CALCULATION COST OF WASTE

It is easy to determine the volume of material sprayed by an applicator that is overspray. First, calculate
the amount of paint that lands on the target part. Second, subtract that amount from the total sprayed
paint.
Overspray (V) = Total Volume of Sprayed Paint - Transfer Efficiency X Total Volume of Sprayed
Paint
Two practical methods for calculating the paint transfer efficiency are shown at the bottom of this
page. To calculate the material cost of overspray, multiply the volume of overspray material times the
cost of the material.
Overspray ($) = Overspray (V) X Material Cost

This calculation can be done on a per part basis or a time basis, whichever is convenient.

OTHER COSTS OF OVERSPRAY

Filter loading and sludge are created as a direct result of overspray. Increased levels of overspray
require more frequent filter changes and higher volumes of sludge disposal. The filter loading, in
particular, is troublesome because not only does it create imbalances in the flow of air through the
booth, but filter loading generally acts to reduce the level of booth air flow, which can create
significantly higher concentrations of booth vapors, booth airborne particulate, and contamination.
Overspray is a source of increased levels of dirt build-up in the booth. As filters restrict the flow of
exhaust air from the booth, overspray lingers to create still higher levels of contamination in and around
the spray booth. This is particularly so with electrostatic applications. In addition to creating the need
for more frequent maintenance, all this contamination can create a major dirt problem, severely
affecting the quality of the finished product.
Ecological cost is a more abstract measurement, but not a less important one. Minimizing the emissions
of airborne solid and vapor pollutants into the local community is the duty of every corporate citizen.
And in the case of paint overspray, responsible manufacturing and efficiency are synonymous; efficient
systems are truly poorer polluters.

CAUSES OF OVERSPRAY
Triggering paint off the part or triggering when no part is present is a common source of overspray.
Improper head to target distances are a cause of increased overspray as are improper angles of
application. Turbulent air flow conditions can create overspray. Mechanical force such as the turn
around points of vertical or horizontal reciprocators can cause consistent bursts of directional
overspray. Insufficient levels of electrostatic force contributes to large amounts of overspray. NA Paint
can implement technology and process control to significantly reduce or eliminate overspray by all of
the above causes.
Excessive atomization is another prevalent cause of overspray. Creating tiny paint droplets, they can dry
out in flight to the target and get swept away by the flow of air. Often, spray guns have their atomizing
and pattern air volumes so high that they are more efficient at fogging than painting.
Of course, choosing the most efficient applicator for your application can contribute to the reduction of
overspray. And, applying that applicator efficiently is very important. For example, a 16 inch wide spray
pattern is not necessary to paint a 4 inch wide part. NA Paint can help you get your process under
control at peak efficiencies.
North American Paint Applications is the world leader in the implementation of methods for the
reduction and elimination of overspray. Not only can we significantly reduce the amount of overspray,
we can implement technology that adjusts air flows under changing filter load conditions to help
maintain a constant flow of air through the booth.

PAINT TRANSFER EFFICIENCY

Transfer efficiency refers to a ratio representing that portion of sprayed paint that does land on the
target part. This number is widely used in calculations involving paint application economics. It is
common for manufacturers to advertise transfer efficiency ratings for their applicators which do not
correspond with the actual efficiency that is obtainable in your paint process. Because this is an
important measure of efficiency, two practical methods for calculating the actual transfer efficiency of
installed systems are shown below. These methods are for single component material applications.

TE by Weight
The most accurate method of calculating transfer efficiency is by weighing the part prior to painting and
after painting. This should be done when the part is completely dry. This method will include in its
result all film build variations, heavy edges, and wrap (paint on the reverse surface).

Paint Solids Weight on Part = Part Weight After Painting - Part Weight Before Painting
This yields the weight of the solids in the coating. Then, we must determine the weight of the paint
solids dispensed from the applicator.
Paint Solids Weight Dispensed = Weight of Dispensed Paint X Paint % Solid Content by Weight

The weight of the dispensed paint can be calculated by multiplying the volume of the dispensed paint by
its density.

Finally, the transfer efficiency by the weight method can be found.

Transfer Efficiency W = Paint Solids Weight on Part / Paint Solids Weight Dispensed

TE by Volume

If it is impractical to weigh parts, a very accurate method of calculating transfer efficiency is by

measuring the volume of solids on the part after painting and comparing that to the volume of solids
that was dispensed. This should also be done when the part is dry. This method will be as accurate as
your model of film build distribution across the part.

Transfer Efficiency V = Paint Solids Volume on Part / Paint Solids Volume Dispensed

The volume of dispensed solids is easily determined in the manner similar to the method above.