24/09/2026
The application method can make a big difference in coating loss.
With spray application, overspray is part of the process.
Not all coating reaches the workpiece. Part of it is sprayed next to the surface and is carried away by the extraction system.
A large part of that coating ends up in filters.
Some coating can sometimes be collected inside an automatic spray machine, but in practice much of the overspray cannot be reused. Airflow, drying and contamination all make recovery more difficult.
This is very different from application methods such as roller coating, curtain coating and vacuum coating.
With these systems, unused coating stays much more inside the process.
With roller coating, coating is transferred directly from the roller to the workpiece. There is no spray cloud around the product, so overspray is avoided.
With curtain coating, coating that does not land on the workpiece falls into the collection area between the transport belts. From there it returns to the reservoir and is pumped back to the coating head.
With vacuum coating, the coating that is not left on the workpiece is drawn back into the machine. It is separated from the air, collected and reused.
This means that with these application methods, the main coating loss is often not during production itself.
It is mainly the coating that is lost when the machine has to be cleaned or flushed.
And that creates an important difference.
Whether you coat 100 metres or 10,000 metres, the cleaning loss of a vacuum coater can remain largely the same.
That is why production volume matters.
The more metres or square metres you produce, the more important the choice of application method becomes.
Of course, not every method is suitable for every workpiece.
Roller coating and curtain coating are mainly suitable for flat or slightly profiled surfaces. Vacuum coating can also be used for profiles and, with the right tooling, even for selected parts of a workpiece.
Spraying remains the most flexible method for complex shapes, but usually comes with more coating loss.
The right question is therefore not only:
Which machine can apply the coating?
But also:
Which application method gives the required finish with the least unnecessary coating loss?