No Drip Atomizing Spray Nozzles: Overview

Are you tired of your dripping nozzle leaving puddles on your equipment and making a mess? Do the liquids you use to treat or coat your materials cost you a great deal of money? EXAIR’s No Drip Atomizing Spray Nozzles have been engineered eliminate drips; these patented nozzles contain a spring mechanism that when the air pressure reaches above 30 psig the valve will open allowing the liquid to escape out.

EXAIR No Drip Air Atomizing Spray Nozzles come in three styles. Internal mix, External mix and Siphon fed. 

One of the most commonly used types of No Drip Atomizing Spray Nozzles is the Internal Mix. The Internal Mix nozzle mixes the liquid and the air inside the cap and produces the finest droplet size out of the three. Due to the fact that the liquid and air are mixed in the cap, Internal Mix nozzles are used on liquids that have a lower viscosity (less than 300 cP). This means that they are usually used on liquids such as water, water soluble/diluted lubricants, lightweight oils, or rust inhibitors.

External Mix No Drip Atomizing nozzles have the highest flow rates and allow the air and liquid flows to be adjusted independently. These are best when precise liquid flow is needed. External mix nozzles can be used when the liquid viscosity is above 300 cP. 

Siphon Fed No Drip Atomizing nozzles require no liquid pressure and can be use dwith gravity fed liquids or siphon liquid from a height as much as 36 in. (91cm). These can be used with liquids up to 200 cP. 

No Drip Atomizing Nozzle
The No Drip Atomizing Spray Nozzles share the same spray patterns as our line of standard atomizing spray nozzles. This means that they are available in Narrow Angle Round Pattern, Wide Angle Round Pattern, Flat Fan Pattern, Deflected Flat Fan Pattern and 360° Hollow Cone Pattern. Along with the five different spray patterns they also come in three different inlet sizes of 1/8″, 1/4″ and 1/2″ NPT.
No Drip Flat Fan Spray Nozzle
Each NPT size also comes in a variety of different sizes in the corresponding spray volume. For example, the 1/8” No Drip Internal Mix Flat Fan Nozzles have for different Nozzles with a flow rate ranging from 3.47 GPH to 28 GPH (13.2 LPH to 105.99 LPH). This gives the No Drip Internal Mix Atomizing Nozzle 36 different variations to fit your application.
No Drip Siphon Fed Round Pattern Atomizing Nozzle
The normal applications for No Drip Atomizing Spray Nozzles Include but not limited to the following:
  • Painting
  • Coating
  • Rinsing
  • Cooling
  • Quenching
  • Wetting,
  • Humidification
  • Dust Control
  • Snow Making

Or any application where drips can harm a products finish or waste valuable liquids. 

For more information on EXAIR’s No Drip Atomizing Spray Nozzles or any EXAIR‘s Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Cody Biehle
Application Engineer
EXAIR Corporation
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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
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Internal Mix Atomizing Spray Nozzles Overview

EXAIR offers an ever-expanding selection of Atomizing Spray Nozzles.  One style with many iterations within the line is the Internal Mix.  Internal mix refers to the physical action of the compressed air atomizing the liquid before they leave the air cap. Because this action takes place inside the nozzle, internal mix atomizing spray nozzles are recommended for lower viscosity fluids. Water, water soluble/diluted lubricants, lightweight way oil, or rust inhibitors are a few examples that can easily be sprayed through these nozzles. The nozzles are also able to spray in five different spray patterns.

Internal Mix Atomizing Spray Nozzles are the perfect choice for fine mist and precise control.

The Internal Mix Atomizing Spray nozzles are available in Narrow Angle Round Pattern, Wide Angle Round Pattern, Flat Fan Pattern, Deflected Flat Fan Pattern and 360° Hollow Cone Pattern. These nozzles can cover anywhere from 1.5″ diameter up to 13′ diameter and almost any dimension in between. To cover this vast array of spray dimensions they are offered in three inlet port sizes, 1/8″, 1/4″ and 1/2″ NPT.

Internal Mix Atomizing Spray Nozzles

Each NPT size offers a variable spray pattern as well as liquid flow rates for each type of spray pattern. The 1/8″ nozzles are available up to 28 GPH of flow rate. The 1/4″ nozzles are able to flow up to 42 GPH. The 1/2″ models are able to flow up to 264 GPH. These flowrates can all be varied to minimal flows by adjusting the liquid needle valve. See the video below for a demonstration of that variability.

These nozzles are all easily installed and can be mounted with the available mounting brackets. One for each size.

