Is Your Spray Tip Worn?

Posted in Painting & Coating

A worn spray tip uses on average 20% more paint and 20% more labor

Sprayer Ship

Assuming paint is $20 per gallon and consumption is 5 gallons per hour and labor is $36 per hour. The total cost is $136 per hour.

If the contractor is spraying with a worn tip labor efficiency will decrease by 20% while paint consumption will increase to 6 gallons per hour. This increases the hourly cost by up to $163.20 per hour. That is an increased cost of $27.20 per hour.

Resulting in a total cost increase of $217.60 per hour long shift.

Signs of a worn spray tip

When a spray tip wears, the orifice gets bigger and rounder, which makes the fan pattern smaller. When a tip with a 12" (305mm) fan wears down to a 5 1/2" (140mm) fan the spray tips outputs 30% more paint on an area that 25% less than when it was new.

  • Painting takes longer
  • More paint gets used
  • The finish may be uneven and have runs.

When the fan has lost 25% of its original size, it is time to replace the tip.

New Tip Old Tip
Spray Patterns.png
12" (305mm)
11" (208mm)
9" (230mm)
5 1/2" (140mm)


Replace tips often for maximum performance

Watch for runs or sags in the spray pattern as signs of a worn tip. Don’t increase pressure to combat these problems. You’ll only waste paint and increase wear on the pump. Simply replace the worn tip. Worn-out tips also wear components in your equipment much faster. By spraying materials with correctly sized tips and replacing tips when necessary, you’ll maximize productivity, save paint and earn more profits.

Five Ways to extend tip life:

  • Spray at the lowest pressure that atomizes the material
  • Strain the material before you spray it
  • Use the correct size filters
  • Clean the filters after every use
  • Clean the tip with a soft-bristled brush.