How to Pick the Right Atomizing Spray Nozzle

Atomizing spray nozzles atomize fluids with compressed air 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, it can be challenging to sift through all the information. But with a few basic questions you can narrow down the right nozzle type for you and your application:

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!

Are you using a pressurized liquid feed? In some cases, a pressurized liquid source is not available for the nozzle, so you would have to rely on a gravity or siphon fed nozzle. While you lose the complexity of having a liquid pump pressurizing your liquid, you do have a few draw backs. Your siphon height is typically with in 36” so your liquid source has to be fairly close to your nozzle. Siphon fed nozzles are hard to turn off and on, they are best used for applications where you are continuously spraying a low viscosity liquid with a low gph.  

Internal Mix Atomizing Spray Nozzles

What is the viscosity of the fluid? Another deciding factor is the viscosity of the liquid you are spraying. Different nozzles are designed for different viscosity. For example, two of the main nozzle types are internal mix nozzles and external mix nozzles. They function just like they sound, internal mix nozzles mix the compressed air and liquid source inside the nozzle. And because of this they typically can not spray liquids over 300 cP. And because external mix nozzles mix the liquid and air outside the nozzle, they can handle liquids well above 300 cP.

What is the liquid flow rate in gallons per hour(gph)? Another factor in choosing the right nozzle is if your application has a set gph you are looking to achieve. Some nozzles are designed to flow more liquid then others. For example, the external mix nozzles inherently flow more liquid then the internal mix. As there is less restriction on the liquid flow. If you are looking for even higher gph you can source a liquid only atomizing nozzle, its going to give you a large bump in gph. But your droplet size will suffer with the liquid only nozzles.

Full Cone Liquid Only Atomizing Spray Nozzle

What droplet size are you looking for? Fine droplet sizes are one of the primary reasons atomizing nozzles are used. Benefits of small droplet sizes include even coating and liquid conservation. Internal mix nozzles will do the best at providing the smallest droplet size possible. While external mix and liquid only will give you larger droplet sizes but they will give you a larger gph some applications need.  

Should I use a No-Drip option?  The No-Drip option positively shuts off liquid flow when the    compressed air supply is shut off.  One benefit of this is appreciated 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.

No Drip External Mix

If you are in the need for a Liquid Nozzle to assist in your facility, please reach out! We have a team of application engineers waiting from 8AM – 5PM EST to help you size and fit a product to your specific application! 

Jordan Shouse
Application Engineer

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EXAIR NEW Product Offering – Full Stream Cone Liquid Atomizing Nozzles

EXAIR has continued to build on a large catalog of Intelligent Compressed Air Products. In catalog 27 we introduced our Atomizing Nozzles ! I’m happy to announce we have added a new line of FULLSTREAM LIQUID ATOMIZING NOZZLES! , they do not use compressed air. The current Full stream nozzles available are our FullStream Cone Liquid Atomizing Nozzles with a 1/4 NPT port.

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EXAIRS new FullStream Cone Liquid Atomizing Nozzle

EXAIR’s FullStream Cone Nozzles, have a full cone spray pattern, are among the most common type of spray nozzles. Full cone spray nozzles are applied to solve cooling, cleaning, washing, rinsing and dust suppression applications throughout industry. Their design is vaneless, which creates wide open internal features to resist clogging and can work well with liquids containing particulate. They produce a uniform distribution in a full cone round pattern. Their right-angle design is compact and operates up to 250 PSIG liquid pressure. They are commonly used with liquids like water, rinse aids or detergents but are also effective with chemicals, pesticides and herbicides. Adjustment of the liquid flow rate is done by varying liquid pressure. FL1010SS @ 2.36 GPH & 60 PSI

Bellow you will see a video of the FullStream Cone Liquid Atomizing Nozzle, FL1010SS,  2.36 GPH @ 60 PSI. 

 

Bellow you will see the Dimensions and Performance of the FullStream Cone Liquid Atomizing Nozzles!

Full stream liquid nozzels

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If you are in the need for a Liquid Nozzle to assist in your facility, please reach out! We have a team of application engineers waiting from 8AM – 5PM EST to help you size and fit a product to your specific application! 

Jordan Shouse
Application Engineer

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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.

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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

 

New Atomizing Spray Nozzles That Will Change Your Spraying Process

EXAIR has continued to build on a large catalog of Intelligent Compressed Air Products. In catalog 27 we introduce (2) new Atomizing Nozzles to add to our product’s functionality and versatility. Today, I want to talk about one of the spray nozzles we added. Don’t worry! Next week, I will talk about the second nozzle, if you must look ahead follow this link.

Deflected fan in use Deflected Fan

Our new nozzle is the Internal Mix Deflected Fan Nozzle. The nozzle produce a flat fan of atomized liquid at a right angle to the nozzle’s orientation. The nozzle is designed for pressure fed application, where the pressurized liquid does not need to be controlled independently from pressurized air. In cases where space is limited, the directed flat fan frees up over 3 3/4″ extra inches of height clearance on the standard nozzle. With the no drip spray nozzle, it can gain you over 4 inches of clearance. This clearance can be very important when you consider the coverage you gain in a tight space.

Deflected Fan Advantage

Let me give you an example. A customer is running a 28 inch conveyor of machined parts through a 6″ tunnel and wishes to spray a solvent across the parts evenly.  In the past we would have needed to use the AF2010SS No Drip nozzles.  The AF2010SS nozzle would have done a great job, but the nozzle would need to be mounted at the top of the tunnel.  The overall length of the nozzle would limit the spray distance to 2 3/4″ inches.  With only 2 3/4″ of spray, it would require 11 nozzles to cover the 28″ span.  With the AD2010SS the bulk of the nozzle and the no drip body can be mounted behind the spray nozzle, which allows the spray distance to be 5 1/2″ which would cover a wide 8 1/4″ area.  With 8 1/4″ of coverage, what would have required (11) nozzles now only requires (4) nozzles.

Dave Woerner
Application Engineer
Davewoerner@EXAIR.com
@EXAIR_DW