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When the powder coating rate of an electrostatic spray gun suddenly drops sharply, don't just replace the gun in after-sales service: the root cause often lies in the entire spraying process.

Author: BOSTAR Technical Content CenterTechnical Review: BOSTAR Spray Application Engineering GroupPublished: July 16, 2026Updated: July 22, 2026

Scope: General electrostatic spraying adjustment logic. This does not replace equipment-specific manuals.

In electrostatic powder spraying production, the most likely type of failure to cause misjudgment is "Yesterday's powder was normal, today's powder suddenly can not be sucked".The scene often suspects the spray gun, high-pressure bag or controller first, and it is easy to directly recommend changing the gun after sales.But the powdering rate is the result of the combined action of the entire spraying system, and the spray gun is only one of the nodes.

Grounding link, powder state, compressed air, fluidization and powder supply, powder pipes and venturi pumps, spray room air extraction, workpiece shape, hanger state, wire speed, gun spacing, high voltage and current limitations, any change may make the surface look like "no static electricity of the spray gun".

When the powder rate suddenly drops, it should be determined whether the fault belongs to the public system, single gun, workpiece grounding or powder process before deciding whether to disassemble the gun or replace the part.

In electrostatic powder spraying production, the most likely type of failure to cause misjudgment is "Yesterday's powder was normal, today's powder suddenly can not be sucked".The scene often suspects the spray gun, high-pressure bag or controller first, and it is easy to directly recommend changing the gun after sales.But the powdering rate is the result of the combined action of the entire spraying system, and the spray gun is only one of the nodes. Grounding link, powder state, compressed air, fluidization and powder supply, powder pipes and venturi pumps, spray room air extraction, workpiece shape, hanger state, wire speed, gun spacing, high voltage and current limitations, any change may make the surface look like "no static electricity of the spray gun". When the powder rate suddenly drops, it should be determined whether the fault belongs to the public system, single gun, workpiece grounding or powder process before deciding whether to disassemble the gun or replace the part.

The English edition of this article is being prepared. Please refer to the Chinese version linked above, or contact us for engineering support in English.

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