Spray Application - Industrial Coating Guide - Whitford Worldwide
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Industrial Coating Guide
By Category Automotive Commerical Bakeware Reprographics Construction Oil and Gas Mold Release Water/Wastewater Others
By Brand
Xylan Resilon Xylan XLR Eternitex Dykor Xylar Excalibur
By Application Coil Dip/Spin Powder Spray Textile


Wet coating is loaded into a spray gun and, under pressure, atomized as it is sprayed onto the surface of the item. This is done by either handheld or automated spray guns that coat parts as they pass by on a production line.

Types of Spray Application

Conventional air spray:

  • Inexpensive.
  • Fine atomization.
  • Smooth finish.
  • Good for low- to medium-viscosity fluids.
  • Least effective transfer efficiency.


High Volume Low Pressure (HVLP):

  • Controlled low-pressure air spray.
  • Lower fluid delivery rates.
  • Works well with low-viscosity fluids.



  • Typically air atomized, but other delivery methods, including rotating disk & bell available.
  • Electrically charged paint is attracted to ground parts which improves
  • Proper conductivity of liquid coating is required.
  • Best for parts needing "wrap-around", e.g., wire goods.
  • Possible difficulty penetrating deep recesses, tends to build up on edges
    of recesses.


Tumble Spray:

  • Parts are tumbled in revolving mesh basket while alternately being sprayed and dried until completely coated.
  • Good for small parts with shapes that might stick or "chain" together.
  • Slow, but simple operation.



  • Small parts do not need to be racked after being coated.
  • Properly sprayed products have a smoother, cleaner appearance than



  • Overspray: Typically, 35% to 50% of the coating is lost during
  • Slow production: Even the best automated spray lines can process no more than 1,500 pieces per hour — half that of other application methods.





Automated spray gun

Automated spray gun shown here.

Dykor Xylan Xylar    
Resilon Excalibur    


Click on the following links to download information on Xylan in PDF format.

pdf icon

Getting Started with Xylan

Application of the Xylan 1000 Series for large parts

Application of the Xylan 1424 Series for small parts


For more information visit our product information portal – Product Knowledge Network


Useful Information WRC Program Iso Specifications Test Methods
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