Spray Nozzles, Nozzle Experts

Five Reasons to Visit Spray.com

admin — Tue, 24 Jan 2012 14:49:48 +0000

You’ll find our recently updated website easier than ever to use. You’ll also find new, helpful resources that can help you optimize your spray operations.

Five Reasons to Visit Spray.com

Download valuable white papers on spray technology that address ways to reduce air and water use, minimize clogging, improve efficiency, increase throughput and more. Whitepaper Library
Watch videos of the latest advances in spray technology. Our video library includes tutorials on Pulse Width Modulated (PWM) flow control, precision coating with viscous liquids, effective removal of stubborn residues with high-impact tank cleaning equipment and more. Video Library
Use our online tools to speed calculations on flow rate, spray coverage, pressure drop and more. SprayWare Tools
Update your reference files, request technical seminar information, schedule an on-site evaluation and more. Tell us what you need and we’ll send you a customized package. Information Center
Subscribe to email updates about spray technology. We send out product and technology news on a regular basis. Don’t miss out – subscribe today to make sure you are informed about new advancements on a regular basis. SprayNews

There’s much more – product animations, computational fluid dynamics models showing the effects of gas flow on spray performance, schedule of upcoming events where our products will be on display, online ordering and more. Why not visit today and make sure you have the latest information on spray technology for your operations?

Six Strategies to Reduce Water Consumption – Strategy 2 and 3

admin — Mon, 12 Dec 2011 11:56:42 +0000

Nozzles made from harder materials generally provide longer wear life. Standard materials are brass and stainless steel but more durable spray nozzles are available in speciality materials like HASTELLOY®, in various carbides or with ruby orifices.
A synthetic ruby orifice is frequently used for web trimming because it provides superior spray precision for a sharp, crisp edge and up to 2000 times greater wear resistance than brass. In addition, the stream remains steady even in the early stages of wear.

Worn nozzles are a common problem in the manufacture of Pulp & Paper. Determine the optimal maintenance schedule based on the specifics of your opperations.
Replace worn nozzles regularly. The cost of replacing nozzles is a lot less than the costs of wasted water or chemicals.

A comprehensive nozzle maintenance program will help ensure trouble-free performance of your spray system as long as it is performed properly and routinely. Since this is a critical step in spray system optimization, we offer nozzle maintenance workshops and nozzle audits as a service to our customers. Workshops typically include a review of the customer’s current program and recomendations for improvement, on-site inspection of spray nozzles and training of maintenance personnel.

PWM Flow Control

admin — Sun, 04 Dec 2011 19:34:55 +0000

Pulse Width Modulation (PWM) Enables Flow Rate Control Without Changing Spray Pressure

Benefits

Flexibility: Achieve a wide range of flow rates with a single nozzle
Immediate flow adjustments: Using AutoJet spray controllers, response time of electrically-actuated PulsaJet spray nozzles is almost instantaneous
Reduced clogging: Maintain low flows even with large spray orifices for improved reliability and reduced maintenance
Reduced misting: Low flow operation using larger orifices at low pressures reduces the misting common at higher pressures and improves transfer efficiency and safety
Uniform coating/improved quality: Constant pressure operation prevents variations in spray angle and drop size for more even coating over a wide range of flow rates

PWM Food Processing

Examples of PWM Flow Control Applications in Food Processing:

Spraying flavors or oils onto bread, pastries and rice cakes
Surface coloring with egg coating, milk protein, or caramel
Moistening dough with water to maintain proper consistency
Misting bread with water to improve seed adhesion
Spraying food ingredients onto products or into trays
Spraying water on hamburger patties, vegetables and pizza prior to freezing to maintain proper weight
Spraying antimicrobial agents onto meat & poultry for food safety
Spraying sunflower oil on peanuts
Spraying aroma onto coffee and other food products

What You Need for PWM Flow Control

A fast spray nozzle
Electrically-actuated PulsaJet nozzles achieve speeds up to 10,000 cycles per minute and are ideal for PWM flow control. PulsaJet nozzles also offer accurate spray placement, excellent spray pattern integrity and a choice of hydraulic or air atomizing spray tips.

