The Dangers of Powder Coating Dust Emissions

Powder Coating Defined

Created as an environmentally healthier alternative to traditional fluid-based paint, powder coating still poses various occupational health risks to workers.

First patented in 1945 by Daniel Gustin, the original process flame-sprayed powder coatings onto metal. In the early 1950s, the process was improved and patented by a German scientist who discovered that preheating parts and then dipping them in powder was safer than flame-spraying. By the 1960s, electrostatic spray guns replaced the former method and became a mainstay in the powder coating industry.

Powder coating is used mainly to create a thick, tough finish that is more durable than conventional paint. It is a dry finishing process that uses electrostatically charged powder made of thermoplastic or a thermosetting polymer to coat metal surfaces. It is then baked in a curing oven to set and create a smooth coat. It is used via a spray gun that applies an electric charge to emit the coating onto the metal surface.

Industrial Uses

Powder coatings are widely used for the manufacture of items such as:

Appliances – ovens, washers and dryers, water heaters, refrigerators 

Automotive Parts – bumpers, steering wheels, brake assemblies, valve covers,

Construction – earth-moving equipment, structural steel, doors, downspouts

Consumer Goods – electronics, sports equipment, patio furniture, baby strollers

Machinery – power tools, heavy machinery, tanks, motors

Occupational Risk from Powder Coating

While power coatings contain no solvents, thus rarely release volatile organic compounds, fine, invisible dust particles (a common type of particulate matter) can create fire and explosion risks as well as serious health problems when contact is made with eyes and skin. Dust emissions are particularly harmful when inhaled.

Toxic Substances

Respirable dusts are a health risk on their own but, when they contain toxic substances, the situation becomes a serious threat. Consider the toxins commonly found in powder coatings:

Crystalline Silica is a mineral commonly used in powder coatings to increase hardness and durability. It is linked to diseases such as silicosis and lung cancer.

Heavy Metals are used for pigmentation and corrosion resistance. Lead, chromium, arsenic, and cadmium are common substances and can cause nerve damage, even cancer.

Isocyanates provide high gloss finishes as well as weatherability. These organic compounds are linked with asthma and other respiratory diseases.

Triglycidyl Isocyanurate (TGIC) is a solid epoxy hardening agent and is known to cause genetic harm and birth defects.

To underscore the negative health effects of powder coating toxins, an excerpt from a 2024 OSHA review is provided below. Referring to violations found at a manufacturing company that used powder coatings, the review included: 

Left unchecked, exposure to unsafe levels of the chemicals found has numerous health hazards. Triglycidyl isocyanurate can cause birth defects; dust may lead to Chronic Obstructive Pulmonary Disease, and an increased risk of cardiovascular disease; arsenic is a known carcinogenic that can also cause skin lesions; lead can cause permanent cognitive impairment; and beryllium can scar lung tissue permanently.

Mitigation Strategies

As with all manufacturing dusts, mitigation begins with maintaining vigilant cleaning and sanitization practices and requiring workers to wear masks and protective clothing while working with powder coatings. Proper ventilation is a must. However, companies can go further by preventing dust emissions before they occur by installing indoor air cleaning systems, such as dust collection equipment.

At AIR Systems, we help our customers by identifying areas of potential risk and supplying them with stellar air cleaning products. Contact us today for a free estimate with one of our skilled and experienced clean air specialists.

Recommended Product

DC-2 Industrial Dust Collector

$16,663.00

The DC-2 Industrial Dust Collector is great for removal of smoke, dust, fumes, and other airborne contaminants from a variety of industrial metalworking applications. The DC-2 Industrial Dust Collector combines a powerful motor with maximally efficient, fire-retardant filters, providing impressive protection while sitting in a relatively small footprint.