SPRAY COATING

Synergy Spray Systems provide high-precision spray coating solutions tailored for industrial, food, pharmaceutical, and manufacturing applications. Our high-performance spray nozzles ensure uniform coating application, reducing material waste while enhancing product quality.

We offer spray coating solutions for:

• Continuous bed movement coating – Automated and efficient material application
• Stop-start bed movement – Precise and controlled coating at intervals
• Drum coating systems – Ensuring even surface coverage for pellets, tablets, and food products
• Fluidized bed coating – Effective 360° coating for powders, granules, and small particles
• Dosing control for coatings – Optimized spray volume to prevent excess application

Our spray systems provide accurate, cost-effective, and reliable performance, making them ideal for industrial painting, food glazing, pharmaceutical tablet coating, and waterproofing applications.

Complete Spray Coating Systems for Maximum Efficiency

Our spray coating nozzles are designed to:

Deliver uniform coating distribution for consistent product quality.

Be integrated into automated production lines for high-speed precision spraying.

Reduce material waste by ensuring targeted spray application.

Improve adhesion with optimized droplet size and coverage.

Work with a variety of materials, including adhesives, paints, oils, food glazes, and protective films.

Key Considerations for Effective Spray Coating

Precise Targeting of Spray Application

• Over-spraying wastes material and contaminates unwanted areas.
• Under-spraying reduces coating effectiveness and product quality.
• Adjustable spray angles ensure accurate liquid placement on the target area.

Spray Uniformity & Drop Size Control

• Most sprays are not evenly distributed – Nozzles should be selected based on the desired spray patter.
• Flat fan nozzles are ideal for continuous spraying, while full cone nozzles work best for stationary coatings.
• Finely atomized sprays increase surface area, ensuring better adhesion and coating coverage.

Selecting the Right Nozzle for Viscous Liquids

• Many coatings, such as oils, glazes, and adhesives, are thick and challenging to spray.
• Air atomizing nozzles with external mixing are ideal for high-viscosity liquids.
• Prevents clogging, maintains consistent spray patterns, and improves material flow.

Nozzles for Spray Coating Applications

Air Atomizing Nozzles

Produces ultra-fine mist sprays for precise and controlled coating.
Ideal for food coatings, adhesives, and chemical treatments.

Hydraulic Atomizing Nozzles

Provides high-pressure spray for industrial coatings.
Used in paint, powder, and protective coating applications.

Flat Fan Nozzles

Ensures even coverage for continuous bed movement applications.
Ideal for food processing, automotive painting, and waterproofing.

Cooling Tower Nozzle

Provides fine droplet misting for delicate surface treatments.
Best for textiles, pharmaceuticals, and protective film coatings.

Full Cone Nozzles

Produces uniform spray distribution for consistent coating results.
Used in metal finishing, corrosion protection, and industrial coatings.

Types of Spray Coating Systems

Continuous Bed Movement Coating

• Automated spray bars are used over conveyor belts to coat products as they move continuously.
• Ideal for food glazing, waterproofing, metal finishing, and protective coatings.
• Uses flat fan nozzles for even liquid distribution across moving surfaces.

Technology Features:
• Air-activated nozzles – Start and stop spraying based on object detection.
• Pulse width modulation control – Allows precise dosing without affecting spray continuity.
• Electrically or pneumatically activated spray nozzles – For high-speed operations.

Stop-Start Bed Movement Coating

• Spray application occurs when the conveyor stops, ensuring complete product coverage.
• Used in multi-layer coating processes, powder coating, and industrial painting.
• Full cone nozzles are used for even liquid distribution on stationary objects.

Drum Coating Systems

• Ideal for tablet and pellet coating in pharmaceutical, confectionery, and chemical industries.
• Uses a rotating drum to evenly coat products from all angles.
• Ensures uniform coverage with minimal liquid waste.
• High-precision air atomizing nozzles are used to create fine mist sprays for optimal adhesion.

Fluidized Bed Coating

• Used for coating powders, granules, and small particles in pharmaceuticals and food processing.
• Products are suspended in an air stream, allowing 360-degree coating application.
• Ultra-fine spray nozzles are used for precise material application without clumping.

Dosing Control for Spray Coating

Applications
✔ Precision dosing is critical for coating applications.
✔ Over-spraying leads to wasted material, while under-spraying results in poor-quality coating.
✔ Our advanced dosing technology ensures:
• Accurate liquid volume per product cycle.
• Automated control based on conveyor speed.
• Adjustable spray pressure for different viscosities.

Why Choose Synergy Spray Systems for Spray Coating?

FAQs

What are spray coating systems used for?

Spray coating systems are used to apply uniform coatings, adhesives, and protective films on various surfaces in industries such as:
✔ Automotive & Aerospace – Paints, corrosion protection, and waterproofing.
✔ Food Processing – Oil, glaze, flavoring, and preservative application.
✔ Pharmaceuticals – Tablet coating for controlled drug release.
✔ Manufacturing & Metal Finishing – Powder coating, industrial painting, and protective layering.
✔ Electronics & Packaging – Adhesives, lubricants, and anti-static coatings.

What are the benefits of using spray nozzles for coating applications?

✔ Uniform Coating Distribution – Ensures even application with minimal overspray.
✔ Cost-Effective Material Usage – Reduces waste and improves efficiency.
✔ Customizable Spray Patterns – Adjustable for different product types and surfaces.
✔ Clog-Resistant Design – Works with thick and viscous coatings.
✔ Compatible with Automated Systems – Supports high-speed production lines.

How do I choose the right spray nozzle for coating applications?

The right nozzle selection depends on:
✔ Coating Type – Thin liquids vs. viscous materials require different nozzle designs.
✔ Application Method – Continuous spray, stop-start spraying, or drum coating.
✔ Coverage Requirements – Wide-area coverage or targeted spraying.
✔ Surface Material – Metal, food, tablets, or plastic coatings.

What types of spray nozzles are best for spray coating?

✔ Air Atomizing Nozzles – For fine mist coatings in food, pharma, and adhesives.
✔ Flat Fan Nozzles – For even distribution on conveyor-based applications.
✔ Full Cone Nozzles – For thicker coatings and stop-start spray systems.
✔ Hollow Cone Nozzles – For lightweight coatings requiring delicate application.
✔ External Mix Air Atomizing Nozzles – For viscous coatings like oils and adhesives.

What is the difference between continuous and stop-start bed movement spraying?

✔ Continuous Bed Movement – Used for conveyor-based spraying where products move continuously.
✔ Stop-Start Bed Movement – Used for precise coating when the product stops under a spray bar.
✔ Drum Coating – Ideal for pellets, tablets, and bulk materials requiring complete coverage.
✔ Fluidized Bed Coating – Provides 360-degree coating on suspended particles.
Each method is suited to different industrial applications to ensure uniform coating while optimizing material usage.

What are the challenges of spraying viscous liquids like adhesives or glazes?

Viscous liquids present challenges such as:
🔴 Clogging issues – High-density coatings can block standard nozzles.
🔴 Uneven spray distribution – Some nozzles may not atomize thick liquids properly.
🔴 Excess material waste – Poor control leads to over-application.
✔ Solution: Use external mix air atomizing nozzles, which allow better control of droplet size and spray coverage.

How does droplet size affect coating application?

✔ Fine mist sprays – Better for even, thin coatings with fast drying times.
✔ Larger droplets – Used for thicker coatings, but may lead to uneven layers.
✔ Optimized atomization – Ensures improved coating adhesion and reduced material waste.