As a finishing professional, every investment in your equipment should directly contribute to optimizing your operations and improving your bottom line. When it comes to finishing applications, few technologies offer the same potential for significant material savings, reduced emissions, and superior finish quality as electrostatic spray guns. This guide will help you understand the power of electrostatic technology and how it can revolutionize your painting projects on conductive substrates.
Navigating the many variables in selecting the ideal electrostatic spray gun for your finishing operation can be a bit overwhelming. This is precisely why you should consider consulting with the experts at Spray Equipment & Service Center. We offer an incredible amount of industry knowledge and experience, helping you make informed decisions that allow you to spend less and profit more. We are here to be an invaluable resource for you.
We learn about your operation from multiple perspectives to ensure we uncover every opportunity for output, efficiency and savings. We look at:
Goals, objectives, and opportunities
Tools, applications, and processes
We work backward from your process, manufacturing routine, and output goals to form the basis for our recommendation, whether it’s replacing a spray gun or designing a custom-crafted solution. We focus on the results most important to you and your business goals. Our experts will help you arrive at the best possible solution.
What You Need to Know About Electrostatic Spray Guns
When used correctly, electrostatic spray guns significantly increase both finish quality and production throughput. They are renowned for their ability to deliver an even coating, which translates directly into less wasted paint and substantial cost savings. This enhanced transfer efficiency also plays a crucial role in decreasing emissions, helping you meet and maintain compliance with environmental regulations.
The core principle behind electrostatics is the spray gun applies an electrical charge to the paint particles as they leave the nozzle. Simultaneously, the object being painted (the substrate) is electrically grounded. Because opposite charges attract, the charged paint particles are strongly drawn to the grounded workpiece. This powerful attraction leads to a "wraparound" effect, where paint that might otherwise miss the target or become overspray is pulled to the sides and even the back of the object.
This magnetic-like attraction ensures more paint adheres to the surface, resulting in a more efficient application. Electrostatic guns have a high transfer efficiency of up to 90 percent. The ROI for electrostatic sprayers is quickly realized in many applications and operations, as it is common to achieve a 30 percent increase in transfer efficiency versus other types of spray guns. This means a substantial reduction in material consumption and also less costs for cleanup and disposal.
Electrostatic spray guns are highly versatile and can be used with a variety of coating materials. They are particularly effective with both solvent-borne and water-borne electrostatic coatings specifically formulated to carry a charge.
Selecting an Electrostatic
Electrostatic spray guns continue to evolve at a fast pace, and the variation among electrostatic spray guns allows for a wide range of applications, from small-scale jobs to high-volume industrial finishing lines. The choice depends on the specific needs of the painting process, the type of coating, the desired finish quality, and the budget.
Manual spray guns are handheld and used for jobs requiring operator control and flexibility, while automatic sprayers are typically integrated into robotic or production lines for high-volume, consistent applications. Some electrostatic sprayers are specifically designed for solvent-based paints, while others are optimized for waterborne coatings.
The Graco Pro Xp series has several models and additional specialty combinations of spray nozzles and air caps. The Pro Xp offers smart controls that help you analyze performance, adjust voltage, and simplify troubleshooting. One example is the Quick Fan Adjust, which provides operators with a spring loaded quick fan knob to easily switch from a full fan pattern to a narrow pattern without having to stop the sprayer.
Painters experience less muscle strain and fatigue when using these ergonomic, lightweight guns. The durable, easy-to-repair components are backed by a three-year warranty and A+ Service.
Let’s look at two Graco electrostatic spray guns from the Pro Xp series,
Graco Pro Xp85 Air Spray Electrostatic Gun
The Graco L85T10 is their top-selling manual electrostatic gun, a go-to sprayer for a wide range of general-purpose electrostatic paint applications. It’s built for reliable performance with standard and specialty coatings, even with water-based materials.
With an 85 kV power supply and a 1.5 mm nozzle, it delivers excellent spray patterns and transfer efficiency. Its internal power supply enhances maneuverability, and the standard display allows for on-the-fly voltage adjustments, ensuring operators never miss a corner. The alternator speed indicator light ensures turbine speed is running at the correct level.
Pro Xp85 Air Spray Aerospace Manual Electrostatic Gun
The new Graco L85T75 is engineered for contractors who need to quickly cover large areas with the finest finish, especially when working with high-solid materials and abrasive coatings. While named "Aerospace," its strengths lie in its specialized aerospace air cap, high-wear electrode, and precision 1.5 mm high-wear nozzle, which ensure consistent, even atomization at high paint flow rates.
But don’t let the name fool you. This electrostatic spray gun isn’t just for painting airplanes; it’s for any high-volume, high-performance application. It excels in demanding environments where speed, durability for abrasive materials, and the finest finish on large areas are critical, extending beyond just aerospace to any high-volume, high-performance application.
Ancillary Equipment Needed to go Along With Your Electrostatic Sprayer
To truly maximize your investment in a Graco electrostatic spray gun and unlock its full potential, remember that the gun is often just one component of a complete, high-performance system. Contracting professionals consistently pair these advanced electrostatic guns with top-selling pump packages like the Merkur® Air-Assist Fine Finish Spray Package or the Triton® Air Spray Package.
Depending on the specific electrostatic spray gun you choose, you'll likely need additional, crucial equipment such as pressure pots, double diaphragm pumps, air compressors, or even specialized control units to optimize material delivery and spray performance. These components work in tandem with your electrostatic gun to ensure consistent material flow, precise atomization, and superior transfer efficiency, ultimately leading to significant paint savings and a flawless finish. You can explore these essential complementary items and more in our online store to build out your complete, high-efficiency spray system.
Dispelling the 2 Primary Myths About Electrostatic Sprayers
It's common for paint operators to assume that electrostatic spray guns are either too expensive or too complex for their operations, or even unsafe. Let's address these two primary myths head-on.
Myth 1 on Cost: While the initial investment for an electrostatic spray gun can be higher than traditional air-assist or conventional approaches, leading to some initial sticker shock, the ROI is often easily calculated and significant. While there might be a slight learning curve, most of the standard operating procedures for electrostatic systems align closely with best practices already in place for general paintwork, minimizing the need for huge changes in your existing processes or controls.
Myth 2 on Safety: The concept of electricity near flammable paint understandably causes concern. It's true that electrostatic systems generate more electrical charge, inherently increasing a potential risk. However, when proper procedures are followed, electrostatic systems are safe and often include robust safety features, such as automatic shutdown mechanisms that de-energize the system under unsafe conditions. The safety precautions and grounding procedures required for electrostatic systems are best practices that should be in place for all paint operations, regardless of the technology used.
We Can Help You Select the Right Electrostatic Sprayer for Your Operation
Spray Equipment & Service Center has supplied industrial finishing equipment to many North American businesses for over 50 years. Our experts help you select the right paint electrostatic spray gun and accessories for your operation. We also provide qualified technical support and added value through:
Solutions Expertise: We listen and craft solutions to fit your unique business needs and goals.
Relationship-Focused Approach: We build trust by being responsive, meeting deadlines, and working hard to meet your highest expectations.
Industry Leadership: We have talented, experienced professionals at your service, here to keep your business as simple and profitable as possible.
We have the right equipment and parts in stock when you need them, and we are just a phone call away (866-953-0526).