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Spray Insights

Reducing Energy Use Through Spray Technology


Oct 22

There are probably spray operations in your plant which use far more energy than is necessary. The challenge is these wasters are not easily recognized. Let’s go to the source and identify some simple strategies for optimizing applications and reducing your energy use.

Right-Sizing Spray Nozzles for the Right Energy Use

How important is using the right-sized spray nozzles in reducing energy use? The answer may surprise you. If your plant’s nozzles aren’t properly sized for each spray application, the result can be a ripple effect of inefficiencies.

Significant amounts of energy can be wasted because the pump size is larger than is necessary and requires more power to operate. The right-sized nozzles can minimize pump size, reduce equipment costs, and save energy on every shift. If you’re heating water for a spray operation, incorrectly sized nozzles will spray more water than is optimal, requiring more heating and wasting more energy.

It's also important to consider the big picture. Most plants use hundreds of nozzles in various operations, including cleaning, humidification, cooling and more. Every nozzle that is incorrectly sized leads to waste that can easily be prevented. In addition, right-sizing nozzles can reduce energy use without compromising effectiveness.

You can find more ways to save energy and resources in our Sustainability Simplified Handbook. Read the handbook to learn the role spray technology has in saving energy, water, chemicals, coatings, money and time.

Reducing Compressed Air Consumption

Here is an eye-opening fact: compressed air can easily account for 1/3 of a plant’s total electricity usage.

For many plants, that major energy expense seems unavoidable. They view compressed air as a fixed cost, and it gets overlooked when process improvements are considered. If that’s the case in your operations, the following insights may change your perspective and your bottom line for the better.

Your plant may be able to save tens of thousands or even hundreds of thousands of euros annually by significantly reducing compressed air consumption. High-efficiency drying and blow-off options can dramatically increase efficiency, reduce operating costs, and optimize performance. For example, air knife packages powered by blower air can reduce operating costs by 95% or more.

In addition, optimizing your drying and blow-off operations can help reduce noise, improve worker safety, and deliver more precise and repeatable performance.
What types of changes should you consider? To compare the options for reducing compressed air consumption, check out our white paper

Automating Tank Cleaning

Production equipment requires regular cleaning to function properly. That’s an efficiency best practice which hasn’t changed, even though technology continues to evolve. But when it comes to efficiency, the method of cleaning your plant can make all the difference in energy use.

If your workers are manually cleaning tanks and totes, or using the fill-and-drain method, automation may offer an opportunity to save significant amounts of energy, millions of liters of water, and substantial amounts of chemicals. In addition, automated vessel cleaning is consistent and repeatable, meaning you can better plan and budget for the energy required in cleaning.
Automating tank cleaning can also minimize downtime — manufacturers report reductions in cleaning time up to 90%. You can also improve worker safety and minimize labor costs.

To learn how changing tank cleaning equipment helped one manufacturer save energy, water, money and time, download the case study. 

Why Saving Water Means Saving Energy

When a plant looks to save energy, a smart place to start is by reducing water use.

By decreasing water use in applications, plants frequently observe a significant reduction in energy use in the process. This is a cascade effect because the energy required to operate pumps, heat water and treat wastewater decreases proportionally as water use is reduced.

The performance of pumps, sensors and other hydraulic and pneumatic devices all affect the performance of your spray nozzles. With our spray controllers and automated spray systems we can help you improve product quality, reduce the use of water and costly chemicals and create a more efficient, cleaner and safer work environment.

At Spraying Systems Co., our water-saving initiatives have helped customers save millions of kWs every year. Customers often experience rapid ROI — in many cases, upgrades pay for themselves in months, if not weeks. Even water-intensive industries have the potential to significantly reduce water and energy use by making simple changes in their operations.

To see how this works in a real-world application, read our case study showing how one paper mill is saving more than US$93,000 annually on water, energy and treatment costs.
Our spray technology experts help customers save millions in energy costs alone. We can help you evaluate essential applications throughout the plant and suggest solutions to reduce energy, water and chemical use on every shift. 
Contact your local spray expert today.