As industries race toward carbon neutrality, “going electric” often seems like the obvious path. Electricity feels cleaner, more modern, and easier to integrate into sustainability goals—especially compared to fossil fuels.
But when it comes to curing processes, the story isn’t that simple.
At WolfRayet, we design gas catalytic infrared ovens, and many of our customers are committed to reducing both their energy consumption and carbon footprint. Yet, as I dug deeper into where our electricity actually comes from in the U.S., the results were surprising—and important for any manufacturer trying to make data-driven environmental decisions.
Here’s the current breakdown of U.S. power generation:
In other words, nearly 60% of our electricity still comes from fossil fuels!
That means the “clean” electricity powering your plant—or your EV car you drive—may originate from burning natural gas or coal.
Each energy source produces very different emission profile.
Also, it is a fact that the average amount of fossil fuel energy ( Nat. Gas or Coal) produces 1 KW (3,412 BTUs) is 10,000 BTUs. Based on this fact the emissions are as follows…
CO₂ emissions per KW by energy source…
NOₓ emissions per KW by energy source…
Weighted across the U.S. grid, electricity generation produces roughly 0.367 kg CO₂ and 0.299 g NOₓ per KW.
So, while electric systems emit nothing directly, the electricity they use still carries an indirect carbon and NOₓ burden.
While CO₂ drives global warming, nitrogen oxides (NOₓ) are a direct health hazard—they contribute to smog, acid rain, and respiratory disease.
Both matter, but NOₓ has a more immediate human health impact.
If your facility’s electricity is generated mostly from natural gas or coal, running electric infrared ovens doesn’t eliminate your carbon footprint—it shifts it upstream to the power plant.
You can verify your region’s electricity mix using the EPA’s Power Profiler:
👉 https://www.epa.gov/egrid/power-profiler
Comparing Energy Sources in Manufacturing
Let’s look at what happens when you choose electric infrared (IR) versus gas catalytic infrared (IR) ovens for your curing line.
In this example, let’s compare an electric oven with 330 KW/Hour connected load with an equivalent gas KW/Hour of 1,000,000 BTU/Hour connected load. Remember the energy equation where 1 KW = 3,142 BTUs.
Electric Infrared Oven
While the oven itself doesn’t generate pollutants, the power plants feeding it certainly do.
Gas Catalytic Infrared Oven
That’s less than half the CO₂ and no NOₓ emissions.
Why Gas Catalytic IR Is Different
Gas catalytic infrared ovens convert natural gas or propane into heat through a platinum-catalyzed reaction, not open combustion.
This process produces infrared energy, water vapor, and CO₂, but no NOₓ or particulate emissions.
It’s a clean reaction that directly converts 80% of the BTUs in Natural Gas into radiant heat—no flame, no exhaust gases, and minimal waste.
| Oven Type | CO₂ (lbs./MMBTU) | NOₓ (lbs./MMBTU) |
| Electric IR | 230.28 | 0.585 |
| Gas Catalytic IR | 117 | 0.000 |
| Gas Convection | 117 | 0.1 |
The Efficiency and ROI Advantage
Beyond emissions, gas catalytic IR ovens offer practical benefits:
The Bottom Line
If your goal is truly to reduce total carbon footprint, not just shift where emissions occur, gas catalytic infrared ovens are often the more sustainable choice.
They offer:
Final Thoughts
Reducing emissions is critical—for the planet, for our health, and for business sustainability.
But achieving that goal requires a complete view of the energy lifecycle, not just the endpoint.
If you’re currently using electric or convection ovens, switching to gas catalytic infrared can lower your carbon footprint, reduce operating costs, and support your company’s sustainability goals—without compromising performance.
Curious about how this could work for your process?
Reach out to info@wolfrayet.com to learn more.
East Texas Trailers coats big. Really big. They manufacture over 75 different types of trailers, from utility and dump trailers to tilt decks, livestock, and pipe trailers, with hundreds of options.
