The reliability and reproducibility of thermal sprayed coatings depend, apart from all other coating parameters, on a regular powder flow into the energy source. During the coating development, all parameters are optimized in respect to the coating application. Unfortunately with some desired coating conditions, the powder feeding becomes a difficult process. Quality management is not just a topic for medical and aerospacial industry, it has become increasing importance to all branches. Therefore the mechanic, volumetric powder dosing, which is now state of the art for thermal spraying, will be replaced by gravimetric supported and / or digitally controlled systems which combines high precision and permanent data control and storage. In this presentation the powder feeding process is described, beginning at the powder stock and ending at the injection into the energy source. Technical difficulties are discussed and actual solutions to improve the process are presented.