Atomisation optimisation

Atomisation optimisation in the mixing room

Atomisation and application optimisation is a key building block for consistently high surface quality in paint mixing rooms and adjacent preparation areas. It includes precise coordination of nozzles, air caps and needles in combination with HVLP, RP, airless and airmix systems as well as electrostatic application. Controlled pressure and air volume regulation together with stable air treatment ensure constant atomisation parameters. In addition, controlled viscosity and temperature provide an optimum spray pattern. Film thickness measurements and transfer efficiency analyses deliver robust key figures for process approval and quality assurance.

Use & benefits

Atomisation optimisation systems are used in automotive production, industrial and plastics coating as well as in bodywork and refinishing. Whether for topcoats, fillers, primers or clear coats – a precisely tuned atomisation setup increases transfer efficiency, reduces overspray and rework, lowers material and solvent consumption and ensures uniform film builds on all parts. With the right documentation and traceability, verifiable approvals and fully comprehensive digital traceability are achieved.

Tasks & set composition

When configuring the application system, the focus is on selecting the right guns and applicators – depending on process requirements, HVLP, RP, airless, airmix or electrostatic systems are used. Nozzles, air caps and needles are selected based on the desired film build, viscosity and application speed. Process control includes precise pressure and air volume regulation, coordination of spray pass timing and distance as well as integration into dosing systems. Clean air treatment with drying and oil separation ensures reproducible results, while filters and regular gun maintenance ensure long service life. Monitoring viscosity and temperature keeps the spray pattern constant and measuring devices record film build and applied quantity. All process data is documented in a structured way – including labels/QR codes, PDF/CSV exports, serial numbers, users and limit checks.

Product areas & integration

The portfolio includes spray guns and applicators, precise nozzle and air cap systems, control and sensor technology, air treatment with filtration, hoses, manometers and electrostatic components. These are complemented by devices for film thickness measurement, viscosity and temperature control as well as a QC/recipe software for digital evaluation and process monitoring. We define room layout, material and air routing and measuring point layouts, and integrate all atomisation parameters into quality workflows, report storage and audit processes to ensure reproducible and fully documented coating results.

Key benefits at a glance

• Outstanding surfaces – reproducible film builds & fine atomisation
• Efficient – higher transfer efficiency & less overspray
• Safe & clean – conditioned air, grounding/ATEX & stable media handling
• Traceable – PDF/CSV reports, labels/QR & limit checking

Top manufacturers – atomisation optimisation

• SATA – HVLP/RP guns, air caps & air management.
• DeVilbiss – guns, nozzles & regulators.
• Iwata – application guns & accessories.
• Walther Pilot – application, valve & mixing technology.
• Wagner – airmix/airless & electrostatics.
• Sames Kremlin – airmix/airless, valve technology & ES.
• Graco – airless/airmix & regulators.
• Krautzberger – guns, nozzles & systems.
• Mirka – surface preparation & cleaning.
• 3M – PPS, respiratory protection & process accessories.
• beschicht. – QS templates, QR/label sets & customised setups.
• ensutec – mixing-room workstations, ATEX components & air routing.
• KAMATEC – workshop equipment, handling & accessories.

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