They powder coat these steel trailers ranging from 8ft to 44ft in size. When the decision to move from liquid to powder coating for performance and environmental reasons was made, the East Texas Trailers team conducted extensive research. They needed the most efficient and effective way to get these huge steel parts coated quickly and deliver a beautiful, flawless finish. They also wanted the best technology with excellent ROI.
John Peters of East Texas Trailers, explains, “We build steel trailers, with 75 different trailer models available. We powder coat main frames and all the miscellaneous parts the trailers need, like ramps and fenders. The more we looked into the curing options available to us, the more we realized that using gas catalytic IR oven technology as a pre-gel oven (used to quickly gel the powder before the full powder cure) was a real contender, with some major advantages.”
GCIR (Gas Catalytic IR) ovens are a flame-less technology that heat only the surface of the part, rather than the entire component, bringing the powder to required temperature quickly and efficiently. In this case, its primary function is to facilitate the gelling process of newly applied powder coatings by applying heat that initiates the chemical change within the coating. The IR heat softens the powder, allowing it to flow and adhere better to the surface, resulting in a smoother more uniform finish and reduces the overall curing time. As there is less airflow in the pre gel oven, the powder is not blown off. This enables shorter gaps in production when doing color changes. The reduced curing time also allows manufacturers to increase throughput and improve process efficiency.
After extensive research and in-depth discussions with the WolfRayet team, East Texas Trailers chose to implement Gas Catalytic IR ovens from WolfRayet.
Peters continues, “The WolfRayet team explained the many advantages the Galaxy System could bring to our business. One of the major deciding factors was that the GCIR prevented us from having to overbuild our facility just to accommodate the traditional oven system, so construction costs were lower. Another huge advantage was the new WolfRayet oven helps us cure multiple colors at once without suffering from cross contamination and colors mixing in the oven. With 20 different stock colors offered, plus custom color matching, that’s a huge advantage in terms of throughput.”
The Galaxy systems allow manufacturers to achieve a smaller operational footprint and often deliver cost savings in the form of increased throughput, better quality and reduced energy costs. The sustainability advantages, including lower temperatures, less energy consumption and no NOx are a bonus.
As another beautifully coated trailer comes off the finishing line, Peters notes:
“The support received from the WolfRayet team was excellent, installation was easy, and the system is very user friendly – a quick and simple process. We’ve already noticed an increase in output with reduced operating costs. It’s a definite win.”
Coatings for Texas sized trailers to small hydraulic cylinder parts can all be improved with a safe, flameless, NOX free WolfRayet Gas Catalytic oven.
Gas catalytic IR ovens heat only the surface of the part, not the entire component. A beautiful finish is realized via improved flow and reduced contamination. They are highly economical, delivering more energy in a smaller footprint, resulting in compact systems and reduced floor space. Savings are also realized via decreased energy consumption, and the rapid heat-up/cool down means they are easily switched off when not needed.
WolfRayet ovens can be used to gel a coating, for full cure, or as a dry-off or booster oven. For example, a WolfRayet pre-gel oven can be positioned in front of a conventional convection oven to begin the gelling/curing process to improve the final cured product. A WolfRayet dry-off oven can also be considered for moisture removal and enhanced transfer efficiency on hot flock parts.
Check out the easy way to speed up and improve coating quality at Fabtech this year! WolfRayet will bring all the advantages of gas catalytic IR oven technology to booth D40643
The Top 5 Tips When Sourcing a New Powder Coating Oven
Choosing the right oven for powder coating can make a big difference in your productivity and finish quality. Gas catalytic infrared ovens offer significant advantages over convection ovens. They offer efficient energy use and quick curing times. Here are the top 5 tips to keep in mind when selecting the best oven for your powder coating needs:
Bonus Tip!
Gas Catalytic Infrared Ovens can be used as a Pre-Gel Oven in front of a convection oven!
