In this video, I will show you how to refurbish a 1/4″ NPT No-Drip Atomizing Nozzles with the RBK20 Rebuild Kit.
If you have any questions, you can contact an Application Engineer at 800-903-9247.
In today’s market, the cost of consumable products are on the rise; especially with paints, oils, and yes, even the cost of water. You can help alleviate some of that cost by being more effective in spraying with less liquid. The EXAIR Atomizing Nozzles can accomplish both of these objectives. By using compressed air, the liquid can be sheared into smaller micron-sized droplets. As a reference, if the diameter of a particle is reduced by one-half, this will multiply the number of droplets by eight. With a smaller diameter, it will increase the surface area and coverage of the droplets; thus, requiring less liquid in your application. In combination with a variety of spray patterns, you can accurately target the liquid onto the product instead of around the product. EXAIR manufactures three families of Atomizing Nozzles; Internal Mix, External Mix, and the Siphon Fed. In this blog, I will be focusing on the External Mix Atomizing Nozzles.
The External Mix Atomizing Nozzles are designed, like the name suggests, to atomize the liquid outside the nozzle. This means that the liquid and air streams will not come into contact until it reaches the outward atomizing area (reference photo above). Both the air and liquid supply will have to be pressurized, and they can be controlled independently. This type of Atomizing Nozzle will allow for higher viscous fluids, above 300 CPS, to be used in spraying applications. With the external mixing, it will help to reduce the drying effect of the solution and interrupting the system. EXAIR manufactures these nozzles with stainless-steel construction making them compatible with many different kinds of liquids and can be used in many applications like washing, coating, cooling, quenching, and dust control.
EXAIR carries three different body sizes in 1/8” NPT, ¼” NPT, and ½” NPT ports; so, you can create a light mist or a monsoon. The maximum liquid flow rates through each body size is controlled by the air caps and liquid caps. These caps are easily interchangeable for each body size to modify the spray patterns, control the amount of fluid, and reduce any downtime if cleaning is required. The amount of liquid to be applied is easily adjusted by the inlet air pressure, liquid pressure, and the liquid adjusting stem. So, you can dial in the exact amount of fluid required for your process to eliminate any waste or excess. They have a compact design to mount inside tight areas, and we also carry mounting brackets for easy attachment and positioning. Versatility is very important in saving, applying, and spraying costly fluids, and the External Mix Atomizing Nozzles have it.
To help reduce excess fluid even more, EXAIR has a No Drip option. This patented design is used to keep the expensive liquid from dripping out of the Atomizing Nozzles during off cycles. When the compressed air is turned off, a valve inside the body will create a seal on the liquid side. For delicate applications, the unwanted drips will not occur with the No Drip option to ruin the finish of your product. This option also enhances the function of the External Mix Atomizing Nozzle for intermittent processes. It will keep the liquid inside the body of the nozzle; so, when air pressure is applied, the Atomizing Nozzle will give an instant spray. The minimum air pressure required to open the No Drip valve is 30 PSIG (2.1 bar) for the ¼” NPT and the ½” NPT port sizes, and 20 PSIG (1.4 bar) for the 1/8” port size; still allowing for flexibility in compressed air adjustments. Unlike some manufacturers, there is no need to run a separate compressed air line to operate the no drip function. The External Mix Atomizing Nozzles with the No Drip options can give you the best performance in efficiency, effectiveness, and flexibility without any drips.
If you need to maximize the liquid dispersion and minimize liquid consumption, the EXAIR Atomizing Nozzles are the products to use. Even if you have a viscous fluid, the External Mix Atomizing Nozzles can still shear the drops into a fine mist, saving the amount of expensive consumable oils and liquids. If you have an application involving liquid spraying, an Application Engineer at EXAIR can help determine the correct model for you.
I have been working with a customer from the grain milling industry. They take a grain like corn, and mill it to sizes that range from coarse product like grits to fine product like flour. The customer had a special application where steam was injected into a mixing screw process to add moisture to the grain. Steam can be expensive and dangerous to work with, due to the energy required to make, store, transport and use, along with the high temperatures and pressures involved.
