saint clair SYSTEMS

Temperature & Viscosity Control

saint clair systems PAINT DEFECTS TROUBLESHOOTING

norcross saint clair SYSTEMS
norcross Temperature & Viscosity Control

Paint Defects
Troubleshooting Guide

E L I M I N AT E F I N I S H I S S U E S & I M P R O V E PRODUCTIVITY

W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

The painting industry has always been heavily reliant on technology and
engineering to make the business both feasible and cost effective. If it weren’t
for advancements in mass production, the ability to produce such enormously
complex systems as an automobile, in large volume and high quality simply
wouldn’t be possible.

But for all the advances made in the paint process, things are not always perfect.
Defects can–and do–happen in paint jobs, which means lost time, money and
business for everyone. That’s why it’s important to find and eliminate paint
problems on the line before they interfere with your bottom line.

W W W . V I S C O S I T Y. C O M
W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

CONTENTS

Summary 2
Orange Peel 4
Color Inconsistency 5
Off Color 6
Poor Adhesion 7
Substrate Inconsistency 8
Dry Spray 9
Gloss Variations 10
Improper Gloss 11
Mottle 12
Dirt 13
Craters 14
Poor Coverage 15
Blisters 16
Pinholes (Outgassing) 17
Solvent Pop 18
Runs & Sags 19
Spitters 20

W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Orange Peel
A coat of paint that should be smooth and
unblemished instead, forms with a texture across the
entire surface of application which resembles the peel
of an orange, hence the name.

CAUSES SOLUTIONS

Substrate too warm Adjust ambient or substrate temperature to

control solvent evaporation rate

Substrate too cold Adjust ambient or substrate temperature to

control solvent evaporation rate

Excess reducing solvent Restrict the amount of reducing solvent

being added to adjust viscosity

Solvent evaporating too quickly Add a small amount of solvent or change to

a “slower” solvent

Incorrect spray gun pressure (see Adjust spray gun pressure

atomization below)

Incorrect nozzle in spray gun (see Change spray nozzle

atomization below)

Applying excess paint Ensure paint applied is consistent in solid

content and viscosity

Improper paint viscosity Ensure correct paint viscosity is supplied

to atomizer

Improper atomization (particle size) Adjust gun or bell to obtain proper

atomization rate (particle size)

Insufficient flash time Adjust line speed or flash tunnel

temperature to assure proper flash-off
before entering curing oven

4 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Color Inconsistency
Variations in the application of the paint lead to
differences in color instead of the desired uniform
appearance.

CAUSES SOLUTIONS

Variations in application parameters Check for variables in spray application

Variations in paint (separation, settling, etc.) Confirm that paint is properly mixed in tank
and that it is circulating at an acceptable
rate ( >1 FPS )

Variety of substrates (plastics, steel, Different substrates take paint in different

aluminum, alloys, etc.) ways. Confirm that the proper paint and
process is being used for the substrate.

Improper flake lay (metallics & micas) Check for proper mixing, agitation, and
circulation rate (>1 FPS ). Confirm proper
film build to promote consistent flake lay
(excess film allows flake lay variation)

Inconsistent film build Check gun/bell setup for proper atomization,

and robot for proper pattern and overlap

Striping (inconsistent film application) Check gun/bell setup for proper atomization,
and robot for proper pattern and overlap

Contamination Check lines and equipment for

contamination from a previous color

5 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Off Color
This differs from Color Inconsistency in that, though
the color appears uniform, the shade, intensity or
appearance simply does not match the requirement, often
set by a sample panel or color meter reading.

CAUSES SOLUTIONS

Bad paint Check paint status with manufacturer to

assure that it meets specification

Excess reducing solvent added Adding solvent can shift color. Assure that
the minimum amount of solvent is being
added during color setup (preferably 0%)

Low film build Confirm that the film build is sufficient to

prevent lower layers or the substrate to
bleed through

Improper flake lay (metallics & micas) Check for proper mixing, agitation, and
circulation rate (>1 FPS ). Confirm proper
film build to promote consistent flake lay
(excess film allows flake lay variation)

Contamination Check lines and equipment for

contamination from a previous color

Bad color meter Assure that the proper color meter (make/
model) is being used for the application and
that the meter is properly calibrated

6 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Poor Adhesion
Paint is flaking, peeling or cannot pass a cross-hatch
tape-pull test. This may be interlayer adhesion either
(between clearcoat and topcoat, or top coat and primer),
or substrate adhesion (between the substrate and the first
coating layer).

