When your powder coating oven restricts the size of jobs you can take on, it’s not just limiting your capacity—it’s capping your revenue. That was the challenge facing Baird & Whyte, an Onehunga-based powder coating specialist with roots stretching back to 1945. Known as NZ’s original powder coating experts, this family-oriented, New Zealand owned and operated business needed equipment that matched their reputation for quality. After partnering with Egmont Air to design and install a custom powder coating oven, they now operate one of the largest in Auckland and have seen a significant boost in capability and revenue.
The Challenge: Outgrowing an Outdated System
For Paul Shaw, Managing Director of Baird & Whyte, the limitations were clear. With an existing setup that included a 22-metre continuous sprayline and traditional static spray booths, the batch oven had become a bottleneck for larger projects—and that meant watching potential revenue walk out the door. “Before we got in contact with Egmont Air, the old oven was restricting us for bigger projects, which in turn restricted our revenue base,” he explains.
The solution needed to be more than just a bigger box. It had to deliver precise temperature control, energy efficiency, and seamless integration with existing workflows.
A Collaborative Approach from Day One
From the initial conversation, Paul knew Egmont Air was the right fit. “From the day I talked to them, I knew they were going to be good. These are the guys I wanted to deal with. Everything they said they did, and it was awesome. It was actually like clockwork, was brilliant.”
Cameron from Egmont Air conducted a thorough site visit at their Princes Street facility to understand exactly what Baird & Whyte needed. Detailed CAD drawings followed, requiring only a minor adjustment to the door opening. “The communication with Cameron was just on point,” Paul adds. “Absolutely fantastic. Always knew where we were going, and you couldn’t ask for anything else.”
Technical Excellence: What Makes This Powder Coating Oven Different
Egmont Air designed a purpose-built powder coating oven incorporating several advanced features:
Modulating burner system: Unlike outdated on/off or high/low systems, the modulating burner maintains temperature accuracy within single digit 1.0°C – even when running at 200kW and 200°C. The burner ramps up or down according to load, so a half-filled oven uses less energy.
Shiplap panel construction: The unique interlocking panel system maintains an airtight seal during the constant expansion and contraction of heating cycles, preventing heat loss and structural issues like buckling. The panels feature 100mm thick, high-density rockwool insulation for superior thermal retention.
Optimised air recirculation: Side channels distribute heated air evenly across the full length of the oven. The air flows from the floor upward through the product, exits through the ceiling, and recirculates for consistent coverage.
NZ-made PLC control panel: Schneider PLC controllers with universal ladder-logic programming give operators full control over the heating process, with options for custom interlocks to integrate with other factory systems.
Paul has noticed the difference in daily operation: “Egmont Air put a modulating burner on the oven. At the moment, I feel it’s working very, very well in comparison to our old oven.”
Business Impact: Bigger Jobs, More Revenue
The new powder coating oven has fundamentally changed what Baird & Whyte can offer their customers. With one of the biggest ovens in Auckland, they’ve solidified their position as a true one-stop powder coating factory—capable of handling everything from small component batches to the oversized projects that previously went elsewhere.
“Since we installed the new oven from Egmont Air, it’s opened up a huge path,” Paul says. “Since our existing customers have known about our new oven, they’ve been sending their biggest stuff to us, which has obviously increased our revenue base.”
The oven runs five days a week, 40 hours a week, handling the larger projects that previously went elsewhere. For a company that has built its reputation on quality results over nearly 80 years—including notable projects like powder coating the Manulua sculptures for Auckland War Memorial Museum—the expanded capacity means they can take on even more ambitious work.
Frequently Asked Questions
What is a modulating burner and why does it matter for powder coating?
A modulating burner adjusts its output continuously based on demand, rather than simply switching between on and off states. For powder coating, this means highly accurate temperature control (within 1°C or better) and significant energy savings, as the burner reduces power when the oven is partially loaded.
How long does a powder coating oven take to heat up?
Initial preheat time varies depending on ambient temperature and product mass, typically taking 15–30 minutes or longer. Once heated, subsequent bake cycles reach optimum temperature much faster.
Why is panel construction important in a powder coating oven?
Heating cycles cause significant expansion and contraction. Egmont Air’s shiplap panel system maintains an airtight seal throughout this movement, preventing heat loss, structural weakening, and buckling. High-density rockwool insulation helps retain thermal energy efficiently.
Can a custom powder coating oven integrate with existing factory systems?
Yes. Egmont Air’s NZ-made PLC control panels use Schneider controllers and universal ladder-logic programming, allowing for custom interlocks to interface with other factory processes as needed.
A Straightforward Recommendation
For Paul, the verdict is clear: “If you’re in the powder coating business, I highly recommend Egmont Air. They’re fantastic to deal with.”
Ready to Upgrade Your Powder Coating Operation?
Whether you’re looking to expand capacity, improve energy efficiency, or gain better temperature control, Egmont Air designs custom powder coating ovens to suit your specific requirements. We handle everything from initial site visit through to installation, backed by full industrial warranty and ongoing support.
Get in touch with our team to discuss your project: Contact Egmont Air