Application: Spray base coats and primers evenly
What this application is about
Various wet-spray processes are suitable for industrial application. Depending on the medium, component geometry, batch size and quality requirements, application can take place with a manual paint spray gun, a coating gun, an automatic spray gun or within a painting and coating system.
What the coating must achieve in the process
The application mainly concerns metal, plastic, wood, glass, ceramics 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.
Challenges in spray application
Even small fluctuations in material pressure, viscosity, distance or movement control can change the coating visibly or functionally. Typical requirements include:
- complete but not excessive wetting
- defined layer thickness and drying
- good coverage of edges and recesses
- Adaptation to water or solvent-based systems
- fast material change with different primer qualities
- Avoidance of runs, dry areas and overspray
Matching primers and base coats to the subsequent process
Primers create adhesion, equal substrates or support corrosion protection. The decisive factor is that the primer wets the substrate sufficiently and forms an even basis for the next coating, adhesive or sealing layer. Too high layer thicknesses can prolong drying or affect the adhesion of the entire system.
For different materials such as metal, plastic, glass or composite components, pretreatment and primer must fit together exactly. The permissible overpainting time is specified by the material system.
- even wetting without flaws
- defined wet and dry layer
- clean edges and transitions
- Ventilation and overpainting windows
- quick change between different primers
Krautzberger application technology for this application
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 manual paint spray guns and automatic spray guns with suitable flat or round jet nozzles, material pressure vessels, membrane pumps and finely adjustable pressure regulators. The technically and economically suitable combination is selected for the specific medium, components and required production output.
Typical components and areas of application
The application is used in different industries and component groups. Typical examples are:
- Adhesive primer before painting or bonding
- Corrosion protection primers on metal
- Plastic primers for difficult substrates
- Primers on wood and MDF
- Primers for glass, ceramics and composites
- automated pre-coating of serial components
From manual application to automated installation
Application can be integrated as a separate station or directly into a multistage coating system. Flash-off time and subsequent coating must be coordinated with cycle time and component transport.
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.
Advantages of a coordinated spray solution
- improved adhesion of subsequent layers
- even substrate and defined corrosion protection
- less scrap by stable pre-treatment
- Flexible processing of different primers
- Reproducible production processes
- coordinated material supply and spraying technology
Application trials 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.
In the test, wetting, adhesion, coating thickness and ventilation behaviour are tested on the original substrate; in particular for plastics, a pre-treatment should be considered where appropriate.
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
Matching solution for your process
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
A durable coating or adhesive layer begins with the surface. Primers can improve adhesion, compensate for unevenness or protect against corrosion. Depending on the material and industry, the task they have to perform differs.