The customer was aware of our products from previous work we had done involving Super Air Knives. He approached me about the Atomizing Nozzles and whether they could be used to replace the steam injection system. We reviewed the process details such as target flow rate, the spray pattern desired, and the available distance from the target we had to work with. We determined that (3) of the EF1030SS – External Mix Flat Fan, each capable of delivering 14 Gallons Per Hour, were the solution. The nozzles would be placed equidistant along the mixing screw, to provide an even delivery of water.
To operate the nozzles, all that is needed is a supply of water, and 3.5-15.1 SCFM of compressed air at 10-95 PSIG. Varying the liquid and air pressure will change the flow rate and pattern size of the spray. Charts are published to help with the set-up and tuning of the nozzles to match the process needs.
The use of the Atomizing Nozzle allows for precise application of very fine droplets. For the External Mix type, droplets sizes of 39 to 57 micron are possible. Smallest droplet size is achieved by operating at higher air pressures and lower liquid pressures.
EXAIR also manufactures Internal Mix type nozzles and even a Siphon type, that can operate under siphon or gravity fed conditions (no liquid pump/pressure is required.) Nozzles are available with flow rates from 0.1 to 303 Gallons per Hour, in flow patterns such as Narrow Angle Round, Wide Angle Round, Flat Fan, and 360° Hollow Circular.
To discuss your application and how the EXAIR Atomizing Spray Nozzle can be a benefit at your facility, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.
Fog. Nobody likes driving in it. It’s downright perilous to sailing vessels on the open water, but especially those near the shore, or other watercraft. Flights get delayed or cancelled, stranding travelers in airport terminals far from home, and keeping many from pressing matters that necessitated the speed of an airline flight in the first place. Oh, and it’s ALWAYS where the bad guy is hiding in the movies. You can tell by the ominous low-string music that starts playing right before things get real nefarious.
You know who LIKES fog, though? Greenhouse operators. Their plants get plenty of water to sustain their growth from the well-irrigated soil, but the leaves & petals can wither and get discolored if the humidity isn’t kept at a high level.
The same is true for the parts of a greenhouse that folks don’t see when they’re selecting the annuals to plant on the next nice spring weekend (which we should be coming up on quite soon here!) – like the seed germination chambers. I had the pleasure of helping a greenhouse operator recently, who needed to replace some old, and malfunctioning, nozzles in one of their germination chambers. They were interested in the extremely fine mist that our Atomizing Spray Nozzles produce. After some experimentation with a couple of different flow rates & patterns, they determined that the Model AW1020SS (Wide Angle Round Pattern, Internal Mix) Atomizing Spray Nozzles provided optimal results.
As the fogging systems in their other chambers start to fail, they’ve been replacing them with the AW1020SS’. We shipped them two earlier this week.
EXAIR Atomizing Spray Nozzles offer an incredibly wide range of flow rates, patterns, and adjustability to suit most any application that requires a fine liquid mist. If you’d like to find out more, give me a call.
Caller: Do you sell rebuild kits?
Me: Yes, but…why?
This is a WAY oversimplified summary of the start of a popular conversation that an EXAIR Application Engineer might have with a caller looking to restore a particular product to proper operation. Truth is, most of our products have no moving parts, and if you supply them with clean, dry air, they’ll run maintenance free, darn near indefinitely. We’ve documented this in specific cases regarding a Reversible Drum Vac from 1999, a Vortex Tube from 1987, and a Cold Gun from 1985.
Caller: So…DO you sell rebuild kits?
Me: Yes, but…only when necessary.
It’s important to note that none of the products mentioned above needed any parts replaced to return to service. Sometimes, a good cleaning is all that’s required. We can help you with a video tutorial if you want to know how to restore a Reversible Drum Vac, an Air Knife, or an Atomizing Spray Nozzle, for instance. And we’re making new videos all the time for product maintenance, operation, tips & tricks, etc.
Caller (again): So…you DO sell rebuild kits?
Me: Yes, of course! I mean, who wouldn’t sell rebuild kits for their products?
Take our Safety Air Guns, for example. We offer Service Kits, if the trigger and/or internal valve of a Soft Grip or Heavy Duty Safety Air Gun starts to wear or leak, it’s super easy to replace. We’ve also got replacement springs for the “fail shut” feature of the ball valve of a Super Blast Safety Air Gun. Just about anything else that could be wrong with a Safety Air Gun’s performance can be addressed by cleaning the nozzle.
