One Cure, Double Protection: The Power of Dry-on-Dry Technology

Dry-on-Dry Powder Coating: Faster Curing, Better Coverage, and a Smaller Footprint.

Applying two powder coatings in one go? That’s the promise of our dry-on-dry technology—an energy-efficient coating solution. In fact, this innovative approach maximizes efficiency by applying a dry-on-dry powder coating process. Developed by The Protech Group, this technique streamlines production while improving edge protection and reducing CO₂ emissions, all without compromising durability or finish quality.

WHAT IS DRY-ON-DRY COATING TECHNOLOGY

In fact, in this system, the topcoat is applied immediately after the primer, and the layers are cured together. As a result, this method enhances crosslinking and ensures strong adhesion of the cured coating. Furthermore, it delivers benefits similar to those observed in dry-on-dry coating processes.

The Protech Group also engineered a low-bake version of this technology, allowing both coats to cure at lower temperatures or in less time, resulting in even faster throughput and lower energy consumption.

HOW DOES IT WORK?

The system combines the EF26 primer and PE40.AG topcoat, both of which have been specifically adapted to deliver optimal results with this coating method. Together, these technologies work seamlessly to maximize performance and efficiency.

• EF26 (EF-SERIES) is a highly reactive epoxy primer that provides excellent edge coverage at a low layer thickness.
• PE40 .AG (AG-KOTE) is a Qualicoat, Qualisteelcoat and GSB-certified topcoat with strong outdoor resistance and exceptional degassing performance.

Both products are energy-efficient coatings. As a result, once both layers are applied, curing can start at 150 °C, showcasing the advantages of dry-on-dry powder coating in industrial finishing.

DOUBLE THE BENEFITS

Furthermore, combining one-cure and low-bake methods leads to the benefits inherent to a single-step powder coating operation, including:

• Faster production times
• Lower bake temperatures
• Reduced energy usage
• Significantly lower CO₂ emissions

PROVEN PERFORMANCE

To validate the system’s effectiveness, our R&D team conducted salt spray testing (ASTM B117-07) on bare steel pretreated with iron phosphate and passivation. As a result, the testing measured corrosion and blistering over time, providing valuable performance data. Moreover, the results demonstrated the real-world effectiveness of dry-on-dry powder coating systems.

1. EF26 + PE40 .AG – 70–90 µm total thickness
2. EF26 + PE40 .AG – 90–110 µm total thickness
3. PE40 .AG only – 80 µm total thickness

Corrosion formation – results

Corrosion	EF26 + PE40 .AG (+- 80 µm)	EF26 + PE40 .AG (+- 100 µm)	PE40 .AG (80 µm)
After 500 hrs	Yes (S)	Yes (S)	Yes (S + E)
After 1000 hrs	Yes (S)	Yes (S)	Yes (S + E)
After 1500 hrs	Yes (S+E)	Yes (S)	Yes (S + E)
After 2000 hrs	Yes (S+E)	Yes (S)	*

S = Scratch, E = Edge

• No primer: corrosion starts after 750 hours
• With primer: corrosion delayed to 1250 hours
• Thicker total layer: no corrosion after 2000 hours

Blistering – results

Blistering	EF26 + PE40 .AG (+- 80 µm)	EF26 + PE40 .AG (+- 100 µm)	PE40 .AG (80 µm)
After 500 hrs	No	No	3 S (2) (E)
After 100 hrs	No	No	4 S (3) (E)
After 1500 hrs	2 S (2) (E)	No	4 S (5) (E)
After 2000 hrs	2 S (2) (E)	No	*

S = Scratch, E = Edge

• No primer: blisters at 750 hours
• With primer: delayed to 1500 hours
• Thicker system: no blistering at 2000 hours

The result? Using a primer, even in a thin layer, dramatically improves performance and is a core reason why dry-on-dry powder coating significantly boosts corrosion and blister resistance.

• Corrosion: Without a primer, edges are more prone to accelerated corrosion. A dry-on-dry powder coating process significantly improves edge protection, extending corrosion resistance up to 2,000 hours due to its application advantages.
• Blistering: no primer means early failure. Adding a primer significantly delays or prevents blister formation, underscoring the efficacy of dry-on-dry powder coating.

A primer + topcoat outperforms topcoat-only systems in every way, especially when the total thickness is increased with a dry-on-dry powder coating system approach.

WHY DRY-ON-DRY MAKES A DIFFERENCE

More than just improving efficiency, a high-performance powder coating system delivers a meaningful enhancement in overall quality:

• Better edge protection
• Enhanced long-term durability
• Faster production cycles
• Lower energy costs and CO₂ emissions

It’s a smarter, more sustainable approach to high-performance powder coating, especially when using modern dry-on-dry powder coating technology for advanced results.

Curious how this method could improve your coating line? Get in touch with our team and discover the potential of dry-on-dry powder coating for your business.