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Types of Spray Guns for Tablet Coating Machines: Air Spray, HVLP & Atomization Explained

December 16, 2025

Table of Contents

Introduction

In the world of tablet coating machines, choosing the right spray gun is crucial. It determines coating uniformity, material efficiency, and overall pharmaceutical coating process performance. Whether you are working on a sugar coating pan or a tablet film coating process, understanding the differences between spray guns helps procurement professionals make smarter decisions, improve production quality, and reduce material waste.

Air Spray Guns: The Classic Choice

What Are Air Spray Guns?

Air Spray Guns are the traditional workhorses in tablet coating machines. They use compressed air to atomize the coating liquid into fine droplets, which evenly cover the tablets in the coating pan.

Why Choose Air Spray?

Versatility: Works well with a variety of coating materials, from sugar to film coatings.
Simplicity: Easy to operate and maintain, making it popular in many pharmaceutical plants.
Cost-Effective: Lower initial investment compared to advanced spray systems.
Good Coverage: Provides uniform coating when properly adjusted.
Widely Available: Compatible with most tablet coating machines on the market.

Considerations

Air spray guns tend to have higher overspray and material waste, which can affect tablet film coating efficiency. If you aim to reduce material loss, consider exploring more advanced spray technologies.

HVLP Spray Guns: Efficiency Meets Precision

What Does HVLP Mean?

HVLP stands for High Volume Low Pressure. These guns use a high volume of air at low pressure to atomize the coating material, reducing overspray and improving transfer efficiency.

Benefits of HVLP in Tablet Coating

Material Savings: Less coating material wasted due to reduced overspray.
Better Control: Finer atomization ensures smoother, more consistent coatings.
Environmentally Friendly: Lower emissions of volatile organic compounds (VOCs).
Improved Safety: Reduced airborne particles improve the working environment.
Ideal for Film Coating: Perfect for delicate tablet film coating processes requiring precision.

What to Watch Out For

HVLP guns can have a higher upfront cost and may require more maintenance. However, long-term efficiency gains often outweigh initial investment.

Atomization Spray Guns: The Future of Coating

Understanding Atomization Technology

Atomization spray guns use advanced technology to break the coating liquid into ultra-fine droplets, often combining air and mechanical forces. This results in superior coating uniformity and efficiency.

Why Atomization?

Ultra-Fine Droplets: Ensures even coverage and reduces defects.
High Transfer Efficiency: Minimizes waste and maximizes coating material use.
Adaptable: Works with various coating materials, including complex pharmaceutical formulations.
Supports Advanced Coating Machines: Ideal for high-end pill coating machines and fluid bed coaters.
Enhanced Process Control: Allows fine-tuning of spray parameters for optimal results.

Downsides

Atomization guns can be more complex and costly, requiring skilled operators and regular calibration. Yet, for top-tier coating quality, they are worth the investment.

Comparing Spray Gun Types: A Quick Look

Here’s a comparison table for quick reference:

Spray Gun Type	Atomization Method	Material Efficiency	Cost	Maintenance	Best For
Air Spray	Compressed Air	Moderate	Low	Low	Sugar Coating, General Use
HVLP	High Volume, Low Pressure Air	High	Medium	Medium	Film Coating, Precision Applications
Atomization	Advanced Air/Mechanical	Very High	High	High	High-End Coating Machines, Complex Formulations

This comparison helps pharmaceutical engineers and procurement professionals quickly select the right spray gun for their tablet coating machines.

Practical Tips for Procurement Professionals

What Should You Look For?

Compatibility: Ensure the spray gun matches your machine model and coating material.
Efficiency: Prioritize guns that reduce waste and improve coating uniformity.
Maintenance: Consider ease of cleaning and availability of spare parts.
Supplier Support: Choose suppliers offering training and technical assistance.
Budget vs. Quality: Balance upfront costs with long-term savings and product quality.

Real-World Insight

A pharmaceutical company switching from air spray to HVLP guns reduced coating material use by 20% and achieved a smoother finish.
Another firm using atomization guns for a fluid bed coater achieved remarkable consistency in film coatings, improving customer satisfaction.

Conclusion

Choosing the right spray gun for your tablet coating machines is more than a budget decision—it impacts product quality, operational costs, and environmental footprint. Whether you choose Air Spray, HVLP, or Atomization, each technology has a specific place in the pharmaceutical coating process.

For optimal performance and reliable support, consider JIANPAI’s advanced spray gun solutions. With precision-engineered equipment and professional guidance, you can upgrade your coating line, enhance material efficiency, and achieve consistent, high-quality tablet coatings.

Ready to transform your coating process? Contact JIANPAI today and explore our full range of tablet coating machines!

Frequently Asked Questions (FAQ)

Q1: What is the main difference between Air Spray and HVLP guns?
Air Spray uses high-pressure compressed air, causing more overspray, while HVLP uses high volume, low-pressure air to reduce waste and improve efficiency.

Q2: Can I use the same spray gun for sugar coating and film coating?
Some spray guns are versatile, but HVLP and Atomization guns are generally better for delicate tablet film coating processes.

Q3: How often should spray guns be maintained?
Maintenance typically occurs after every batch or shift to prevent clogging and ensure consistent spray quality.

Q4: Are atomization spray guns compatible with all tablet coating machines?
No. They are best suited for advanced or high-end tablet coating machines. Always check compatibility with your supplier.

Q5: Does using HVLP spray guns reduce environmental impact?
Yes. HVLP guns reduce overspray and VOC emissions, making them a greener choice in pharmaceutical manufacturing.

Q6: Which spray gun is best for complex pharmaceutical formulations?
Atomization guns are ideal for complex formulations due to ultra-fine droplet control and high transfer efficiency.