Once obtaining the desired spray nozzle, you will need to think about the size of the spray nozzle tip. The spray nozzle tip will need to be calibrated to provide the optimal spray pattern, liquid flow rate, and pressure for the application. This factor ensures that the spray nozzle tips will provide the optimal amount of liquid for the task without leading to water waste. Here at Lechler, we provide spray nozzle solutions that are designed and engineered for your operations. Let us help you decide on the best nozzle for your application.
Why Spray Nozzle Size and Calibration Matter
Every application will require varying amounts of sprayed liquid, whether you are using cleaning solutions for tank scrubbing, water sprayed as a mist for dust suppression, or applying liquid-based fertilizers for crops. These liquids can interact differently with spray nozzle tips. Some liquids have a heavier rate and density than water where they fall faster and in larger droplet sizes due to gravity. Other liquids may be lighter, which will be impacted by the flow rate as it may disperse in a wide area when leaving the nozzle orifice and not reach the desired application.
Selecting the right spray nozzle size and calibrating it allows you to control the speed in which the liquid leaves the orifice, the direction of the spray, the size of the droplet, and whether the droplets are coarse or fine. You also have greater control over the gallons per minute (GPM) and the liquid pressure.
Understanding Spray Nozzle Tip Sizing
When choosing spray nozzle size, you have to determine the GPM (capacity) of the liquid for the application. The GPM represents the flow rate of the liquid traveling through the nozzle tip with a specific pressure. When it comes to nozzle size, the capacity as well as the flow rate typically stays the same no matter the size. Most manufacturers will have a chart specific to the application industry and nozzle type that will list the pressure, droplet size, GPM, and nozzle spacing, and speed of the liquid. With this chart, you can select the nozzle based on these factors.
Factors That Affect Nozzle Size
Many aspects of the application will have a direct impact on the size of the spray nozzle tips. The spacing of the spray nozzles and the boom height are just some of the things to be considered. Depending on the height and spacing of the nozzles will determine the liquid coverage, overlap of the droplets, and the liquid drift. You want to pick a nozzle that will account for drifting and have overlapping spray patterns without over-saturating the application or not providing uniform coverage.
The requirements of your application also play an important factor. Does the application need coarse or fine droplets? Will you be working with high or low water pressure rates? Does a specific area have special equipment that could become damaged depending on the size of the droplets? Understanding the answer to these questions can help you select the right sprayer nozzle tip.
Matching Size to Application
There are four specific aspects of the application to help match the sprayer tip size. The first aspect is to determine the application rate. You want to understand how many gallons of liquid you will be applying per acre or area (GPA). Next, you want to figure out the speed of the liquid that will be coming out of the spray nozzle. Low and high pressure nozzles will form varying droplet sizes at different rates. You also want to understand the spacing of the spray nozzle pattern when using a boom. Lastly, you want to evaluate the liquid's characteristics. The density, viscosity, and potential drift will also be a determining factor.
How to Choose the Right Nozzle Tips
By figuring out the GPA, liquid speed, and spray nozzle spacing, you will be able to calculate the gallons per minute (GPM) that can help you pick the nozzle. The first part of the calculation involves taking the GPA and multiplying it by miles per hour (MPH) and by the width of the nozzle spacing from the center of one nozzle to the next nozzle. Then you want to divide this figure by 5940 to obtain the GPM for the spray nozzle tip.
The number 5940 is a constant number that makes it easier to do the unit conversion measurements when sizing spray nozzles. The number will always be used when calculating MPH, GPA, and GPM.
Now that you have GPM, you can look at the spray nozzle chart and find the GPM. Then look for the droplet size (coarse or medium) and the liquid pressure to narrow your choices down to the correct nozzle type.
The Importance of Tip Calibration
Once you've determined the size of the spray nozzle tip, you will need to calibrate it to the application. Calibrating the nozzle tip ensures that the application receives the right amount of liquid. To calibrate the nozzle, you want to set the flow rate and pressure (if applicable). Then perform a test with the sprayer at the specific sprayer speed and time how long it takes to cover the area.
Next, take the sprayer and use a container to catch the water as you spray the liquid into the container at the same speed for the same length of time. Then you want to measure the liquid as this measurement determines the spray nozzle's output. By having the average nozzle output, you can see if it meets the flow rate for the application. If not, you can adjust the speed, nozzle size, or pressure.
When to Replace Spray Nozzle Tips
Replace spray nozzle tips if you notice visible cracks, pitting, or leaks. You also want to replace the tips if you notice an increase in liquid drift, uneven coverage, or poor flow rates. Another time when you may replace the spray nozzle is if there is a significant change in the spray pattern that is not caused by clogs or can be cleared away after cleaning the spray nozzle tip.
Spray Nozzle Tip Cleaning and Storage
To clean a spray nozzle tip, you want to remove it from the rest of the spray assembly. You can then soak the tip in the cleaning solution and use a very soft bristle brush to gently scrub any stuck on dirt or grime. Rinse off the spray nozzle tip thoroughly before reinstalling. If you plan to store the spray nozzle tip after cleaning, ensure that the tip is completely dry to prevent rust or corrosion. Place the nozzle tip in a safe location or you can use a spray nozzle holder designed for tip storage.
Optimize Your Spray System with Lechler USA Today
Whatever your application, you require spray nozzles that are engineered with the most durable materials, are anti-clogging, and will seamlessly integrate in your existing operations. Here at Lechler, we provide customized spray technology solutions tailored to your specific industry and application. Reach out to us today so view our wide selection of spray nozzle products and accessories.
