Application: Spray functional coatings and corrosion protection in industrial processes
What this application is about
The right solution starts with the entire process rather than an individual gun. Spray pattern, nozzle design, material pressure, delivery, component movement and cleaning must be considered together to keep the application stable and repeatable.
Purpose and benefits of the coating
The application mainly concerns metal, plastic, glass, ceramics, wood and composites. The required effect occurs only when coating material, substrate, layer thickness and subsequent drying or curing fit together. The spraying process must therefore be adapted to the concrete material system and the real production conditions.
Alongside surface quality, material consumption, cleaning effort, system availability and reliable repeatability also matter. A sound technical solution therefore combines controlled atomisation with a stable material supply that is easy to regulate.
What matters with the application
Even small fluctuations in material pressure, viscosity, distance or movement control can change the coating visibly or functionally. Typical requirements include:
- defined layer thickness for the required function
- even coverage of edges and complex geometries
- Processing of different viscosities and solid matter components
- material-compatible seals, nozzles and lines
- stable material pressure at long production times
- controlled drying or curing after application
Functional layer instead of pure colour application
With functional coatings, the focus is not only on optics. The layer can protect against corrosion, chemicals, moisture, wear or UV action or take on targeted electrical, thermal and tribological properties. The required function occurs only when the surface, pretreatment, layer thickness and hardening fit together.
For the spraying technique this means: wet layer and edge cover must be reproducible. In the case of filled or pigmented media sedimentation and abrasiveness shall be taken into account.
- Substance and pretreatment
- Target layer and permissible variation
- Edges, holes and complex geometries
- Pot Life and Curing Window
- Material compatibility of nozzles, seals and cables
Spraying technology and material supply from Krautzberger
Krautzberger treats application and material supply as a connected system. Depending on the task, manual and automatic spray guns, suitable air and material nozzles, material pressure tanks, diaphragm pumps, pump and lifting stations, and material pressure regulators can be combined.
In automated processes, spray guns can be integrated into mounts, lifting devices, axes or robots. Material changeover valves and flushing equipment support applications with several colours or media. The specific selection depends on viscosity, solids content, application quantity, cycle time and component geometry.
For fine surface finishes, various XLINE nozzle combinations and spray patterns are available. With highly viscous, abrasive or sedimenting media, sufficiently large flow cross-sections, suitable material combinations, agitators and pressure-stable delivery become more important.
The focus is on hand and automatic spray guns, XLINE nozzle combinations, material pressure vessels or diaphragm pumps, material pressure regulators as well as several media material exchange valves and flushing systems. The technically and economically suitable combination is selected for the specific medium, components and required production output.
Typical applications
The application is used in different industries and component groups. Typical examples are:
- Corrosion protection of metal components
- Protective coatings for machine and appliance housings
- Chemical-resistant coatings
- Electrically insulating or conductive varnishes
- Abrasion-resistant and wear-reducing surfaces
- functional coatings in automotive, electronics and construction
Process integration and automation
The application can range from the manual single position to the automated painting system. For series processes, spray webs, overlap, switching points and material supply are matched to the required layer thickness.
In addition, component feed, extraction or ventilation, cleaning, media change and accessibility for maintenance work must be taken into account during the system integration. This keeps the process stable not only in the pattern run, but also in everyday production.
Benefits for your production
- technical function and surface quality in one process
- even, reproducible layer formation
- reduced overspray and material consumption
- Flexible processing of different lacquer systems
- Integration into existing production lines
- coordinated solution from application and supply
Process design at the Krautzberger technical centre
Liquid media and coating materials with similar names can differ considerably in viscosity, solids content, solvent base, wetting and drying. A reliable choice of spray gun, nozzle and material supply should therefore be made using the original material and a representative component.
Before series start, adhesion, layer thickness, spray pattern, drying and component cover should be tested with original material and real geometry.
On this basis, the spray pattern, material quantity, pressure, distance, movement and cleaning sequence can be defined. The result is an application solution suited to the medium, the geometry and the intended production process.
Related products
All products
Find the right application solution together
Looking for a spray gun, an automatic spray gun or a complete material supply for this process? Krautzberger helps you select and design suitable spray technology, nozzle configurations, delivery and regulation.
Contact Krautzberger to discuss your medium, component, production volume and desired result. Together, we assess how the process can be implemented safely and economically.
Industries for this application
Functional coatings can protect surfaces from corrosion, moisture or abrasion and give other technical properties. Which function is in the foreground depends on the component and its use in the respective industry.
