Roller Coated Plates vs. Spray Coated Plates – Which is Better for Your Project?

Why do people always confuse these two types of boards?

In the aluminum sheet processing industry, roll coating and spray coating are two completely different processes. However, many buyers cannot distinguish between them and often make decisions based solely on price. Only after the sheets are installed do they discover problems: uneven color, paint cracks at bends, fading after two years…

This article will help you thoroughly understand the differences between the two.

First, let's talk about the processes: one is 'printing,' and the other is 'spray painting.'

Roller coating , simply put, is like printing newspaper. The aluminum coil is unrolled on the production line and passes under rotating rollers, where the coating is evenly 'rolled' onto the surface of the aluminum sheet. It then enters an oven for curing and is finally rewound. The entire process is continuous, like a flowing river.

Spray painting is like applying paint to a wall with a spray gun. Aluminum panels are hung up one by one, the spray gun atomizes the paint and sprays it onto the panels, and then they are placed in an oven to cure. This is an intermittent process, done one panel at a time.

This difference in manufacturing process determines the fundamental difference between the two types of boards.

Seven dimensions to see the difference between the two

1. Coating uniformity

Roller coating uses machine-controlled roller pressure, resulting in a very uniform coating thickness with an error within ±0.002mm. Spray coating, on the other hand, is greatly affected by manual operation, leading to inconsistent coating thickness and a tendency to produce an 'orange peel' effect (an uneven surface resembling orange peel).

2. Color difference control

Roller coating is a continuous production process; a whole batch of panels is like being cut from the same roll of 'cloth,' resulting in a completely consistent color. Spray coating, on the other hand, is processed piece by piece; there may be color differences between panels applied today and those applied tomorrow, which is especially noticeable on large areas of light-colored exterior walls.

3. Surface flatness

Roller-coated panels have a smooth, mirror-like surface. Spray-coated panels, on the other hand, are difficult to make perfectly flat because the paint is atomized and falls onto the surface.

4. Applicable styles

Spray coating has an advantage in this respect. It can process various irregularly shaped parts, curved surfaces, and carved panels because it is a single-piece process. Roller coating is mainly used for flat surfaces and shallow bends, and it cannot handle complex shapes.

5. Environmental performance

Roller coating boasts a paint utilization rate of over 95%, with virtually no waste. In contrast, spray coating has a paint utilization rate of only 50%-60%, with a significant amount of paint becoming paint mist that dissipates and requires specialized recycling and treatment.

6. Production efficiency

Roll coating is a continuous, high-speed process suitable for large-volume orders. Spray coating is a single-piece process, slower, but more flexible for small-batch orders.

7. Cost

For large-volume orders, roller coating has a more advantageous unit cost. For small-volume orders and irregularly shaped parts, spray coating is more economical.

A table summarizing

So, how do you choose? Here's the situation regarding selecting roller-coated plates:

The project covers a large area (several thousand to tens of thousands of square meters).

High requirements for color consistency

Pursuing surface flatness

Mainly flat or shallowly bent shapes

When selecting a spray-coated panel:

Small project area

It has a large number of irregularly shaped parts and curved surfaces.

Limited budget and low surface finish requirements

No one is better than anyone else; it's just a matter of who is more suitable for your project.

What level of quality can DIXXIN achieve with its roll-coated sheets ? Buyers can rest assured.

Advantage 1: Large scale ensures timely delivery.

DIXXIN has three fully automated roller coating production lines with a daily output of 160,000 square meters . For orders of 20,000 square meters, production can be completed in about a week , which is very important for projects with tight deadlines.

Advantage 2: Stable quality, every batch is tested.

Our roller-coated plates have a coating uniformity controlled within ±0.002mm, a color difference ΔE ≤ 0.5 (imperceptible to the naked eye), and show no paint peeling during T-bend tests from 0T to 3T. Each batch of products is tested, and the data is traceable.

Advantage 3: The entire process, from base material to finished product, is controllable.

We use our own Luoyang Yuxin primary aluminum coils, avoiding recycled waste . The coating uses high-quality fluorocarbon or polyester paint with a fluorine content of no less than 70%. From aluminum coils to finished products, everything is completed in our own factory, without any outsourcing.