APL is in the final stages of constructing its new 'Cube' vertical powder coating plant, which will be the only one in the country.

Two large glass façades, one measuring 31m long by 9m high, have been incorporated using APL's 150mm Structural Glaze system with Crystal Gray 12.76mm glass from Sunguard in the United States, via local supplier Metro Performance Glass. This glazing choice has enabled APL to control solar heat gain while allowing good light transmission and glass transparency from the outside.

Sun path analysis for the extensive high level glazing indicated the desirability of solar control for a building where significant heat would be generated by the curing ovens that are the final stage of the powder coating process.

The choice of the Italian 'Cube' powder coating technology, where aluminium extrusions (usually 7m in length) are hung vertically in the process rather than arrayed horizontally, was made in order to minimise the plant footprint at APL's Te Rapa site. The company's current main powder coating line — a horizontal one — is 100m long by 22m wide, while the new plant has an area 36 x 20m, with a height of 11m in the pre-treatment, spraying and curing chambers.

The new plant will operate in tandem with the current lines to cater for volume growth. One advantage of the Italian system is the use of a chromium-free pre-treatment solution which will reduce environmental impact, and simplify on-site effluent treatment and disposal. Reuse of sprayed powder is also maximised in the new process.