Why Choosing the Right Spray Nozzle Matters

Every application requires the right angle, droplet distribution, and coverage when it involves spraying liquids. When you have the right spray nozzle, it ensures that the liquid reaches the desired surface to do a particular job.

The wrong nozzle may provide uneven coverage, which would require another round of spraying. This issue creates liquid waste and increases operational costs for the company. The nozzle should not only be designed to handle the liquid that you are spraying, but also to spray it efficiently where you can conserve liquid and boost productivity.

Using the following spray nozzle selection guide allows you to better understand the types of nozzles available and what to consider when making a choice.

What are the Different Types of Spray Nozzles

Spray nozzles are categorized by the type of spray pattern that is created with the liquid. This spray pattern can provide an even coverage depending on the needs of the application. Here are several nozzle products to consider.

Flat Fan Nozzles

Flat fan nozzles provide a flat type of spray pattern much in the shape of a fan or flat triangle. The liquid takes a narrow diameter near the orifice and a wider body as the liquid moves outward. It has a single hole to disperse the small to medium droplets for band spraying. These nozzles are commonly used for cooling, cleaning, or to apply liquids to applications.

Hollow Cone Nozzles

Hollow cone nozzles have a cone or donut shape where the outer diameter ring has the most water flow with an open center. This type of nozzle can create small to medium-sized droplets. Applications that use hollow cone nozzles include cleaning, gas cooling, humidifying, and applying liquids.

Full Cone Nozzles

Full cone nozzles spray in a cone shape much like hollow cone nozzles yet sprays the liquid across the entire diameter for a round impact area. With medium to large droplet sizes, this nozzle is ideal for cleaning, cooling, and liquid application.

Misting Nozzles

Misting nozzles work by pushing out the liquid from the orifice as the liquid strikes a pin. This pin helps to break up the liquid into fine droplets. Depending on the nozzle design, you can create large mist type droplets or finer fog-like droplets. Misting nozzles are commonly used for odor control, scrubbing, humidification, and applying coatings.

Air Atomizing Nozzles

Air atomizing nozzles use a combination of compressed air and liquids to form very fine droplets. This fine spray can be in a spray pattern or cone pattern depending on the design of the nozzle. Companies use these nozzles for gas cooling, lubrication, humidifying, coating, and misting.

Solid Stream Spray Nozzles

Solid stream nozzles will spray liquids directly from the nozzle without being impinged or changed in shape. These nozzles come in different designs and are capable of providing one solid stream or multiple streams at once. These nozzles are ideal for cleaning, liquid application, and cooling.

Factors to Consider When Selecting Nozzle Selection

There are many factors to consider when it comes to picking out a nozzle selection for your industry application. You have to be aware of the spray pattern and coverage, droplet sizes, how the droplets will impact the surface of the application, the flow rates of the liquid, and other factors. These aspects are important, as the wrong nozzle could cause the droplets to not reach the target area or not be compatible with existing equipment.

Droplet Sizes

Droplet sizes are the most important factor for applications. If the droplet size is too small, it may not be effective for certain applications such as cleaning. On the other hand, if the droplet is too big, it could oversaturate the application and cause damage.

Minimizing Spray Drift

In some instances, the spray from the nozzle may drift from the target area of the application. This is considered spray drift. There are a range of different issues that could cause this problem including the environment, boom height, or water pressure. Keeping these situations in mind can help reduce spray drift for finer spray applications that use misting nozzles and air atomizers.

Nozzle Size and Flow Rate

Flow rate is the amount of the liquid that will flow through the nozzle. This can be influenced by a range of factors such as pipe size, liquid pressure, and nozzle height. You want to select a nozzle that can accommodate the desired flow rate for the application. Having the desired flow rate ensures that the desired spray angle for flat cone and hollow cone nozzles are achieved.

Material Compatibility

Different liquids can have a reaction to the materials used for the spray nozzle, especially chemicals. You want to select materials that are durable and long lasting. Some common spray nozzle materials include brass, plastics, ceramics, and stainless steel. Brass is usually affordable for the budget but is the least durable. On the other hand, stainless steel can last four to six times longer.

Best Practices for Nozzle Selection & Use

Calibrate the Sprayer

Calibration helps you to figure out how much spray volume is applied for the application. Calibrating the sprayer allows you to determine the amount that is required so you do not spray too much or too little for the job.

Optimize Droplet Spectrum

Flat fan nozzles that are designed as pre-orifice nozzles help to eliminate movement from the spray pattern that may cause drift. The design of the nozzles lowers the internal operating pressure. This factor results in larger droplets that are even distributed along the application.

Drift Management

Managing drift for spray nozzles can be accomplished in a variety of methods. You can reduce the pressure so that the flow rate creates larger liquid droplets or lower the boom height if environmental factors are causing the liquid spray to move. Another solution includes using an accessory such as a drift-reducing nozzle.

Need Help Selecting the Right Nozzle

Selecting the right nozzle depends on a varying number of factors. If you are unsure about which nozzle to select for your application, contact Lechler for assistance. With our services, we can learn about your project and provide the best advice so you can purchase the right spray nozzle.