Powder Coating Services Vasai - 7-Tank, 3 Ovens, Job Work Vasai - Mumbai - Palghar

Powder coating is a dry finishing process where electrostatically charged powder particles are sprayed onto a grounded metal component and then cured in an oven at 180–220°C to form a hard, durable, and protective finish. The result is significantly tougher than conventional liquid paint — more resistant to chipping, scratching, corrosion, and UV degradation. Powder coating is used across industrial, architectural, automotive, and consumer product manufacturing for both functional corrosion protection and decorative surface finish.

The 7-tank powder coating pre-treatment process is the chemical surface preparation sequence performed on metal components before powder is applied. At Aero Enterprises Unit I, the 7-stage sequence covers: Stage 1 — alkaline degreasing (removes oils, lubricants, and contamination), Stage 2 — water rinse, Stage 3 — activation (surface conditioning for phosphate crystal nucleation), Stage 4 — zinc phosphate or iron phosphate conversion coating (builds the adhesion layer), Stage 5 — water rinse, Stage 6 — passivation sealing rinse, Stage 7 — DI water final rinse before booth entry. Tank concentrations are verified and adjusted daily. This sequence is the reason Aero Enterprises achieves Class 5B cross-hatch adhesion on every batch — not the powder brand.

The complete powder coating process at Aero Enterprises Unit I runs in four stages: (1) 7-tank chemical pre-treatment — degreasing, phosphating, and sealing to prepare the metal surface for adhesion; (2) electrostatic powder spraying — charged powder particles applied uniformly to the grounded component in dedicated spray booths; (3) oven curing — components held at 180–220°C in thermostatically controlled ovens for complete polyester crosslinking; (4) quality verification — DFT measurement, cross-hatch adhesion test (ISO 2409), impact resistance test, and colour conformity check before batch dispatch approval.

Powder coating thickness — measured as Dry Film Thickness (DFT) — is the depth of the cured coating on the component surface. At Aero Enterprises Unit I, the target DFT range is 60 to 120 microns on flat faces and a minimum of 50 microns on inside bend radii and punched hole bores. DFT is measured using a calibrated digital magnetic thickness gauge on a minimum of 10 measurement points per component type on every production batch. Coating on bend radii and hole bores is always thinner than flat faces — measuring only flat faces produces misleading results.

Epoxy powder coating uses an epoxy resin base instead of polyester, giving it superior chemical resistance and adhesion compared to standard polyester powder. It is used for electrical enclosures, indoor panels, and components requiring chemical resistance. The limitation of epoxy powder is UV instability — it yellows and chalks under direct outdoor sunlight. For outdoor applications, epoxy powder is used as a primer coat under a polyester top coat, combining epoxy's adhesion and chemical resistance with polyester's UV stability. At Aero Enterprises Unit I, zinc-rich epoxy primer combined with a polyester top coat is available for outdoor and coastal installation components.

MS powder coating — mild steel powder coating — is the application of a polyester or epoxy-polyester powder coat finish to mild steel (MS) fabricated components. Mild steel requires the full 7-tank pre-treatment sequence before coating, including zinc phosphate conversion coating, because bare MS oxidises rapidly and provides poor adhesion without a phosphate conversion layer. At Aero Enterprises Unit I, MS powder coating covers all fabricated mild steel components including brackets, enclosures, frames, panels, and hardware across the full RAL colour range.

Yes. SS powder coating at Aero Enterprises Unit I uses a modified pre-treatment chemistry appropriate for stainless steel — standard zinc phosphate chemistry for MS does not provide the same conversion crystal structure on stainless surfaces. SS 304 and SS 316 components are pre-treated with appropriate chemistry, then electrostatically coated and cured at the standard temperature profile. SS powder coating is specified when a specific RAL colour or textured finish is required on a component that also needs the base corrosion resistance properties of stainless steel.

Aero Enterprises Unit I at Survey No. 109, Richard Compound, Manchipada Road, Vasai Phata, Vasai East, Palghar 401208 provides industrial powder coating services in Vasai, Palghar, Virar, Nalasopara, Bhayandar, Mira Road, and the broader Mumbai metro region. The facility operates a 7-tank pre-treatment line, two electrostatic spray booths, and three curing ovens including a crane-operated 4×10×10 ft oven for large and heavy assemblies.

Aero Enterprises Unit I stocks standard production colours in regular inventory including RAL 9005 matt black, RAL 9003 signal white, RAL 7035 light grey, RAL 6005 moss green, and RAL 5002 ultramarine blue. The full RAL colour standard is available with minimum order quantity and colour change lead time for non-stock colours. Finish options include matte, satin, gloss, textured, and wrinkle finishes in polyester, epoxy-polyester, and zinc-rich epoxy primer powder types.

Powder coating cost for sheet metal components at Aero Enterprises Unit I is calculated per square foot of surface area, adjusted for component geometry complexity, pre-treatment requirements, colour specification, and batch volume. Components with complex geometry — deep recesses, small hole patterns, or tight internal corners — require additional spray time for coverage consistency. Zinc-rich epoxy primer plus polyester top coat is a two-coat process and is priced accordingly. Contact the engineering desk at for a specific coating cost against your component drawing and batch volume.