Air Control Applications: Product Selection Guide
Specifying the Best Air Control Nozzle for Your Application
Whether you're in the automotive, surface treatment, food processing, die casting, or steel industry, you're likely concerned about process improvement, air consumption and noise reduction. Air control nozzles are one component that can improve the quality of your production while reducing operating costs. Plus, specifying the right air control nozzle can reduce noise problems in your plant, which is particularly important for complying with OSHA safety regulations. Our products are expressly designed to improve performance, reduce noise, and save on air costs in most drying, cooling and conveying applications. Here are some examples.
- Our air control nozzles convert a low-pressure volume of compressed air into a targeted, high-velocity concentrated stream or flat fan of high-impact air. This creates a better quality air pattern than open pipes, drilled holes and many other air control nozzles. That means dependable, repeatable performance that can improve your process
- Noise from compressed air is one of the biggest environmental hazards in the workplace today. Using air control nozzles can reduce the perceived noise from compressed air by over 50 percent
- Compressed air is an expensive utility. A properly designed and maintained air control system can save hundreds or even thousands of dollars each year in operating expenses. So in addition to improving your processes and making your workplace quieter, air control nozzles can pay back their cost many times over
More information on noise reduction and cost savings
Key Considerations for Selecting Air Control Nozzles
There are five main characteristics that should be considered when selecting an air control nozzle. They are capacity, effective spray coverage, sound level, lineal impact force and specific impact force. Each characteristic plays a role in choosing the most effective nozzle for a given application.
Capacity
Capacity for a flat fan air control nozzle varies with spraying pressure. In general, the relationship between scfm (Nl/min) and pressure is as follows:
scfm1 (Nl/min1) = (psi1 or bar1)n
scfm2 (Nl/min2) = (psi2 or bar2)n
where "n" is the exponent applying to the specific nozzle type (i.e., flat spray nozzles = .50).
Effective spray coverage
Spray coverage is described as the width of the spray pattern for a flat fan air control nozzle. Effective spray coverage is the width of the fan, which comprises a minimum spray force measurement. This coverage can be used as a guide for spacing nozzles.
Effective spray coverage varies for different types of air control nozzles. While effective coverage is relatively consistent above 40 psi (2.8 bar), it may decrease at lower pressures. In general, effective coverage increases as distance from the nozzle increases.
More information on spray coverage
Sound level
Capacity and nozzle design both affect noise levels. In general, higher flow rates increase noise levels. Other factors include air pressure and obstructions in the nozzle's path. Spraying the nozzle against objects will increase sound levels.
More information on sound level
Lineal and specific impact force
There are two types of impact to consider when selecting air control nozzles: lineal impact and maximum specific impact. Both lineal and specific impact increase with pressure. When capacities are the same, a nozzle with a smaller coverage will have greater impact than one with a wider coverage.
Lineal impact indicates relative force per unit distance across the spray width. Flat spray patterns have fairly uniform impact distribution across the effective spray coverage. Spacing of nozzles in a header according to the effective spray coverage will provide consistent lineal impact across the entire length of the target surface.
Maximum specific impact is a direct indication of spray intensity applied to a surface. It provides maximum force per unit area information, which can be used to compare spray effectiveness under various conditions.
More information on lineal and specific impact force
Product Performance Overview
Review various air control products and key specifications including:
- Maximum coverage
- Maximum capacity
- Maximum pressure
- Inlet connections
- Available materials
Tips for Using Air Control Nozzles
- Always select the lowest flow nozzle that will achieve the desired result to maximize air consumption savings and noise reduction.
- Install a pressure regulator and gauge in the air line before the air control nozzles and regulate pressure down to the absolute minimum necessary to achieve the desired result. Lower pressures improve safety, reduce noise, and could save hundreds of dollars a year in operating costs!
- To minimize noise, increase the distance between the target surface and the nozzle, if possible. Remember that noise is caused by air impacting on the target work-piece, particularly edges or holes.
- Install adjustable ball joints with air control nozzles to provide simple, accurate adjustment of nozzle orientation.
- Don't aim the nozzle straight at the target for cleaning applications. Angle the nozzle 15° to 45° to ensure that the contaminant is removed from the product surface.
- WindJet® air control nozzles, in an appropriate material, can be used with CO2, Nitrogen, steam, or other compatible gases for special heating or cooling applications.
- To create an air curtain, nozzles don't always need to be positioned as closely as on an air knife. Nozzles can be up to 12" (30 cm) apart depending on the application.
- You can aim the air control nozzle to "wipe" sideways across a moving target at a comparatively shallow angle for many blow-off applications. This can reduce the number of nozzles needed.
- Angle WindJet Airknife Manifolds like a snowplow above a moving conveyor so that the contaminant is forced off the belt, rather than back.
- Proper filtration of compressed air is key for efficient air control nozzle performance. Be sure to use a filter/separator to remove excess oils and water.
Visit iSpray for selection assistance and easy online ordering. Or, contact your local sales and engineering office.
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