Archive for July, 2009

Paint Nozzles/High Pressure

RotoClean® Spray Attachments

RotoClean nozzles provide a quick and easy method of unclogging spray tips without removing them from the spray gun in high pressure and airless painting applications. The RotoClean attaches to the spray gun and includes a tungsten carbide orifice insert which can be rotated 180° by the RotoClean handle to face the opposite direction. This rotation allows obstructions to be blown out the larger opening in the back of the tip as liquid passes through the spray gun. Models are available to fit most airless spray guns.

UniJet® TC Spray Tips

UniJet TC spray tips feature a large tungsten carbide orifice insert for maximum erosion resistance. The tip orifice insert is recessed in a solid stainless steel tip body to protect against damage. They provide a high impact flat spray pattern with feathered edges for even coverage when sprays overlap.

TC spray tips are designed for use with No. 11430 high pressure UniJet nozzle bodies.

RotoClean Spray Attachment

UniJet TC Spray Tip

Steelmaking

Flowline of Steelmaking

Research/Testing

Spray Analysis and Research Services, a division of Spraying Systems Co., was established in 2000 to help solve spray problems and optimize spray performance. Our services help eliminate excess scrap and reduce maintenance and operating costs. Backed by 70 years of experience in spray analysis and working with more than 200 industries, we deliver fast, actionable solutions for real manufacturing challenges.
Operations that require precision spraying typically benefit the most from spray analysis. Chemical, food, pharmaceutical and pulp/paper manufacturers with coating, spray drying, gas cooling and marking applications are among those who utilize our services.
Whether you utilize our consulting, prototyping and/or testing services, you will gain specific, documented information you can put to use immediately. You are under no further obligation to us. If you request further assistance, we’ll refer you to other divisions within our organization for nozzle/system purchase or production. Or, you can choose to implement the solution yourself or contract with others. Once we’ve delivered the solution you need, our role is complete. However, most of our customers use our services on an on-going basis in an effort to optimize spray performance to keep pace with changing process conditions and changing technology.

Tools of Our Trade:

Computational Fluid Dynamics (CFD): Simulate and predict spray performance using actual process conditionsc
Phase Doppler Analyzers: Based on the principles of light scattering interferometry, these point sampling, flux-sensivie instruments are most effective in measuring the drop size and velocity of medium to large sprays
Particle/Image Analysis: measures the size and shape of drops emitted from both opaque and transparent sprays
Laser Diffraction Particle Analyzer: uses light scattering to measure small to medium sprays with a curve-fitting program that converts the light intensity distribution into drop size distribution
Spray Nozzle Patternator: measures spray distribution by collecting the liquid into channels aligned perpendicular to the spray nozzles. This volumetric distribution data is used to determine the optimal spray nozzle height and overlap required in various applications

Additional instruments available in our labs: customized wind tunnel, impact measuring device, laser imaging, AutoJet Modular Systems and fluid handling/mixing equipment.

Spray Lubrication Technology Solutions to:

Reduce misting
Reduce consumption of costly lubricants
Extend die life
Improve quality by reducing scrap
Lower maintenance costs

Spray Lubrication Solutions

The VMAU offers:

Versatility: You select the options and accessories you need to achieve the spray performance required for your application.
Independent control of liquid, atomizing air and fan air allows you to fine tune spray capacity, drop size and spray patterns, reducing overspray and operating costs.
Uniform and consistent spray patterns are assured because of baffling system, air cap placement and O-ring seal.

High Transfer Efficiency (HTE) Spray Set-ups are the next generation of HVLP/LVLP, and are exclusive only to Spraying Systems Co. HTE set-ups provide a much higher transfer rate compared to standard air atomizing nozzles. Transfer efficiencies can reach as high as 85%, spraying at only 5 psi (0.35 bar) air and liquid making HTE set-ups ideal for lubrication.

Our28JJAU Spray Gun Spray is an electrically actuated compact spray gun designed for low pressure applications that require a smaller spray gun. Using lower pressures, exact air/liquid mixtures can be maintained and precise performance results. This makes it easier to attain uniform lubrication.