CAUSES SOLUTIONS

Substrate not clean Check pretreat processes to assure that the

surface is properly prepared for paint application

Primer applied too dry or too thin Review primer process for appropriate
application (no dry spray, etc.)

Base coat applied too dry or too thin Review base coat process for appropriate
application (no dry spray, etc.)

Excess solvent in coating Assure proper solvent load in layer that is

failing adhesion test as excess solvent can
cause improper curing and poor adhesion (see
Blistering and Solvent Pop below)

Excessive flash time between coats Especially for wet-on-wet applications, assure
that the lower layers are properly prepared for
application of the next coating layer

Drying conditions inappropriate Review oven settings and confirm recommended

profile to assure suitable peak substrate
temperature and timing for proper curing

7 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Substrate
Inconsistency
Inconsistencies like mold or grinding marks, dents,
scratches, etc. in the surface of the part causes appearance
issues when painted, particularly when viewed from
different angles.

CAUSES SOLUTIONS

Poor surface preparation Assure that smooth continuous surface is

presented to the painting operation

Poor primer coverage If primer layer is too thin it may not be able to
properly fill minor surface imperfections

Poor basecoat coverage If the basecoat layer is too thin it may not be
able to hide variations in the substrate

8 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Dry Spray
The term “Dry spray” refers to a phenomenon where
the paint does not flow out and the atomized particles
appear more like sand or microbeads on the surface of
the coating. This will usually be accompanied by adhesion,
color and gloss issues.

CAUSES SOLUTIONS

Insufficient solvent in coating Add a small amount of solvent to the

coating blend

Solvents in coating are “too fast” Change to a “slower” solvent

Paint is too warm when applied Reduce temperature of paint being supplied
to atomizer

Atomized particles are too small Adjust gun or bell to obtain proper
atomization rate (particle size)

Ambient air temperature is too warm Control ambient air at a lower temperature

Shaping air is too warm Reduce temperature of shaping air to slow

solvent evaporation rate

9 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Gloss Variation
A glossy finish is inconsistent, with some areas
across the surface having a lower gloss than others.

CAUSES SOLUTIONS

Uneven curing of the base coat Inspect and ensure proper flash off and oven
settings and confirm recommended profile to
assure suitable peak substrate temperature
and timing for proper curing prior to clearcoat
application

Uneven curing of the clear coat Confirm oven settings and recommended profile
to assure suitable peak substrate temperature
and timing for thorough, uniform curing

Insufficient film build Confirm that the clearcoat film build is sufficient
and uniform across the part

Improper resin/catalyst mix Review resin to catalyst ratio and confirm that
there is sufficient mixing taking place, and
extend static mixer length if required

Uneven clearcoat application Adjust gun or bell to obtain proper atomization

rate (particle size) to assure that the particles
are not caught in the booth draft during certain
parts of the coating process

10 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Improper Gloss
This differs from Gloss Variations in that the entire
surface is consistent, but the gloss is either lower or
higher than required. This may be based on sample panels
or a gloss meter reading.

CAUSES SOLUTIONS

Bad clearcoat Check clearcoat status with manufacturer to

assure that it meets specification

Insufficient film build Confirm that the clearcoat film build is

sufficient and uniform across the part

Improper resin/catalyst mix Review resin to catalyst ratio and confirm

that there is sufficient mixing taking place,
and extend static mixer length if required

Improper atomization (particle size) Adjust gun or bell to obtain proper

atomization rate (particle size)

Improper clearcoat viscosity Ensure correct clearcoat viscosity is supplied

to atomizer

Improper clearcoat temperature Ensure correct clearcoat temperature is

supplied to atomizer

Insufficient flash time Adjust line speed or flash tunnel temperature

to assure proper flash-off before entering
curing oven

Incorrect curing conditions Review oven settings and confirm

recommended profile to assure suitable peak
substrate temperature and timing for proper
curing

11 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Mottle
For metallic paints, the color pigments separate
from the metallic flakes, creating an uneven
appearance of color.

