Round spray air cap and a nozzle overcome the Faraday cage effect

CUSTOMER: General industrial manufacturing, metal

GRACO EQUIPMENT: Pro Xp85 manual electrostatic spray gun with a round spray air cap and spray nozzle, a Triton spray package

CHALLENGE: A manufacturer of aluminium grilles, registers, diffusers and louvres had trouble getting full paint coverage in the back corners of their parts. This was due to a common problem associated with electrostatic guns called the Faraday cage effect.

When trying to paint into corners with electrostatics, the charged paint has a tendency to go the closest ground, which generally does not include the deepest corner.

To combat this problem, painters would turn off the electrostatics on their Graco ProXp 85 manual electrostatic guns to push the paint into the corners using only air. Although a very common solution, it can be inefficient.

It reduces the transfer efficiency capabilities of the gun and creates a lot of overspray. Sometimes operators also forget to turn the electrostatics back on, causing even more wasted paint. 

SOLUTION: A standard Pro Xp air cap and spray nozzle did not create the right spray pattern required to get into the back corners while still using electrostatics.

Their local Graco representative suggested trying the medium round spray nozzle and air cap. It would allow painters to use a smaller fan pattern and drive paint into corners without turning off electrostatics.

By keeping electrostatics and manipulating the spray pattern, they could drastically cut down on overspray, increase transfer efficiency, and overcome the Faraday cage effect.

RESULT: With the round spray air cap and spray nozzle the manufacturer has seen much better coverage on the first coat. Paint usage is down, and transfer efficiency is up.

Painters no longer need to turn off their gun’s electrostatics to overcome the Faraday cage effect. The round spray air cap and spray nozzle provide a simple solution.