PulsaJet® 10000
Designed for accurate spray placement and spray pattern integrity in high-speed or low-capacity applications, the PulsaJet 10000 offers many benefits:

High-speed capability enables faster line speeds and increased productivity.
Four models available with up to 10,000 cycles per minute.
Fast on-off operation (pulse width modulation) provides better control of flow rate.
- Pulse width modulation allows a significant reduction in flow by regulating the on/off time that the valve operates. Short pulses of on-time and longer pulses of off-time produce a spray pattern that appears continuous but actually reduces the overall flow delivered to the target surface.
Minimizes overspray and saves costly fluid consumption.

PulsaJet® 10000 and the Model 2250 AutoJet® Spray Controller
When paired with our Model 2250 AutoJet Spray Controller, the PulsaJet 10000 is capable of pulse width modulation at extremely high speeds – up to 10,000 cycles per minute. The Model 2250 Controller provides much faster response times than comparable PLCs – making it ideal for lubrication.

WindJet® Air Knife Packages

Customize a drying package to your exact requirements with ease. We offer everything you need – the air knives, the blowers, and all the accessories.
The benefits of our Air Knife Packages are many:

High performance air knives
Low maintenance, energy-efficient direct drive blower
Clean heated air
Low operating noise – no sound enclosures required
Easy to install
Single-source ordering convenience

Air Knife Drying Packages Using Blower Air

Air Control Nozzles Using Compressed Air

Choose from:

WindJet® nozzles that convert a low-pressure volume of compressed air into a targeted, high-velocity, concentrated stream or flat fan of high-impact air
- AA727 WindJet nozzles produce a flat fan pattern
- AA707 WindJet nozzles produce a round pattern
UniJet® nozzles that deliver a uniform flat spray pattern of air with medium velocity;
FloodJet® nozzles that also provide a flat spray pattern but are suitable for use with air and steam
WindJet Air Guns
WindJet Manifolds
WindJet Air Control System
Accessories including fittings, hoses, magnetic mounting bases and more.

Air Control Nozzles Using Compressed Air

WindJet® Air Nozzles

Air nozzles can help you improve performance, reduce noise and save on air costs in drying, cooling and conveying applications. Options include:

WindJet nozzles that convert a low-pressure volume of compressed air into a targeted, high-velocity, concentrated stream or flat fan of high-impact air
Compact WindJet nozzles with performance similar to standard WindJet nozzles but are just 1-5/8″ long, and ideal to install in spaces with limited space
WindJet variable air amplifiers that deliver a superior amplified air stream for fast drying and blow-off
WindJet manifolds equipped with WindJet nozzles mounted on a pipe to produce a flat fan spray with very high impact

UniJet Blow-Off Nozzles and WindJet Air Nozzles

WindJet air control system for controlling the flow of compressed air to a WindJet manifold
WindJet air gun – handheld air blow-off gun that is ideal for mobile air control applications
UniJet® nozzles that deliver a uniform flat spray pattern of air with medium velocity
FloodJet® nozzles that also provide a flat spray pattern but are suitable for use with air and steam

Lubrication Packages

Excessive misting
Over-application of lubricant
Inadequate coverage of the workpiece
Inability to target lubricant precisely
Excessive tool wear

Pressure tank
Valve panel
Hook-up kits
Up to 16 automatic spray guns

Faster reaction times, better continuous spray performance and lower maintenance due to fewer moving parts are a few of the additional benefits provided by these packages.

You’ll find a wide range of spray nozzles and systems to cover presses of all sizes and lubricants of varying types and viscosities. Your local sales engineer can help you configure the package best-suited to your operation.

Air Atomizing Nozzles

Air atomizing nozzles are among the most versatile of all spray nozzle types and commonly used in many applications such as die lubrication, spray coating, moisturizing, humidification, gas conditioning and dust control.

