In the leather industry’s spraying sector, every drop of product counts. Transfer efficiency — the percentage of sprayed material that actually deposits onto the treated surface compared to what is dispersed into the environment — is one of the most important indicators for evaluating the performance of an industrial atomiser. Yet, surprisingly, many tanneries continue to choose their spray guns without systematically considering this parameter.
In a context where raw material costs are constantly rising and environmental regulations are becoming increasingly stringent, optimising transfer efficiency is no longer an option: it is a competitive necessity. A high-efficiency spray gun ensures that the product — whether paints, waxes, or dyes — reaches the leather uniformly, reducing waste and processing times.
Choosing an atomiser without evaluating its transfer efficiency can have significant consequences on multiple fronts. The first impact is economic: a low-efficiency spray gun disperses a considerable portion of the chemical product into the air, which is simply lost. In sectors such as tanning, where expensive and specific substances are often used, this translates directly into higher production costs.
The second impact concerns the safety and health of operators. Excessive atomisation generates overspray, which spreads through the work environment, increasing exposure to potentially harmful substances. This leads to greater demands on ventilation systems, more sophisticated personal protective equipment, and in some cases the risk of failing to comply with emission limits set by current regulations.
The third impact is qualitative: an inefficient spray gun tends to deposit the product unevenly, with direct consequences on the aesthetic and functional performance of the treated leather. Coverage defects, halos, or thickness variations can result in rejects and rework, creating additional hidden costs for the company.
Aircom offers a complete range of industrial atomisers designed to meet the specific needs of the leather industry, with differentiated solutions for each type of process and product.
Standard pressure atomisers represent the classic, widely proven solution. They deliver high flow rates and are suitable for applications where production speed is the priority. However, high pressure tends to generate more overspray compared to other technologies, resulting in generally lower transfer efficiency.
HVLP (High Volume Low Pressure) atomisers were developed precisely to address this limitation. By using a higher volume of air at reduced pressure, they allow the product to be atomised in a more controlled manner and deposited on the surface with significantly higher transfer efficiency. This results in less waste, less overspray, and a more uniform finish, while still maintaining satisfactory production rates.
Finally, Aircom’s special atomisers are designed for spraying particular liquids, high-viscosity products, special formulations, or materials that require unconventional atomisation parameters. Even in these cases, the company has developed solutions that prioritise transfer efficiency without sacrificing operational versatility.
Aircom spray guns are certified by renowned and internationally recognised bodies. This is not a secondary technical detail: certifications are objective proof that the declared performance has been verified and validated by independent third parties.
For tanneries operating in international markets or required to meet high quality standards set by their clients, purchasing certified equipment means reducing the risk of disputes and ensuring traceability of production processes. Certifications also facilitate access to incentives and benefits related to environmental sustainability, which are increasingly prominent in European industrial policies.
The benefits of using atomisers with high transfer efficiency are concrete and measurable:
It would be dishonest not to acknowledge that adopting high transfer efficiency spray guns also entails some critical considerations, which it is useful to address clearly.
The initial cost may be higher. HVLP technologies or special atomisers generally have a higher purchase price than entry-level standard pressure solutions. However, the return on investment calculation must account for savings on raw materials, reduction in rejects, and lower management costs for abatement systems.
Maintenance requires attention. HVLP spray guns are precision instruments and require careful, regular maintenance to maintain their declared performance. Companies without structured maintenance procedures may not fully exploit their potential.
A myth to debunk concerns productivity: it is often assumed that high-efficiency spray guns are slower. In reality, modern technologies have closed this gap, and in many cases the reduction in waste and the lower need for rework more than compensates for any differences in application speed.
In this constantly evolving landscape, Aircom has recently launched the ART (Automatic Regulation Technology) spray gun, a new solution that stands out for its promising performance in terms of transfer efficiency. Developed in response to the increasingly specific needs of the leather industry, the ART is built on Aircom’s consolidated experience in designing certified industrial atomisers and positions itself as a tool on par with the best products in the company’s range.
The ART spray gun is designed to offer a level of excellence in product transfer comparable to the most advanced solutions already in Aircom’s portfolio, with the goal of making it accessible to a wider segment of tanneries. Initial technical evaluations indicate it as a concrete response to the demand for tools that combine efficiency, reliability, and ease of use.
For a sector like tanning, where finishing quality is often what distinguishes an ordinary product from one of excellence, having a tool like the ART could represent a concrete competitive advantage. Aircom thus continues to affirm its commitment to innovation applied to industrial spraying, with certified solutions designed to meet the real needs of the market.
For further information on Aircom atomisers and the new ART spray gun, please contact the technical team or visit the official product page.
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Read more 22 April 2024