Solutions for collecting coating powder, dry overspray, sanding residues and contaminants generated during application, colour changes and system maintenance.
Paint and coating systems can generate very different residues depending on the product applied and the stage of the process. Coating powder involves epoxy powders, polyester powders, hybrid formulations, pigments, additives, overspray, booth residues and dust from cyclones or recovery filters.
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Liquid-painting processes instead generate dry paint residues, sanding dust, contaminated filters, booth sludge, droplets, deposits, spray mist and vapours from solvents or thinners. These materials require different strategies. FEVI industrial vacuum cleaners are suitable for collecting deposited dust and residues, while liquid mist and vapours require dedicated mechanical extraction and ventilation systems for booths and drying areas.
FEVI industrial vacuum cleaners and dust collectors suitable for painting and coating systems
The compatibility shown below is application-based. Performance and conductive configurations must be validated by the FEVI technical department according to the type of dust and the zone classification.
Criteria for selecting the paint-system extraction equipment
The selection and correct configuration of FEVI machines must be structured by analysing three fundamental areas of the finishing department:
1. State of the Contaminant
Assessment of the substance to be handled: dry solid overspray, extremely fine and electrostatic sanding dust, damp sludge or unpolymerised liquid paint.
2. Logistics and Colour Changes
Calculation of hourly quantities, frequency of colour changes, the need to prevent cross-contamination between pigments and the type of discharge system, whether a rigid drum or Longopac continuous bag.
3. ATEX Classification
Assessment of the explosion risk generated by finely divided organic powders or by the presence of flammable solvent and thinner vapours outside or inside the system.
Analysis of residues generated by powder-coating processes
Powder coating uses finely divided solid products that are applied electrostatically to the workpiece and subsequently polymerised in an oven. During loading, application, spray-gun cleaning, colour changes, booth maintenance and the emptying of hoppers or cyclones, part of the product settles on surfaces. Powder that has not yet been polymerised is respirable, and cleaning operations can generate significant exposure levels that must be managed in accordance with the material safety data sheet (MSDS).
Dry overspray and booth cleaning: Overspray is the powder that does not adhere to the workpiece. It can be captured by booth cyclones and filters and may sometimes be returned to the process. Recovery from the floor is not automatically possible and depends on purity, the absence of dirt or cross-contamination and particle size. Industrial vacuum cleaning is essential for cleaning booth floors, corners and areas around the filters, avoiding dry sweeping. The use of compressed air must be limited and permitted only while the booth extraction system is operating, to prevent the dispersion of extremely fine dust.
Contamination risk during colour changes: Small quantities of residual powder from the previous colour can cause differently coloured spots, shade variations and visual inclusions, resulting in rejection of the finished product. To minimise this risk, FEVI offers configurations with industrial vacuum cleaners dedicated to specific colours, separate flexible hoses, identified nozzles, separate containers and Longopac bag collection. Filter efficiency alone is not sufficient: the entire path, including the hose, chamber and drum, must be cleaned or dedicated.
Sanding processes before and after painting
Before application, filler is sanded, primer is ground, old coatings are removed and the substrate is prepared. After painting, localised operations may be carried out to correct runs, inclusions and surface defects. These activities generate extremely fine composite dust originating from paint, fillers, resins and substrate materials such as wood, metal and composites. FEVI extraction directly from the sander captures these abrasive particles before they become airborne within the department and compromise the quality of adjacent finishing booths.
Liquid painting: residues, mist and fluids
An industrial vacuum cleaner can be used to collect dry paint residues, sanding dust and small solid fragments located in areas outside the booth. By contrast, liquid paint, catalysts, thinners and unpolymerised products can contain flammable, irritating, corrosive or chemically reactive substances capable of dissolving or damaging filters and seals. They must never be collected using standard models without first verifying the flash point and compatibility with the machine’s construction materials. Furthermore, an industrial vacuum cleaner for dust does not replace the booth ventilation system: liquid mist, spray aerosols and volatile organic compounds (VOCs) generated during spraying or drying require a dedicated solvent-extraction and abatement system.
Technical distinction: Industrial Vacuum Cleaner, Dust Collector and Ventilation
To optimise efficiency and operate in full compliance, FEVI divides the available solutions into three engineering categories:
- Industrial Vacuum Cleaner (High Vacuum): Designed for manual cleaning of booth floors, the removal of deposited dry overspray, managing colour changes and direct connection to sanders and tools. It uses small-diameter hoses and prioritises linear material-conveying force.
- Dust Collector (High Airflow / Low Vacuum): Suitable for capturing lightweight airborne dust during the loading, dosing or transfer of powder into hoppers. It is connected to hoods and downdraught tables and prioritises the volume of air moved. It is not designed for floor cleaning.
- Booth ventilation and filtration: A structural integrated system designed to manage liquid mist, spray aerosols and solvent vapours within the department. It must remain operational during application and drying.
