A Layer of Pallet Rack Protection – Do You Powder Coat or Paint?

The Pros & Cons of Powder Coating vs. Painting Your Pallet Rack

Steel pallet rack is a key component in nearly every warehouse; however, metal corrodes under normal usage over time. So, what is the best way to increase the useable life and improve the durability of your pallet rack? Protecting it with a durable coat of paint is a great first step, but is powder coating or painting the best option?

Both processes coat pallet rack components with a protective layer that prevents oxygen and moisture from penetrating the steel, but that is where the similarities end. They are made from different ingredients and are applied differently. Powder coating is a surface treatment that forms a protective layer against wear and corrosion. Painting is a direct application, either sprayed or dipped. While both finishes are highly durable, UV, moisture, and heat exposure can degrade either finish over time (referred to as chalking). 

Take a look at the pros and cons of these two applications so that you can decide on the best treatment for your storage racking. 

How is Pallet Rack Powder Coated?

Powder coating is a dry finishing process. A powder is electrostatically applied to the surface and then heated. The powder melts and flows together to form a thick, durable finish. There are three steps in pallet rack powder coating.

1. Preparation – Pallet rack parts are thoroughly cleaned to remove dirt, debris, moisture, oils, and other contaminants. The presence of contaminants could hinder powder adhesion in the next steps.
2. Application – Laser-guided equipment navigates several powder-filled spray guns through an electrostatic process that ensures full surface coverage. The metal is grounded, while the spray nozzle imparts a negative electrostatic charge to the powder particles. The particles are shot toward the metal, either mechanically or through compressed air. Once they are in the air, they’re accelerated by the electrostatic attraction between the negatively charged particles and the grounded metallic surface. 
3. Curing – Pallet rack parts are transported to a curing oven, where the powder is melted by extreme heat. Specially formulated polymer resins liquify, bond to metal, and create a solid coating.

Powder Coating: Pros and Cons

Powder Coating Pros

Durable – Powder coating lasts longer than paint. It creates a thick, hard, and even finish that is more resistant than paint to scratches, peeling, cracking, and wear. Powder coating can protect metal for as long as two decades, and the layer it creates can extend the usable life of pallet rack. 

Rust prevention – Powder coating is an excellent method for protecting metal from rust. The coated layer prevents the atmosphere from coming into contact with metal and eliminates the possibility of oxidation.

Single coat and low maintenance – Powder coating is applied as a single layer and requires little maintenance after application. There is no need to use cleaning solutions or solvents to keep it clean because the coating is resistant to corrosion and scratches and is highly durable. Generally, cleaning is only necessary a few times per year.

Safe and environmentally friendly – Powder coating is simply that – powder. It doesn’t contain volatile organic compounds (VOCs) found in paint. This renders powder coating safer than traditional paint.

Recycling overspray – When applying powder coating or traditional paint using a spray gun, a large amount of material is wasted. Overspray is the material dispensed from a spray gun that does not actually reach the intended surface. In the case of traditional paint, this is wasted; however, powder coating can collect and recycle this overspray, which reduces waste and saves material.

Powder Coating Cons

Cost – It is more expensive than painting. The materials and special equipment, such as an electrostatic booth and curing oven, contribute to the higher cost.

Thick finishes – Powder coating tends to produce thicker finishes. It may be possible to create thin powder coat finishes, but it is more complex and can produce an undesirably rough surface.

Painting: Pros and Cons

Painting Pros

Less expensive – Painting has lower setup and production costs than powder coating.

Thinner finish – Paint provides a thinner finish than powder coating.

Painting Cons

Durability – Painting is less durable than powder coating. It is more vulnerable to scratching, which can leave the rack unprotected.

Toxins – Paint contains VOCs, solvents, and other harmful substances to workers’ health and the environment. This makes it harder to work with and costlier to discard.

Multiple applications – Paint requires multiple layers to ensure an even finish and complete coverage.

Consistent application – It is challenging to apply paint with a consistent level of thickness, particularly without dripping.

Is Powder Coating Better Than Paint?

The big question: is powder coating better than paint? Powder coating and painting offer similar benefits. They both help to protect pallet rack components from corrosion and damage. As shown above, each option has advantages and disadvantages. The application that is best for your operation depends on the requirements of your project. Powder coating commonly provides a more damage‑resistant and thicker finish that requires less maintenance than painted finishes. However, it is more expensive and unsuitable for parts requiring thin finishes. Conversely, paint is adequately durable for many applications, can be touched up in the field, and is less expensive than powder coating.

Let us help you make the best choice. We work with trusted pallet rack manufacturers and will ensure that the finish on your system is appropriate for your unique application needs. 

The WOI team offers over 180 years of combined material handling experience to make your space work for you to solve your warehousing challenges. Moreover, we are determined to deliver 100% Customer Satisfaction on each project through our Total Satisfaction Experience™ (TSE). 

The Total Satisfaction Experience focuses on five essential customer experiences:

1.     We will listen to your needs
2.     Execute your project with particular attention to your unique application
3.     Stick to project timelines
4.     Ensure a safe environment
5.     Pay close attention to the detail of the finished product

Our professional installation team ensures that the finished product meets your expectations, and while we are on the job, you can be sure that we follow strict safety protocols.

• Industry Experienced Installation Teams
• OSHA Trained & Certified
• Certified Drug-Free Workplace
• Licensed General Contractor
• Job Safety Analysis
• Forklift, Scissor Lift, and Aerial Lift Operator Trained

Call WOI today for a free consultation and schedule a site inspection —dial (833) 336-7005 or email info@warehouseoptimizers.com. 

WOI proudly serves customers throughout the Southeast, including KENTUCKY, TENNESSEE, NORTH CAROLINA, ALABAMA, AND FLORIDA.