CAUSES SOLUTIONS

High film build Decrease the paint flow rate or increase robot
speed to reduce film build

Insufficient agitation of paint Check for proper mixing, agitation, and

circulation rate ( >1 FPS )

Inconsistent film build Check gun/bell setup for proper atomization, and
robot for proper pattern and overlap

Incorrect nozzle size Change to correct spray nozzle

Improper atomization (particle size) Adjust gun or bell to obtain proper atomization
rate (particle size)

Insufficient air volume Increase air flow to gun

Incorrect fan pattern / overlap Test and correct fan pattern for smooth laydown
and proper overlap to produce even film across
all surfaces of part

Paint layers too heavy Apply thinner layers to control flake lay

Insufficient time between layers Extend time between layers by slowing line or
repeating passes

Solvent too “fast” Switch to a slower solvent to allow more time

for flake laydown and orientation

Poor spray pattern Review robot program and adjust accordingly

12 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Dirt
Specks of dirt and other impurities are visible in
the paint job.

CAUSES SOLUTIONS

Dirty air filters Replace with clean filter media

Poor air flow Identify and correct booth airflow issues

Contaminated substrate Assure clean parts supplied to paint process

from blow-off and/or tack operations

Agglomerated paint Assure paint is properly filtered, agitated and

circulated (>1 FPS )

Contaminated circulation/supply system Assure that system is clean prior to color change
and that paint is transported at a sufficient
velocity (>1 FPS )

13
10 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Craters
Also known as “Fisheyes” or “Cissing”, these are
defects on the paint surface reminiscent of volcanic
or lunar “craters” appear instead of the intended smooth
finish. These are generally caused by low surface tension
areas on the surface of the substrate but can also be caused by
contamination of the wet surface after coating but prior to curing.

CAUSES SOLUTIONS

Surface contamination with oil, grease, wax, Ensure proper cleaning of substrate prior to
silicone or other residue introduction into the paint process

Surface contamination with residue from Enact and strictly enforce rules regulating
clothing, gloves, lotions and antiperspirants the use of products containing silicone

Lubricants from moving parts Assure proper lubrication of conveyors and

other systems without over-lubricating

Release agents from plastic parts Test equipment for silicone contamination

Dirty ceiling and floor filters Perform regular maintenance on all filters
and fans

Transportation or storage materials that Ensure that all materials entering the paint
became contaminated area are free of contamination

Inlet of impure air from another work area Regulate and purify all air entering the paint
and substrate areas

14 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Poor Coverage
Substrate is visible through the topcoat, creating
uneven coloration on the surface.

CAUSES SOLUTIONS

Excess reducing solvent Restrict the amount of reducing solvent being

added to adjust viscosity

Inconsistent film build Check gun/bell setup for proper atomization,

and robot for proper pattern and overlap

Variations in paint (separation, settling, etc.) Confirm that paint is properly mixed in
tank and that it is circulating at an acceptable
rate (>1 FPS )

Atomized particles are too small Adjust gun or bell to obtain proper atomization
rate (particle size)

Electrostatic level set incorrectly Check electrostatic system and adjust as

required

Part not properly grounded Assure that part/mule/conveyor is properly

grounded

Excessive booth draft Check booth airflow and adjust if required

15 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Pinholes (Outgassing)
Caused by gasses that originate from the substrate
or lower layers in the coating structure, these appear
similar to solvent pops but are generally “less violent”
as they occur before the uppermost coating layer has had a
chance to “skin over” (see Solvent Pop” below). These are common
in wet-on-wet applications.

CAUSES SOLUTIONS

Air entrapment during coating Assure that coating is applied with sufficient
flow out time to allow entrapped air to escape
prior to curing

Improper paint viscosity Ensure correct paint viscosity is supplied to

atomizer

Insufficient curing of lower paint layers Assure proper curing is performed on each layer
as it is applied

Improper surface cleaning Assure all moisture is removed from the surface
prior to coating at each stage of the process

Improper mixing of coating Check for proper mixing, agitation, and

circulation rate (>1 FPS ).

Solvent too “slow” Switch to a “faster” solvent blend

16 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Blisters
Usually solvent related, these are bubbles, ranging
from micro-small to very large, that appear in the
surface of the paint. These often are accompanied by
adhesion related defects.

CAUSES SOLUTIONS

High film build Decrease the paint flow rate or increase robot
speed to reduce film build

Flash off time between coats is too short Extend flash off times or increase temperature
to speed flash off

IR lamps used for flash off/drying/baking Ensure proper distance between lamps and
are placed too close to surface, prematurely surface and that the appropriate exposure times
curing the surface of the uppermost layer are used with IR lamps

Poor surface preparation Assure that part surfaces are clean and dry
before sending to the paint operation

Compressed air contamination Assure that all compressed air supplied to

the painting operation is dry and free of all
lubricants and contaminants

Excess reducing solvent added Restrict the amount of reducing solvent being
added to adjust viscosity

17 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Solvent Pop
This is an extreme form of blistering where the
pressure from the “bubbles” formed by the solvent
trapped under the surface is sufficient to actually rupture
the surface of the coating. These are generally of a more
“violent” nature than pinholes, where the gas escapes
through wet, uncured coating.

