Abstract : Powder coating is an electrostatic spray deposition process that involves the spraying of finely ground, electrostatically charged, pre-prepared powder onto the aluminium profiles in order to improve the aesthetic value and impart corrosion resistance. This study is focused on the impact of aluminium profiles sagging during powder coating for the IWIN-S profiles, which have a weight of less than 1 kg weight per metre in the industry. In order to provide continuous support at either end of the profiles Jig rods with two distinct needle orientations are developed to minimise the effects of sagging and ensure consistent coating across the profiles. The design has been validated using the Ansys Workbench software. Implementing new jig rods in the powder coating process prevents profiles from sagging and reduces the amount of LPG and electricity required to coat the profiles. It also reduces the amount of time required to coat each profile. The re-working of pieces with lesser coating thickness and inadequate powder coverage has been significantly decreased, with a productivity improvement of 60–85% per shift.