Which spray to choose: Airless or AirCoat?

In this new article, we will compare AirCoat (air-assisted) spraying technology with the Airless spraying process.

How does AirCoat work compared with Airless? What are the advantages and disadvantages of the two technologies?

We will look at the construction and operation of AirCoat and Airless equipment.

What is AirCoat?

First of all, it’s worth clarifying what air-assisted spraying technology is.

Structure and functions of AirCoat

This spraying process, which is also known as “air-assisted”, combines a pure spray of product as with airless spraying, but is also accompanied by the spraying of a jet of air which surrounds the airless jet to obtain a more concentrated and therefore controlled application.  The air pressure required never exceeds 2 bars.

In practice, a turbine or compressor supplies the compressed air via an air hose to the gun. AirCoat guns therefore have 2 inlets. One for the air and the other for the product to be sprayed.

 

AirCoat applications and project examples

This involves the application of low-viscosity materials, i.e. fairly thin paints, as well as varnishes, lacquers, woodstains, primers and undercoats.

AirCoat sprayers are often used to paint furniture, radiators, doors, window frames and sashes, for example.

Properties of AirCoat

The most important features of AirCoat technology can be summarised as follows:

• Suitable for small and large quantities of materials and profiled surfaces
• Suitable for two-component coatings
• Working speed equivalent to airless spraying
• Precision and concentration of the product on the surface
• Significant reduction in airless mist
• Fine atomisation and high surface quality

 

What does airless mean?

After the AirCoat, it’s the airless’s turn to be reviewed.

Structure and functions of the airless

The airless works in the same way as the AirCoat, but without the compressor and its air supply.

The material is pressurised by a piston or a membrane, depending on the model. The material is conveyed through the sprayer, without the addition of air, to the hose and to the gun. At the end of the gun is the nozzle, where the material is sprayed.

A similar point with the AirCoat, will be the fact that you are always working at high pressure with the airless (between 80 and 220 bar). However, some airless technologies for industrial use can reach even more than 500 bar in the maximum range.

Applications and examples of airless projects

Because the airless operates at high pressure, most materials can be applied directly and without dilution. The field of application is very broad, ranging from low to high viscosity materials, i.e. from varnishes to airless coatings.

Properties of high-pressure airless

Here are the main characteristics of airless spraying:

• High output
• High work speed/efficiency
• Wide range of applications, from painting to coatings
• Suitable for highly viscous materials (piston pumps only)
• Fine atomisation and good surface quality
• Low paint mist formation (with optimum adjustment)

Advantages/disadvantages of AirCoat pumps

This type of technology has both strengths and weaknesses.

Disadvantages of AirCoat

• Only a 30 cm extension possible
• Not suitable for very small quantities such as 1 or 2 litres only
• Only for low-viscosity materials (not exterior products, semi-thick and coatings, for example)
• Gun a little heavier (2 hoses are also connected to it)
• Takes only slightly longer to clean than airless spraying

Advantages of AirCoat

• Perfect for medium and large quantities of material
• More adjustment possibilities (better for small parts or metal fences and objects made of wood or metal)
• Little or no spray mist emitted
• Fast, high-quality work

Advantages/disadvantages of Airless pumps

This technology also has certain strengths and weaknesses.

Disadvantages of airless

• Fewer adjustment options (flat jet and pressure nozzle only)
• Greater risk of fogging than with AirCoat
• Good finish quality, but slightly inferior to AirCoat
• Not suitable for very small quantities such as only 1 or 2 litres

Advantages of airless pumps

• Fast, economical operation
• Highly cost-effective
• Ready-to-spray material without adjustment and with little or no dilution
• Possibility of using highly viscous materials (e.g. plasters)
• Various accessories such as extensions and gaskets available

Conclusion – Airless or AirCoat ?

For us, it’s not so much a question of choosing between Airless or AirCoat. The two systems complement each other well and, when combined, provide a high-quality application for almost any project.

AirCoat pumps offer advantages for small, medium and large projects, such as the renovation of metal fences, woodwork in cottages and kitchens, and companies that have to paint doors or pipes on a continuous basis.

Airless pumps, on the other hand, are particularly well suited to medium- and large-scale projects. Compared with AirCoat technology, the material generally does not need to be adjusted and can be sprayed directly. What’s more, thicker materials such as fire protection, bitumen or coatings can be applied in a high-quality, time-saving manner over large areas.