CAUSES SOLUTIONS

Excess reducing solvent added Restrict the amount of reducing solvent being
added to adjust viscosity

High film build Decrease the paint flow rate or increase robot
speed to reduce film build

IR lamps used for flash off/drying/baking Ensure proper distance between lamps and
are placed too close to surface, prematurely surface and that the appropriate exposure times
curing the surface of the uppermost layer are used with IR lamps

Zone 1 of oven too hot causing premature Check oven profile and assure that Zone 1 is not
skinning of the coating before the substrate set too high
temperature is elevated

Flash off time is too short Extend flash off time or increase temperature to
speed flash off

Solvent too “slow” Switch to a “faster” solvent blend

18 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Runs & Sags

Generally associated with heavy coating areas, the paint
does not adhere uniformly to the surface, forming layers
which slip against one another causing beads, drips, runs and
sags. These are worse in vertical surfaces where gravity exerts a
downward force on the film but can also appear on horizontal surfaces as
the excess paint attempts to flow out from the point of application.

CAUSES SOLUTIONS

High film build Decrease the paint flow rate or increase robot
speed to reduce film build

Improper paint viscosity Ensure correct paint viscosity is supplied to

atomizer

Excess reducing solvent added Restrict the amount of reducing solvent being
added to adjust viscosity

Solvent too “slow” Switch to a “faster” solvent blend

Flash off time between coats is too short Extend flash off times or increase temperature
to speed flash off

Improper atomization (particle size) Adjust gun or bell to obtain proper atomization
rate (particle size)

Incorrect spray gun pressure Adjust spray gun pressure

(see atomization below)

Incorrect nozzle in spray gun (see atomization Change spray nozzle

below)

Substrate surface is too cold when Increase substrate temperature before applying
paint is applied paint

Surface contamination with oil, grease, wax, Ensure proper cleaning of substrate prior to
silicone or other residue introduction into the paint process

19 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

Spitters
Spitters are the result of condensation which forms
when the compressed air used for turbine drive and
shaping air decompresses, falling below the dew point
temperature of the booth, which is generally high due to the
elevated humidity.

CAUSES SOLUTIONS

Turbine drive air cools cup surfaces Heat turbine drive air so it is above dew point
forming condensation which is atomized temperature when released
along with the paint

Shaping air falls below dew point Heat shaping air so it is above dew point
temperature causing water droplets to temperature when released
form in the shaping air stream

20 W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

The successful application of paint in the manufacturing process requires many

variables to be both controlled and in alignment with one another. Identifying and
resolving paint problems before they have the opportunity to impact a production
run are key factors in an efficient business process to maximize revenue and
minimize waste.

At Saint Clair Systems, we design temperature and viscosity control systems as a

means of improving fluid delivery applications. When the correct fluid parameter
control process is in place for your particular application, the incidence of paint
defects will be reduced, providing a range of benefits. Contact Us today if you’ve
been experiencing paint defects and need a reliable solution.

21 W W W . V I S C O S I T Y. C O M
W W W . V I S C O S I T Y. C O M
saint clair systems PAINT DEFECTS TROUBLESHOOTING
norcross

OUR COMPANY

Since 1990, Saint Clair Systems has focused on providing cost-effective

paint temperature and viscosity control solutions for the automotive and
industrial finishing industries. Our team can provide an analysis of
your painting process and offer suggestions based on
the hundreds of installations we’ve seen.

Need Assistance with your

Viscosity Issues?
Contact us for a free consultation

CLICK FOR A CONSULTATION >

DOWNLOAD OUR eGUIDE: CONTROLLING ORANGE PEEL

Discover the 3 biggest factors working against your finish.

saint clair SYSTEMS

Temperature & Viscosity Control

saint clair SYSTEMS

norcross Temperature & Viscosity Control

12427 31 Mile Road, Washington, Michigan 48095, +1 (617) 969-7020

www.viscosity.com

22 W W W . V I S C O S I T Y. C O M