mesh grids are attractive and deliver improved durability after powder coating. Mesh grids for retail slatwall, storage lockers, and office data center enclosures are just a few products that are well-suited to custom powder coating.
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Regardless of your project's needs, our highly efficient powder-coating technology, which is housed in our large 100,000 sq. ft. facility, creates attractive products with minimal lead times.

Industries Served

At Madsen Steel Wire, our powder coating creates improved components for many demanding industries, including the applications in this condensed list:

Automotive: Security barriers, custom wire cages, and vehicle security screens
Recreational Vehicles (RVs): any wire components on the exterior or interior
Industrial & Manufacturing Industries: Wire drying racks, machinery and automation guards, storage lockers, slat walls, tool boxes, cleaning baskets, rod latches
Lighting: Mesh grids for stadium lighting components, high bay wire guards, dock light grills, hangers, hooks
Food and beverage: Refrigeration and oven shelving, wire pastry bag holders, hooks, retail displays, signage holders, bread racks, wire baskets, kitchen trolleys, plate racks, and much more
Recreation: Sporting equipment for hockey, biking, golf, camping, skiing, baseball, racing, and boating, among others
POP Displays: All types of metal wire POP displays such as those found in grocery stores, auto shops, gas stations, bakeries, and other retail settings
Energy & Utilities: Light poles in parking lots and the protective metal wire cages around light fixtures

No matter what your industry, we can create an attractive, high-performing wire product for you. For particularly challenging or unique applications, our team can even develop a completely custom powder coating formulation designed to meet your requirements.

Highest Quality, Fastest Delivery

Industrial Powder Coating Services by Madsen Steel Wire

Madsen Steel Wire has been creating superior-quality wire products since 1938. All of our products are completely made in the USA, including our industrial powder coating services, so you can be certain you're getting the best possible quality.

To learn more about our powder coating services or to get started on a custom project, contact our team today.