A spray controller–plus software
AutoJet Technologies offers a wide range of spray control options for manual or automated PWM flow control
regulation. Basic versions offer PulsaJet nozzle control with manual flow adjustment and advanced versions
provide total automation, optional spray detection/verification and more.

Spray knowledge
Effective PWM flow control requires a strong knowledge of how liquids flow and how spray nozzles work. Turning a spray nozzle on and off very quickly is not enough.

Spraying Systems Co. is the global leader in spray technology. Spray nozzles, turnkey spray systems, custom fabrication and research/testing services comprise the company’s offering. Spraying Systems Co. has ten manufacturing centers and more than 90 sales offices around the world. More information is available at www.spray.co.za or by contacting the company directly on +27 11 6183860 or grant@monitorspray.co.za

Spraying Systems Co opens Durban office

admin — Sun, 04 Dec 2011 08:44:28 +0000

Monitor Engineering based in Johannesburg, sole importers of Spraying Systems Co’s range of spray nozzles, spray controllers and custom spray systems has opened an office in Durban and will no longer soley be working through agents in the KZN region. Due to the changing nature of the company’s extensive product range from supplying just spray nozzles to sophisticated precision spraying equipment, the company feels that expert application assistance and product knowledge is required to assist customers in this region – specifically with the Autojet and Spray Analysis range of products. Autojet Technologies is the turnkey systems division of Spraying Systems Co. and supplies a range of patented spray controllers and top quality spray products, high speed automatic spray guns ,spray lances and manifolds that are engineered for precision spraying ,saving chemicals and water , minimizing manual labour and improving product quality.

Our Spray Analysis division operates the industry’s most sophisticated spray research laboratory. We have the ability to conduct Computational Fluid Dynamics(CFD) ,proof of concept tests, quality control tests, and design prototypes for new product development.

Monitor Engineering has represented Spraying Systems Co. in Southern Africa for over 45 years, supplying spray solutions to industries like food and beverage, pharmaceutical, automotive, chemical, petro-chemical, refinery ,paper, steel, mining and general manufacturing. Our product range includes standard spray nozzles, tank wash and air nozzles, air knife blower packages, lubrication systems, heated systems for spraying viscous liquids like chocolate, custom made spray injectors and Quills for Refinery applications and shower nozzles and headers for the Pulp & Paper industry and a variety of other standard spray products. Our tank wash range of products has expanded so rapidly over that last 6 months that we felt the need to have a dedicated website just for the tankwash market, www.tank-cleaning.co.za

Spraying Systems Co. is the global leader in spray technology. It has the broadest product range in the industry, ten manufacturing facilities and sales offices in more than 85 countries. Spray nozzles, turnkey spray systems, custom fabrication and research/testing services comprise the 70-year-old company’s offerings.

For more information visit www.spray.co.za or contact us on grant@monitorspray.co.za

Six Strategies to Reduce Water Consumption – Strategy 1

admin — Thu, 10 Nov 2011 13:53:55 +0000

At the heart of all spray operations in your mill, is the spray nozzle. It is the component that determines performance in moisturizing, cleaning, lubricating, edge trimming, bleaching, knock-off, gluing and dozens of other applications . Worn nozzles can raise water consumption drastically.

The cost of using nozzles worn by only 15% in your mill can increase by thousands of Rands.

At Spraying Systems Co we have developed 6 strategies to help you save water, chemicals and energy in your mill.

Flow

Centrifugal pumps: Monitor the readings of your flow meter to check for increases in flow.
Use a calibration vessel to measure the flow of a nozzle for a specific time at a specific pressure.
Compare the readings with the manufacturers catalogue or compare them with the same tests conducted on a new nozzle.

Positive displacement pumps: In applications using positive displacement pumps, which provide the same capacity regardless of pressure, the spraying pressure will decrease as the nozzle orifice enlarges. Lower spray velocities and spray impact will result.

Pressure at showers and nozzles

Centrifugal pumps: Monitor for increases in volumes of liquid sprayed. The pressure of the spray could decrease.

Positive displacement pumps: Monitor gauges to detect any drop in pressure and reduction on the impact on surfaces sprayed. The volume of the sprayed liquid may remain the same. Also monitor for any increases in pressure which could be caused by blocked nozzles.

