Spray Nozzles, Nozzle Experts » Applications

Steelmaking

admin — Wed, 29 Jul 2009 10:34:41 +0000

Research/Testing

admin — Wed, 29 Jul 2009 09:31:40 +0000

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:

admin — Wed, 29 Jul 2009 09:28:48 +0000

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

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

admin — Tue, 28 Jul 2009 09:00:29 +0000

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 Control Nozzles Using Compressed Air

admin — Tue, 28 Jul 2009 08:51:27 +0000

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.

Lubrication Packages

admin — Mon, 27 Jul 2009 10:47:13 +0000

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.

Die Lubrication

admin — Fri, 24 Jul 2009 09:15:34 +0000

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

admin — Fri, 24 Jul 2009 08:48:01 +0000

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

admin — Fri, 24 Jul 2009 08:25:45 +0000

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

admin — Thu, 23 Jul 2009 09:38:52 +0000

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.