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Technical reference common causes of spray nozzle problems COMMON CAUSES OF SPRAY NOZZLE PROBLEMS Many spray nozzle problems cannot be easily detected with a visual inspection. You should check the performance of your nozzles for damage during every preventive maintenance shutdown. What to look for depends on your application – sometimes it’s wear from a high-pressure process or caking from spraying a viscous liquid. Nozzle performance can be compromised or rendered totally ineffective by eroded, damaged or obstructed nozzle orifices. EROSION / WEAR HIGH TEMPERATURE Gradual removal of the nozzle material causes the nozzle orifice and internal flow passages to enlarge and/or become distorted. As a result, flow is usually increased, pressure may be decreased, pattern becomes irregular and the spray drops become larger. New Excessive Wear Certain liquids must be sprayed at elevated temperatures or in high temperature environments. The nozzle may soften and break down unless special high temperature resistant materials are used. New Heat Damaged Hollow Cone Nozzle Full Cone Nozzle CORROSION Nozzle material may break down due to the chemical action of the sprayed material or environment. The effect is similar to that caused by erosion and wear, with possible additional damage to the outside surfaces of the nozzle. In particular, the performance of air atomizing nozzles is highly sensitive to corrosion. Even small amounts of corrosion will negatively impact drop size and uniformity. Corroded New Full Cone Nozzle CLOGGING Unwanted solid particles can block the inside of the orifice, restricting the flow and disturbing the uniformity of the spray pattern. Clogged Flat Spray Clean Flat Spray BEARDING / CAKING IMPROPER ASSEMBLY Build-up of material on the inside or outer edges of the orifice can occur and is caused by liquid evaporation. A layer of dried solids remains and obstructs the orifice or internal flow passages. Bearding, the build-up of materials near the orifice of the nozzle, is also detrimental to nozzle performance and can have serious consequences in some nozzle types such as air atomizing. Caked New Some nozzles require careful re-assembly after cleaning so that internal components, such as gaskets, O-rings and internal vanes, are properly aligned. Improper positioning may result in leakage and inefficient spray performance. Over-tightening of nozzle caps onto bodies can cause thread stripping. Improper Assembly Proper Assembly Hollow Cone Nozzle Full Cone Spray Full Cone Spray 14 spray.com | 1.800.95 SPRAY | Intl. 1.630.665.5000
Technical reference preventing and solving spray nozzle problems PREVENTING AND SOLVING SPRAY NOZZLE PROBLEMS Some spray nozzle problems require special testing to detect. Consistent evaluation of the following factors will enable you to detect wear early and take appropriate action. Your own application will determine how often each factor should be checked. The proper frequency could range from the end of every shift to every few months. The checklist that follows should become the foundation of your maintenance program. Good spray tip Visual inspection of nozzle tips and spray patterns show little evidence of wear. An analysis of spray collection data reveals a 30% increase in capacity from the worn tip. Worn spray tip FLOW RATE For centrifugal pumps: Monitor flow meter readings to detect increases. Or, collect and measure the spray from the spray nozzle for a given period of time at a specific pressure. Compare these readings to the flow rates listed in the manufacturer’s catalog or compare them to flow rate readings from new, unused spray nozzles. For positive displacement pumps: Monitor the liquid line pressure for decreases; the flow rate will remain constant. DROP SIZE Drop size increases are difficult to detect. Examine application results for changes. An increase in flow rate or decrease in spraying pressure will affect drop size. SPRAY PATTERN Visually inspect the spray pattern for changes. Check the spray angle with a protractor. Measure the width of the spray pattern on the sprayed surface. If the spray nozzle orifice is wearing gradually, you may not detect changes until there is a significant increase in flow rate. SPRAY PRESSURE (IN SPRAY NOZZLE MANIFOLDS) For centrifugal pumps: Monitor for increases in liquid volume sprayed. The spraying pressure is likely to remain the same. SPRAY NOZZLE ALIGNMENT Check uniformity of spray coverage of flat spray nozzles on a manifold. Spray patterns should be parallel to each other. Spray tips should be rotated 5° to 10° from the manifold centerline. For positive displacement pumps: Monitor pressure gauge for decreases in pressure and reduction in impact on sprayed surfaces. The liquid volume sprayed is likely to remain the same. Also, monitor for increases in pressure due to clogged spray nozzles. PRODUCT QUALITY / APPLICATION RESULTS Check for uneven coating, cooling, cleaning or drying. Check for changes in temperature, dust content and humidity. 15 spray.com | 1.800.95 SPRAY | Intl. 1.630.665.5000
Page 1 and 2: PHARMAceuticals and BIOLOGICS catal
Page 3 and 4: Technical reference Table of Equiva
Page 5 and 6: Technical reference basic nozzle ch
Page 7 and 8: Technical reference drop size termi
Page 9 and 10: Technical reference spray angle and
Page 11 and 12: Technical reference estimating pres
Page 13: Technical reference other spray per
Page 17 and 18: TABLET COATING page Application Ove
Page 19 and 20: Tablet Coating VMAU Spray Nozzles V
Page 21 and 22: Tablet Coating VMAU Spray Nozzles S
Page 23 and 24: Tablet Coating VMAU Spray Nozzles V
Page 25 and 26: Tablet Coating JAU Spray Nozzles JA
Page 27 and 28: Tablet Coating JAU Spray Nozzles JA
Page 29 and 30: Tablet Coating Modular Air Atomizin
Page 31 and 32: FLUID BED processing page Applicati
Page 33 and 34: Fluid Bed Processing Fluid bed gran
Page 35 and 36: Fluid Bed Processing Nozzles and la
Page 37 and 38: Fluid Bed Processing Nozzles and la
Page 39 and 40: Fluid Bed Processing Nozzles for WU
Page 45 and 46: high-shear granulation page Applica
Page 47 and 48: High-Shear Granulation lances for h
Page 49 and 50: spray drying page Application Overv
Page 51 and 52: Spray Drying SV Spraydry ® Nozzles
Page 53 and 54: Spray Drying SB Spraydry ® Nozzles
Page 55 and 56: Application o v e r v i e w effecti
Page 57 and 58: Vessel CleaninG SELECTION AND OPTIM
Page 59 and 60: Vessel CleaninG cip / wip solutions
Page 61 and 62: Vessel CleaninG FIXED SPRAY BALLS D
Page 63 and 64: Vessel CleaninG FLUID-DRIVEN ROTARY
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Vessel CleaninG FLUID-DRIVEN ROTARY
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Page 71 and 72:
Vessel CleaninG REGULATED FLUID-DRI
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Specialty Nozzles ultrasonic atomiz
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Specialty Nozzles ultrasonic atomiz
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Specialty Nozzles windjet ® air no
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Application o v e r v i e w perfect
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Solid Dosage processing fluid bed s
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Solid Dosage processing High-shear
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Solid Dosage processing size reduct
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Solid Dosage processing control opt
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appendix page Accessories 90 Glossa
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appendix accessories accessories o-
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appendix glossary Glossary (continu
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