The successful application of powder coating technology depends on resolving practical issues such as reducing overspray and maximising transfer efficiency. Maximising transfer efficiency requires optimising application parameters that influence powder deposition efficiency. This paper presents the design and development of a predictive fuzzy-logic model for powder coating applications. To improve the performance of the fuzzy-logic model, the model was design based on optimised conditions as determined by statistical analysis. The fuzzy-logic based powder coating system has four application variables as inputs and one output, and gives excellent performance under the conditions investigated. The fuzzy-logic model can easily be implemented in the factory and has the ability significantly to reduce waste while maximising first-pass transfer efficiency.