Hundreds of sizes and styles are available with pressure or siphon feeds, internal or external mix spray setups, a wide range of spray patterns and a variety of materials. All air atomizing nozzles require a liquid line and an air source for the atomizing air. Some versions require a second air line for automatic cylinder operation, clean-out or shut-off.

Be sure to see Automatic Spray Nozzles if you need precise, automated control of intermittent spraying.

Recent additions to our air atomizing line include:

VMAU Anti-Bearding Variable Spray Nozzles reduce the common problem in coating applications of build-up around the air cap and the resulting clogging of liquid and air orifices. A new design prevents drops from falling back onto the air cap and ensures longer clog-free operation
FloMax® air atomizing nozzles produce exceptionally small, consistent drops for efficient evaporative cooling. New smaller capacity versions are now available
Heat Jacket reduces clogs and keeps viscous liquids flowing as they pass through air atomizing nozzles
55400 Valve Package allows electrical components to be mounted separately from the liquid line to extend wear and reduce maintenance

VMAU

55400 Valve Package

Spray Nozzle Accessories

Our full line of accessories can help facilitate nozzle installation and operation, ensure trouble-free performance and extend nozzle life. Choose from:

Strainers to reduce clogging
High-flow self cleaning strainers
Split-eyelet and swivel connectors, ball fittings and couplers to speed installation
Check, shut-off, pressure relief valves and more to regulate flow
Siphon injectors to adjust and lock-in mixture ratios in two-fluid systems
Hoses and magnetic mounting bases for fast, precise nozzle placement
Tank mixing eductor to increase circulation rates of small pumps and prevent settling
Tank wash, air atomizing, air control, QuickJet® and UniJet® system accessories and more

AWT Self-Cleaning Strainer

T-Style Liquid Strainer

AWS Self-Cleaning Strainer

Adjustable Siphon Injector

Die Lubrication

Lubrication applications have unique requirements and specifications. To satisfy specific requirements, a variety of systems, spray nozzles and gun types are available. When choosing spray nozzles and accessories for your application consider:

Your Application Parameters

Using the incorrect nozzle for an application can cause a myriad of problems. Attention must be paid to the spray nozzle capacity, spray pattern and spray distance. Then you must consider the stock size, the lubricant and the process speeds.

Evaluating Nozzles Specifically Designed for Mist Reduction

Consider spray nozzles that are specifically designed to work exceptionally well for controlling mist. Select:

An automatic nozzle with positive shut-off at the spray tip
Low-volume low-pressure (LVLP) air atomizing setup for low-viscosity lubricants
High-volume low-pressure (HVLP) air atomizing setup for high-viscosity lubricants
HTE (high transfer efficiency) nozzle where a larger percentage of spray particles transfer directly from the nozzle to the targeted object
AccuCoat® Electrostatic Chain Lube System that employ positively charged spray droplets that are attracted to the stock’s neutral grounded surface

For information on these and other spray nozzles used in lubrication applications click here.

Setting Up a Maintenance Program

This will help combat inadequate coverage. Worn spray tips distribute too much lubricant. Clogged or damaged tips cause an improper spray pattern. Clean nozzles using proper tools.

Spray Control

Pressurized spray systems offer more consistent, even coverage. A good option for improved coverage control is a turnkey, fully automated system that monitors flow and system operation electronically. Our Die Lubrication system is available in a Pneumatic or Hydraulic package. automatic (air- or electrically-driven) nozzles, manifolds and controllers.

Shower Solutions for Cleaning, Coating, Moisturizing and More

We manufacture an extensive line of showers and have the experience to ensure optimal performance in your operations.

Brush-type showers eliminate nozzle clogging

An internal rotating brush assembly scrubs the interior wall of the shower and nozzle orifices to sweep debris away
Ideal for use with recirculating systems or white water
The brushes operate while showers are in use to maximize machine uptime
Brushes are staggered at 120 degree intervals to allow full system flow
Manual handwheel and automated motor-driven versions available. Existing manual brush-type showers can be easily retrofitted for automatic operation
No operator intervention is needed with automatic brush showers. Cleaning cycles occur regularly via a programmable timer. Dangerous climbing of paper machines is eliminated and personnel can be deployed to other tasks
Manufactured in accordance with Good Manufacturing Practice (GMP).

