Reduce Waste

with
Spray Technique Training
in painting & coating operations

Georgia, April 2016

www.biomasseverband.at

Mr. Christian Angerbauer, Mr. Roland Oberwimmer

Introduction
Spray equipment needs to be compatible with coating
characteristics, finish quality requirements, production
demands, and product characteristics; and
Optimal efficiency (in any type of coating application) is most
effectively and readily achieved by the proper selection, set
up, and operation of spray equipment. This, of course, is
complemented by the ability to recognize and diagnose
application problems.

Training for employees

Spray gun distance to part

Spray gun distance to part should follow recommendations

from paint sheet & gun set up from manufacturer.
Keep gun distance at optimal distance
Be consistent varied distances leads to an inconsistent
film build
Paint performs best at optimal spray distance

Training for employees

Perpendicular to surface

Keep the spray pattern perpendicular to the surface

No arcing or wrist rotation
Use a fluid motion when you spray to reduce material
consumption

Training for employees

Overlap
Consistent 50% Overlap

Training for employees

Banding & Edging

To reduce overspray on a work piece, which essentially

means you spray the outside corners before spraying the
flat center areas. For example, use a vertical stroke at each
end of a large panel, rather than trying to cover the ends
with horizontal strokes. This reduces paint usage and
overspray.
Technique used to reduce overspray on a flat panels can be
used on edges of parts.

Training for employees

Reduce Lead and Lag

Excessive lead and lag wastes paint

Adds to toxicity of paint-related waste such as paper and
masking

Training for employees

Pattern Size & Shape

Always keep as much of the spray pattern on the part as

possible.
Shape the pattern to the part

Training for employees

Pattern Size & Shape

Slender pieces should be coated with a narrow horizontal or
vertical pattern
For a vertical pattern, the gun speed should be increased to
account for the added time the part is in the pattern.
Gun motion should always be lengthwise to the part.

Training for employees

Transfer Efficiency

The amount of paint that is applied to the part.

Even good painters can have a transfer efficiency (TE) of
50% or less.
10% increase in TE can have dramatic effects on costs and
air emissions

Training for employees

Build Efficiency

The amount of part surface that has the optimal

thickness of the coating after spraying.
Very high TE can still produce low quality of work if
the target thickness is not achieved.
Consistency is the key to build efficiency.

Spray painting technologies

Conventional: High overspray levels (65%-70%) BUT
high finish quality, fast working speed
High volume low pressure (HVLP): High finish
quality, great material savings BUT slower working
speed and problems with thicker paints
Air-assist airless: Super fast application speed - one of
the fastest available, High finish quality, low overspray
BUT much higher investment costs
Reduced pressure (RP)/Compliant technologies:
Faster application speed than HVLP, among the highest
finish quality, great material savings - similar to HVLP
Low Volume Low Pressure (LVLP): among the lowest
overspray levels you can purchase, superior finish
quality similar to reduced pressure

Typical efficiencies (application

efficiency, expressed as % solids):

13

Conclusion
Spray equipment needs to be compatible with coating
characteristics, finish quality requirements, production
demands, and product characteristics; and
Optimal efficiency (in any type of coating application) is most
effectively and readily achieved by the proper selection, set
up, and operation of spray equipment. This, of course, is
complemented by the ability to recognize and diagnose
application problems; so
Regular training of employees is necessary to keep efficient