Our Solution

 

Powder coating is an inherently sustainable finish, but just in time manufacturing generates overspray that has traditionally been landfilled or incinerated. Innovakote changes that.

Our low energy “mix and melt” process converts powder coat overspray into new raw material. This eliminates waste and dramatically reduces the carbon footprint of any product that uses our recycled content.

Proven Environmental Impact

An independent life-cycle comparison (cradle-to-gate) showed that replacing virgin raw materials with recycled powder-coat fines results in significant CO₂ reductions:

Carbon Footprint Reduction (Cradle-to-Gate GWP)

(Representative TGIC polyester product)

Recycled Content

GWP (kg CO₂e)

Reduction vs. Virgin

0% (Virgin)

5.92

—

30% Recycled

4.50

24% lower

60% Recycled

3.00

49% lower

90% Recycled

1.51

74% lower

These results were calculated using industry-standard LCA methodology and validated internally by a global powder coating manufacturer. Results remain consistent when applied to recycled raw materials produced through Innovakote’s process.

Using Innovakote recycled material enables:

  •  Major CO₂ Reductions: Up to 74% fewer greenhouse gas emissions compared to using virgin raw materials.
  •  Circularity in Powder Coating: Overspray becomes valuable feedstock instead of waste.
  •  No Loss in Performance: Our recycled content performs the same as virgin powder, meeting OEM and manufacturer specifications.

Recycled Material. Original Performance.

Innovakote’s gentle mix and melt process preserves the full performance of the powder you already trust. Because we simply remelt and reform overspray particles without degrading its chemistry our recycled material retains all the inherent qualities of the original coating:

  • Durability
  • Corrosion resistance
  • Weather resistance
  • Flexibility
  • Adhesion
  • Appearance

Whether the powder was formulated to meet military, architectural, automotive, or other industry specifications, those properties remain intact. We’re not reinventing the chemistry, we’re restoring it to a usable, consistent form.

Virgin-quality performance. Circular-economy footprint.

Cut Sourcing Costs

Innovakote helps reduce material costs across the entire powder coating supply chain.
By turning overspray into a high value raw material, you gain:

  • Lower raw material costs by incorporating recycled chip into new formulas.
  • More stable supply chains with locally sourced, consistent recycled feedstock.
  • Higher value from the powder you’ve already paid for instead of sending a high % to landfill.
  • Three way optimization between applicator, manufacturer, and our manufacturing arm Surplus Coatings to unlock both cost savings and environmental gains.

Cost efficiency and sustainability, built into the same process.

Licensed Manufacturer Success

Surplus Coatings a division of Coatings By PCD, the original licensed Powder Conversion Depot has proven the Innovakote recycling process at industrial scale.
They have produced millions of pounds of recycled content coatings with no quality issues, supplying both (Class A) finished goods to applicators (as proof of concept) and raw material chip to major powder manufacturers.

Their success demonstrates that circular powder coating works today at production volume.

To explore licensing the Innovakote process and opening your own Powder Conversion Depot, please email info@surpluscoatings.com.