EXAIR Atomizing Nozzle

If you would like to discuss your atomizing spray nozzle application or need help determining if an Internal Mix Atomizing Spray Nozzle is the correct fit for your needs, please contact us.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

 

Benefits of Atomized Liquid Nozzles vs. Liquid Nozzles

There are a great many applications that require a spray (as opposed to a stream) of liquid. Certain droplet sizes, and flow rates, are beneficial for certain applications. For example, if you’re fighting a fire, you want as high of a flow rate as possible – the more water you douse the fire with, the quicker it goes out.  You also want a fairly large droplet size, since a mist would tend to evaporate instead of extinguishing the flames.

Pressure washers also benefit from higher (though not near as high as fire hose) flow rates, and droplet sizes.  You want an appreciable flow rate, because that means high velocity, and good sized droplets combine that velocity with their relative mass to “blast” away dirt and detritus from the surface.

Medicine delivery devices, like asthma inhalers, are designed to produce mid-sized droplets, but pretty low (and controlled) flows.  The droplets need to be small enough to efficiently spread the medicine through the breathing passages, but large enough to where they won’t evaporate before they ‘plant’ on the nasal & bronchial membranes to get absorbed.

These are examples of “liquid-only” nozzles…no other media or means of force are used to effect the spraying action.  Most of the time, the droplet sizes in these applications are measured in hundreds of microns, which “liquid-only” nozzles are ideally suited to generate.  Other applications, however, call for much smaller droplet sizes…such as those only attainable through atomization.

EXAIR Atomizing Spray Nozzles use compressed air to create a fine mist of liquid, with droplet sizes as low as 22 microns.

A typical “liquid-only” nozzle is capable of producing droplet sizes of 300-4,000 microns. Atomizing Nozzles’ droplet sizes are consistently under 100 microns, and can be as small as 20 microns!

Small droplet size is key to cost effectiveness in many applications:

  • Think about expensive coatings…the smaller the droplet size, the better and more even the coverage, and the less you have to spray (and pay) out.
  • Or humidification…smaller droplet size means more stays airborne, for longer, and in a larger space.
  • Petroleum based lubricants, by their nature, only require a thin layer for best results.  Smaller droplets make as even and thin of a layer as possible.
  • Dust control is much more effective with smaller droplet sizes, since the longer the mist lingers in the air, the more dust particles the individual droplets will adhere to…and then drop with them to the surface.  This also prevents getting the surface of the material any wetter than it has to be.
142 distinct models. 8 different patterns. Liquid flow rates from 0.1 to 303 gallons per hour. If you’ve got a spraying application, EXAIR has an Atomizing Nozzle for you!

If you’d like to discuss a liquid spraying application, I’d love to hear from you.  Call me.

Russ Bowman
Application Engineer
EXAIR Corporation
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Atomizing Nozzles – No Drip Deflected Flat Fan and 360° Hollow Circular

EXAIR manufactures three types of Atomizing Nozzles – Internal Mix, External Mix, and Siphon Fed.  Within the Internal Mix family, there are two specialty nozzles, the Deflected Flat Fan and the 360° Hollow Circular patterns.

Internal Mix nozzles are for pressure fed applications not requiring independent air and liquid control.

The model AD2010SS is the No Drip version of the Deflected Flat Fan and is shown below. Our patented No Drip design prevents unwanted post spray drips from wasting expensive fluids or ruining product finishes. The benefit to this design is that no secondary compressed air line is necessary to activate the on/off valve for the liquid, which is the case for competitive nozzles.

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Model AD2010SS – No Drip Internal Mix Deflected Flat Atomizing Nozzle

The Deflected Flat Fan patterned nozzle is designed for applications where space is a limited.  The spray pattern is at a right angle to the orientation of the nozzle, allowing the spray to be placed precisely where it is needed in tight quarters.  They are ideal for coating the insides of enclosures and ductwork.

NoDripIMDF

The model AT2010SS is the No Drip version of the 360° Hollow Circular and is shown below.

AT2010SS
AT2010SS – No Drip Internal Mix 360° Hollow Circular Atomizing Nozzle

The 360° Hollow Circular patterned nozzle is designed for applications where the spray pattern is to be orientated away form the nozzle in all directions.  They are ideal where a smooth and even coating is needed on the internal surface of a pipe or duct.  They are also good for processed where a mist is needed over a large area, including dust suppression, humidification, and cooling.

NoDripIM360HC-Pattern

The No Drip feature is a patented† design that has the added benefit of positively stopping the liquid flow when the compressed air is shut off. Post spray liquid flow can cause quality issues from unwanted drips on painted or coated surfaces.  Also, the No Drip feature helps to conserve and save on liquid use, reducing costs of expensive coatings or chemicals.

