Case Studies
New nozzle design increases throughput by decreasing maintenance time in coating application
Maintaining your spray system is an absolute necessity. But what do you do when maintenance time becomes excessive?
One manufacturer with a coating application was shutting down its operation every ten minutes to clean nozzles to ensure even spray distribution and product quality.
To resolve the problem, we conducted extensive research and testing on a header consisting of a new nozzle designed to prevent drops from clogging the nozzle air cap.
Our spray characterization testing validated the header would provide the same performance as the nozzles currently in use but could operate 12-times longer without requiring cleaning.
The manufacturer saved $60,000 annually due to a reduction in labor/maintenance costs and a decrease in production downtime.
Spray performance testing reveals solution to mold problem for one food manufacturer
Mold is a huge problem for any manufacturer, but in the food industry it can be disastrous. We were contacted immediately when one food company detected mold on the outside of glass bottles. The cause of the mold was dried, excess product trapped under the bottle label.
We developed two headers for testing that would allow for maximum flexibility in the number of nozzles used, nozzle height and nozzle spacing. Various spraying pressures, spray angles and nozzle types were evaluated.
The final solution included using multiple nozzle types in multiple positions and spraying from different directions to ensure adequate impact to remove excess product and thorough bottle cleaning.
New nozzle design enables military aircraft components to be coated with highly acidic solutions
An optical equipment manufacturer was unable to successfully coat a glass lens because of leaching resulting from the use of a caustic spray solution. Extensive material testing by the manufacturer yielded no success.
Our solution was to develop a special air atomizing nozzle constructed of Hastelloy® C with all internal wetted surfaces made of Teflon® to eliminate leaching. But, we took it one step further and developed a special internal mixing chamber to ensure the acids are thoroughly mixed prior to exiting the nozzle orifice.
The new nozzle design eliminated the quality control problems previously plaguing the manufacturer and improved coating uniformity as well.
Biomedical application requires new way to spray encapsulated particles
Spraying microparticulates can be challenging due to very precise drop size requirements. And, when the mircroparticulates are sensitive to light, heat or oxygen, the entire process becomes even more complicated. That’s why one drug discovery company turned to us for help.
Our first step was to find a nozzle that could produce the required drop size. Then, to minimize waste and reduce possible operator inhalation of the organisms, we added a mist suppression system. The final stage included the integration of a control system to automate and regulate the spray in preparation for scale up.
Fine-tuning spray application saves one manufacturer hundreds of thousands of dollars
Our customer was using hydraulic nozzles in a coating application and was satisfied with the performance. However, planned process changes prompted an on-site visit and spray system review.
We recommended switching to air atomizing nozzles. Spray characterization testing documented an improvement in spray performance, a reduction in scrap and lower operating costs due to the use of lower pressures and the elimination of high-pressure pumps. Longer wear life of the air atomizing nozzles also added to the bottom line benefit.
The result? Savings of $180,000 annually.
Finding a way to spray even the most difficult solutions
New legislation required our chemical client to find a new way to apply its product to fabric or exit the market. The previous application method did not involve spraying and our client was concerned that its product was “un-sprayable.”
We conducted a wide variety of tests in our lab and determined not only could the product be sprayed, it could be sprayed using a standard air atomizing nozzle.
Successful application of UV coating on glass products on conveyor
One of our clients was seeking an alternate system to apply 10 μm of a UV coating solution to products on a conveyor. The existing system was too slow, too expensive and too easily damaged.
We first conducted spray distribution testing in our labs and then moved to our client’s plant for on-site testing. At the end of the testing period, our client was presented with several possible header options consisting of different types and combinations of both air atomizing and hydraulic nozzles.
Process improvement requires extreme changes in production
Can a solid be successfully heated to liquid form and then spray cooled to create a granulated powder? Our client didn’t think it was possible but hoped it would be.
We went to work in our labs and within weeks provided several powder samples for subsequent evaluation in our client’s labs. The powder passed all the tests both in the lab and during the pilot phase. Plans to scale up to full production have been approved and implementation is underway.
Leading chemical company needs solution to a multitude of problems caused by inconsistent particle size and distribution
The proprietary nature of this application precludes us from providing details. In general terms, we were asked to develop a nozzle that:
- Produced good flows.
- Minimized particle size distribution.
- Helped eliminate particle fines.
- Reduced atomization gas.
- Eliminated nozzle dripping.
The nozzle design was presented to our client and then commissioned for prototype development. The prototypes are still being tested but results to date indicate the nozzles are performing per specification and product quality is enhanced.
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