How Much Extra Paint Does a Spray Gun Use?

How Much Extra Paint Does a Spray Gun Use?

When using a spray gun for paint, you’ll need to have some extra paint on hand to get the job done.

Generally, a spray gun can use anywhere from 20-50% more paint than traditional brush or roller methods. This is because spray guns atomize the paint, breaking it down into small particles that can cover more surface area.

While this may result in a smoother and more even finish, it also means that more paint is required to achieve the same level of coverage.

And it also depends on the type of spray gun that you’re planning to use.

Before you get started, it’s important to make sure you cover everything in your home.  This includes taping off your windows, and remove anything that you don’t want to get ruined.

Even with your best efforts to reduce paint splatter, a spray gun will always leave atomized paint in the air.

Factors that Affect Paint Usage

Knowing what influences paint usage can help you save paint—and money—on your next project. Here are the main factors to keep in mind:

• Type of Spray Gun: Different guns like HVLP, LVLP, and airless sprayers apply paint differently, affecting how much you use.
• Tip Size: The size of your spray gun tip determines how much paint is released per square foot. Choosing the right tip helps control paint flow.
• Surface Texture: Smooth surfaces usually need less paint, while rough or porous surfaces soak up more, increasing usage.
• Type of Paint: Thicker paints like latex or enamel generally require more coverage than thinner ones like stains or varnishes.

Tips for Minimizing Paint Waste With a Paint Sprayer

Here are some tips for minimizing paint waste when using a spray gun:

• Pick a spray gun that fits your project—HVLP guns are often more efficient and waste less paint than airless models.
• Use the right tip size to reduce overspray and avoid using extra paint unnecessarily.
• Practice steady spraying: keep the gun at a consistent distance and speed to get even coverage without wasting paint.
• Strain your paint before spraying to catch any debris or clumps that might clog your gun or cause uneven spraying.
• Clean your equipment thoroughly after every use. Well-maintained gear sprays better and wastes less paint.

Paint Sprayers Vs Roller

Using a paint sprayer, no matter which type you decide to purchase, will always use more paint than a roller.  This is because of atomization.  When the paint is mixed with air inside the gun, it’s shot out of the nozzle is tiny drops. 

Some of those drops won’t make it onto the surface you’re painting.  This is why you mask off all of the things in your area that you want to keep paint free.  That is called paint waste. 

It’s the price you pay for a smooth, professional looking paint job in less time than with a brush or roller.

How Much Spray Paint Do I Need?

It depends on what type of spray gun you have chosen for your job.  This changes the amount of paint you will need to budget for your job.  Does a paint sprayer use more paint than a roller?  You bet it does.  Even with the best paint sprayer, you will use more paint than if you painted with a roller.

So, how much spray paint do you need? What is paint coverage spray vs a roller?  Brushes/rollers 1 can, HVLP sprayers 1.2 cans, Airless sprayers 1.4 cans, and poor spraying technique, 1.5 extra cans.

Application Method	Paint Use Ratio
Brush/Roller	1 Can
HVLP Sprayer	20% More
Airless Sprayer	40% More
Sprayer (Poor Spraying Technique)	Up to 50% More

With An HVLP spray gun, you should plan to have about 20% more paint on-hand than you think you’ll need. This paint budget will make sure you have enough to get your spray painting done.

Most folks use their HVLP spray guns outside for painting exteriors or fencing. 

A standard ratio for using this an interior paint sprayer vs a roller, is about 1.5 cans of paint to 1 can of paint.  But depending on how much PSI you use, your ratio could be 2:1 or even 3:1 on a windy day outside.

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With an airless paint sprayer,  you will use 40% more paint than if you brushed or rolled.  That means 40% of the paint that you’re spraying ends up somewhere else besides your paint surface.

Poor spray painting techniques can increase this ratio to 50/50.

Is it better to roll or spray paint?

Spraying paint gives you a smoother, more even finish that dries faster—perfect for a professional look. Rolling, on the other hand, is more budget-friendly and uses less paint, but it can leave behind streaks, uneven coverage, and takes longer to dry.

Does a paint sprayer use more paint than a brush?

Yes, paint sprayers tend to use more paint because they atomize it—mixing paint with air—so some paint floats away and lands on unintended surfaces. With a brush, nearly all the paint goes straight onto your project, making it more efficient in that sense.

How many square feet does a gallon of paint cover when using a sprayer?

Coverage depends on the type of sprayer and your skill level. Airless sprayers usually have more overspray, so you might cover fewer square feet per gallon. HVLP sprayers create less overspray and can stretch your paint further. Generally, expect about 35 to 40 square feet of coverage per gallon when spraying.

How much Spray Paint does an HVLP Spray Gun Use

High Volume Low Pressure (HVLP) spray guns are fairly comparable to brushes and rollers in the amount of paint that they use.

This is because the flow result is very predictable and you’re usually within 10-12 inches of the surface being painted.  Painting closer to the surface reduces the amount of paint pollution that you put into the air.

With this type of spray gun, you should plan to have about 20% more paint on-hand than you think you’ll need.

High Pressure Spray Guns Work Best Outdoors 

Using a high pressure spray gun with an air compressor atomizes a lot of paint into the air.

You can avoid some paint waste by using a gravity-style paint gun, which accepts the high pressure rate.  But this is an added cost to your tool investment.

This type of spray gun tends to have a premium price point and can cost up to 4x more than your basic paint sprayer.

Airless Paint Sprayers: How Much Spray Paint do They Use

Airless paint sprayers are great for work that needs to take place above your head – such as with a ceiling.

With this type of sprayer, up to 40% of the paint that you’re spraying from the gun is going to end up somewhere else besides the surface you’re painting.

You will also need to make sure your spray gun tips are in good working order. You can multiply your paint use by 2-3x just because you’ve got a blow tip or one that has been overused.

Remember that backrolling may also be necessary to even out the coat of paint that has been sprayed onto the surface.

Keep these tips and ratios in mind before you get started and you’ll be able to save time on your project even if you are using a little extra paint.

Conclusion

While spray guns may use more paint than traditional methods, they can also provide a higher quality finish and save time. By understanding the factors that affect paint usage and following proper technique and maintenance, you can minimize paint waste and achieve the best results for your project.

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