Reduce Downtime of Airless Equipment – Preparing and Planning Properly

Using airless spraying equipment allows a painter to achieve efficiently large surface coverage, improved performance and a very high surface quality, while saving you time and thus improved results and better profits, provided you know how to reduce downtime. If you can do more work in the same time, the bottom line naturally and effortlessly grows. These advantages, however, can easily be eaten up in case a painter does not pay attention to what may look like little things, but which can end up costing a lot of time on the work site. For example, when parts that can easily wear out like filters or nozzles are missing on the job site. If the painter does not have a spare filter or spray tip with him, then the whole work stands still. What a shame that would be. For this reason, how to reduce downtime must be a priority.

The importance of planning

Lack of planning is fundamentally a problem and causes unnecessary costs, regardless of whether you are using an airless paint sprayer or not. Having all the necessary nozzles or filters or even a spare pump can be of vital importance to reduce downtime or eliminate it altogether. This is not about small amounts of money. With hourly rates of 40 € and more, profits are eaten away quickly.

How to reduce downtime?

You can do a lot to reduce downtime with your Airless device. The effort is relatively low and pays off quickly, taking into account the stress and loss of time that arises when the device fails due to lack of wear parts such as seals, nozzles or filters on the site. These are the most important measures:

  • planning for parts prone to wear
  • check the Airless device regularly
  • train employees to work properly with Airless sprayers
  • rely on a dealer with a large stock of spare and wear parts

1. Plan for wear parts

Nothing lasts forever, so it’s clear that accessories such as nozzles, gaskets or filters or other perishable parts need to be replaced regularly due to high wear and tear. This is predictable and thus can be prepared for in advance if the basic knowledge in dealing with paint spraying equipment is available. But what are the essential wear parts? What should you store and absolutely have as quick replacement on the work site?

Spray tips – Material flow under high pressure causes wear on the nozzle over time. The nozzles wear out, the spray pattern changes, becoming more uneven. Overspray increases significantly. Therefore it is important to change the spray tips periodically. When? That depends on the material. Viscosity, solids content and pressure setting play a significant role in spray tip wear. Usually after a few hundred liters, the old spray tips should be disposed of and new tips inserted.

In addition, different spray tips should be available and used for different materials. Thick paint or material with a higher solids content requires larger spray tips, thinner materials smaller nozzle bores. Large surfaces can be optimally and quickly worked on with a wide spray angle, smaller surfaces with a narrow spray width. It is therefore very important that the right spray tips are available. Using just any spray tip won’t do.

Filters – Suction filters, main filters and gun filters are eventually worn or clogged, it’s just an inevitable part of the job. Therefore, you should always have some spare filters with you. In addition, the right filter (mesh size) should be available to match the material and the spray tip.

Gaskets and seals – Gaskets and seals such as those on the tip guards are very easily lost during cleaning. Without these seals it is not possible to work, it will just be impossible to spray because material will start to leak from all places. So think about having a bunch of gaskets and seals too.

Care products – piston oil, tip cleaning or maintenance liquid help to ensure the operational readiness of the paint spraying device in the long term.

Depending on the sprayer type and the urgency of the project, it may be advisable to have important spare parts such as packs or valves on site.

2. Check your airless device regularly

It is recommended to inspect your sprayer every time before you start work. A minute will suffice to look for any clear signs that there might be an issue. For example: is there damage? Is the hose is bent or damaged, is the spray tip in place? This is not a big hassle and experienced users who regularly work with sprayers will know this happens from time to time. This quick inspection not only serves to ensure operational readiness but work safety as well. Problems can be detected and eliminated quickly.

Similarly, problems or irregularities should be recorded and noted during operation. Unfortunately, when several employees work with one sprayer, that does not always happen. As if workers were thinking “Well, my colleague will certainly take care of this”, until the pump then at some point suddenly stands still. Also, worn parts should be noted so that they can be pre-ordered on time. To deal with this problem, we recommend to appoint an employee in the company responsible for the Airless devices. Problems, worn tips and filters can be reported to this employee, so missing material can be ordered in time and the operational readiness is guaranteed. Ideally, the employee responsible for the Airless equipment should be trained with appropriate training on the subject. Then once a month, he or she is also able to make a visual and functional check on the sprayers and to check the stock for wear parts.

For reasons of safety and operational readiness, each sprayer should be checked once a year for safety and function by a specialist workshop.

3. Train employees to handle Airless equipment properly

Competence and expertise in dealing with Airless sprayers are not only important to produce high quality surfaces and to avoid overspray, but also help to increase the operational readiness of the sprayers and reduce downtime. Users who know and understand the structure and operation of their paint spraying device can solve minor problems quickly and know when tips and filters need to be replaced.

All these points are part of the one-day course “Introduction to spraying” offered by our partner Paint Tech Training Academy in the UK and Ireland:

  • initial machine setup
  • guns, tips, filters
  • pressure, viscocity
  • products
  • health and safety
  • masking
  • spraying techniques
  • cleaning and maintenance
  • fault finding

4. Rely on a dealer with a large stock

A specialist dealer can advise, repair and supply spare parts quickly. Therefore, a good dealer is important for the smooth use of Airless paint spraying technology. The expert advice is vital to find the right paint sprayer for you. A large spare parts warehouse guarantees quick delivery and a workshop with specialist technicians allows speedy repairs. All important factors when it comes to reducing downtime and ensuring the use of spray technology.

We stock the largest array of Airless equipment and spare parts in Europe! Visit our online store here.

For all further questions and for the planning of the operational readiness of airless devices we are glad to assist you under tel. +49 (0)30/2201 5436, via mail at info@airless-discounter.de or over our contact form here below. As usual, enjoy your spraying!

By |2018-11-27T13:08:17+00:00November 27th, 2018|Accessories, Spare parts|0 Comments

Leave A Comment