There is a demand for nozzle extensions for coating areas that are difficult to reach, such as grooves, hollow profiles and the inner surfaces of pipes. A new modular spraying system can make it possible to achieve optimum and reproducible coating results even in problematic areas.

There is a huge demand for nozzle extensions for coating areas that are difficult to reach, such as grooves, hollow profiles and the inner surfaces of pipes. A new modular spraying system can make it possible to achieve optimum and reproducible coating results even in problematic areas.

The new generation of nozzle extensions can be used for both manual and automatic spray guns. The extensions are designed as a modular system. All parts are screwed together and not brazed, as in previous systems, which means that the parts are ordered separately and can be changed if required. A standard range of extension lengths (100 to 1000 mm) covers virtually all requirements.

The modular system allows custom combinations of extensions to be put together for the most varied applications, reducing the number of spare parts required and simplifying cleaning and maintenance. All materials - including water-based materials - can be sprayed, as the needle, nozzle and material pipe are made of stainless steel. This construction also ensures that the extensions are tough and resistant to wear. The outer pipe is made of aluminum for low weight; this characteristic, combined with the system’s compact design, provides for easy handling.<

Precise Finishes

The new air caps with round/wide jet adjustment are compact and are designed to fit into small openings. The required jet width can be adjusted with an adjustor screw and hex-head wrench. This feature is integrated into the spraying cap to ensure that it is protected and cannot be changed by mistake.

In order to cover as many requirements and object geometries as possible, the system not only offers straight-spraying caps but also caps that spray the material at an angle of 45 degrees or 90 degrees. Furthermore, the wide range of nozzle sizes ensures that spraying can be performed precisely, while at the same time saving material. The new range also includes round jet spraying caps without an adjustor screw, and as well as extensions with internal mixing.

The length of the needle for opening and closing the spraying process is determined precisely for the spray gun model concerned. The material-carrying pipe is screwed in as an extended nozzle and is surrounded by the air pipe. The air therefore flows between the outer wall of the material pipe and the inner wall of the air pipe. The air pipe itself is easily screw-fitted to the spray gun using a retaining nut.

To ensure fine atomization and optimum transfer efficiency, pressure tanks or pump systems should be used. Gravity feed cups can be used only to a limited extent for spraying with extensions (for pipe lengths up to a maximum of 300 mm). Syphon feed cups are unsuitable due to their lower injector effect.

Customized Extensions

Special extensions also can be manufactured to meet specific requirement profiles, such as extensions with an extremely small outer diameter, or those that can spray backwards. There are also spraying caps that can be fitted with a flat plate. In this case, the material strikes the plate at 90 degrees to produce a fan-shaped spray.

A further specialty is the so-called “pipe crawler,” which was designed for the internal coating of long pipes. It is an automatic spray gun with its air and material connections arranged axially, allowing it to be drawn through the pipe on a special carriage.

As finishing professionals search for ways to improve the finish quality on complex-shaped components and in hard-to-reach areas, suppliers will continue to develop new technologies to help them meet their goals.


For more information call 877.WALTHER, e-mail sales@waltherpilotna.com or visit www.waltherpilotna.com.