5 Important Factors When Selecting an Atomizing Spray Nozzle

The most recent EXAIR Webinar is up and ready to be viewed as an on demand video. This presentation showcases five important factors when selecting an atomizing spray nozzle. Throughout the webinar you will gain several key takeaways that are outside of the five factors as well. If you have a liquid spray application and are not sure where to start, this video has a wealth of information for you. As always, the Application Engineer department is also here and ready to assist as needed. We can walk through any application with you and help right over the phone, through email, or even live chat.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Big Nozzle, Big Award…Again!

The year was 2016, and it was quite a time for sports fans:

  • Team USA dominated at the Summer Olympics in Rio de Janeiro. Swimmer Michael Phelps won five Gold Medals, and gymnast Simone Biles won a Gold Medal on her own, and another for the team event, contributing to the 46 total Gold Medals won by United States Olympians.
  • The Chicago Cubs and Cleveland Indians took the World Series to all seven games…and extra innings in Game Seven. That makes it hard to disparage either team, but the Cubs prevailed, winning the Fall Classic for the first time in 108 years.
  • World Series heartbreak notwithstanding, Cleveland sports fans were pretty happy a few months earlier when the Cavaliers cinched the NBA Championship in seven games, defeating the heavily favored Golden State Warriors…who beat the Cavs in both of their regular season games that year.

Another big winner (non-sports) that year was EXAIR Corporation’s Model EF5010SS External Mix Narrow Angle Flat Fan Pattern 1/2 NPT Atomizing Spray Nozzle…it won Plant Engineering’s Product of the Year Bronze Medal Award in the Fluid Handling category. Yes, there’s a Compressed Air category, and our products have won a TON of those too…as well as some other categories:

  • Material Handling (Line Vacs)
  • Maintenance Products (Super Air Nozzles)
  • Environmental Health (High Lift Reversible Drum Vac)
  • Automation & Controls (EFC Electronic Flow Control)
Just a few of our past Product of the Year award winners in categories other than “Compressed Air”.

Anyway, now it’s 2021, and the No-Drip version of that Atomizing Spray Nozzle – Model EF6010SS – has won Plant Engineering’s GOLD Medal Award in the Fluid Handling category. Model EF6010SS offers the same performance as the EF5010SS:

  • Liquid flow rates from 141 to 303 gallons per hour (tested with water)
  • Flat fan spray dimensions from 15″ wide (6″ from target) to 25″ wide (15″ from target)
  • Atomized spray at a distance of up to 35 feet away

And, of course, the No-Drip feature means you can instantly stop liquid flow by shutting off the compressed air supply, up to 180 cycles a minute, if needed. This is a great feature to have to cut down on the cost – and the MESS – associated with overspraying.

Our comprehensive line of Atomizing Spray Nozzles has options for most any liquid that can be sprayed, with a wide range of flow rates and pattern size/shapes. The 1/2 NPT External Mix Narrow Angle Flat Fan model is ideally suited for liquids with higher viscosities where a higher flow rate/thicker coating is needed, as opposed to a humidification or misting application, where a smaller Atomizing Spray Nozzle might be specified. Some current, successfully reported, applications include:

  • Snack food provider – applying flavoring to bulk snack materials.
  • Commercial bakery – spraying cooking oil onto pans used in a conveyor oven.
  • Sporting goods manufacturer – applying adhesive to the tops of skateboard decks to glue the grip tape on.

If you’d like to discuss a particular liquid spraying application, I’d love to help…give me a call.

Russ Bowman, CCASS

Application Engineer
EXAIR Corporation
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NEW 1/4″ HollowStream™ Cone Liquid Atomizing Nozzle – IN STOCK And Ready To Ship!

Lately, around the globe, we are all getting a little too used to hearing this from vendors. “Okay, so I have your order for one piece, and that is going to be on hold for 8 weeks until we can get parts in.” At EXAIR, we are able to state our products are in stock and ready to ship same-day on orders received by 2 PM ET that are shipping within the US or Canada. There is no exception when it comes to our brand new 1/4″ NPT HollowStream™ Cone Liquid Atomizing Nozzle.

1/4″ NPT HollowStream Liquid Atomizing Nozzle

Since introducing our first liquid only nozzles (no air required) we have been working to add these hollow cone pattern nozzles add to our liquid spray nozzles (complimenting our full cone spray nozzles). There are six flowrate capacities with a 1/4″ NPT inlet. These capacities will range from .06 GPM (.23 LPM) up to 2.5 GPM (9.45 LPM) flow rates. The HollowStream provides a ring of liquid upon your target that can be used for cooling, cleaning, rinsing, or suppression of dust. By only using the outer ring to cover a similar space as a full cone spray the amount of liquid is reduced. This is all done by a pressurized liquid supply.

