Ranjha Paints Powder Manufacturing Process: What Makes Our Powders Different

The foundation of any high-quality powder coating is the raw materials used in its formulation. At Ranjha Paints, we source premium-grade materials and carefully control the pre-mixing stage to ensure consistency and performance:

• Resin Selection: We use high-quality epoxy, polyester, hybrid, and specialty resins selected for their specific performance characteristics—whether it's chemical resistance, UV stability, or mechanical strength
• Hardeners: Precise hardener selection ensures optimal cross-linking during curing, resulting in coatings with excellent hardness, flexibility, and chemical resistance
• Pigments: We use premium pigments that provide vibrant, consistent color while maintaining excellent lightfastness and weather resistance. Color consistency across batches is a hallmark of our manufacturing process
• Additives: Specialized additives are incorporated to enhance flow, leveling, gloss control, texture formation, and other performance attributes. Each formulation is tailored to specific application requirements

During pre-mixing, these raw materials are carefully weighed and blended in precise ratios. This stage is critical—even minor variations can affect final powder performance. Our controlled pre-mixing process ensures every batch starts with the right foundation.

Extrusion is where the pre-mixed raw materials are transformed into a homogeneous mass. This stage is crucial for achieving uniform powder properties and consistent finish quality:

• Melting Process: The pre-mixed materials are fed into a twin-screw extruder where controlled heat melts the resin and blends all components into a uniform melt. Temperature control is critical—too hot can degrade materials, too cool results in incomplete mixing
• Homogeneous Mixing: The extruder's twin screws ensure thorough dispersion of pigments and additives throughout the resin matrix. This homogeneous mixing is what gives our powders their consistent color and performance characteristics
• Chip Formation: The molten material exits the extruder and is immediately cooled on a cooling belt or cooling rollers. As it solidifies, it forms thin chips or flakes that are easy to handle and process in the next stage
• Rapid Cooling: Quick cooling prevents premature cross-linking and preserves the powder's reactivity for later curing. Our controlled cooling process ensures the material maintains optimal properties for grinding

The extrusion stage is where chemistry meets engineering. Our experienced operators monitor temperature, screw speed, and feed rate to ensure every batch is processed under optimal conditions.

Grinding transforms the cooled chips into fine powder particles. Particle size and distribution are critical factors that affect powder flow, application efficiency, and finish quality:

• Micronization: The cooled chips are fed into precision grinding mills (typically ACM or pin mills) where they are reduced to fine particles, typically in the 10-90 micron range. This micronization process is carefully controlled to achieve the desired particle size
• Particle Size Distribution: Not all particles are the same size—distribution matters. We control the grinding process to achieve a narrow particle size distribution, which ensures consistent powder flow, uniform film thickness, and smooth finish appearance
• Temperature Management: Grinding generates heat, which can affect powder properties. Our grinding systems incorporate cooling to prevent heat buildup and maintain powder quality throughout the process
• Optimized for Application: Different applications require different particle sizes. Fine powders provide smooth finishes, while coarser powders work better for textured effects. We tailor particle size to match application requirements

Particle size control is where science meets art. Our grinding process is optimized through years of experience to produce powders that flow smoothly through spray guns, provide excellent coverage, and deliver the finish quality our customers expect.

The final stages of powder manufacturing ensure that only the highest quality product reaches our customers. At Ranjha Paints, we maintain rigorous quality control protocols:

• Precision Sieving: Ground powder is passed through precision sieves to remove oversized particles and ensure uniform particle size distribution. This step is critical for preventing application issues like orange peel or uneven coverage
• ISO Certification: As an ISO certified coating company, we follow documented quality management systems that ensure consistency across all production batches. Every step is monitored, recorded, and verified
• Flow Testing: We test powder flow characteristics to ensure optimal performance in spray guns and fluidized bed systems. Good flow properties mean easier application and better finish consistency
• Color & Gloss Verification: Every batch is tested for color accuracy and gloss level to ensure it matches specifications. We use spectrophotometers and gloss meters for objective, repeatable measurements
• Sealed Packaging: Approved powder is packaged in moisture-resistant, sealed containers that protect it from humidity, contamination, and UV exposure during storage and transport. Proper packaging ensures the powder maintains its properties until application

Our comprehensive quality control process ensures that every kilogram of powder leaving our facility meets the exacting standards required for industrial applications.