Powder coating offers a durable, clean finish that stands up to wear and corrosion—but only if the process is controlled from start to finish. Many powder coaters across New Zealand focus heavily on ovens and spray equipment, yet overlook one of the most critical components of a successful finish: air extraction.
We’ve seen first hand how inadequate or outdated extraction systems can lead to costly quality issues, workplace hazards, and inefficient operations. This blog explores the most common powder coating problems caused by poor extraction—and how to prevent them with smart system design and maintenance.
- Contaminated Finishes from Airborne Dust
One of the leading causes of defects in powder coating is dust settling on parts before the powder has cured. This results in a rough or bumpy surface, commonly referred to as “inclusions.” These contaminants can come from grinding, sanding, or simply dirty air circulating through the workshop.
Solution:
High-efficiency dust extraction is essential—especially in prep and spray zones. Egmont Air designs systems that create negative-pressure environments to actively remove airborne particles before they land on your coated surfaces. Using HEPA-grade filtration also ensures the air being recirculated is clean and safe.
- Overspray Build-Up and Product Cross-Contamination
Powder overspray not only wastes material but also increases the risk of unwanted particles ending up on other products—especially when changing colours or powder types.
What goes wrong?
Without proper capture and filtration, overspray settles on floors, walls, or even on freshly coated parts. This can create inconsistent colour finishes or unwanted textures.
Solution:
Install booths with high-volume airflow and self-cleaning cartridge filters. Egmont Air booths are designed with an automatic reverse-pulse cleaning system that keeps filters clean without stopping production. We also offer modular booths with extended canopies to contain and extract overspray effectively—reducing clean-up time and improving finish quality.
- Fire and Explosion Risks from Combustible Powders
It’s a critical but often overlooked fact: powder coating dust is combustible. When fine powder particles accumulate in enclosed spaces and meet a spark or static discharge, the result can be catastrophic.
Solution:
Egmont Air’s extraction units meet safety standards and are designed with explosion vents, fire suppression options, ATEX options, and anti-static ducting. Whether you operate a small spray booth or a large-scale plant, we tailor systems to reduce risk and keep your operation compliant with NZ health and safety regulations.
- Inconsistent Airflow = Inconsistent Quality
Even with the right powder and equipment, poor airflow can cause turbulence, dead zones, or uneven powder deposition—all leading to visible surface defects.
Solution:
Proper airflow design ensures that powder flows smoothly and lands evenly. Egmont Air’s systems use strategically positioned ducting and dampers to manage airflow direction and pressure, creating consistent results every time. We can also integrate sensors and smart controls to actively monitor and balance airflow.
- Increased Maintenance and Downtime
A dirty extraction system doesn’t just affect product quality—it can slow down your workflow. Blocked filters, caked ducting, and inefficient fans all add up to more downtime and higher operating costs.
Solution:
With Egmont Air’s modular design, maintenance is quick and efficient. Systems can be easily accessed for filter changes or inspections, and we offer servicing plans to keep your extraction running at peak performance. This reduces unplanned outages and keeps your production line flowing smoothly.
What Makes Egmont Air Different?
While many suppliers sell “off-the-shelf” extraction units, Egmont Air offers fully custom-engineered solutions designed for New Zealand’s powder coating market. From our CAD-drafted layouts to our Kiwi-made booths and filter units, everything is built with precision, energy efficiency, and compliance in mind.
Whether you’re operating in Auckland, Christchurch, or a rural workshop in Taranaki, we’ll assess your site, understand your process, and install a system that improves both product quality and workplace safety.
If you’re struggling with poor finish quality, high powder waste, or excessive clean-up time, your extraction system might be the culprit. A well-designed extraction system isn’t a luxury—it’s a foundational part of any professional powder coating operation.
Egmont Air offers complete fume, dust, and overspray extraction systems, tailored for New Zealand’s powder coating businesses. Get in touch today to book a site assessment and learn how we can help you eliminate defects, reduce risks, and create a cleaner, more efficient coating environment.