Dip Spin vs Rack Spray Coating Process & Equipment | The DECC Company

Dip Spin


Usually priced by the pound, in a dip-spin, bulk application coating process parts are dumped into a perforated basket and immersed into a coating. The basket is then raised from the vat and spun at a high RPM, which removes any excess coating with centrifugal force. The parts are cured and the process is repeated as needed depending on the coating recipe or thickness requirements.

Rack Spray


Priced per piece, the DECC Company applies functional coatings almost exclusively via a rack-spray process. Whether it be on our electrostatic line, our hand spray line, or in our Research & Development department, almost every part we process is individually hung on a fixture, coated, cured on the fixture and then hand packed into customer dunnage.

Below you can find a white paper that is based on actual case studies and current market data.

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Rack Spray

Pros

  • Less cost overall
  • Less labor
  • Faster Turn Around
  • No need to Scrap
  • No Need to Sort
  • Direct Ship to End Customer

Cons

  • Not suitable for small to mid-sized fasteners or hardware with numerous stamping geometries

Dip Spin

Pros

  • Ideal solution for a vast majority of small to mid-size fasteners or hardware and for numerous metal stamping geometries

Cons

  • Overall cost is affected when considering Cost of Poor Quality (COPQ)
  • Bends and pockets can result in pooling of coating
  • Thinner gauged metal can bend & distort in processing
  • Geometries can get tangled
  • Nearly flat parts can nest, causing voids or inconsistent coverage, or becoming fused together
  • Cost of sorting & packing
  • 20% Fallout requiring reworking or scrapping

The True Cost


In almost every case, dip-spin pricing is less expensive than a rack-spray price. However, this is true if you take the dip-spin pricing vs the rack-spray pricing at face value only. When taking into account the cost of poor quality (COPQ) of a dip-spin application for certain parts, rack-spray pricing could end up more advantageous in the long run.
Download Infographic PDF here.

Bracket Weldment
Cost to MFG:
$0.15
Lot Size:
5,400
Part WGT:
.26lbs

Ship to Dip-Spin Coating

$0.052 Coating Process* *Assumes .26lbs per pc @ $0.20 per lb
+$0.019 Return to MFGR* *Assumes an LTL Shipment One-Way @ $109
+$0.008 100% Sort Parts* *Assumes 1500 pcs per hr @ $12.00/hr labor
+$0.057 Scrap 20% of Coated Parts* *Cost to produce 1080pcs/Remaining good pcs
+$0.003 Pack Remaining Good Parts* *Assumes 4000 pcs per hr @ $12.00/hr labor
Ship To End Customer
Competitors
Dip-Spin $0.289

Ship to Rack-Spray Coating

$0.113 Coating Process
No need for returns, sorting, or scrapping
Ship To End Customer
Rack-Spray $0.283
The DECC Company

True Cost Analysis of a Dip-Spin VS Rack-Spray Price

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The DECC Rack Spray Solution



Less Waste


Until recently, even though a dip-spin application would not be ideal for some complex part geometries, it was the only effective way to ensure complete coverage on a component outside of a manual hand-spray, which would be too costly or not feasible for high-volume production. As a result, manufacturers would just have to succumb to the fact that they would need to sort, scrap and/or rework their product after the coating application.

The Best Coverage


To combat this situation for current and potential customers with complex part geometries, DECC has installed two six-axis FANUC robots for touchup purposes on the back end of our electrostatic line. Utilizing this method, DECC is able to coat most of the part with our electrostatic guns and then obtain complete coverage with our robots, ensuring every nook, cranny, and crevice of a component is covered.

When To Use Dip Spin


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Dip-spin is the ideal solution for a vast majority of small to mid-size fasteners or hardware and for numerous metal stamping geometries. In these cases, it would not make sense to pursue a rack-spray application as the benefit would not outweigh the cost. Dip-spin coating has been the gold standard for these types of components and will continue to be in the future.

If you have any questions on what is best for you, let us know!

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