Why In-House Powder Coating Makes ALL the Difference

In 1985, Urban Group’s story began in a humble garage in Fairfield, Levin, where Ormond Stewart started his own engineering business. What began as a small home operation quickly grew, and within a few years, our company had evolved into one of New Zealand’s largest manufacturers of gates and fences. 

Our name changed from Fairfield Engineering Co. to Urban Group to reflect our focus on boundary and landscape solutions, but we never lost our flair for technical engineering and our spirit of ingenuity. 

A quarter of a century later, Urban Group built a 2000m² fabrication facility, allowing us to put our ingenuity to use, producing gates locally and responding to customers' bespoke needs. However, within just three years, it became apparent that more was needed. 

The Powder Coating Problem 

In providing the highest quality fences and gates to the residential and commercial market, Urban Group realised that the powder coating quality was crucial to the finish of the final product. In addition, with larger gates, we often struggled to find facilities with ovens large enough. When customers wanted specific bespoke colours, it could mean longer wait times - if it was even possible. In turning around projects quickly, we found it was often the wait on powder coating and the additional time needed to transport to and from. Plus, it was heartbreaking to create a perfect finish only to have it damaged being transported to or from the powder coaters. 

A Game-Changing Investment 
In 2013, we commissioned a powder coating facility our their Levin manufacturing plant. This was not just any facility — it was designed with precision to meet our unique needs. With ovens measuring 2.4m x 8m, it became one of the largest powder coating facilities for gates and fences in New Zealand.  

As the demand for bespoke gates grew, so did the need to be able to provide smaller runs for different colours. The facility was designed as a batch plant, allowing flexibility for small production runs and frequent colour changes, essential for Urban Group's tailored projects and fast turnarounds.  

Urban Group’s Managing Director, Fergus Stewart, says, “One of the things we value about having powder coating in-house is the ability to respond quickly to customer requests. Sometimes a product is needed urgently and we’re able to move things around to deliver it in almost impossible timeframes.” 

Quality, Craftsmanship, and Control 

But equipment is only half the story. In addition to a state-of-the-art facility, we knew they needed expert operators. Early on, we brought in Johnny Lake, whose expertise and sharp attention to detail quickly made him an invaluable part of the team. His expertise has helped foster a culture of excellence. 

For Urban Group, powder coating isn’t just a process; it is an art. Our high-end residential gates demand a defect-free finish and achieving that requires precision at every stage — pre-treatment, application, and post-process inspection. The team takes this so seriously that we often inspect the work under a microscope. If even the smallest imperfection is found, we strip the product and start again. It is a time-intensive process, but it is what sets Urban Group apart. 

Today, Urban Group is more than just a manufacturer - we’re innovators, problem-solvers, and perfectionists. From that small garage in 1985 to our cutting-edge facilities today, we continue to be passionate about our products and our service.

If you’re looking for a knowledgeable partner to help you deliver excellence on your next fencing or gate project, get in touch today.