Drop sizes

As nozzle orifices wear, the liquid flow increases or the spraying pressure drops, resulting in larger drop sizes. Larger drops result in less total liquid surface area.
Actual drop size

Impact

Check for premature wear of the felt or any other related problems. In applications with centrifugal-type pumps, impact may actually increase because of the increased flow through the nozzle.

Spray Pattern

Visually inspect the spray pattern to detect any changes in uniformity.
Streaks and heavier flows in the centre of the pattern, accompanied by a decrease in the effective spray angle coverage typify deterioration.
Measure the width of the spray over the surface sprayed.
If the nozzle wears gradually, you may not be able to detect any changes until a significant increase of flow is evident.

Spray patterns of both tips show little difference. Spray collection in tubes gives dramatic evidence of 15% increase in capacity.

Air Knife Drying Packages Eliminate Compressed Air Use in Drying and Blow-Off

admin — Fri, 04 Nov 2011 13:11:22 +0000

WindJet Air Knives powered by energy-efficient regenerative blowers provide excellent performance in drying and blow-off operations and eliminate the need for costly compressed air. Operating costs can be reduced by as much as 95 percent when the packages are used in a wide range of operations including debris and dust blow-off, removal of excess water and moving products.

WindJet Air Knives feature a unique 1/8″ leading edge along the length of the knife to direct a consistent and controlled air stream that retains its integrity further downstream and eliminates spotting and blotching. The air stream produced by the knives entrains ambient air to increase the total volume of air and maximize drying and blow-off efficiency.

Unlike other blower types, the regenerative blowers included with the packages are rugged, reliable and require infrequent, minimal maintenance. Plus, no sound enclosure is needed because the blowers provide low noise operation. Each air knife package is customized for the application. Air knives are available in lengths from 6” to 36” and two air slot sizes, .040” and .060”. Regenerative blower assemblies are available from 5.5 to 30 HP. Packages include pressure relief valve, pressure gauge, air inlet filter, filter monitoring gauge, vibration dampener, fittings and mounting adapter.

New Spray Nozzle Catalogue for Paper Industry

admin — Wed, 13 Jul 2011 14:53:27 +0000

Pulp and Paper Industry Catalog, 66A, has just been published by Spraying Systems Co. This 108-page catalog includes detailed information, including performance data, on a wide range of showers and spray nozzles widely used by paper mills around the world.

In addition to product information, the catalog includes a technical reference section and specification guidelines to help users select the best products for specific applications. Another section addresses spray optimization and provides tips to ensure trouble-free operation once equipment is installed.

Showers, shower nozzles, web trimming nozzles, air atomizing and automatic nozzles, black liquor nozzles, stock chest cleaning equipment, air nozzles and air knife packages are just a few of the product lines included in the catalog.

Pulp and Paper Industry Catalog can be requested or downloaded at www.spray.com/papermaking

Spraying Systems Co. is the global leader in spray technology. It has the broadest product range in the industry, ten manufacturing facilities and sales offices in more than 85 countries. Spray nozzles, turnkey spray systems, custom fabrication and research/testing services comprise the 70-year-old company’s offering.. More information is available at http://www.spray.co.za or by contacting the company directly at grant@monitorspray.co.za or +2711 6183860.

Reduce oil consumption by up to 90 percent

admin — Thu, 17 Feb 2011 07:31:56 +0000

Our AutoJet® Lubrication Systems provide a highly efficient method of applying lubricants and corrosion protection fluids on bands (coils) and blanks as well as wire or other type of materials in pressing and stamping operations.

Reducing production costs and operating efficiently are important considerations. So is finding the right lubrication system. As the world leader in spray technology, we can help you find the system for your process.

The L210 AutoJet Lubrication System is designed for low-viscosity solutions and is typically used with hydraulic spray nozzles.

The Type P400 System is used in processes with high-viscosity lubricants up to 600 centistokes (mm2/sec) being sprayed with air-atomized spray nozzles, the unique features of the systems ensure that you will not run any risk of polluting or creating any oil mist.

