When asked what your annual costs to powder coat, most coaters will total pounds consumed annually times the price per pound. Is there more? The .. Read more answer is yes. We will look at applied cost of powder coating and evaluate why one powder may be better than another. Applied cost is calculated in dollars per square foot. We will also look at wasted cost like too much powder and what does that cost you. These are hidden costs that could be converted to real profits. Lastly, we will discuss rework and what does rework cost. Some coaters measure rework but don't measure the cost of rework.