Getting higher productivity from your powder coating operation is easy if you pay attention to ALL the components of your system. In this and future XTreme XChange™ issues, we'll cover some of the ways to keep your system at peak performance. In this first issue, we'll tackle Cyclone Efficiency.
A Cyclone is a cylindrical device that separates particulate materials entrained in an air flow. Cyclones by design are separators, not filters, so there is always some loss. By centrifugally spinning the particles around the cyclones' perimeter, the particles drop to the bottom for recovery. In ITW Gema's case, oversprayed powder from the booth recovery process air is separated. By using centrifugal force, the powder/air mixture enters the cyclone and is directed downward through the cone-shaped body, increasing in speed as it spirals to the bottom. A high percentage of the powder drops out for reuse and a small amount of powder is left entrained in the airflow and is sent to the waste container.
Cyclone Efficiency is simply a matter of how much powder is reusable, versus what was put in. Normal cyclone efficiency is dependent on a number of factors including airflow, powder type, particle size, shape and density. Typical cyclone efficiency ranges from 90 to 97%. This is calculated based on the amount of oversprayed powder which actually goes into the cyclone and how much powder is returned for reuse. This is not to be confused with system utilization, but simply a measurement of the cyclone separators' efficiency.

Airing Out Cyclone Problems
Cyclones have become so good at what they do, that powder coating system owners and operators tend to forget about them. Until there's a problem!
If you notice a drop in your powder reclamation, air leaks could be the culprit. Air leaks are caused by bad gaskets and seals at connection and transition points and by access doors on some models of cyclones that are left open or not closed properly. If your cyclone experiences a lower powder reclaim efficiency, check for air leaks first!

Next issue, we'll talk about Transfer Efficiency and how it relates to Cyclone Efficiency and System Utilization.