Precision Valve Technology Drives Overspray Reduction in Automotive Paint Systems

Pre-configured paint control panels integrate pressure regulation, flow measurement, and proportional valve control to support consistent application quality in robotic spray systems. (Image courtesy of Emerson)

Emerson’s modular panel assembly enables plug-and-play installation of automation components into robotic paint arms—reducing setup complexity and enhancing real-time control. (Image courtesy of Emerson)

Automated painting in vehicle manufacturing is a complex process where even small inefficiencies scale into major operational and environmental costs. A persistent challenge is overspray—the portion of sprayed paint that fails to reach the target surface. Studies suggest overspray rates of 30–40%, representing not only wasted media but also contributing to substantial volumes of paint sludge (PS), which requires regulated treatment.

The root of this inefficiency lies in how robotic paint arms manage compressed "shape air”, the air used to shape and deliver the atomised paint. As robots shift dynamically around the vehicle body, spray angles change constantly. Maintaining consistent transfer efficiency under these conditions depends heavily on the speed and precision of pressure and flow adjustments in real time.

At the centre of improvement efforts is proportional control technology. Traditional systems often rely on valves with response times exceeding 130 milliseconds, which can lag behind the movement of the robot. Recent advancements in direct-acting pressure regulation are addressing this gap.

New-generation regulators—such as the AVENTICS™ ED07—achieve response times as low as 80 milliseconds. These valves feature dual solenoids, integrated sensors, and closed-loop feedback algorithms. By embedding control intelligence within the valve itself, the system can make instantaneous adjustments based on live data, bypassing the robot’s main controller and reducing latency.

This fast-response capability directly improves spray pattern control, increasing the proportion of paint that adheres to the intended surface. As a result, both media consumption and sludge generation are significantly reduced, yielding quantifiable cost savings and operational improvements.

To support ease of integration, this technology is often delivered as part of a pre-engineered solution: a compact control panel incorporating pressure regulators, flow sensors, proportional atomiser valves, and I/O terminals. Designed for straightforward installation into robotic arms, these systems reduce engineering complexity while enabling precision control.

As manufacturers continue to pursue higher efficiency and sustainability, advanced valve and sensor technologies are proving to be key enablers in modernising paint processes. By focusing on tighter control of flow dynamics, it is possible to improve application quality, minimise waste, and optimise resource use across high-throughput environments.

For more information visit: https://www.emerson.com/en-us/automation/industrial-factory-automation/factory-automation

Article by Christopher Logue, Global Director of Business Development, Factory Automation and Transportation Industries, Emerson.

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