Choose from various nozzle options depending on shower location and use: DiscJet®, NeedleJet or ShowerJet hydraulic nozzles.

Pipe-in-pipe showers offer added protection

Ideal for use when the shower, feed tubes or nozzles require protection from operating environment and accidental damage
Outer slotted tube encloses a conventional pipe manifold
Inside manifold slides in and out for quick maintenance
Economical alternative to other traditional box-style showers
Easily configure up to three zones for separate control of nozzle sections
Lightweight for easy installation

Can be used with automatic air atomizing spray nozzles with integrated strainers.

Brushless showers – basic and effective

Designed for use with fresh water and operations where nozzle clogging is unlikely
Economical

Can be used with hydraulic nozzles.

Add automatic spray control to enhance performance and simplify operation

An AutoJet® Technologies spray controller can be added to any of our showers to optimize spray nozzle performance, lower operating costs and automate operation. More critical operations such as coating and moisturizing tend to experience the greatest efficiency and performance gains resulting from precise control of our automatic spray nozzles.

Improve Quality with Good Maintenance Procedures

Spray nozzles are designed for long-lasting, trouble-free performance. However, like all precision components, spray nozzles do wear over time. Spray performance can suffer and costs can rise. How quickly wear occurs is dependent on a variety of application specific factors.

Common problems and prevention/troubleshooting tips

Plugging

Very common with use of reclaimed or white water
Nozzles, lines and shower can plug due to debris and long fibers in the water
Use proper water clarification devices
Use strainers
Be sure to specify nozzles with adequate free passage
Conduct maintenance on a regular basis
Use automated self-cleaning showers

Corrosion

Many chemicals are extremely corrosive
Specify nozzles in the appropriate materials: 316 or 304 stainless steel depending on chemical concentration. Avoid iron and mild steel

Scale Build-Up

Control hardness level of the water
Use chemical additives as needed
Conduct maintenance on a regular basis

Slime and Odor

Implement an effective biocide program to control biological growth
Use chemical additives as needed
Eliminate areas with stagnant water
Conduct frequent wash-ups

Caking

Build-up can occur inside the nozzle or on the exterior
Conduct maintenance on a regular basis

Value of good maintenance procedures

If you neglect your nozzles, you’ll watch your energy, water and chemical costs increase. Even slight wear can cost tens of thousands of dollars annually in creased operating expenses. Assess your operations and determine maintenance frequency needed to preserve product or process quality. Good maintenance is an easy and inexpensive way to ensure optimal spray system performance.

Increase Precision, Lower Costs with Precision Spray Control

In many operations such as coating and moisturizing, spray precision is a necessity. Often, the best way to achieve optimal spray performance is by adding automatic spray control.

The benefits of automatic spray control are numerous

Quality is improved through precise and even coating or wetting.
Overspray is minimized – chemical and coating consumption is reduced, worker safety improved and better transfer efficiency is achieved.
Manual intervention is minimized – the controller can receive a signal to detect moisture content, volume of solution being sprayed, line speed or other conditions to automatically make adjustments based on operating conditions.
Inspection and maintenance costs can be decreased – integrated devices can send signals to the controller when flaws are detected, so the marking process can be initiated or clean-out cycles activated and more.
Regulatory compliance and emission control can be improved with automated spray systems designed specifically for pollution control.

Automatic spray control can be achieved by tying into an existing control system, adding a PLC or adding an AutoJet spray controller. AutoJet controllers are designed specifically to optimize the performance of our automatic spray nozzles.

Reducing Air Consumption Lowers Operating Costs

Many mills use pipes with drilled holes or slits for drying or blow-off. This approach is extremely inefficient and consumes high volumes of costly compressed air.

Should you use compressed air and air control nozzles or blower air and airknives?

Here are a few guidelines:

Use compressed air and air control nozzles if:

Your application needs maximum impact
The nozzles need to be more than 4″ (10.2 cm) from the target surface

Use blower air and air knives if:

Your application needs velocity instead of impact
The air knives can be placed less than 4″ (10.2 cm) from the target surface
The oil in compressed air causes quality control problems

Two ways to reduce air consumption

1. Compressed air nozzles

Air control nozzles that sue compressed air convert low-pressure volumes of air into a targeted, high-velocity stream or flat fan air pattern and provide many benefits:

Significant improvements in drying or blow-off by increasing impact on the target
A significant decrease in air consumption compared to open holes or slits in pipes
Reduced noise level

UniJet Blow-Off Nozzles and WindJet Air Control Nozzles

WindJet Air Knife Packages

2. Air knife packages with blower air

Using an air knife in conjunction with blower air produces a uniform, high-volume, consistent air stream along the entire knife length. The result is high-quality, consistent drying or blow-off. Plus the operating costs associated with an air knife package are quite low – even lower than the cost of using air control nozzles with compressed air.

There are several types of blowers available. Regenerative blowers offer several performance advantages:

Lower noise
Lower maintenance
Longer life
Lower operating costs
Operates at lower speeds and achieves lower flows
Fully customized solutions

Optimal Performance in Your Papermaking Spray Operation

Spray nozzles are precision components designed to yield very specific performance under very specific conditions. The performance of your spray nozzles can be affected by other system components such as showers, controllers and accessories. To achieve optimal performance in your spray operations, it is essential to select the proper nozzles and ancillary components as well as establish an inspection and maintenance program.

If your spray system isn’t performing optimally, you could be faced with costly problems like these:

Quality control issues
Unscheduled production downtime
Increased maintenance
Increased consumption of chemicals, water and electricity
Environmental issues

The cost of wasted water alone can quickly amount to tens of thousands of dollars in a spray system that isn’t optimized and experiencing slight degradation.

Learn more about how to:

Custom Design Nozzles

Need a Customized Solution? We Can Help with Everything from Private-Labeling to Design and Fabrication of Nozzles, Lances, Injectors, Headers and More

With more than 87,000 different spray nozzles from which to choose, our standard product line meets the needs of many customers. However, many OEMs and some end-user customers call on us for specialized solutions – which we are able to accommodate with ease. Some of the more common requests include:

Private labeling with unique part numbers
Special materials of construction
Custom maintenance and operating instructions
Special packaging
Design and manufacture of custom devices to ensure efficient liquid delivery to the nozzles and help optimize spray system performance
- Custom spray injectors and lances are often required in special materials, in special lengths and with special connections
- Custom headers and manifolds are frequently needed for applications where nozzle placement and positioning are critical

We also work with customers that are looking for a new way to spray or a nozzle for a unique application. In addition to designing a unique nozzle, we typically build prototypes, fabricate small product runs for testing and conduct the performance testing in our spray labs prior to the initial production run.

If your machinery/equipment or production process requires a spray product that is a little or a lot out of the ordinary, don’t hesitate to ask. We’ll apply our 70 years of spray expertise to efficiently develop a cost-effective solution.

Pressure Wash Nozzles

Optimizing Performance in Pressure Wash Operations

Spray nozzles may seem like a small component in a pressure wash operation, but they can have a huge impact on your profitability. Using the wrong nozzles or worn nozzles can easily cost tens of thousands of dollars annually:

A poor quality wash can results in lost customers
Excessive downtime and increased labor costs can result when nozzles don’t perform properly
Operating costs can escalate from spraying more water and chemicals necessary to do the job
Pump wear and increased energy bills can result as pumping equipment operates at higher levels to keep up with increased flow rates or pressure losses

Full Range of Pressure Wash Products

We offer nozzles that clean faster with less streaking, nozzles that reduce chemical consumption and nozzles that last longer and minimize maintenance time.

WashJet® Spray Nozzles: Available in threaded and quick-connect options, these high-pressure, high impact solid stream or flat fan spray patterns provide uniform distribution. There are several styles from which to choose including MEG/QCMEG, IMEG/QCIMEG and ZMEG/QCZMEG depending on wear life and level of stabilization required
PowerJet® Spray Nozzles: Oscillating solid stream delivers a flat spray pattern that is 50% more powerful at the same pressures than conventional flat spray nozzles
Spray Nozzle Maintenance Program: Learn what causes nozzle wear and how to prevent costly problems from occurring

ZMEG and Quick Connect QCZMEG Spray Nozzles

IMEG Nozzles

PowerJet Nozzlee

Wide Range of Two-Fluid Solutions for Precise, Trouble-Free Spraying in Dry and Semi-Dry FGD Scrubbers

When it comes to effective removal of SOx, NOx and Mercury, the performance of the spray nozzles is critical. Improperly sized drops can cause wetting and incomplete absorption and lead to other costly problems such as excessive maintenance, reduced efficiency of downstream equipment and more.

FloMax® Air Atomizing Nozzles

When tight control of drop size and spray coverage are required, there’s no better choice than our FloMax nozzles. And, that’s why they are quickly becoming the industry standard for removal of a wide range of pollutants.

FloMax nozzles are not traditional air atomizing nozzles. Patented multi-stage atomization processes result in FloMax nozzles producing very small drops using minimal compressed air and energy. These small drops reduce the dwell time required for complete evaporation and reduce the risk of wetting.

FloMax nozzles offer other advantages as well:

Uniform spray pattern
Significantly higher turndown ratios than standard air atomizing nozzles for maximum operating flexibility
High flow rate per nozzle so fewer nozzles can be used
Choice of materials to resist harsh environments – Hastelloy®, Stellite®, reaction-bonded silicon carbide and stainless steels are widely used
Large free passage reduces the risk of clogging and allows use of lower cost water sources such as river water, basins and run-off water
Durable, long-wearing parts require little maintenance. But when needed, maintenance is fast and easy and requires no special tools
Many lance configurations are readily available to simplify installation. Choose from 0°, 45° and 90° lightweight lances are available in standard materials with quick-release or bolt-on flanges and with quick delivery. Adapters, cooling jackets, purge tubes and protective tubes can be added.

Other Two-Fluid Nozzle Options

In some applications, standard air atomizing nozzles can be used and our ¼ J nozzle is often the nozzle of choice. Standard lances for these nozzles are readily available with several connection, spacing and material options.

1/4 J AA Nozzle

FloMax X Nozzle

FloMax A Nozzle

Clog-Resistant FullJet® Nozzles Provide Superior Cleaning of Mist Eliminator Equipment

Uneven cleaning of mist eliminator equipment has serious consequences and yet is a fairly common problem. Hard residue often forms on the blades, reducing the area for the gas to pass through. These restricted openings will ultimately compromise the performance of the scrubber and the mist eliminator. One of the best ways to avoid build up is to use spray nozzles for washdown that provide even, thorough cleaning of each blade.

Our FullJet spray nozzles are ideally suited for washing mist eliminator equipment:

Unique vane design produces a true and stable full cone spray pattern that provides superior cleaning without damaging the blades
Large, free passage design minimizes clogging and helps ensure the integrity of the spray pattern. Reduced clogging also results in less maintenance time
Wide range of material options:
- Molded FullJet nozzles are available in Kynar® or polypropylene with a PVDF vane and offer excellent chemical and corrosion resistance. Capacities range from 2.4 to 26.0 gpm (9.1 to 98.4 l/min) with a choice of three spray angles – 70°, 90° and 120°
- Brass with a 316 stainless steel vane or all 316 stainless steel versions are also available. Capacities range from 1.4 to 58.2 gpm (5.3 to 220 l/min) and 60°, 90° and 115° spray angles

Plastic FullJet

MFP FullJet

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