Electrostatic paint guns have a number of benefits, including an excellent finish quality and a very high transfer efficiency of up to 90%. To get the full benefit of electrostatic guns you can follow a few simple steps. There are several factors in the spray booth that can impact the effectiveness of electrostatic painting.
By following these simple steps, you will see an increase in production, a decrease in material usage, and long-term money savings.
PROPER GUN SET-UP
The right air and fluid pressure are critical for transfer efficiency. Too much air pressure will cause turbulence in the sprayed material, resulting in excessive overspray and reduced transfer efficiency. The key is to use high enough air pressure to get a high-quality spray pattern, but low enough to optimize transfer efficiency. Fluid pressure should be minimized to reduce bounce-back of material on the substrate.
SPRAY PATTERN HEIGHT
Your spray pattern height needs to match the part you are spraying. Material blow-by from too large a spray pattern reduces transfer efficiency. The tip should be sized to the largest spray pattern height for your parts, but not bigger. We recommend purchasing a spray gun with a fan pattern adjustment knob. As your part size varies, the operator can use it to adjust the spray pattern height to match the part.
Operator technique can affect transfer efficiency by 10 to 30%. Because of this, operators should be trained on the correct spray techniques so transfer efficiency is maximized. Training should include spraying the right distance from the part, spraying perpendicular to the part, and triggering and de-triggering at the right time.
GROUNDING IN THE MIXING ROOM
All components in the paint mixing room must be properly grounded to optimize electrostatic guns. This includes the operator, the parts being sprayed, the electrostatic gun, and other objects in the mixing room. Next, the mixing room and gun both need to be clean. Using gun covers and clean part hangers increases the attraction of the coating material to the part.
AIR CONDITIONS IN THE MIXING ROOM
Air conditions in the mixing room also impact the transfer efficiency of your electrostatic gun. Cross drafts, downdrafts, and high-velocity air exhaust can deflect the paint away from the target, decreasing the electrostatic system’s operating efficiency. Temperature and humidity can also significantly affect the efficiency of electrostatic systems. Ideally, the mixing room should be an enclosed, controlled environment.
EFFICIENT SPRAYING WITHOUT A MIXING ROOM
Even without a mixing room, you can achieve excellent results and high transfer efficiency. Graco’s HydroShieldTM is an electrostatic spray system for waterborne materials that doesn’t require an isolated mixing room to operate. Combined with the Pro XpTM WB electrostatic guns , it delivers incredible results. Click below to read more about HydroShield, one of the safest and most operator-friendly electrostatic spraying systems on the market.
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