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It is easy to determine the volume of material sprayed by an applicator that is overspray. First, calculate
the amount of paint that lands on the target part. Second, subtract that amount from the total sprayed
paint.
Overspray (V) = Total Volume of Sprayed Paint - Transfer Efficiency X Total Volume of Sprayed
Paint
Two practical methods for calculating the paint transfer efficiency are shown at the bottom of this
page. To calculate the material cost of overspray, multiply the volume of overspray material times the
cost of the material.
Overspray ($) = Overspray (V) X Material Cost
This calculation can be done on a per part basis or a time basis, whichever is convenient.
CAUSES OF OVERSPRAY
Triggering paint off the part or triggering when no part is present is a common source of overspray.
Improper head to target distances are a cause of increased overspray as are improper angles of
application. Turbulent air flow conditions can create overspray. Mechanical force such as the turn
around points of vertical or horizontal reciprocators can cause consistent bursts of directional
overspray. Insufficient levels of electrostatic force contributes to large amounts of overspray. NA Paint
can implement technology and process control to significantly reduce or eliminate overspray by all of
the above causes.
Excessive atomization is another prevalent cause of overspray. Creating tiny paint droplets, they can dry
out in flight to the target and get swept away by the flow of air. Often, spray guns have their atomizing
and pattern air volumes so high that they are more efficient at fogging than painting.
Of course, choosing the most efficient applicator for your application can contribute to the reduction of
overspray. And, applying that applicator efficiently is very important. For example, a 16 inch wide spray
pattern is not necessary to paint a 4 inch wide part. NA Paint can help you get your process under
control at peak efficiencies.
North American Paint Applications is the world leader in the implementation of methods for the
reduction and elimination of overspray. Not only can we significantly reduce the amount of overspray,
we can implement technology that adjusts air flows under changing filter load conditions to help
maintain a constant flow of air through the booth.
TE by Weight
The most accurate method of calculating transfer efficiency is by weighing the part prior to painting and
after painting. This should be done when the part is completely dry. This method will include in its
result all film build variations, heavy edges, and wrap (paint on the reverse surface).
Paint Solids Weight on Part = Part Weight After Painting - Part Weight Before Painting
This yields the weight of the solids in the coating. Then, we must determine the weight of the paint
solids dispensed from the applicator.
Paint Solids Weight Dispensed = Weight of Dispensed Paint X Paint % Solid Content by Weight
The weight of the dispensed paint can be calculated by multiplying the volume of the dispensed paint by
its density.
Transfer Efficiency W = Paint Solids Weight on Part / Paint Solids Weight Dispensed
TE by Volume
Transfer Efficiency V = Paint Solids Volume on Part / Paint Solids Volume Dispensed
The volume of dispensed solids is easily determined in the manner similar to the method above.