Rugged, Stainless Steel Liquid Nozzles Available to Ship From Stock: The FullStream Cone Nozzles

New to EXAIR’s line of Liquid Atomizing Nozzles are the FullStream Liquid Only Atomizing Nozzles. This family of nozzles does not require any source of compressed air to operate, just a supply of pressurized liquid.

They produce droplets by spinning the liquid and breaking its surface tension through a precise orifice or by impacting the liquid onto the surface of the nozzle. Compared to EXAIR’s Air Atomizing Spray Nozzles, these nozzles generate more liquid volume and produce a coarser spray pattern. This higher liquid volume is beneficial for industrial applications including cleaning, cooling, rinsing, dust suppression, and washing. Constructed of Type 303 stainless steel, these durable and rugged nozzles are ideal for industrial applications. They’re available in three sizes: ¼ NPT, 3/8 NPT, and ½ NPT these nozzles can achieve flowrates ranging from 0.5 GPM to 17.64 GPM.

This style of nozzle is a good fit for general-purpose applications in industry and will commonly be used to spray inexpensive liquids such as water, rinse aids, or detergents. They’re also effective for spraying a variety of chemicals, pesticides, and herbicides.

Adjustments to the nozzle’s liquid flow rate can be achieved by regulating the liquid pressure supplied to the nozzles. As we increase the liquid pressure, the flow through the nozzle will increase. As the pressure increases, not only do we increase the overall liquid flow rate but also the size of the spray pattern. If a tight tolerance in liquid flowrate is needed, the Air Atomizing Nozzles will provide more precise control over the application of fluids.

The FullStream Cone Nozzles produce a full cone spray pattern and are among the most common style of spray nozzle available on the market today. They produce a uniform distribution of liquid in a cone shaped round pattern. Their tangential flow is vaneless, creating open internal features that are resistant to clogging for liquids with suspended particles.

The nozzles are manufactured out of Type 303 stainless steel for durable and rugged applications up to a maximum temperature of 800°F. With absolutely no moving parts, these nozzles are Built to Last. All sizes are available in stock to ship today with an order in by 2:00 EDT.

Tyler Daniel
Application Engineer
Twitter: @EXAIR_TD

Siphon Fed Air Atomizing Spray Nozzles

Siphon fed nozzles are a great alternative for spraying where no liquid pressure is available. EXAIR has 3 sizes from 1/8 NPT, 1/4 NPT and 1/2 NPT nozzles along with “No-Drip” nozzles in the same sizes. Siphon fed nozzles require no liquid pressure and can be used with gravity fed liquids or lift liquids from a siphon height as much as 36′ (91 cm). Siphon fed nozzles work best with thinner liquids up to 200 centipoise.

Siphon Fed model

EXAIR Air Atomizing Nozzles are manufactured from 303 stainless steel for durability and corrosion resistance. The siphon fed nozzles can be easily implemented where a tank can be installed and lower the cost of the installation by not requiring a liquid pump, just point of use compressed air.

In addition to the sizes and no drip option the siphon fed nozzle comes in two spray patters. The round pattern offers more liquid pass through and can be used in cleaning, rinsing, cooling and coating applications.

No Drip Siphon Fed Round Pattern Atomizing Nozzle

The siphon fed flat fan pattern nozzles are great where no liquid pressure is available and a thin coating is needed over a wide band. Flow rate is adjustable via the adjusting valve.

For non-pressurized liquid spraying solutions, you want to consider our siphon fed air atomizing nozzles. Please contact any of our Application Engineers if you have questions regarding our Air Atomizing Spray Nozzles.

Eric Kuhnash
Application Engineer
Twitter: @EXAIR_EK

Atomizing Spray Nozzles: Breaking Down The Spray Patterns

Once upon a time, there was a process engineer that needed to solve a production issue on a rinsing line. They had used a spray nozzle that had too large of a spray pattern, with too much volume. And used a hollow cone pattern with not enough heat removal…Okay, so maybe I took this a little too far into the fairytales. I have legitimately had a very similar discussion with customers that are trying to find a spray pattern that is “Just Right” for their needs – the Goldilocks discussion of spray patterns. The best part of Atomizing Spray Nozzles from EXAIR is that we do help you find the nozzle that fits your needs. The shape of the spray pattern is one of the key variables that is decided first.

When determining what spray pattern is needed we need to take into account the purpose of the spray, whether it be to coat, rinse, cool, or add humidity. To go along with the purpose we need to understand the geometry of the part/target and whether the part is stationary, is the part moving, or is the nozzle moving. Once those variable are determined then we can select one of the three main spray patterns to drill down the final selection.

The main three patterns are:
Round Pattern
Flat Fan
Hollow Cone

FullStream – Round Pattern Liquid Atomizing Nozzle rinsing parts after coating.

Round Pattern – These are found in air atomizing and liquid atomizing. The air atomizing are available in both siphon fed liquid or pressure fed liquid. These are also broken into narrow angle or wide angle round. The diameter of the full cone spray of liquid will expand on both styles however the narrow angle tends stay more concentrated and can often be seen in rinsing, washing or heavy coating applications. Distance from the target that the nozzle can be will also help with whether a wide angle or narrow angle will be needed.

Flat Fan Spray Pattern rinsing parts after a chemical wash.

Flat Fan Pattern – These are currently offered in the air atomizing spray nozzles and both siphon fed or pressure fed options. They are also offered in narrow angle flat fan, wide angle flat fan, and deflected flat fan. These options will all be dictated by the target area needing covered and the distance to the target area. Flat fan pattern nozzles are often used with fine surface finish coatings that are being applied to either moving parts, or with nozzles that move around stationary parts.