By focusing on these tips, you can make a smart decision when selecting a Gas Catalytic Infrared oven, over a convection oven. Boosting efficiency, quality and reducing the running cost of your powder coating operations.
Compass Powder Coating in Middletown, Connecticut has recently installed a WolfRayet Gas Catalytic Infra Red powder coating oven. It has revolutionized their business. They can now powder coat MDF as well as metal substrates. It has turned out to be a real game-changer for the company.
The system is featured in the December 2023 edition of Finishing and Coating magazine. You can read the full article here.
The article is entitled "Compass Headed In The Right Direction" and is written by Tim Pennington, Editor In Chief, Finishing and Coating.
Mike Chapman, Chief Technical and Strategy Officer for WolfRayet, formerly of Vulcan Catalytic Systems, was the key designer of the powder coating system used by Troy Greenberg, owner of Greenberg Casework. Woodworking Networking Magazine has published an extensive article, explaining the processes used in powder coating MDF. This system has proved to be a 'game changer' for Troy. Read the full article here.
Mike Chapman from WolfRayet spoke with FinishingAndCoating.com’s Editor-in-Chief Tim Pennington, about the new company’s product lines for the heat-sensitive substrate market.
WolfRayet launched in 2022 to design and manufacture gas catalytic IR ovens and pre-gel ovens for the metal powder coating industry, as well as entire powder coating systems for MDF and heat-sensitive substrates.
“Over the years, the powder suppliers have become very creative in developing some of these really super-low bake powders,” Chapman says. “We’re down in the 240 to 265 degrees range now, so that means we have to have a part in the oven for approximately six minutes to get the full cure.”
WolfRayet set up demonstration lines at their Texas facility to showcase the various levels of systems, including the Galaxy 6, 8, and 10 systems designed for medium to large-scale operations. Each system can be customized at the initial design stage. The Galaxy Lyte is an easy-to-use small-scale system. Suited for low-volume coaters to achieve a high-quality coating finish.
“The only way that we can really show how it works is we decided we had to put production lines in a building here in Gainesville, Texas,” he says. “The Galaxy Ultra Light, which is really an entry-level for less than $100,000, where a coater can get into the business of kitchen cabinets and such.
Chapman says the gas catalytic IR technology, together with PLC systems, gives total process control.
“Altogether, it is an exciting new high-tech, low-operating cost solution,” he says. “Our complete systems deliver a perfect cost-effective cure for all powder coaters.”
Visit https://wolfrayet.com
Read the full article at the Finishing and Coating website
Gainesville, TX
WolfRayet, a new company that designs and manufactures Gas Catalytic IR powder coating ovens and offers entire powder coating systems for MDF and heat sensitive substrates, has launched.
WolfRayet offers Gas Catalytic Infrared ovens for powder coating, MDF and other heat sensitive substrates. The WolfRayet Galaxy product range includes:
Mike Chapman, WolfRayet Chief Technical and Strategy Officer explains:
“At WolfRayet our mission is to apply the latest design and technology to manufacturing. Working with application partners we can deliver complete systems. Every system can be used to powder coat MDF and other heat sensitive substrates.
Explaining the oven technology, Chapman continues:
“We believe that our Gas Catalytic IR technology, together with PLC systems, gives total process control. Altogether it is an exciting new high tech, low operating cost solution. Our complete systems deliver a perfect cost-effective cure, for all powder coaters.”
Many will know Mike Chapman as the founder of Vulcan Catalytic Systems which is now owned by Heraeus. WolfRayet is pleased to have Mike leading the development and implementation of this exciting industry sector. He has been the industry leader in the powder coating of MDF that utilized his gas catalytic IR development over the past 35 years.
Wolfrayet will showcase all three of the Galaxy lines in November at their Gainesville facility . Customers will be able to coat their wood based products on the line that best suits their production requirements.
WolfRayet is headquartered in Gainesville Texas.
For more information contact: Fiona Levin-Smith
Tel: 520.345.7513