As powder-coating technology continues to evolve, the stability and consistency of raw materials have become essential to achieving reliable performance on the production line. At PCOTEC, our manufacturing system is built on digital automation, precision dosing, and strict batch-control standards, enabling us to deliver materials that meet the demanding requirements of modern coating formulations. This article offers an inside look at how our production system operates—from reaction control to traceability—and why it allows us to support customers with dependable, high-performance solutions.

1. Intelligent Manufacturing & Automated Reaction Control

PCOTEC’s core production processes are built on DCS (Distributed Control System) and PLC (Programmable Logic Control) automation.
The DCS platform manages key operations such as polyester esterification and TGIC addition/closure reactions. Operators can monitor and adjust temperatures, pressures, levels, and agitation speeds directly from a centralized control room. Complex heating and holding programs are executed automatically, minimizing manual error and ensuring batch-to-batch stability.

PLC interlocks further enhance safety and precision—particularly during dilution, washing, and filling. Critical steps such as polyester dilution only proceed when the Resin temperature reaches a safe threshold, preventing gelation accidents and guaranteeing reliable reaction control.

2. Precision Dosing and Homogeneous Mixing

Accurate raw-material feeding is fundamental to consistent product quality.
Our feeding system uses high-precision loss-in-weight scales and mass flowmeters to dose solid and liquid materials—including polyols, polyacids, cyanuric acid for TGIC, epoxy chloropropane, and styrene—with exceptional accuracy. Each formulation is locked within the MES system, and deviations immediately trigger alarms and halt production.

During mixing, Polyester Resins are homogenized using variable-frequency anchor or paddle agitators during reaction, followed by high-speed dispersers during dilution. TGIC materials undergo high-efficiency alkaline ring-closure reactions and multi-stage counterflow washing to remove inorganic impurities, ensuring purity and stable performance in powder-coating systems.

3. Digital Traceability & Comprehensive Batch Management

Every batch produced at PCOTEC carries a unique batch/lot number throughout its lifecycle—from raw-material entry to finished-product delivery.
Through MES integration, data from DCS, PLC, and LIMS is unified to create a complete digital record. Scanning a product’s batch number provides immediate access to:

• Raw-material origins and inspection reports

• Full reaction temperature/pressure curves

• Dosing records and operator information

• In-process QC data and final inspection results

This end-to-end traceability system allows rapid root-cause analysis and targeted recall if needed, significantly strengthening customer confidence and quality assurance.

4. Production Equipment Supporting Consistent Quality

Our facilities are equipped with advanced reactors, distillation columns, thermal-oil heating systems, crystallization lines, centrifuges, thin-film evaporators for ECH recovery, filtration systems, and automated packaging units.
These assets ensure that both polyester and TGIC production processes operate under controlled conditions, enabling us to meet high standards for reaction completion, purity, safety, and efficiency.

5. Standardized Operating Procedures (SOPs)

PCOTEC operates under a fully established SOP framework covering production, testing, equipment operation, and safety:

• Production SOPs define every step—from equipment checks, raw-material preparation, dosing, reaction control, transfer, to final packaging.

• QC SOPs standardize methods for acid value, viscosity, epoxy equivalent, hydrolyzed chlorine, melting point, and other key metrics.

• Maintenance SOPs ensure equipment remains in optimal condition through preventive servicing and calibration.

• Safety & Environmental SOPs govern emergency response, hazardous-waste handling, and emissions management, fully aligned with ISO45001 and ISO14001 standards.

6. Process Standards for Key Product Lines

Polyester Resins

Production follows a controlled process—material prep, esterification, endpoint monitoring, cooling/dilution, filtration, and packaging.
Each batch must meet internal specifications for acid value, viscosity, gel time, color, and solids content.

TGIC

Manufacturing involves raw-material prep, addition reaction, alkaline ring-closure, multi-stage washing, ECH recovery, crystallization, centrifugal drying, and filtration.
Core quality metrics include epoxy equivalent, hydrolyzed chlorine, melting point, volatiles, and color, with hydrolyzed chlorine control being the top priority.

Conclusion

PCOTEC’s production system combines digital automation, precision engineering, strict SOPs, and robust traceability to deliver stable raw materials for powder-coating formulations. With advanced reaction control, reliable batch consistency, and comprehensive quality management, we provide manufacturers with raw-material solutions that support high performance, safety, and long-term reliability in their coating systems.