If you follow along with our blog, you will notice that we have recently published a few entries relating to our Atomizing Nozzles. Today, I would like to continue this trend and focus on our Siphon Fed Atomizing Nozzles.
When recommending an Atomizing Nozzle for a particular process, we try to obtain as much “general” information as possible about the application, such as:
What type of spray pattern do you need?
How wide of an area needs to be covered?
What kind of flow rate needs to be achieved?
Is the liquid source pressurized?
What is the viscosity of the liquid?
While all of this information is going to help simplify the selection process, when we get a reply that the liquid isn’t pressurized, the choice becomes a little less complicated.
Our Siphon Fed Atomizing Nozzles are the preferred solution in applications where a pressurized liquid source isn’t available. With a steady supply of compressed air, these nozzles are able to draw the liquid into the nozzle with suction heights up to 36″ for our 1/8″ NPT and 1/4″ NPT nozzles, and up to 24″ for our larger 1/2″ NPT Models. They can also be gravity fed as well.
These nozzles mix the fluid internally and are capable of handling viscosity up to 200 centipoise. Depending on the size of the nozzle and supply air pressure, flow rates can range from 0.4 GPH up to 60 GPH with either a round or flat fan spray pattern. There is also an adjusting valve for more or less liquid flow as needed to fit the demand of the application.
We also offer these nozzles with our patented No Drip feature which positively stops the liquid flow when the supply air pressure drops below 30 PSIG, eliminating the need for any additional valves or supply lines.
If you have an application requiring a fine mist of atomized liquid, give me a call 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.
If you’ve ever cleaned around the house (and who hasn’t?), you’re probably familiar with atomized liquid spraying…it’s what happens when you squeeze the trigger on that bottle of cleaner that breaks down the stove top grease in the kitchen and the ring-around-the-tub in the bathroom.
There’s a variety of industrial and commercial applications that require an atomized liquid spray too…applications that are beyond the scope of an operator with a trigger-operated spray bottle. That’s where EXAIR Atomizing Spray Nozzles come in. We have three types: Internal Mix, External Mix, and Siphon Fed. Depending on what you want to spray, and how you want to spray it, one of these is likely going to work better than the others for you. Today, we’re going to examine the Internal Mix Atomizing Spray Nozzles.
Better mist: Because the liquid & air come together inside the air cap, this results in very fine atomization.
Range of adjustment: Regulating either the liquid or air pressure supply will change the flow rate AND the flow pattern, giving each individual nozzle a wide performance band. The needle valve can “fine tune” the flow and pattern with even greater precision.
Area of coverage: With five patterns (Narrow or Wide Angle Round, Flat Fan, Deflected Flat Fan, and 360° Hollow Circular) and 72 distinct models to choose from, you can get spray patterns from 2″ (1/8 NPT Narrow Round Model AN8010SS) to 13 feet (1/2 NPT 360° Hollow Circular Model AT5010SS.)
Flow rate: Again, because of the many models available, you can get from 0.6 gallons/hour (Model AN8010SS again) to 264 gallons/hour (1/2 NPT Wide Angle Round Model AW5030SS.)
No-Drip option: The standard Models have a needle valve, which, as mentioned above, gives you the ability to make minute changes to the flow rate & pattern. If the application calls for rapid on/off control, or the chance of an errant drip after flow is not stopped might be a problem, the needle valve can be replaced with a No-Drip assembly. This positively shuts off liquid flow, at the exit of the liquid cap, when air pressure is secured.
Easy installation: All of our Atomizing Spray Nozzles have female NPT (1/8, 1/4, or 1/2) ports. The 1/8 and 1/4 NPT models can be adequately supported – and positioned – with a Stay Set Hose, and all models (even the 1/2 NPT) can be used with an appropriately sized Swivel Fitting. If you want to use your own tubes or hoses, we’ve got “clip-in” style Mounting Brackets.
Interchangeability: The only difference between any model of the same-size Atomizing Spray Nozzle is the Liquid and/or Air Cap. If your application’s liquid spray requirements change, or vary, you don’t need to replace the whole nozzle; just one (or in some cases, both) of the caps.
I like some better than others, but I don’t believe I’ve ever had bad pizza. That’s why I was pretty excited when I got to talk to a caller from a popular pre-packaged pizza crust maker. When these crusts leave their oven, they spray a coating of seasoned oil on them. This not only flavors, but preserves the quality from the time they make & package them to the time I celebrate life with a tasty slice, right out of my oven.
They were using inexpensive liquid-only nozzles that led to an inconsistent application of the oil…sometimes too much; other times, too little. And, it was always spraying, even in between the individual crusts as they came down the conveyor, leading to wasted oil that had to be cleaned up later.
They were already familiar with our Super Air Nozzles, as they had several Model HP1125SS 2″ High Power Flat Super Air Nozzles in use for blowing off the packages prior to labeling, so the caller asked if we might have a solution for the oil too.
