Revolution in paint application: how does electrostatic atomization work?
Learn how electrostatic atomization works and the benefits it brings to your coating processes.
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Request consulting & savings analysis now
With electrostatic spray technology you can cut your paint costs by up to 80% while improving quality, environmental footprint and occupational safety. Less overspray, shorter cycle times and lower energy costs make it the most efficient spray technology on the market.
We provide personal consulting, calculate your savings potential and can perform an on-site demonstration on request – using your coating material and your parts.
We’ll get back to you within 24 hours on business days – expert advice, no obligation.
Electrostatic Spray Guns – efficient coating & perfect surfaces
Electrostatic spray guns generate a high-voltage field that draws paint particles to the workpiece. The result: maximum transfer efficiency, less overspray and reproducible quality – ideal for serial coating in production lines, robots and industrial applications.
Airspray-ES – finest atomization
Airspray-ES guns provide excellent fine atomization at low air pressures – perfect for visible surfaces, furniture, plastic and metal parts. They achieve uniform film build with minimal overspray.
AirCombi-ES – performance & precision combined
AirCombi-ES systems combine material pressure with electrostatic charging and air assistance. This technology enables high area output and excellent surface quality with optimal material utilization – ideal for metal and plastic coatings.
Advantages of electrostatic technology
- Up to 50% less overspray and paint savings
- Homogeneous film thickness even on edges and recesses
- Stable processes thanks to consistent electrical parameters
- Suitable for lines, robots & manual applications
Top manufacturers of electrostatic spray guns
- Sames (formerly Kremlin) – Nanogun+, Inogun, AVX (Airspray / AirCombi, manual & automatic). Very high transfer efficiency and stable process integration.
- Graco – Pro Xp Auto & Manual, ProBell rotary atomizer. Proven industrial ES technology with integrated high-voltage generator for lines & robots.
- Ransburg – Electrostatic systems (RansFlex RXi, Vector R70 / R90) for industrial series applications, suitable for solvent- & waterborne coatings.
- Binks – Pumps, pressure tanks and material supply systems, ideal in combination with electrostatic guns.
- DeVilbiss – High-precision spray guns (Advance HD, Trans-Tech®, ProLite) with optional ES configuration for premium visible surfaces.
- Wagner Industrial Solutions – GM 5000 EA / EAC / EA 03, EA 04, Rotomat 500. Automatic ES systems “Made in Germany” for lines & robots with up to 50% paint savings.
- Nordson – Trilogy / Encore HD / IPS-20 controls. Complete electrostatic coating systems incl. high-voltage control and metering units.
- Anest Iwata – WA-ES / WRA-ES series (Airspray with ES charging). Compact designs, precise atomization and high energy efficiency.
- Krautzberger – Automatic spray guns with optional electrostatic unit. High precision, durability and easy integration into process equipment.
- Walther Pilot – ES-capable automatic spray guns and complete systems for serial applications in metal and plastic coating.
- Sagola – ES versions of the V series (V4000 Auto ES) for industrial high-performance coatings. Robust construction and high repeatability.
- Larius – Electrostatic Airless / AirCombi systems for industrial high-performance applications, Made in Italy.
- SATA – German precision “Made in Kornwestheim.” SATA stands for long-lasting quality, fine atomization and ergonomic handling. The SATAjet X series uses a special labyrinth air system for an exceptionally uniform spray pattern.
- Beschichtpunkt – Specialist in application technology and gravity spray guns focusing on precise atomization, ergonomics and high surface quality.
- Colad – Paint shop supplies, masking materials & mixing systems for efficient coating processes.
- Elcometer – Precise measuring & testing technology for film thickness, adhesion, climate & surface preparation.
- Mirka – Abrasives, polishing systems & dust extraction for perfect surface preparation.
Typical applications
- Metal fabrication, mechanical & plant engineering
- Plastic and furniture coating
- Commercial vehicles, agricultural machinery, aerospace
- Solvent- & waterborne coatings (depending on system)
Grounding & safety in electrostatic coating
For efficient and safe electrostatic coating, proper grounding of all components is essential – from the gun and workpiece to the paint booth. Only with sufficient dissipation of electrical charge can the electrostatic effect work to its full potential.
- Workpiece grounding: All parts to be coated must be reliably grounded (resistance ≤ 1 MΩ).
- Gun and pump grounding: Connect high-voltage unit and material supply via dedicated grounding points.
- Operator safety: Antistatic footwear and conductive flooring reduce residual voltages.
- ATEX compliance: Grounding prevents sparking and meets requirements for explosive atmospheres.
Proper grounding not only ensures consistent coating results, it is also a prerequisite for operational safety. We support you in planning, testing and documenting your grounding concepts – in line with the requirements of DGUV Information 209-052 “Electrostatic Coating” .
Guides & resources
Maximize your production efficiency with electrostatic coating
Find out how electrostatic coating can boost your production efficiency and cut costs.
Learn moreWhy dissipative gloves are essential for electrostatic coating
Learn why dissipative gloves matter and how they contribute to safety and quality.
Learn moreFrequently asked questions about electrostatic guns
What is an electrostatic spray gun?
An electrostatic spray gun electrically charges paint particles, which are then attracted to the grounded workpiece. This results in higher efficiency, uniform films and significantly less overspray.
How is an electrostatic spray gun maintained?
Regular cleaning and maintenance are crucial: electrodes and nozzles must remain clean and dry to ensure consistent high voltage. Air passages, seals and insulators should be checked regularly, and wear parts (e.g. needle seal, electrode) replaced in good time. Proper maintenance extends service life and maintains coating quality.
Are waterborne coatings suitable?
Yes – with suitable systems (e.g. indirect charging or isolated supply). We test your materials for conductivity and ensure ATEX and safety compliance.
