Common causes of bad spray patterns
If you’re experiencing a poor spray pattern while using an airless paint sprayer, it could lead to various issues such as tails, striping, uneven colour distribution and other streaks or disturbances. Identifying the root cause of these problems will help you determine the best solution for achieving an optimal spray pattern. Here’s a closer look at five common causes and steps contractors can take to resolve them.
Cause 1 – Partial clogging of the spray tip
Over time, the coating you’re spraying may dry and build up around the orifice of the spray tip, leading to uneven material flow. In such cases, it’s advisable to clean the tip using the appropriate water or solvent recommended by the paint manufacturer. If cleaning doesn’t work, consider purchasing a replacement spray tip.
Cause 2 – Incorrect Pressure Setttings
Airless sprayers require consistent pressure to atomise the coating effectively. Inconsistent spray patterns are often caused by one of two issues: either the pump is not providing the right pressure or the pressure was not set correctly by the operator.
If the sprayer fails to maintain consistent pressure, check the pump packing. These packings create a tight seal around the piston rod, ensuring even pressure during operation. Additionally, inspect the condition of the ball and seat components located at the top and/or bottom of the airless piston stroke, as they help maintain pressure balance. If you notice the sprayer leaning to one side and returning rapidly, this may indicate a worn ball and seat.
Another common issue stems from user error. The operator must set the sprayer’s pressure correctly to achieve an optimal spray pattern. Insufficient pressure can lead to tails, while excessive pressure results in overspray, wasted material, increased cleanup time and higher operational costs. Adjust the pressure as needed to minimise these issues. If the sprayer is already operating at maximum pressure, consider using a hose with a larger diameter.
Cause 3 – Using an oversized tip
Every airless paint sprayer has a maximum recommended tip size. Utilising a tip that exceeds this size can result in low-pressure issues. Make sure the tip is suitable for the type of material you are spraying to avoid these problems.
By addressing these common causes, you can improve the performance of your airless paint sprayer and achieve a better finish in your projects.
Cause 4 – The tip is worn out
After prolonged use, spray tips will eventually wear out, resulting in an uneven spray pattern characterised by excessive overspray and increased material waste. If a tip is worn out and has exceeded its usable life, it’s time to replace it with a new, high-quality spray tip.
Wagner offers a range of reversible, fine-finish and HEA spray tips, providing unique options for various applications and environments.
- Our TradeTip 3 tips has a long-lasting orifice that provides more usable life while achieving up to a 22% wider fan pattern.
- The Tradetip 3 Fine Finish tips achieves a particle size up to 27% smaller than a standard tip and is pressure-rated at 5,000 PSI.
- Our HEA Pro tips are optimised to spray all architectural paints and coatings at 1000 PSI at production speed, decreasing overspray by up to 55% to allow you to keep on spraying.
Cause 5 – The material is too viscous
In certain cases, the material being too viscous (thick) can also cause issues with the quality of the spray pattern. If this is the case, it’s time to add the proper thinner to the fluid per the manufacturer’s recommendations.
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