Energy Savings By Use of the Correct Spray Nozzle

Rising production costs and fierce competition iscorrect nozzle, but payback can probably be
resulting in manufacturing companies looking at allcounted in months and in some case weeks.
aspects of savings, especially energy savings.As an ongoing maintenance program, substantial
Spray nozzles of the right specification can lead tosavings will be made by regular inspection and
significant savings in both energy and rawmaintenance of the spray operation and possible
materials.replacement when nozzles become worn, through
One of the overlooked areas is the use of theblockages, corrosion, wear and accidental damage
correct spray nozzle. Whilst frequently ignored inRegular maintenance of the spray nozzles must
the manufacturing process, it is often this item ofbe undertaken to ensure the nozzles have
equipment that is the most important. Headeroptimum spray performance.
tanks, pumps sophisticated controls, pipe workAll nozzle configurations should be analysed on a
are all immaterial if the spray nozzle "at the sharpregular basis to ensure that the spray pattern,
end" is not delivering the right amount of fluidflow and operating pressure cannot be improved
(flow rate) at the correct spray angle and withupon, possibly with new nozzle technology, or the
the right spray pattern. This can lead to excessivefact that the application process has not changed.
wear on the pumps and ancillary equipmentThe latter being the case then a new specification
resulting in higher energy consumption and relatedshould be sought.
costs.As well as energy savings, raw material savings
The phrase it sprays, is often used, but howmust also be taken into consideration and it is
effectively is often not considered.feasible to experience water reduction of up to
In addition to these more obvious savings there40% in certain industries and spray nozzle
are a many "hidden" savings to be made.applications.
Expensive down time and failed equipment couldAlso to be taken into consideration must be the
be contributed to poor nozzle performance.application where the spray fluid is not water, but
Production lines designed to operate continuouslymore expensive chemicals or fluids. With correct
are expensive items if shut down owing to badlynozzle design even greater savings may be
performing spray nozzles and this failure couldachieved.
affect the total production plant with the resultingEnergy savings can be made in pump operation
unsuccessful distribution to customers, which inand it some case it is possible to reduce the
turn may affect their production.number of pressure pumps, thereby saving
All this from the wrong or poor performing sprayconsiderable operating costs and associated
nozzle!!maintenance cost.
The correct spray configuration is essential toTo summarise, energy savings, raw material
maximise the spraying operation and continuoussavings and a reduction in the wear and tear of
spray nozzle development will lead to greaterother equipment can all be experienced if the
beneficial savings.correct spray nozzle is specified.
In addition, the wrong or worn out spray nozzleThe specification must include nozzle material,
will eventually lead to poor finished products andspray angle, spray pattern, flow and pressure.
possible rejection of expensive products. ThisWith all these set correctly a regular maintenance
could result in extra production to make goodprogramme should be undertaken. With the
these shortfalls, with the resulting increase incorrect specification and maintenance schedule
energy costs. All this will reduce profit margins.then energy and raw material savings can be
Initial investment will be required to introduce theexpected.