Choosing the Best Paint Sprayer System
Electric & Pneumatic Airless Paint Sprayer Pumps
Advantages of Airless Paint Sprayers:
- Less Paint Waste - Conventional air spray uses air to atomise the paint towards a surface. This disperses many particles of paint into the air, creating overspray. Airless spray pumps hydraulically atomize the paint without the use of air which not only minimizes overspray but reduces solvent usage.
- Fast Application - with more paint reaching the substrate than conventional air atomised spray systems, steelwork can be coated much quicker and at a greater thickness. Up to 250 metres2/hour.
- No thinner required - due to the high-pressure pumps, heavy-duty viscous paints can be applied without the need of thinners making it safer spraying with less odour.
- One pass Coverage - with spraying at high pressure and minimum wastage it is very easy to spray the substrate in one pass to cover it.
Disadvantages of Airless Paint Sprayers:
- Quality of finish - with an airless pump the paint finish is not the same as air spray and it is difficult to get a high gloss finish
- Poor Control - with airless spray you can only reduce the pressure and change the tip to alter the spray fan. With air spray, you can adjust the fan width and amount of paint on the gun
- No good for spraying small quantities of paint (i.e. less than 5 Litres)
Airless Spray Tips Explained
Air Assisted Airless Paint Sprayer Pumps
This is a combination of airless and air spray where atomisation is created by using 50-70% of the normal airless pressure required to create paint atomisation. With this lower amount of airless pressure, the spray pattern would have tram lines bottom and top. This is known as tailing in the industry. By introducing a small amount of air (25-30psi) to the paint alongside the spray tip the tramlines are eliminated and a fully atomised spray pattern is achieved.
Advantages of Air-Assisted Airless Paint Sprayer:
- More control than airless, with fan pattern and paint adjustments on the gun, but with a similar speed of application
- Better transfer efficiency through spray nozzles than airless and conventional air spray
- Better quality finish to the product than airless, more like air spray finish. Ideal for higher gloss fine finishing
Disadvantages of Air-Assisted Airless paint sprayer:
- More Expensive
- Some paints cannot be sprayed through an air-assisted airless
Electrostatic Paint Sprayer System
Electrostatic spray guns work with Air-Assisted spray pumps and Pressure Pot tanks.
The paint to be applied is charged with a negative charge up to 90KVA. When the paint is sprayed from the gun it goes for the closest earth which is the substrate which is earthed. The charge in the paint causes a large percentage of the paint to be attracted to the edges and rear of the workpiece causing a wrapping effect
Advantages of Electrostatic Paint Sprayer System:
- Greatly reduced overspray
- Paint saving which reduces VOC limits
- Low booth maintenance
- Labour saving
- Less spraying ability required
Disadvantages of Electrostatic Paint Sprayer System:
- The substrate must be earthed properly
- Paint must be suitable for electrostatic use
- Spray guns are costly to replace and must be handled with care
- Paints that contain zinc cannot be sprayed through an electrostatic paint system
Watch This Video Where We Explain The Differences Between Airless, Air-Assisted Airless, and Electrostatic
Conventional Air Spray Equipment
- Suction Feed - the material is drawn from a fluid container by creating venturi across the top of the syphon tube fitted in a cup.
- Gravity Feed - the material is gravity fed from a cup positioned above the spray gun.
- Pressure Feed - the material is fed to spray guns via pressure pot or remote cup under pressure. The pressure is applied by air within the pot to force material up the hoses to spray nozzle.
Paint is atomised by high pressure, high volume air bombarding paint coming out of the fluid tip, which breaks it up into a cloudy spray pattern. A solid coat of material is achieved by overcoating several times in various directions.
Advantages of Conventional Air Spray:
- Very good finish achieved - ideal for high gloss finishing
- Good control ability - adjustments to fan pattern and paint can be made on the gun
- You can use very small amounts of paint
Disadvantages of Conventional Air Spray:
- Poor transfer efficiency: 60% waste, i.e. overspray
- Slow application rate
- Can only spray low viscosity paints
- Usually have to add thinners to apply
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