We also recently added Rebuild Kits for our Atomizing Spray Nozzles to inventory. These contain all of the seals (and moving parts, for the No-Drip models) to restore an EXAIR Spray Nozzle to rated performance.
For other products, we can also provide replacement gaskets & seals for the Reversible Drum Vac & Chip Trapper products, O-rings for the Line Vacs, Chip Vacs, and Heavy Duty Dry Vacs, new elements for Filter Separators & Oil Removal Filters…just to name a few.
Bottom line: if your EXAIR product isn’t performing the way it used to, give me a call. It will be my pleasure to help you get it working like new, so that you can continue to get the most out of it.
Five years ago, I wrote a blog about my (then) 11 year old son’s first-ever week away from home at Boy Scout Summer Camp. He’s departing again this weekend, but his troop has decided to venture “out of Council” this year, to Camp Howard W. Wall…it’s on the south coast of the island of St. Croix, in the US Virgin Islands.
They met last week to cover the final (and finer) details of international travel, flight schedules, logistics, etc., and activities…Camp Friedlander has a “blob:”
But Camp Wall has an OCEAN:
I’ve been thinking a LOT about the changes I’ve seen in the wide-eyed kid I dropped off at a camp that I drive past twice a day, and the smirking teenager that I’m driving to the airport on Sunday morning. And those changes are providing perspective on not only how fast those five years have passed, but how much can happen in that span.
In 2011, I was a wide-eyed “Dread Newbie” at EXAIR. One of my very first meetings with the rest of the gang was to be trained on our brand new Atomizing Spray Nozzles…we only had three styles to choose from, but two of them came in four distinct models, and one came in FIVE. They were ALL Internal Mix, because hey, who doesn’t like the maximum range of adjustability that comes with being able to vary your flow rate and spray pattern size by adjusting liquid AND air supply pressures?
OK; it turns out that was just the beginning…within the year, our Engineering Department had developed:
External Mix – three styles, thirteen distinct models, to allow for independent adjustment of flow rate (by liquid pressure) and spray pattern (by air pressure.)
Siphon Fed – two styles, seven distinct models, that could be siphon OR gravity fed, for situations where it’s not practical to pressurize the liquid supply.
And, four years after that, looking back, it seems like THAT was just the beginning…we now have:
*Two sizes – the original 1/4 NPT and the new(er) 1/2 NPT.
*Sixteen styles – each available with our No-Drip option (so technically I guess we have thirty-two)
*Forty-five distinct models – we’ve got a flow rate/spray pattern combination for just about any application
And, like the rest of our catalog products, they’re all in stock, ready to ship today, on time, like we do 99.97% of the time…that’s actually one thing that HASN’T changed in the 17 years that we’ve been keeping track.
If you’d like to talk about Spray Nozzles…or any EXAIR products (old or new,) give me a call.
Atomizing spray nozzles atomize fluids to create a fine spray in a variety of patterns for a variety of uses. They are commonly used to mark products, paint or coat, cool, reduce dust, lubricate and clean parts.
With the numerous types of Atomizing Nozzles sold by EXAIR, it can be challenging to shift through all the information. We can help you to narrow down the field to quickly find the correct Atomizing Nozzle for your application. In a summary, here are the basic questions that need to be answered:
1.) Are you using a pressurized liquid feed?
2.) What is the viscosity of the fluid?
3.) What is the liquid feed rate in gallons per hour (gph) or liters per hour (lph).
4.) Should I use the No-Drip option?
EXAIR’s flow chart with easy-to-follow steps will walk you through the decision tree and land you at the best Atomizing Spray Nozzle for your application. In answering these simple questions, this chart will guide you to the correct page in our current catalog to get additional information and specifications. Click on Link below to determine the best nozzle for you.
When it comes to spraying a fine mist, EXAIR has a great range of Atomizing Nozzles. If you follow the flow chart, you will get the best product to spray your liquid and reduce waste. If you have any problems or questions, you can contact one of our Application Engineers at EXAIR.