How To Choose the Perfect Spray Nozzle

How To Choose the Perfect Spray Nozzle

Selecting the right spray nozzle for your application can be overwhelming with all the options available. Nozzles significantly impact the efficiency of your operations, the quality of your product, and your overall bottom line. By making minor adjustments to your equipment, you can achieve significant savings. One such example saw a snack food producer $10M by switching to a lower-capacity nozzle. To read more about this case, click here. This article will provide the basic knowledge you need when choosing a nozzle. We encourage you to contact your local spray expert for additional information.

What Factors Affect Your Nozzles Choice?

When selecting a spray nozzle, it's crucial to consider the following factors:

1. Spray Pattern: The spray pattern of a nozzle determines the shape of the spray, which can be a flat fan, solid stream, full cone, or hollow cone. Each pattern is suitable for specific applications. For instance, flat spray nozzles are ideal for cleaning, rinsing, and coating, while full cone nozzles are great for washing, rinsing, and dust control.
2. Flow Rate: The flow rate of a nozzle, measured in gallons per minute (gpm) or liters per minute (lpm), indicates the volume of liquid that the nozzle can spray in a minute. The right flow rate depends on your specific application requirements.
3. Operating Pressure: The pressure at which a nozzle functions is known as the operating pressure and is measured in pounds per square inch (psi) or BAR. Higher spray pressure generally results in a higher flow rate for a given nozzle.  Higher pressure can also generate greater impact and finer drop sizes. Use our flow rate calculator to easily determine your operating pressure. 
4. Material: The material of the nozzle should be chosen based on the type of liquid being sprayed and the operating conditions. Common materials include brass, stainless steel, and many plastic materials, including polypropylene, PVC, PTFE, and PVDF.
5. Connection Type: The connection type of a nozzle, such as threaded, flanged, or quick-connect, should be compatible with your existing equipment.
6. Drop Size: The size of the droplets produced by a nozzle is critical in determining the right nozzle for your application. Smaller droplets are ideal for humidification, cooling, or coating applications. They provide extensive surface coverage and rapid evaporation, essential in precise applications. Conversely, larger droplets are more suitable for high-impact applications like cleaning, heavy-duty rinsing, or direct product application.

Always consider the specific requirements of your application when choosing a spray nozzle. If you're unsure, consult with a spray technology expert.

Spray Pattern Basics

Understanding the different types of spray patterns is crucial when selecting the right nozzle. Here's a brief overview of the common spray patterns:

Flat Spray	Flat spray nozzles produce a flat fan or sheet-type spray pattern, ideal for cleaning, rinsing, and coating. They offer spray angles ranging from 1° to 170° and flow rates from .003 to 1237 gpm.
Solid Stream	Solid stream nozzles produce a continuous, unbroken line of liquid. Common applications include cutting, cleaning, injecting, and targeted cooling. They operate at a spray angle of 0°
Full Cone	Full cone nozzles produce a solid cone-shaped spray pattern with a circular impact pattern.  They’re perfect for washing, rinsing, and dust control. They provide spray angles from 15° to 170° and flow rates from .05 to 8728 gpm.
Hollow Cone	Hollow cone nozzles produce a ring-shaped pattern suitable for cooling, washing, and dust control. They offer spray angles from 43° to 180° and flow rates from .05 to 3320 gpm.
Fine Spray	Fine spray nozzles are considered distinctly not because of a unique spray pattern but because of the small droplets they produce, which are ideal for humidifying, fogging, and dust control. They provide spray angles from 30° to 165° and flow rates from 49.2 to 8,160 gph.
Air Atomizing	Air atomizing nozzles produce very finely spray droplets, using compressed air for atomization rather than hydraulic pressure.  They are used for coating, humidifying, and fogging and are available with a wide range of flow rates and spray patterns.