Model AT5010SS 1/2 NPT 360° Hollow Circular Pattern Atomizing Spray Nozzles are ideal for smooth, even coatings in large pipe or duct ID’s, or for a mist or fog over a large area.

Hollow Cone – This pattern is available in both liquid atomizing and air atomizing. The liquid atomized hollow stream nozzle is great for rinsing, or washing parts. The center of the cone being hollow can help to conserve liquid where it is not needed. The air atomizing hollow cone 360° nozzle can spray so wide it has been used for inside pipe wall cleaning / coating as well as for dust suppression in large areas.

No matter the application, there is a combination of spray nozzles that should fit “just right”. The Application Engineer team here at EXAIR are all equipped with knowledge and experience to help determine what is needed or at the very least some methods to get to a final solution. If you would like to discuss the needs within your facility, contact us.

Brian Farno
Application Engineer

Choosing the Right Air Atomizing Nozzle

Atomizing your liquid has many benefits. You will use far less product, while covering more surface. Whether you are covering, coating or cooling, atomization is your best option. EXAIR has a vast selection of Air Atomizing Spray Nozzles, and it can appear difficult to select the best one for your application, but with some of these tips and guidance, you will be able to find exactly what you need.

In choosing a nozzle, there are a few standard details and a few necessary questions we need to get out of the way.

  1. All of our nozzles are Stainless Steel
  2. There are options with 1/8″, 1/4″ and 1/2″ NPT inlets
  3. Max temp is 400°F
  4. All Nozzles are CE compliant
  5. Do you have adequate compressed air at the point of use?
  6. Is your Liquid pressurized?
  7. How far from your product will / can the nozzle be mounted?
  8. What is the Viscosity (cP) of your liquid?
  9. How many gallons per minute do you need to disperse?

EXAIR’s Air Atomizing Nozzles all have 3 components. The nozzle itself (see #2 above), the liquid cap that controls the liquid flow, and the air cap that controls the air flow / pattern. For the most part these are inter changeable based upon the original size of your nozzle. For example, you could fit a new air cap onto the same liquid cap and change from a round pattern to a flat pattern (Note -not all are caps interchangeable). By using these variables, we are bale to get many different flow rates, patterns and coverages.

There are also 3 groups of nozzles, Internal Mix, External Mix, and Siphon Fed, based on how your liquid is fed to the nozzle. Here is an excerpt from our catalogue that explains this very well:

Let’s assume that your liquid is pressurized. You now have 2 choices, internal and external mix. Internal mix will only work if your air pressure and liquid pressure are pretty close to the same (within about 20-25 psi of each other). These mix the air and liquid inside the nozzle, so if more pressure is received on either side, it could back pressure the other side. The external mix nozzles can have a wide variety of pressures on either side, as these mix externally of the nozzle. Lastly, if your liquid has a viscosity of 300 cP or higher, your only option is the External Mix Nozzle – see below for a viscosity table…

We need to have a solid understanding of the centipoise (cP) of the liquid. To save you some time in looking this up, here are some examples of common products and their centipoise. As you can see above, the cP can determine the type of nozzle you can use effectively.

By this time, we should have narrowed the nozzle down to the style (Siphon Fed, Internal Mix, or External Mix). Now we need to find the right size, and spray pattern for your specific application. The main data points you need to have are 1) Spray pattern (width etc…) 2) Liquid Pressure 3) Air Pressure 4) distance from the nozzle to the surface you are spraying (ideally this is variable). Once you know these data points, you can proceed.

PRO TIP: Use the catalogue section for reference – click here to get it online . Or you can open up a chat on our website and ask us to send you one (M-F 7AM -4PM EST), or you can send an email or request by phone that we send you a physical printed copy!!! Yes these still exist!!! With the catalogue section in hand, you will have each performance table readily available to start narrowing down your choices. Pro tip #2 – you can also download drawings…

To find the best size and pattern fit, you will want to focus on the lookup tables in the catalogue section. First, an idea of how your nozzles will need to mount (their location, distance from target) and a desirable spray pattern to cover your target will be helpful. For instance, you may need a fan pattern to cover a wide area. Let’s say that you need to cover an area that is about 12″-13″ wide, we can look for a nozzle that will meet that requirement. Keep in mind that if you need to cover 60″, you may need 1, 2, 3 or more nozzles depending on the other information required.

Back to our example of a 12-13″ spray… You will next need determine how many gallons per hour this nozzle would need to spray. How fine, or thick of a covering do you need? Sometimes this is an unknown, so we will look at liquid and air caps that are in a mid range, so that you can adjust with the air and liquid pressures. Let’s assume you need to apply close to 4 gallons per hour. We can now find both factors on the look up table below. The second row, under 30 psi liquid shows 4.1 gallons per hour, when we use 26 psi of air pressure. As we slide over the width, we see that this will give us a 13″ width of spray pattern (when the nozzle is 9″ away – that is width “B” in the spray pattern above). Pro Tip # 3- start with your non variable of width (spray pattern) needed, and work back from there. We can always find ways to adjust the air and liquid pressure, but you will still need the pattern to cover.

The application engineers at EXAIR are ready to help as well. We can walk you through the steps and ask the right questions to assist you in selecting the correct nozzles. If you can grab a few pictures and or videos to share, as well as the data mentioned above, we will be able to get you to the best solution.

Application Engineer

Brian Wages

EXAIR Corporation
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