Spray Dimensions and Pattern

The small footprint of the nozzle matched with the spray volume and pattern is ideal for tight-fitting areas or areas where manifolds of multiple nozzles are required. The maximum through passage is also large enough to permit some slurries and particulate to pass through when recycling the rinse or wash water is needed.

If you would like to discuss your spray application and determine if the 1/4″ NPT HollowStream Cone Nozzle is right for you, contact us. We look forward to helping you determine the correct product that will make the most efficient use of your resources.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Liquid Spray Nozzles Improve Gummy Candy Production

One of the more popular treats for kids and adults are gummies.  They can be sweet, sour, and in different shapes and colors.  A candy company that makes gummy bears was looking for a better way to spray food-grade oil onto their product.  They contacted EXAIR about our Air Atomizing Spray Nozzles. 

We discussed their setup and process for making the gummy candies; or in this case gummy bears.  The sugary mixture is poured into molds that are coated with corn starch.  The corn starch helps to keep the gummy from sticking to the mold.  Once hardened, the bears will be released from the molds and travel through a stainless-steel spinning drum.  In here, they apply a light food-grade oil onto the bears.  This process will hide the starch and give the candy that glazed and colored feature.  The drum was near 60” (1.52 meters) long and spun at 19 RPM.  The gummy bears would tumble along the length of the drum at a designed production rate of 2000 Kg/hr. (4,400 Lbs./hr.).  They used drip tubes along the top to apply the food-grade oil onto the gummy bears.  They noticed that the color was not as good and the coverage was spotty.  The oil pump was metered in a range of 0.35 – 3 gal/hr. (1.32 – 11.3 l/h).  The temperature inside the drum could reach up to 150oF (65oC), and the viscosity of the food-grade oil ranged between 190 – 400 cps.  In order to get the best results for quality, they had to reduce their production rates to about 1,700 to 1,800 Kg/hr. 

To determine the correct solution, we had to dive a bit more into their application.  The details of the EXAIR Atomizing Nozzles are measured with water as the liquid.  Since they are using an oil at different temperatures, the specific gravity will change slightly.  For their oil, the specific gravity is 0.92 at 20oC and 0.89 at 65oC.  We can use Equation 1 to convert the required flow rate from the food-grade oil to water.

Equation 1:

Q1 = Q2 * SQRT (SG2 / SG1)

Q1 – Flow of water (gph)

Q2 – Flow of oil (gph)

SG1 – Specific Gravity of water

SG2 – Specific Gravity of oil

The Specific Gravity of water is 1.  With the range of specific gravity for the oil, we can calculate the range that is needed as indicated by water.  Then we can make a selection as referenced by our data in the catalog.  Since we want to make sure that we can cover the range of the metered oil pump, we will use the maximum flow rate of 3 gph.  In adding the values, we get the following:

@20oC  Q1 = 3 gph * sqrt(0.92) = 2.88 gph

@65oC  Q1 = 3 gph * sqrt(0.89) = 2.83 gph  

Since the viscosity ranges above 300 cps., I recommended the External Mix Atomizing Nozzles to be mounted along the length of the rotating drum.  The External Mix can handle viscous liquids up to 800 cps.  Unlike the drip method, the EXAIR Liquid Atomizing Spray Nozzles use compressed air to shear the oil into small droplets and to disperse the oil in a wide pattern.  With the smaller particle size, we can get more coverage area which will allow them to use less food-grade oil.  The coverage area on the gummy bears was near 15” (38cm) as they rolled down the drum.  I also recommended the No-Drip option to allow for versatility in their process.  The No-Drip option for the Atomizing Nozzles is a very nice option which will stop the liquid solution from dripping when not in use.  When they needed to apply the oil, they would just turn on the compressed air to the Atomizing Nozzle.  It made it very easy to control.  This was important to reduce excess usage and non-conforming parts. It also keeps the inside of the drum oil free during cleaning cycles.   

EB2010SS

From the data above, I recommended three pieces of the model EB2010SS, No Drip External Mix Wide Angle Flat Fan Pattern.  The spray pattern was 14” (35.6cm) wide to cover part of the 60” (1.52m) length of the drum.  With an estimated 1 gph for each nozzle, we would be able to spray the maximum requirement as calculated above (2.88 gph).  After installation, they were able to get a consistent deep color of the gummy bear at the maximum production rate of 2,000 Kg/hr.  They also noticed that with the fine particle spray, they were able to use less oil.  With the three pieces of the model EB2010SS, they were able to reach maximum production rates with less food-grade oil and reduce scrap rates.

If you have a liquid that you would like to spray evenly, efficiently, and effectively; EXAIR Atomizing Nozzles can do that for you.  You can contact an Application Engineer for help.  For the customer above, they were able to create those gummy treats for kids and adults.  Yummy.

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

Picture: Giant Gummy Bear by Alexas_FotosPixabay licence.