Spray Equipment Guide: Airless vs. HVLP for Painting Contractors

Spray Equipment Guide: Airless vs. HVLP

Airless Sprayers

Airless sprayers use hydraulic pressure (1,500 to 3,500 psi) to atomize paint without compressed air. The high pressure produces a fine fan pattern that moves fast.

Best for:

• Large exterior surfaces (whole-house, barn, fence)
• Latex paints and thick coatings that clog HVLP guns
• Production work where speed matters more than transfer efficiency

Transfer efficiency: 65-70%. Roughly 30% of material becomes overspray. Mask everything within 10 feet.

Tip sizes: 0.013-0.017 for latex wall paint; 0.009-0.011 for stains; 0.019-0.023 for elastomeric. First two numbers x 2 = fan width in inches; last digits = orifice in thousandths of an inch.

HVLP (High Volume, Low Pressure)

HVLP guns operate at 2-10 psi at the cap, using high air volume to atomize. Much less overspray than airless.

Best for:

• Cabinets, doors, and furniture finishes
• Lacquers, varnishes, and fine furniture coatings
• Automotive and high-end residential work
• Any setting where overspray must be minimized (occupied homes)

Transfer efficiency: 75-90%. Less waste, less masking.

Requires: Separate compressor or turbine unit. Not practical for thick latex without significant thinning.

Quick Decision Guide

Situation	Use
Exterior whole house	Airless
Interior walls, production	Airless
Kitchen cabinet spray	HVLP
Trim in occupied home	HVLP or brush
Deck stain	Airless
Custom furniture	HVLP

Source: PCA Education Foundation; Graco application guides.