Industrial spray nozzles go through extreme use on a daily basis for business operations. They carry a wide range of liquids, such as chemicals, water, semi-viscous substances, and additives based on the application. Due to this constant use, clogs can form along the spray nozzle. When dealing with a clogged spray nozzle, understanding the reason for the clog allows you to determine the best method to perform maintenance. Find out how to unclog spray nozzle and tips on preventing such clogs in the future.
Common Causes of a Clogged Spray Nozzle
Identifying the cause of the clog is vital. When you know why the clog is happening, you can take the appropriate steps to clear it out the first time. If you misidentify the reason, you may end up performing multiple cleanings that are ineffective and repetitive. Here are some common causes for clogged spray nozzles.
Residue Build-Up
Residue from liquids and semi-viscous liquids may congeal or cling to surfaces. This build-up can continue to form with the nozzle's orifice. When there is residue build-up, you may see the spray pattern change where it is not providing full coverage. You may also see dripping nozzles, a nozzle that provides lower flow rates, or a complete stoppage.
Particulate Contamination
You may be using a liquid that has additives which bind together to form a clog along the orifice. Other times, the liquid you are using could have contaminates such as dirt, calcium, other particles that are bigger than the nozzle’s orifice. These particulates may reside in the bottom of storage tanks and be stirred up by the movement of the liquid.
Improper Maintenance
Performing maintenance can allow you to detect possible issues with the spray nozzle. These issues could be corrosion caused by the type of liquids or chemicals used in the application, erosion, or wear. When liquids corrode, erode, or wear out the metal of the spay nozzle, they can cause it to flake. These metal flakes can build up and clog the opening of the nozzle.
How to Unclog Your Spray Nozzle
You'll want to first evaluate whether the problem lies with the spray nozzle or the lance and pipe system. While it may seem like there is a clog in the nozzle, low water pressure or a clog further in the pipe system could be the cause. Once you have determined that you are dealing with a clogged spray nozzle, you can take the necessary cleaning steps.
Safety Tips
Ensure that the application is turned off to prevent the system from moving the liquid through the pipes. You want to use the correct personal protective equipment (PPE), such as gloves, goggles, and long clothing when handling the nozzle if you are dealing with any harmful chemicals. These chemicals may still leave residue on the nozzle as you clean it.
Determine the type of liquid used in the application so that the cleaning solution you use will not negatively interact with it. If the system uses heated liquids, wait until the equipment cools off before handling the metal parts.
What You'll Need
There are several different tools to use depending on how you plan to unclog and clean the spray nozzle. The different methods include using solvents, nozzle cleaning tools, and soaking away the clog.
If you are using solvents, you want to have rinse water available, the solvent, pliers, and protective gloves. When using a nozzle cleaning tool, you will need the tool and a container for the rinse water.
For soaking the clog, you should have two containers, one filled with your cleaning solution, and the other filled with clean rinse water. You may also need a soft brush.
Step By Step
Using the solvent method, you want to follow the instructions on the solvent to create the solution. Some solvents may need to be diluted or require proper ventilation due to the fumes. Soak the nozzle in the solvent for a specific amount of time depending on the strength of the solvent. With the pliers, remove the nozzle and rinse clean.
If you are using a nozzle cleaning tool, the tool will come with several attachments which may include a brush, a plastic pick, a spanner wrench, and a utility hook. You want to rinse away any build-up particulates and then use the brush along with the pick to dig out hard to remove grime. Then rinse the nozzle.
To soak away the clog, place the nozzle into a cleaning solution. Let the nozzle sit in the solution for at least 45 minutes. If there is any remaining debris, you can use the soft brush to remove it. Then rinse off the nozzle.
Tips to Preventing Clogged Spray Nozzles
Best practices to avoid clogged spray nozzles is to select high quality nozzles that are free flowing when using liquids that have additives. You want to size the orifice of the nozzle to the types of particulates that may be encountered in the liquid. Also, may want to install strainers further up in the system to catch particulates before they reach the nozzle.
Once selecting the right nozzle and strainer, you should establish a cleaning schedule to periodically remove and clean the nozzles. Adjust the schedule based on how often the nozzles get clogged. This practice will lessen the amount of cleaning that is required which will lead to fewer operational downtimes.
Select the right cleaning solution based on the liquids sprayed from the nozzle, the nozzle's materials, and the type of contaminate buildup that is encountered. You may need to use stronger solutions for grime that are difficult to remove, or weaker solutions to prevent damage to the nozzles. When the nozzle is not in use, store it in a dry container to protect it from dust and grime.
Does Your Spray Nozzle Need to be Replaced?
There will come a time when the spray nozzle needs to be replaced. If you are cleaning the nozzle too often or the cleaning solution is no longer effective, you may need to replace the nozzle. You should also replace the nozzle if there are visible signs of wear and tear or damage. Another factor is when the nozzle is showing signs of damage when using a cleaning solution, as the metal may have become too weak.
Select high quality nozzles that are anti-clogging and corrosion resistant from Lechler. Lechler nozzles are made from high quality materials that are durable and provide consistent coverage as well as flow rates. Our nozzles can improve the performance of your application while being cost-effective to your budget.
Choose Lechler for Your Spray Nozzle Needs
Lechler offers a wide selection of spray nozzles such as flat fan, hollow cone, and full cone along with misters as well as atomizers. Whether you need a liquid or air nozzle, we can engineer and design the spray nozzles that fit into your operational setup. Contact us today!
