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.

• 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-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.

• 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

• 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.

Our new die lubrication packages eliminate many of the problems encountered in stamping operations:
• Excessive misting
• Over-application of lubricant
• Inadequate coverage of the workpiece
• Inability to target lubricant precisely
• Excessive tool wear

Designed to deliver the precise amount of lubricant to a precise location, our hydraulic and pneumatic die lubrication packages include:
• Pressure tank
• Valve panel
• Hook-up kits
• Up to 16 automatic spray guns

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.

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.

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.

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

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

• 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:

• Lower operating costs by reducing air consumption costs
• Increase precision and lower costs with precision spray control
• Improve quality with good maintenance procedures
• Optimize the performance of Showers

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.

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

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.

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

Our advantages include:

• Extensive product line – more nozzle types in more sizes, materials, capacities and connections than other manufacturers. Plus a wide range of spray lances and injectors
• Manufacturing facilities around the world equipped with spray laboratories. Spray coverage, flow rate, drop size, spray angle and various quality control tests are conducted routinely and test data is available upon request
• Global manufacturing of silicon carbide and other special materials: We do not rely on outside suppliers to produce our silicon carbide nozzles. Our in-house capability allows us to control delivery and offer more competitive pricing. Hastelloy®, Stellite® and other high performance alloys are material options for most nozzles in addition to a wide range of metals and plastics

Learn more about our products for:

Wet FGD, emergency quench, air oxidation, humidification

Mist eliminator washdown

Dry/semi-dry FGD, chemical injection

Gas cooling/conditioning

Desuperheating steam also requires a high level of precision to ensure the proper evaporation and reduce the temperature of the steam.

In critical applications such as these, our spray performance laboratories and technical expertise are especially important. A wide variety of nozzles can be used:

• High efficiency air atomizing nozzles
• Hydraulic fine spray nozzles
• Narrow spray nozzles
• And more

Depending on the specific requirements of your application, we may recommend drop size testing to determine performance prior to nozzle selection. We may also recommend special materials to ensure long nozzle wear life.

• In-house engineering specialists
• Staff qualified to ASME and AWS standards
• Manufacturing code compliance: ASME B31.1 power piping and B31.3 process piping
• Testing in accordance to ANSI and ASTM standards
• Comprehensive project management and documentation

Recent custom lance/injector projects include:

• Heavy duty desuperheating lances
• Injection quills designed for corrosion inhibition, freeze prevention, NOx control
• Multi-nozzle lances for cooling in towers, ducts, dryers and kilns

Be sure to consult with one of our sales engineers to obtain selection assistance, drop size information, considerations on injector options.

The most recent enhancements to our spray dry nozzle lines include:

• Easy configurability to exact specifications
• Drop size control via the nozzle’s capacity and pressure to minimize powder waste
• Hand-tight design eliminates the need for tools and reduces maintenance time
• Maximum free passage core and cap design to reduce clogging
• New anti-bearding design reduces the risk of contamination and simplifies maintenance
• Integrated check valve to help avoid wetting inside the dryer
• A broad range of carbide options for orifice and core can help improve wear resistance

Special materials and coatings are available if our standard line of tungsten carbide materials doesn’t provide the needed wear resistance required for your application. Be sure to request a consultation.