Features & Benefits

Exact metering of the lubricant guarantees absolute repeatability:
L210: precise indexing of pumps
P400: precise air pressure control
Optimum distribution of the lubricating fluid on the coil (top, bottom, both sides)
Easy to maintain due to pneumatic lifting cylinders
Quick and easy assembly
No misting or pollution of the work environment
Optional installation of additional nozzles for spot lubrication of critical points
Solenoid valves direct the return flow of different lubricants to the proper container
Surplus amounts of lubrication oil remain in the coil lubricator and are returned to the supply container
Containers are non-pressurized and can be filled during operation
Effective full-flow filters guarantee that no contaminants are allowed to enter the pump or the nozzles
Easy change-over between various lubricants

Automate Tank Cleaning totes, vats and vessels

admin — Wed, 08 Dec 2010 13:57:10 +0000

If tank cleaning in your facility involves filling and draining or manual cleaning, there’s an unneces-sary profit leak in your plant. There are dozens of ways to automate cleaning of tanks of all sizes and all of them will significantly reduce:

Cleaning time
Manual labor
Water, chemical and energy use
Wastewater disposal costs

Tanks will be cleaner and returned to service more quickly enabling increases in production time. Operating costs will be lower and profits will be higher.

Savings of $50,000 per tank aren’t uncommon. Most plants have multiple tanks, so it is easy to see how automating cleaning of multiple tanks can save hundreds of thousands of dollars per year by reducing operating costs and increasing production time.

Selecting the right automated tank cleaning product primarily depends on:

Tank size
Level of impact required to remove the residue in the tank
The chemicals used for cleaning and the temperature of the cleaning liquid

Options include spray balls, stationary tank cleaning nozzles, high-impact fluid-driven units, motorized tank cleaners and fully automated tank cleaning systems. Ask your tank clean¬ing equipment supplier for a no-obligation on-site evaluation to determine which solution is best for your application and to provide a pay-back analysis. The evaluation is usually free and is an efficient way to get the automation process started.

Reduce your operating costs by adding a spray controller.

admin — Thu, 18 Nov 2010 14:46:22 +0000

If variations in your spray operations affect the quality of your product or process, you can reduce your operating costs by adding a spray controller. Adding spray control usually yields these benefits:

Reduced use of costly chemicals, water and energy
Reduced manual operation and monitoring, freeing workers for other tasks
Reduced maintenance time by minimizing or eliminating overspray and misting
Reduced scrap through improvements in quality
Reduced downtime for set-up and batch changes

There are many spray control options available:

Fluid delivery systems that include standard pump and motor sets provide can optimize the performance of a wide range of nozzles including tank cleaning nozzles
Basic spray controllers provide precise on/off liquid and air control for automatic spray nozzles
More sophisticated controllers provide advanced timing control to optimize the performance of automatic spray nozzles, electronically monitor pre-set spray variables in real-time and offer advanced fault monitoring to alert operators to problems. Some can be pre-programmed to monitor and automatically adjust spray performance based on process variables such as conveyor speed, temperature and batch control
Fully automated systems are available for advanced spray operations such as gas cooling, lubrication, panel board spraying, antimicrobial application, coating with viscous fluids and more.

Reductions in operating costs will obviously depend on your spray application and the level of spray control selected. Often, the cost of adding spray control or a fully automated system can be recouped in just a few months.

Here are just a few examples of how manufacturers are using spray control to lower operating costs:

Meat processors are applying precise doses of antimicrobials onto meat and/or into packaging prior to vacuum sealing. A spray controller uses a trigger signal from an indexing conveyor to activate the spray. Chemical consumption is dramatically reduced without compromising food safety.

Bakery and snack food manufacturers coat conveyors with grease to prevent products from sticking to the belts. Instead of pouring grease on the conveyors, a simple automated system is used to pull grease directly from a container and coat the conveyor uniformly without any waste or mess. Considerably less grease is used and downtime for maintenance to clean up the excess lubricant is eliminated.

Manufacturers of engineered wood products use automated spray systems to apply release agents to boards and conveyors during processing to prevent boards from sticking to belts, variations in board thickness and bursting. The even application of the release agent has resulted in scrap reduction by as much as 95% and release agent consumption has been cut by at least 50%