Spray Applications for Aluminium
Unlock higher quality, throughput and sustainability with optimized spray applications for Aluminium. We combine the world’s largest range of spray nozzles and automated systems with local expertise and advanced spray labs to deliver uniform film build, precise cooling and cleaner operation across continuous casting, levelers, rolling and strip processing.
Why Optimized Spray Applications for Aluminium Matter
- Quality and consistency: Correct droplet size, impact and pattern uniformity deliver the surface finish, film weight and mechanical properties Aluminium producers require.
- Throughput & OEE: Precise, repeatable spray improves line stability at any speed, reducing stops, rejects and rework.
- Cost reduction: Right-sized application cuts water, oils and chemicals while minimizing compressed air use and energy.
- Sustainability: Less consumption, overspray and mist mean lower emissions, safer work areas and cleaner effluent.
- Traceability: Recipe-driven control standardizes results across shifts, products and sites.
Key Challenges in Spray Applications for Aluminium
- Uniform cooling and quench control on complex profiles and wide strip without distortion
How we help: zoned headers with closed-loop control to line speed (stable pressure in bar; precise flow in L/min), - Consistent film build for lubricants, release agents and coatings as line speed changes
How we help: Precision Spray Control (PSC) uses electrically actuated PulsaJet® nozzles to modulate duty cycle at constant pressure - keeping spray angle and droplet size optimal while recipe setpoints in L/m² and header zoning match the spray width to the strip.. - Edge control and frequent width changes without streaks, stains or waste
How we help: multi-zone headers with independent on/off and flow per zone, edge-targeted sprays, recipe selection by product width and high-frequency spray control to maintain uniform coverage during accelerations, gaps and slowdowns. - Overspray, misting and fouling that create safety hazards and extra maintenance
How we help: enclosed coil lubricators with mist extraction, anti-drip valves, integrated filtration and easy-clean designs. - Clogging and downtime from emulsions and fines in harsh mill environments
How we help: tip strainers and self-cleaning filters, clog-resistant nozzle design, quick-disconnect/change tips, pressure/flow monitoring with alarms, and standardized spares to minimize changeover time. - Data, traceability and repeatability across shifts, products and sites
How we help: AutoJet® recipe-driven control with PLC integration, audit trails and digital setpoints.
Why Choose Spraying Systems Co. for Your Aluminium Spray Applications?
- Global player, local experts: Europe-based specialists who understand Aluminium casthouse, rolling and finishing operations - and speak your language.
- 100,000+ products and systems: The world’s largest range of spray nozzles, headers and systems - including AutoJet®, PulsaJet®, CasterJet®, WindJet® and TankJet® products.
- Advanced spray laboratories: Our lab experts can verify droplet size, impact and distribution at your viscosity and temperature.
- Intelligent control: Recipe-based automation, PSC duty-cycle control and PLC integration for stable quality at any speed.
- Sustainable by design: Reduce water, oil and chemical use; lower energy and mist; extend component life.
- Proven in Aluminium: Documented gains in film-weight control, scrap reduction, throughput, cleanliness and much more.
Continuous Casting Cooling for Aluminium
CasterJet® nozzles deliver uniform, high-impact cooling for continuous casters to stabilize shell formation and surface quality. Purpose-engineered spray patterns and zoned headers keep edge-to-centre temperatures consistent, preventing sticking, butt curl and cracking. Closed-loop control holds flow (L/min) and pressure (bar) on target as casting speed changes, improving yield while reducing water and energy use. For even tighter control, PSC-enabled high-frequency spraying and “no product, no spray” logic help cut mist and runoff.
Find out more about our Continuous Casting Cooling for Aluminium solution.
Levelling Lubrication
Our levelling lubrication solution applies a precise, uniform film to the strip and/or work rolls to minimize friction and prevent marking. Precision Spray Control (PSC) on PulsaJet® nozzles modulates duty cycle at constant pressure, keeping droplet size and spray angle stable as line speed changes so film build stays consistent. Recipes are set in L/m², and zoned headers match spray width to the product for tight edge control and minimal waste. Enclosed applicators with mist extraction help reduce mist, overspray and runoff for a cleaner, safer work area. Integrated PLC control adds traceable setpoints and “no product, no spray” logic to cut lubricant use without risking dry spots.
Selective Roll Cooling for Aluminium
Selective Roll Cooling shapes the roll’s thermal profile with zoned, high-impact sprays to stabilize strip flatness and crown in hot and cold mills. AutoJet® controllers modulate each zone’s flow (L/min) at constant pressure - so droplet size, spray angle and impact stay consistent as speed and load change. Recipes store edge/center spray maps and target application rates, enabling fast correction of edge wave or center buckle while minimizing water and energy use.
Learn more about our Selective Roll Cooling for Aluminium Application.
Gas Conditioning for Aluminium Smelters
Gas Conditioning for Aluminium Smelters controls potline and anode-bake off-gas temperature and humidity so the baghouse runs safely and efficiently. Using controlled spray injection with finely atomized droplets, we provide evaporative cooling and humidification to a tight approach-to-saturation, improving particulate capture without wetting filters. Our AutoJet® system closed-loop controls adjust flow (L/min) to real-time gas temperature and volume (m³/h), ensuring complete evaporation before the baghouse and stable operation across load changes. Where required, we integrate reagent injection to help neutralize acid gases while tuning droplet size and coverage to cut buildup and maintenance.
Learn more about our Gas Conditioning for Aluminium Smelters
Strip Processing
Our strip processing solutions - covering annealing, blow-off, cleaning, degreasing, pickling, quenching, rinsing and coating - demands precise, repeatable spray control to meet the requirements. AutoJet® systems with Precision Spray Control (PSC) modulate duty cycle at constant pressure to keep droplet size, spray angle and impact consistent as line speed changes, while recipes in L/m² ensure target film weights and chemical dosing. Zoned headers and edge control match spray width to coil width for uniform coverage with minimal waste, and WindJet® air knives provide efficient blow-off/drying using compressed-air or blower systems. Optimized nozzle selection and placement reduce overspray, mist and runoff, lowering effluent and supporting sustainability targets.
Contact Your Aluminium Spray Specialist
With 15+ years of experience in the Aluminium industry, Matthias Bodingbauer helps mills from levelling lubrication and selective roll cooling to quenching, coating and smelter gas conditioning. Our specialist works with local spray experts and advanced labs to validate the right nozzles, headers and control strategy for your line, quality targets and sustainability goals.