After considering the size of the crust and the distance at which they needed to install the nozzle, they decided to try a Model AF2010SS Internal Mix Flat Fan Pattern No-Drip Atomizing Spray Nozzle. This applies a consistent and even coating of oil, and, by feeding a signal from the oven controls into a solenoid valve in the compressed air supply line, they’ve eliminated the excess spray, leading to savings in material cost and cleanup time.
If you’d like to know more about how EXAIR Atomizing Spray Nozzles can save you time, mess, and liquid, give me a call.
Today, I would like to focus on 2 specific Atomizing Nozzles – our No Drip Internal Mix Deflected Fan Nozzle and our Internal Mix 360° Hollow Circular Pattern Nozzle.
The No Drip Internal Mix Deflected Fan Atomizing Nozzle produces a flat fan of atomized liquid at a right angle to the nozzle’s orientation and is designed for use in pressured fed applications where the liquid doesn’t need to be controlled independently from the pressurized air. This nozzle is the perfect choice in processes where mounting space is limited like spraying solvent on conveyed parts inside a small chamber or coating the inside of an enclosure. The patented No Drip feature positively stops the liquid flow when the supply air pressure drops below 30 PSIG, eliminating the need for any additional valves or supply lines. This is especially beneficial in applications using expensive fluids or where drips can ruin a finished product. This nozzle is available with 1/4″ NPT inlets and flows as high as 6.9 gallons per hour.
Our Internal Mix 360° Hollow Circular Pattern Atomizing Nozzles produce a circular spray pattern, the ideal solution when trying to coat the inside of ductwork or where a broad mist of atomized liquid is necessary, like dust suppression or humidification. Available in 1/4″ NPT with flows as high as 14.7 GPH and spray diameters up to 53″ in diameter depending on air and liquid supply pressures. With the 1/2″ NPT, we can achieve up to 150 GPH with a spray diameter up to 156″. Our standard Atomizing Nozzles also feature an adjustment valve to provide control of the flow rate, making them easy to adapt to a specific requirement.
If you have an application requiring a fine mist of atomized liquid, please contact one of our application engineers and let us know how we can help in making the best product selection to fit your need.
From pneumatic hand tools like impact wrenches or nail guns to larger scale industrial applications like stamping presses, the use of compressed air can be found in almost any industry. In fact, it is often referred to as a “fourth utility” next to water, gas and electric.
Take for example in construction, workers will use a pneumatic riveter to join steel framing because of the power generated by the tool over an electrically powered device, not to mention it provides for a safer operation by removing an electrical hazard. Many companies use compressed air operated diaphragm pumps or air motor driven pumps to move expensive or viscous liquid from one location to another. These types of pumps are self priming drawing the liquid in and provide positive displacement meaning they fill and empty the liquid chamber with the same amount of liquid through a common inlet and outlet.
Amusement parks have used compressed air in some capacity in the operation of thrill rides like roller coasters or to enhance the effect of certain attractions. Compressed air can be found in hospitals where it is used for specialized breathing treatments or to power surgical instruments in an operating room. Educational facilities use compressed air for laboratory testing. You can even find compressed air in the tires on your car. Basically, when you think about it, compressed air is being used just about anywhere.
Here at EXAIR, we manufacture Intelligent Compressed Air Products to help improve the efficiency in a wide variety of industrial operations. Whether you are looking to coat a surface with an atomized mist of liquid, conserve compressed air use and energy, cool an electrical enclosure, convey parts or dry material from one location to another or clean a conveyor belt or web, chances are we have a product that will fit your specific need.
To discuss your particular application or for help selecting the best product, contact an application engineer at 800-903-9247 for assistance.
We recently chatted with a customer that was looking to improve the lubrication system for multiple blanking lines. Blanking involves the cutting of sheet metal in a single step, to separate the piece form the surrounding stock. The part that is cut out is the desired product and is called the ‘blank.’ This operation can be moderate to fast in speed, and the process creates heat, so a lubricant is used to cool and decrease the wear on the tooling. Our customer was looking for a better way to apply the lubricant.
We proposed the model AN2010SS, a No Drip, internal mix, narrow angle, round fan Atomizing Nozzle. The nozzle uses compressed air to create a mist of the liquid with very fine droplet size. When using for the lubricant, a fine layer can be applied over the entire surface without areas of over coverage and waste. This leads to lower costs for lubricant, and less mess on the blanks.
To simplify the process, the No Drip model was chosen. The No Drip style has the added benefit of positively stopping liquid flow when the compressed air is turned off. There is no need to independently control the liquid flow via a control system and valve.
Finally, to control the compressed air side, we recommend the Electronic Flow Control (EFC.) Utilizing a photoelectric sensor, the open position of the press can be detected and using 1 of many program options, the compressed air can be turned on and off to accurately control the application of the lubricant. Due to the excessive amount of lubricant being used, the customer was applying every other cycle. The first blank would be overly lubricated so that there would be some remaining for the next. With the Atomizing Nozzle and EFC, the right amount of lubricant can be applied for each cycle. The result is reduced lubricant usage, and a better operation.
If you have questions regarding Atomizing Nozzles or any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.