FEVI filtration technologies and Longopac containment
PTFE cartridges and automatic ICLEAN cleaning: Coating powders are fine, lightweight, adhesive and electrostatic. FEVI uses cartridges with a PTFE membrane that limits caking and promotes rapid dust release. The fully automatic ICLEAN system cyclically cleans the cartridges by isolating one at a time during operation, maintaining stable airflow and avoiding manual interruptions during prolonged cycles.
Longopac containment and PULSE cleaning: The PULSE system regenerates the cartridges using pressure differentials and is combined with Longopac continuous-bag collection. This architecture is ideal for colour changes and mobile cleaning because it allows fine dust to be sealed and divided into sections, reducing dispersion and eliminating transfers from the drum.
Absolute HEPA stages: HEPA filters, such as H14 filters, can be included as additional safety stages where pigments or toxic components are present. The class, efficiency and MPPS value must be taken from the documentation for the individual machine. A HEPA filter increases collection efficiency but does not automatically make the industrial vacuum cleaner ATEX compliant or replace capture at source.
Regulatory framework and ATEX explosion risk
Organic powders used in industrial coating processes can be highly combustible. Likewise, vapours, mist and gases produced by liquid paints and cleaning solvents can form hazardous explosive atmospheres. The risk classification must clearly distinguish gas- and vapour-classified areas, such as Zone 2 or Zone 1, from dust-classified areas, such as Zone 22 or Zone 21, analysing the frequency and duration of the explosive atmosphere both outside and inside the machine. The need for an ATEX machine depends on the risk assessment, MSDS documentation and the characteristics of the substances. An industrial vacuum cleaner equipped only with an antistatic filter is not suitable for an ATEX zone. The entire system, including conductive flexible hoses, spirals, connections, metal extensions and collection bags, must maintain complete electrical and equipotential continuity to dissipate electrostatic charges and prevent ignition sparks. Dust collectors such as FEVI DTX 2500 AIRCLEAN ATEX cover conductive dust group IIIC in Zone 22, while compact brushless models such as FEVI BSL 120 cover group IIIB, making preliminary verification of the alloy or pigment essential.
Quick configuration selection guide
Scenarios in non-classified areas (No ATEX)
- Localised sanding and small power tools: FEVI PULSE 11XM, 11XA or FEVI 220 ICLEAN;
- Extremely fine sanding dust with sealed discharge: FEVI 221 PULSE or FEVI TDC30 ICLEAN in the Longopac configuration;
- Professional cleaning of powder-coating booths and overspray: FEVI 350 ICLEAN for single-phase applications or the three-phase blower power of FEVI TDC30 ICLEAN;
- Capturing dust clouds from hoppers or dosing units: FEVI DTX 1500 BASIC for a single airborne source or FEVI DTX 2500 AIRCLEAN.
Scenarios in regulated or hazardous areas
- Localised cleaning and colour changes in Zone 22, Group IIIB: FEVI BSL 120 BASIC ATEX 22 with a 20-litre stainless-steel drum;
- Maintenance of classified booths and colour changes in pneumatic Zone 22 or Zone 21 applications: Pneumatic FEVI S PN ATEX Venturi range;
- Suspended combustible dust from hoods or hoppers in Zone 22: FEVI DTX 2500 AIRCLEAN ATEX 2-22 centrifugal dust collector;
- Large multi-booth industrial systems: Where several lines or distant booths are present, the FEVI technical department designs customised centralised systems with an external central vacuum unit, isolation valves, automatic dampers and fixed piping networks dedicated to the chromatic separation of the flows.
Key parameters to verify before configuration
Before defining the proposal, we assess the paint-system variables together: type of process, whether powder or liquid; chemical composition of the applied product and resin; material safety data sheets (MSDS); nature of the waste, including deposited dust, suspended dust or fluid sludge; particle size and hourly overspray volume; total number of colours and frequency of colour changes; need for recovery and sieving for reuse; ATEX zone classification and dust or gas group, including IIB, IIIB and IIIC; line parameters, including piping length and diameter, bends, pressure losses, simultaneous operation and daily operating hours; and the availability of an electrical supply or industrial compressed-air network.
Request a sizing assessment for your booth
Do you need to collect dust or residues inside a painting or coating system?
Describe the implemented coating process in detail, whether powder or liquid, the type of product and resin used, the safety-data-sheet specifications, the nature of the residue to be collected, including dry overspray and sanding dust, the hourly quantities generated, the daily frequency of colour changes, total piping length, any ATEX classification of the department and the preferred collection system, whether a rigid drum or Longopac bag. Our engineering team will assess the correct airflow and vacuum-pressure parameters, filtration class, cartridge-regeneration method and the most suitable conductive accessories. Contact us to configure the ideal extraction system according to your booth and coating process.
Painting and Coating System Solutions FAQ
Which industrial vacuum cleaner should be used for powder coating?
