EXAIR Atomizing Spray Nozzles for Coating, Cleaning, Cooling

A recent customer in the automation / tool making industry had a need to spray a mold release agent onto some specialized tooling. Originally, the customer had planned to use some sort of pressurized sprayer. After some initial tests to prove the concept, the customer found that the moving mechanical parts of the sprayer became fouled by the release agent. And cleaning the internal parts was not easy to do.

No Drip Atomizing Nozzle
No Drip Atomizing Nozzle

In their search for a more permanent solution, the customer came across EXAIR Atomizing Nozzles. After going through some application type questions to narrow the focus down to one model, we determined that the customer would be best served by model AF1010SS (Internal Mix, Flat Fan Pattern Atomizing Nozzle). The customer had a couple of questions about the nozzle in order test the product.

  1. Is it possible to disassemble the nozzle and clean it completely? The answer is yes, the Atomizing Nozzles can be completely disassembled to allow for cleaning, maintenance or replacement of worn parts.
  2. Are the nozzles solvent resistant? The answer is also yes; the Atomizing Nozzles are made of AISI303 type stainless steel and can be cleaned with any normal solvent based cleaner.

Earlier in this article, I mentioned that we went through some application type questions. Here is a list of general questions that we normally ask a customer about their application in order to determine which in our selection would be best suited.

  1. What is the volume of liquid flow (G/Hr) needed for the application?
  2. What is the viscosity (cP) of the liquid being applied?
  3. What are the required spray pattern, size and shape required?
  4. Is the liquid under pressure (by pump or pressure pot)? If so, what is the liquid pressure?
    1. Side note: we have options for non-pressurized liquid by using our siphon fed nozzles.

If you have an application where you have a liquid that needs to be applied in atomized form to a target, or perhaps a humidification application, please give EXAIR Atomizing Nozzles your consideration.

Jordan Shouse
Application Engineer

Send me an email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

Siphon Fed No-Drip Atomizing Spray Nozzles

With 142 distinct models in stock, the Atomizing Spray Nozzles are easily EXAIR Corporation’s most diverse product line. If you need a reliable method of creating a fine mist of liquid flow with a flow rate as high as 303 gallons per hour (or as low as 0.1 gallons per hour,) with a spray pattern as large as 13 feet (or as small as 2-1/2 inches) in diameter, look no further – we have a spray nozzle for you, on the shelf and ready to go.

Siphon Fed models are the subject of today’s blog – they don’t require that the liquid be under pressure; you can feed them from the vessel the liquid comes in from a siphon height of up to 36 inches, or, for higher flows, from a gravity height of as low as 6 inches.

EXAIR Siphon Fed Nozzles work with non-pressurized liquids, either siphoned (left) or gravity fed (right.)

All Atomizing Spray Nozzles are available with EXAIR’s patented No-Drip option, which positively shuts off liquid flow when the compressed air supply is shut off.  One benefit of this is realized in coating applications, where an errant droplet of liquid would mar an otherwise smooth, even coating.  Operationally, though, it also means you can precisely turn the liquid flow on & off, in short, quick bursts, up to 180 times a second.

By far, the simplest way to do this is with a valve installed in the air supply line to the Atomizing Spray Nozzle.  A manual 1/4 turn ball valve works fine if you want the operator to control it.  Solenoid valves are often used to automate the process, and if you’ve got something to open & close the valve, you’re all set.  For example, if you want to spray coolant onto a cutting tool, just wire the solenoid valve into the on-off switch of the machine, like in the example shown to the right.

Alternately, our EFC Electronic Flow Control System provides a ready-to-go solution.  It comes pre-wired; all you have to do is plumb the valve into the air supply line and plug it in to a 120VAC grounded wall outlet.  When the photoelectric sensor “sees” the part you want to spray, it opens the valve.  When the part passes, it shuts the valve.  Easy as that.

I like this whole video, but if you just want to see the EFC Electronic Flow Control & Atomizing Spray Nozzle in action, skip to the 4:05 mark.

If you have a need to spray a fine, controllable liquid mist, EXAIR has a wide range of solutions.  Give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
Visit us on the Web
Follow me on Twitter
Like us on Facebook

EXAIR Siphon Fed Air Atomizing Nozzles: Overview

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 when spraying these liquids.

The EXAIR Atomizing Nozzles can accomplish this by using compressed air to shear the liquid into small micron-sized droplets.  By reducing the diameter of a particle by half, this will multiply the number of droplets by eight.  This will increase the surface area and coverage of the droplets; thus, requiring less material in your application.  EXAIR manufactures three families of Atomizing Nozzles; Internal Mix, External Mix, and the Siphon Fed.  In this blog, I will cover the Siphon Fed Atomizing Nozzles that EXAIR manufactures.

When no liquid pressure is available, the Siphon Fed Atomizing Nozzles will create a vacuum to draw the liquid into the nozzle.  This action is done by the unique design of the air cap.  As the velocity of the air passes through the air cap, a low pressure is created by a venturi.  The Siphon Fed Atomizing Nozzles can draw liquid from a suction height of 36” (91 cm), or it can be gravity fed from 18” (46 cm) away.  They are manufactured from stainless steel for durability and corrosion resistance.  The Siphon Fed models can spray viscous fluids up to 200 centipoise, and are 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 rate through each body size is controlled by the air cap and liquid cap.  A unique feature of the EXAIR Atomizing Nozzle is that the 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.  Here is a video that shows how this can be done:

The amount of liquid to be applied is easily adjusted by the siphon height, the inlet pressure, and the liquid adjusting stem.  So, you can dial in the exact amount of fluid required for your process to eliminate any excess waste. They are very compact and easy to install.  We carry mounting brackets for each size to allow for easy mounting and positioning.   Versatility is very important in saving, applying, and spraying costly fluids; and, the Siphon Fed Atomizing Nozzle has it.

Siphon Fed No Drip Option

To help reduce waste 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.  When the compressed air is turned off, a valve inside the body will create a seal on the liquid side.  For delicate applications, the No Drip options will eliminate unwanted drips that can ruin the finish of your product.  This option also enhances the function of the Siphon Fed 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.  Unlike some manufacturers, there is no need to run a separate compressed air line to operate the no drip function.  The Siphon Fed Atomizing Nozzle with the No Drip option is compact, efficient, and precise without any drips.

If you need to maximize the liquid dispersion and minimize liquid consumption, the EXAIR Atomizing Nozzles are the products to use.  Instead of researching the requirements for liquid pumps or pressure pots, the Siphon Fed Atomizing Nozzle can draw the liquid through the feed line and start spraying.  It can help reduce the cost of your project as well as save you money on your consumable products.  If you have an application involving liquid spraying, an Application Engineer at EXAIR can help determine the correct model for you.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Video Blog: 1/4″ NPT No Drip Atomizing Nozzle Repair Kit Installation

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.

John Ball

Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb