SPRAY COATING

Synergy Spray Systems delivers advanced spray coating systems tailored for high-performance applications in pharmaceuticals, food processing, surface finishing, and precision manufacturing. Our technology ensures accurate dosing, fine atomization, and efficient coverage—whether you're working with spray paint machines, viscous liquids, or fluidized bed equipment.

Continuous Bed Movement Spraying

In high-speed production lines, continuous bed movement systems apply coatings while the product travels under a spray bar. These systems typically use hydraulic flat fan nozzles to deliver a consistent linear spray pattern.

Challenge: Products spaced intermittently on conveyors require spray-on-demand activation.

Solution: Use air-activated or electrically actuated spray nozzles, capable of pulsing at up to 150 times per second using pulse-width modulation. This minimizes waste while maintaining coating continuity.

Stop-and-Go Conveyor Spraying

In this method, products are transported and paused beneath spray bars during coating cycles

Nozzle Type: Full cone nozzles are ideal, providing even liquid distribution over stationary targets.

Enhancement: Combine with air actuation and atomization to reduce droplet size and increase coating adhesion, particularly important for surface finishing and precision coating.

Drum Coating Systems

For bulk items like tablets, pellets, or granules, drum coating offers a rotating environment where product movement ensures full surface coverage.

Used In: Pharmaceuticals, confectionery, food coating.

Nozzles: High-precision air atomizing nozzles create a fine mist, maximizing random coverage as materials tumble.

Benefit: Greater uniformity and less clumping in batch coatings.

Fluidized Bed Coating Systems

Fluid bed coating suspends granules or tablets in an upward air stream. Sprays are introduced into this airflow to achieve even 3D coverage.

Function: Mimics liquid-like movement of solids and spray for thorough, multi-angle coating.

Nozzle Requirements:

Uniform droplet size

Controlled spray patterns

Accurate flow rates

Dosing & Accuracy in Coating Systems

Accurate dosing is critical

Overcoating wastes materials and may affect product performance.

Undercoating leads to defects and quality rejection.

To maintain consistency:

Use electrically modulated nozzles with high-speed cycling.

Integrate line speed monitoring for real-time dosing adjustment.

Targeted and Controlled Spray Coverage

Effective spray paint equipment must ensure

Precise targeting to minimize overspray and undercoating

Consistent spray angles and flow patterns

Spray mapping involves:

Calculating spray angles and spray height using basic trigonometry.

Understanding that most fan spray patterns have weaker edges and need overlap to ensure full coverage.

Importance of Droplet Size in Coating Quality

Smaller droplets

Improve surface adhesion

Ensure even distribution

Dry faster, minimizing clumping and drying delays

Larger droplets

Bounce or splatter

Create uneven, thick coatings

Increase drying times and product sticking in fluid bed and drum systems

Fluidized Bed and Drum Coating: A Comparison

  
      Feature
      Drum Coating
      Fluidized Bed Coating
    
      Motion
      Rotational
      Air-induced “floating”
    
      Coverage
      Moderate
      High (3D surface coverage)
    
      Spray Control
      Medium
      High precision required
    
      Common Use
      Tablets, confectionery
      Granules, capsules, small pellets
    
      Equipment
      Rotating drum, spray lance
      Vertical chamber, spray manifold

Feature	Drum Coating	Fluidized Bed Coating
Motion	Rotational	Air-induced “floating”
Coverage	Moderate	High (3D surface coverage)
Spray Control	Medium	High precision required
Common Use	Tablets, confectionery	Granules, capsules, small pellets
Equipment	Rotating drum, spray lance	Vertical chamber, spray manifold

Industry-Specific Use Cases

Pharmaceuticals

Tablet film coating, enteric protection, time-release layers.

Food

Glazing, flavor coating, oil misting, anti-stick sprays.

Metals

Anti-corrosion coatings, spray paint metal finishes, rust preventatives.

Automotive

Primers, surface treatment, protective layer applications.

Electronics

Conformal coatings for moisture and static protection.

Why Choose Synergy Spray Systems?

Expertise across sectors: From fluid bed manufacturers to spray gun Qatar support.

Precision-engineered nozzles for both low-viscosity and thick coatings.

Quick-change technology to reduce maintenance downtime.

On-site consultation and custom fabrication of spray systems.

Support for legacy and modern automated spray coating lines.