The best spray gun depends on the type of coating you're applying, the finish quality required and your production environment.
Different spray gun technologies are designed for different applications:
Gravity-fed spray guns are ideal for precision finishing, smaller batches and frequent colour changes.
Pressure feed spray guns are suited to continuous production and larger components, where an external pressure pot or pump supplies the coating.
Air spray guns provide excellent atomisation and are commonly used where a high-quality decorative finish is required.
Air-assisted airless spray guns combine high productivity with superior finish quality, making them ideal for many industrial finishing applications.
Airless spray guns are designed for rapidly applying high-build coatings to large surfaces.
Automatic spray guns provide repeatable, consistent coating application in robotic and automated production lines.
Choosing the correct spray gun helps maximise finish quality, improve transfer efficiency and reduce coating waste.
The main difference is how coating material is supplied to the spray gun.
Gravity-fed spray guns use a paint cup mounted above the gun, allowing the coating to flow into the gun using the force of gravity. They are ideal for smaller jobs, colour changes and precision finishing.
Pressure feed spray guns receive coating from an external pressure pot or fluid transfer pump. They are well suited to larger production runs where a continuous supply of coating is required.
Suction feed spray guns draw coating from a container positioned beneath the gun. They can hold larger paint capacities than gravity cups and are often used where larger quantities of coating are required without an external pressure system.
Each system offers different advantages depending on production volume, coating type and application requirements.
These spray technologies atomise coatings in different ways.
Air spray uses compressed air to atomise the coating, producing excellent finish quality and precise control. It is commonly used for high-quality industrial finishing applications.
Air-assisted airless combines hydraulic fluid pressure with a small amount of compressed air, providing higher transfer efficiency and faster application speeds while maintaining an excellent finish.
Airless spray guns atomise coatings using hydraulic pressure alone. This allows high-build coatings to be applied quickly over large surface areas, making them ideal for protective coatings and industrial production.
The most suitable technology depends on the coating, finish requirements and productivity goals.
Industrial finishing applications often require excellent atomisation, consistent coating delivery and high transfer efficiency.
For decorative and fine finishing applications, gravity-fed and pressure feed air spray guns are commonly used. These are ideal for applying primers, topcoats, stains, lacquers, varnishes and other industrial finishing coatings across sectors such as woodworking, furniture manufacturing, metal fabrication and general industrial production.
Where higher productivity is required, air-assisted airless spray guns provide an excellent balance between finish quality and application speed.
The most suitable spray gun will depend on the coating material, component size and production process.
Protective coatings are often thicker and require higher material output than decorative finishes.
Airless spray guns are commonly used for applying high-build primers, epoxies, zinc-rich coatings, fire protection coatings and other protective finishes because they can deliver large volumes of coating quickly and efficiently.
For applications requiring both excellent finish quality and high productivity, air-assisted airless spray guns can provide an effective alternative.
Selecting the correct spray technology helps ensure the coating achieves its intended film thickness, appearance and long-term performance.
Industrial spray guns are designed to apply a wide variety of coating materials, including:
Primers
Topcoats
Polyurethane coatings
Epoxy coatings
Lacquers
Varnishes
Wood stains
Industrial enamels
Waterborne coatings
Solvent-based coatings
The suitability of a particular spray gun depends on the coating viscosity, required finish quality and production requirements. Selecting the correct nozzle size and spray technology helps achieve optimum atomisation and coating performance. For the best results, always refer to the coating manufacturer's technical data sheet (TDS) for the recommended spray equipment, nozzle size, operating pressure and application guidelines.
Selecting the correct fluid nozzle is essential for achieving consistent atomisation and finish quality.
As a general guide:
Smaller nozzle sizes are suitable for lower-viscosity coatings and fine finishing applications.
Medium nozzle sizes are commonly used for general industrial coatings.
Larger nozzle sizes are better suited to primers and higher-viscosity materials.
The ideal nozzle size also depends on the spray technology, coating manufacturer's recommendations and the finish being produced.
If you're unsure which nozzle is most suitable, it's always advisable to consult the spray gun manufacturer's recommendations or seek technical advice before beginning production.
Regular cleaning is essential to maintain spray performance and extend the service life of your spray gun.
After each use, flush the spray gun and fluid lines using the appropriate cleaning solution, then clean the air cap and fluid nozzle thoroughly. Inspect the nozzle, needle and other wear components regularly, and replace worn parts as required.
Before beginning any spraying operation, it's also good practice to carry out a test spray to confirm that the spray pattern and atomisation remain consistent. Routine maintenance helps reduce downtime and ensures reliable finishing performance.
When using an Elcometer spray pump, visit our YouTube channel for step-by-step demonstrations showing how to correctly flush and prime your equipment.
Clean, dry and oil-free compressed air is essential for producing a high-quality finish.
Moisture, oil and airborne contaminants can affect atomisation, cause coating defects such as fisheyes and blistering, and reduce the overall appearance of the finished coating.
Using an appropriate compressed air filtration system helps remove contaminants before they reach the spray gun, improving finish quality, increasing equipment reliability and reducing costly rework.
A spray gun is only one part of an efficient spray finishing system. Depending on the application, a complete system may include:
Spray gun
Pressure pot or fluid transfer pump
Compressed air filtration system
Air and fluid hoses
Pressure regulators
Fluid regulators
Spray tips, needles and nozzles
Disposable paint cup systems
Automatic spraying equipment
Selecting compatible equipment throughout the system helps ensure consistent coating delivery, maximise transfer efficiency and improve overall productivity. If you're unsure which spray equipment is best suited to your application, our technical team is on hand to help. Contact Elcometer on +44 (0)161 371 6000 for advice on selecting the right spray gun and equipment for your coating, production process and finishing requirements.
While some spray guns are capable of applying a wide range of coatings, there is no single spray gun that is ideal for every application.
Different coatings vary in viscosity, drying characteristics and finish requirements. Similarly, production environments differ in terms of component size, application speed and required finish quality.
Choosing the correct spray technology, fluid nozzle, air cap and fluid supply system for each application helps achieve the best possible finish, improve transfer efficiency and reduce material consumption. Matching the spray equipment to the coating and application is one of the most effective ways to improve productivity and coating performance.
If you are unsure which spray gun technology is best suited to your coating or application, our technical team can help you select the most suitable solution. Contact Elcometer on +44 (0)161 371 6000 for expert advice on spray equipment selection.