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The choice depends on the quantities, layout and zone classification. In non-classified areas, FEVI models with automatic cartridge cleaning can be considered, including the single-phase FEVI 350 ICLEAN, the three-phase FEVI TDC30 ICLEAN for long operating cycles or FEVI HDC 355 ICLEAN for large systems. Compatible ATEX models must be used in classified areas.
Le polveri di verniciatura non polimerizzate sono considerate esplosive?
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Yes. Most organic powders used in coating processes, including epoxy, polyester and hybrid powders, can be highly combustible or explosive when finely divided, airborne and dispersed in the correct concentrations. The risk assessment must always analyse the specific formulation using the MSDS.
Tutte le cabine e i reparti di verniciatura industriale sono soggetti a vincoli ATEX?
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No. Classification does not automatically apply to the entire facility. It depends on the type of substance applied, the actual probability that an explosive atmosphere will form and its duration. Dust-classified Zones 21 and 22 follow different principles and markings from Zones 1 and 2 for flammable gases and vapours.
Un aspiratore certificato ATEX per polveri può essere impiegato per i vapori di solvente?
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No. A marking for dust atmospheres does not determine the unit’s compatibility with solvent vapours or flammable gases, which require separate dedicated ventilation, extraction and chemical-abatement systems. The collected material must always correspond to the machine’s internal certification.
Quale tipo di aspiratore conviene scegliere per agevolare il cambio colore in cabina?
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For limited and localised quantities, compact FEVI PULSE 11XA or FEVI BSL 120 BASIC ATEX 22 models can be considered, subject to verification of the zone and dust group. For industrial volumes, pneumatic FEVI S PN ATEX systems or large three-phase blower units are preferable, combined with dedicated piping and accessories.
L'adozione del sistema di scarico continuo Longopac è utile per separare i colori?
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Yes. Longopac is extremely useful because it allows the collected powder to be isolated, sealed and divided into continuous-bag sections without transfer from a drum. However, to prevent cross-contamination between colours, the flexible hose, vacuum chamber and filters must also be carefully cleaned or exclusively dedicated.
La polvere di vernice o l'overspray raccolti dall'aspiratore possono essere riutilizzati?
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Reuse is permitted only when colour purity, particle size and the complete absence of dirt or cross-contamination satisfy the aesthetic requirements of the process and the manufacturer’s instructions. Material manually collected from the workshop floor must never be considered reusable.
Si rende sempre necessario installare uno stadio di filtrazione assoluta HEPA?
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No. The final filtration class depends on pigment particle size, the chemical composition of the additives and the specific department risk assessment. Where extremely fine airborne dust or toxic components are present, a HEPA filter is a useful additional stage whose efficiency and sealing performance must be verified.
La presenza di un filtro HEPA assoluto rende l'aspiratore idoneo per le aree ATEX?
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No. Microscopic mechanical filtration efficiency, represented by HEPA, and the explosion-protection marking of the structure and motors, represented by ATEX, are completely separate and independent industrial characteristics.
È consentito effettuare le operazioni di pulizia della cabina soffiando con aria compressa?
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The use of compressed air must be strictly limited because it can redisperse fine dust throughout the environment. Where it is necessary to clean complex gaps, the operation must be carried out only while the booth’s extraction and ventilation system is active and operating.
Qual è la differenza fondamentale tra un aspiratore industriale e un depolveratore?
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An industrial vacuum cleaner operates at high vacuum pressure to remove and convey solids and dust deposited on floors or machinery through narrow piping. A dust collector operates at high airflow and low vacuum pressure to capture and remove clouds of lightweight airborne dust through hoods or extraction arms.
Il depolveratore centrifugo FEVI DTX 2500 può essere utilizzato per pulire i pavimenti?
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No. It is not the correct technology or solution. The DTX range consists of high-airflow dust collectors designed to filter large volumes of air and capture suspended airborne dust. Manual cleaning of booth floors using nozzles and accessories requires the vacuum pressure of an industrial vacuum cleaner.
Il modello compatto brushless FEVI BSL 120 è idoneo per raccogliere i liquidi?
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No. FEVI BSL 120 BASIC ATEX 22 is engineered and configured exclusively for collecting and handling completely dry dust and solid residues.
Quando si rende realmente necessario progettare un impianto centralizzato fisso?
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A fixed centralised system becomes necessary when the finishing department contains several booths or coating lines, when cleaning points are far apart, when several operators work simultaneously or when overspray quantities are too high to be managed using mobile units, requiring centralised discharge outside the department.
L’installazione di un aspiratore industriale FEVI elimina al 100% i difetti di verniciatura?
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No. No individual machine can eliminate defects on its own. An industrial vacuum cleaner is highly effective in containing environmental dust and limiting cross-contamination between pigments, but the final quality of the finished workpiece depends on several factors: substrate preparation, the efficiency of the booth air filters, correct electrostatic application, temperature and polymerisation times inside the ovens.