When the compressed air supply is shut off, the No Drip nozzle positively seals off the flow of liquid, eliminating over spray and drips. The design allows for just one compressed air line, there is no need for an additional to control the No Drip mechanism.

If you have questions about Atomizing Spray Nozzles, or would like to talk about any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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† Patent #9156045

 

No Drip Internal Mix Atomizing Nozzles

Eliminate drips to conserve valuable liquids and improve product finishes!  EXAIR’s patented No Drip Atomizing Nozzle provides the same great performance as the the standard atomizing nozzles with the added benefit of positive liquid flow stoppage when the compressed air is shut off.

The No Drip option eliminates the occurrence of post spray liquid flow that results in unwanted drips that can mar a finish on painted or coated surfaces.  Also, excess liquid loss is minimized saving on expensive materials like chemicals or coatings.  When the compressed air is shut-off, the No Drip nozzle positively seals off the flow, eliminating the chance for a drip or lost liquid. Only one compressed air line is needed, as the line to combine and atomize the liquid also provides the no drip operation and control.

The No Drip Atomizing Nozzles are available in (3) types – Internal Mix, External Mix, and Siphon Fed.

The Internal Mix type operates under the principle that the air and liquid come together and mix ‘internal’ to the nozzle.  This type provides the finest atomization and smallest droplet size. The Internal Mix type of nozzle can be used with liquids up to 300 cP in viscosity.  Both the air and liquid sides are pressure fed.  The No drip Internal Mix Atomizing Nozzles are best for pressure fed applications not requiring independent air and liquid control.

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A No Drip Internal Mix Flat Fan Nozzle applying anti-corrosion fluid to stamped parts

The No Drip Atomizing Nozzles are available in (3) sizes – 1/8, 1/4, and 1/2 NPT – to provide a wide range of flow rates and pattern sizes.  The No Drip feature does not impact the flow rates compared to the standard models.  Minimum air pressure operation is 30 PSIG for the 1/4 and 1/2 NPT, and just 20 PSIG for the 1/8 NPT models.

Like the standard Internal Mix Atomizing  Nozzles, spray patterns include narrow and wide angle round, flat fan, deflected flat fan and a 360° hollow circular pattern offering a wide selection to best meet the application needs.

Operation at up to 180 spray cycles per minute is possible.  Air and Liquid Caps can be switched out to change the pattern and flow rates.

Typical Applications

  • Painting
  • Coating
  • Rinsing
  • Cooling
  • Quenching
  • Wetting
  • Humidification
  • Dust Control

Advantages

  • No post spray drip
  • Adjustable
  • Easily used with EFC
  • Minimizes air and liquid consumption
  • All stainless steel construction
  • Fine atomization
  • Interchangeable liquid and air caps
  • Compact

If you need an Atomizing Spray Nozzle or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Internal Mix Atomizing Spray Nozzle Used In Feed Additive Process

Last week I took a call from an agricultural customer looking to replace the spray nozzle used in their feed additive process. The soy oil/beeswax solution they are applying to the feed, is slightly viscous (close to 100 cP) which seems to be clogging the tight clearances inside the current nozzle, resulting in varying flow rates and an erratic spray pattern. They had tried to contact the current manufacturer several times for a solution but were unhappy with the lack of assistance they were receiving, not to mention the long lead times of 6-8 weeks for a replacement.

After further discussion, they confirmed they weren’t as concerned with the flow rate or spray pattern, as they were with the nozzle potentially getting clogged.  They were able to obtain some internal dimensions of the existing nozzle and after further review, I recommended they use our Model # AF1030SS Internal Mix Flat Pattern Atomizing Nozzle as a replacement. This nozzle has larger inside diameters which would reduce the potential for clogging. Our Internal Mix Atomizing Nozzles mix the liquid and air inside the air cap and produce the finest atomization. The flow rate can be changed by adjusting the control valve on the nozzle and/or by adjusting the liquid pressure. Internal Mix nozzles are capable of handling fluids up to 300 Centipoise. All of our Atomizing Nozzles are In STOCK, so delivery is never an issue.

Model AF1030SS Internal Mix Flat Fan Pattern Atomizing Nozzle

When considering an Atomizing Nozzle for an application, there are some general parameters that can be helpful in making the best selection.

  1. Do you have a pressurized liquid source?
  2. What is the fluid viscosity?
  3. What spray pattern best fits the process?
  4. How much flow (GPH/LPH) do I need?

If you have an application requiring a fine mist of atomized liquid spray, please contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN