Custom Lances / Injectors

Not every application can be satisfied by a standard spray header or lance. Special requirements are quite common and can range from special materials/coatings, unique connections, larger size/length or special shapes due to physical limitations.

When a standard lance or header is not available, there are basically three options: 1) build it yourself, 2) find a local fabricator to implement your design, or, 3) have the manufacturer of your spray nozzle design and fabricate a custom solution.

The last option is usually your best option for a variety of reasons. Obtaining a complete solution — spray nozzles and headers or lances — from a single source ensures optimal nozzle performance. It also ensures your headers or lances are designed by a company with expertise in spray technology. And, you have the convenience of working with a single supplier.

Not all nozzle manufacturers offer this service. But, custom fabrication is one of our core offerings. We have the engineers, manufacturing/testing facilities and certifications required for almost every project, along with a proven track record.

In addition to high quality headers and lances, you can expect quality project management from us as well. For projects requiring thorough documentation, we develop a written project plan, handle coordination between all the departments in your plant as needed and provide a comprehensive Data Book so you have all the documentation you need.

So the next time your application requires a new way to connect the nozzle to the spray system, be sure to give us a call. Given our extensive experience, it is likely we’ve completed a project similar to yours. This translates into design and fabrication time savings as well as cost savings. We’re confident you will find our custom design and fabrication services to be a high quality, high value solution.

Visit our Custom Lances/Injectors page for more information.

Historically, control of spray nozzles in most manufacturing plants has been a manual task or handled via a PLC. However, new options from AutoJet® Technologies, our turnkey systems division, have changed the way many plants approach spray system control.

Our new dedicated spray controllers save on programming time with pre-defined, pre-tested control modules that are application specific. Spray controllers are able to optimize the performance of air atomizing nozzles and automatic spray nozzles because they provide very fast response times — up to 10 times faster than PLCs — and have nozzle performance data built in.

If product quality is affected by spraying, or high-cost fluids are being sprayed, the benefits of precision spray control can be significant. The following spray control strategies may help you increase efficiency and improve product quality:

• Closed loop temperature control (constant temperature, fluid pressure varies).
• Closed loop flow control (constant flow rate, fluid pressure varies).
• Open loop pressure control (constant fluid pressure).
• Open loop flow control (constant flow rate with tight tolerances).
• Open loop flow pulse width modulation (constant flow rate and constant fluid pressure).
• Open loop batch control (variable spray parameter for multiple spray applications on a single line).
• Open loop speed control (constant application rate, variable fluid pressure).
• Open loop speed pulse width modulation (constant application rate, constant fluid pressure).

Visit our Automated spray control systems page for more information on how automated spray control systems often pay for themselves quickly through productivity gains and lowering of costs such as labor and production consumables.

Spray Analysis and Research Services, a service of Spraying Systems Co., was founded to help customers find new ways to spray, solve challenging application problems and optimize spray performance. Through our services, we help customers:

• Lower spray system operating costs by reducing consumption of compressed air, water, chemicals and/or electricity.
• Test new concepts to keep pace with regulatory/environmental issues and process changes.
• Reduce maintenance time by identifying alternate spray nozzles or header configurations.
• Enhance quality control and quality assurance to reduce waste.

Our innovative problem solving takes place in our fully-equipped spray laboratories. The largest in the world, our labs are filled with specialized instrumentation for characterizing sprays. If we can’t meet your requirements using a standard solution, our engineers will develop a custom solution. We handle it all — design, prototyping, fabrication and testing to validate performance.

Even if you don’t have an immediate need, you may benefit from an initial meeting. We’ll take a look at your current spraying operation, discuss new applications and offer recommendations/ideas. You and your colleagues may prefer to take advantage of our educational presentation on the latest advancements in spray technology or one of our customized “lunch and learn” sessions. There’s no obligation with any of these options. Consider it a way to learn more about spray technology and ways you may be able to improve spray performance in your application.

Visit www.spray.co.za for more information on spray nozzles and nozzle applications.

If your application requires the use of one or two air knives, you may discover our new WindJet low flow air knives can help you improve quality and reduce your energy costs. These nozzles provide a uniform air flow across the entire length of the air knife for fast drying and blow-off using minimal air.

There are no moving parts, so our WindJet low flow air knives are maintenance free. Plus, noise level is reduced — 69 dBA in most applications. These air knives are ideal for conveyor cleaning, food drying, environmental separation, parts drying/cooling, scrap removal and more.

Visit the WindJet Air Knife page for more information.

Spray technology is advancing quickly. If you’ve been using the same nozzle type for an extended period of time, you may find newer designs available that offer significant benefits such as reduced air or liquid consumption, longer wear life, minimal clogging and more. Here are two of our recently introduced nozzles that may help optimize your spray application.

New Automatic Air Atomizing Spray Nozzle for High-Speed Operation
Our new AA29JAUCO electrically-actuated automatic spray nozzle is specifically designed for high speed, short duration spraying. It can operate as continuous duty or as a high-speed gun cycling up to 1,000 times per minute. Unmatched in versatility and speed, the AA29JAUCO is ideal for food processing, marking, sealing, coating and lubrication applications.

Stainless steel construction, with wetted parts made of stainless steel, Ryton®, TEFLON®, Viton® or PEEK™, ensures long-lasting durability and crisp/clean shut-off. Plus, the AA29JAUCO features a built-in stainless steel clean-out needle that automatically activates during each spray cycle for maximum protection against clogging and our new “threadless” Drip Free™ air atomizing spray set-ups for ease of installation and positive shut-off. The maximum fluid orifice for the AA29JAUCO is 0.08″ (2.0 mm) and has a maximum flow rate of 44.7 gph (169 l/h).

Visit the Automatic Spray Nozzles page for an unmatched selection of Automatic Spray Nozzles and Control Options.

In many applications, the use of anti-bearding spray set-ups can help reduce clogging. These set-ups change the air current around the spray tip to prevent drops from falling back on the nozzle and causing build-up. In some cases, users can run their spray operations up to 20-times longer without shutting down.

The addition of a heat jacket can ensure trouble-free atomization of hard-to-spray liquids such as waxes, adhesives, starches and syrups and minimize maintenance due to clogging. When spraying an extremely difficult solution such as chocolate, an automated system may be required.

Heated automated systems use closed-loop temperature control to ensure liquid temperature is ensured all the way from the tank to the target. The pressure tank and liquid and air lines are usually jacketed or heated to ensure consistent flow rates and clog-free operation.

Dedicated spray controllers can automatically adjust spray performance to compensate for changes in operating conditions. This minimizes clogging in many applications. However, when spray nozzles do clog, it is detected immediately and operators are notified to minimize scrap and lost production time.

A spray system that is not working optimally can very quickly cost your operation tens – even hundreds – of thousands of dollars annually. When nozzles become partially blocked, spraying efficiency is compromised and process and/or product quality typically deteriorate. Scrap, maintenance time and lost production can also quickly escalate.

Simple But Effective Ways to Prevent Clogging
Proactive maintenance is the best way to prevent clogging problems from occurring but even well maintained systems can experience problems from time to time. Most spray systems can be efficiently maintained in good operating condition by manually cleaning nozzles at regular intervals. But a word of caution – only use materials that are much softer than the nozzle orifice surface. It is very easy to damage the critical orifice shape and/or size and produce distorted spray patterns or excess flow. When nozzles become clogged and manual cleaning with the appropriate tools doesn’t solve the problem, try soaking the orifice in a non-corrosive cleaning chemical to soften or dissolve the clogging substance.

Most applications can benefit from adding strainers, which are an easy and economical way to minimize clogging. Strainers, including spray nozzles with built-in strainers, trap larger particles and prevent debris from entering the spray nozzle orifice or vane.

Popular and effective strainer types include:
Integral strainers can often be ordered as part of the nozzle itself and are available in a variety of mesh sizes and materials for standard and quick-connect spray nozzles.

T-strainers and simplex/duplex basket strainers are another option. Most allow a system to be quickly shut down for strainer basket cleaning or change-out. Some can be cleaned on the fly without shutting down the pipeline.