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How to reduce overspray and improve transfer efficiency

Overspray happens when more coating is applied than needed – or when it misses the target surface altogether.

Common causes include:

• Incorrect spray distance: Holding the gun too far away leads to wider dispersion and more airborne material.
• Improper angle: Spraying at anything other than 90° to the surface creates uneven application and higher loss.
• High air or fluid pressure: Too much pressure atomises the paint too finely, making it harder to control.
• Wrong tip or guard size: A mismatch between the material and the spray tip causes poor atomisation and increased bounce-back.
• Environmental factors: Wind, humidity, and temperature fluctuations can all contribute to material drifting off-target.
• Lack of training or bad habits: Inconsistent spray patterns, overcoating, or overlapping errors often stem from poor operator technique.

Understanding these factors is key to identifying where efficiency is lost and how to fix it.

Selecting the correct tip and guard for your spray gun’s application is fundamental. High volume low pressure (HVLP) systems, for example, deliver lower pressure with higher air volume, which reduces bounce-back and improves material adhesion. You can explore our full range of tips, guards and spray guns on the Airblast website to find the right fit for your setup.

High pressure may atomise paint too finely, causing it to drift and miss the target. Conversely, low pressure can result in poor coverage. Aim for a balanced setting where the paint atomises well and reaches the surface without excessive force. Fluid flow should be consistent and matched to the type of coating being used. Thick coatings need slower flow rates, while thinner materials may require higher flow.

The optimal spraying distance is typically 6 to 10 inches (15 to 25 cm) from the surface. Holding the spray gun too far increases overspray, while being too close can cause runs and uneven finishes. Keep the gun perpendicular to the surface to ensure consistent coverage.

Operator skill significantly impacts transfer efficiency. Regular training ensures operators use best practices in equipment handling, spraying technique, and maintenance. Supervisors should monitor performance and address habits such as tilting the gun or spraying too fast. If you are unsure on how to use a spray gun, Airblast Eurospray can provide training for all our products to help operators use equipment safely and efficiently. You can enquire about training here.

A controlled environment reduces external variables like air turbulence and temperature changes that can increase overspray. Enclosed spray booths with proper ventilation and filtration can help contain and direct the spray more effectively. Airblast offers a wide range of spray booths and spray rooms designed to create these optimal conditions – improving coating quality, reducing waste, and protecting both operators and the environment.

Clogged tips, worn seals, and misaligned guns all contribute to inconsistent spray patterns and higher overspray. Regular maintenance checks, cleaning routines, and calibration help maintain optimal performance. Airblast offers professional servicing and support to help keep your spray equipment in peak condition, minimising downtime, reducing costly overspray, and ensuring consistent results. You can book in your servicing here.

Reducing overspray and improving transfer efficiency isn’t just about saving money – it also leads to better finishes, faster turnaround, and a safer work environment. Implementing the strategies above can result in substantial long-term benefits for your operation.