Exploring Dry Film Lubricants

By Brandon Hare

In powder coating operations, keeping parts moving smoothly through high- temperature environments isn't just a nice-to-have, it's essential. Conveyor systems, ovens, and moving components demand effective lubrication to prevent wear and ensure reliable production. However, oil and grease-based lubricants can present challenges that negatively impact a quality powder coat.

Traditional lubricants have the potential to drip, which can degrade and even ruin a good finish. In an environment where cleanliness and coating quality are non-negotiable, this is a serious concern. Replacing oil- and grease-based lubricants with dry film lubricants can provide significant benefits. These high-performance alternatives are designed to handle the heat, keep things running clean, and protect parts without creating new problems.

What Are Dry Film Lubricants?
You may be surprised to learn that dry film lubricants weren’t born on the factory floor. They started in the aerospace and defense industry, where components must perform in extreme temperatures and pristine conditions. As you can imagine, in space or military applications, a dripping lubricant isn’t just inconvenient, it can be catastrophic.

Dry film lubricants are coatings made with solid lubricant materials like polytetrafluoroethylene (PTFE), molybdenum disulfide (MoS₂), or graphite. They are suspended in a carrier that evaporates or cures after application, leaving a thin, solid film. This film reduces friction and wear between moving parts, all without the stickiness of traditional lubricants.

Because these lubricants dry solid, there are no drips, no mess, and no splatter, which means no powder sticking where it shouldn’t. The result is a durable, clean lubrication layer that performs where oils and greases fall short, especially under high heat and in environments sensitive to contamination.

Over time, manufacturers of all kinds have come to understand the potential of dry film lubricants; among them, the powder coating industry. Powder coating lines, with their intense heat and strict cleanliness standards, are an obvious application. In addition, as environmental regulations pushed for lower volatile organic compounds (VOCs) in industrial settings, dry film lubricants gained even more traction. They help facilities stay compliant while keeping operations clean.

Why They Matter in Powder Coating Systems
Anyone who has spent time in a powder coating facility understands the challenges traditional lubricants can introduce to the process. However, dry films tackle these issues head-on. They stay put where applied, don’t drip, and maintain their integrity under extreme heat. This results in fewer rejections and less rework—a win for any shop.

Let’s take a look at some common areas where traditional lubricants can be an issue, starting with conveyor chains. They run through cure ovens that can exceed 400 degrees Fahrenheit. At those temperatures, oils and greases can either burn off or leave behind carbonized residue, both of which are bad news for your coatings.

Another area of concern is overspray zones. These are areas where powder hangs in the air, turning wet lubricants into dust magnets that lead to buildup, contamination, and mechanical failures. And, if a lubricant drips on a part mid- process, in a booth or oven for example, you’ve just invited fisheyes, streaks, or adhesion problems into your finish. No one wants that; especially your customers.

Finally, a word of caution: As with traditional lubricants, some dry film lubricants may contain silicone, which will lead to defects in your finish. For powder coating applications, be sure to select a silicone-free product.

Application and Benefits
There are multiple application methods for dry film lubricants, providing flexibility for powder coaters. Whether it’s spraying, brushing, dipping, or using automated systems, there’s a method to suit every production line. Following application, the lubricant goes through a curing process, sometimes with added heat, sometimes at room temperature. This forms a solid, bonded layer.

Dry film lubricants offer a variety of benefits to powder coaters, as well as manufacturers in general, including:

• High-temperature stability: Many dry films are functional even beyond 500 degrees Fahrenheit.
• Low friction: Reduced wear on chains, rails, and rollers means less frequent part replacements and longer equipment life.
• Extended maintenance cycles: Dry films last longer between applications, reducing maintenance time and cost.
• Cleaner operations: No oil migration means less mess and virtually no powder buildup on machinery.
• Less downtime: Fewer necessary applications translate to more uptime.
• Better finish quality: Elimination of fisheyes or streaks from wandering lubricants.

When Dry Films Don’t Fit
While dry films offer a wide range of benefits, they aren’t a silver bullet. There are some applications where liquid lubricants are a better fit. Knowing when to use dry films, and when not to, helps teams make smart lubrication choices.

When it comes to machinery that takes a beating, for example as a result of heavy loads or shock loads, a thin dry film may not cut it. Greases or thicker lubricants might be a better option. Similarly, in areas where water exposure is a possibility and moisture resistance is desired, wet lubricants often provide a better seal. And, in cases where a machine is constantly being adjusted or taken apart, dry films can wear away faster, which could require more frequent touch-ups. In such cases, dry film lubricants might not be the best choice.

Trends and Future Developments
As is the case in most technologies, the world of dry film lubrication is advancing quickly. Innovations are expanding where and how dry films can be used, making them an even more attractive option across a wide range of industries.

Smart coatings utilize new formulations that can visually show wear and/or alert teams when maintenance is needed. Food-safe options, certified with the National Sanitation Foundation (NSF), are making dry films viable for food processing and packaging. In nano-enhanced films, graphene, copper, and boron nitride nanoparticles can enhance performance, boosting thermal resistance and durability. Nano-additives are also being explored that have the ability to form dynamic tribofilms, regenerating as they wear and extending lubricant life. And, with eco- friendly solutions top of mind for many, there is a growing push for non-toxic, biodegradable dry films that can help to meet sustainability goals.

For powder coating shops, dry film lubricants should be on the radar. They offer a clear path to cleaner operations, fewer defects, and less downtime. Plus, they help meet environmental standards without sacrificing performance.

Maintenance and operations teams would be wise to take a close look at where dry films could replace traditional lubricants. Not only does this move support smoother production and better finishes, but it can also extend equipment life and cut maintenance costs.

As technology continues to evolve, dry film lubricants are poised to play a larger role in industrial maintenance. Companies that adopt them early will gain an edge, keeping lines running clean, parts moving reliably, and products looking flawless.

Brandon Hare is vice president of Digilube Systems.