Spray Nozzle FAQ

Start with three numbers: the flow rate you need, the pressure available on the line, and the coverage you have to hit. From those, the pattern (flat fan, full cone, hollow cone or spiral) and the material follow from the duty. Our flow rate guide walks the math, and the spray angle guide covers coverage. Or send the duty to us and get a sized recommendation back.

Spray angle is set by the distance to the target and the width you need to cover. Coverage width roughly equals 2 × distance × tan(angle/2). The closer the nozzle, the narrower the effective band. Wide angles (80–120°) suit close-range cleaning; narrow angles (15–40°) reach further with less atomization loss. See the spray angle guide for worked examples.

Flat fan nozzles produce an even line of spray, ideal for cleaning strips, coating and roll cooling where uniform coverage per metre matters. Full cone nozzles fill the entire circle with even coverage, the workhorse for washing and scrubbing. Hollow cone nozzles concentrate the spray on the ring edge with finer droplets, which suits gas cooling, dust suppression and scrubbing. The types of spray nozzles guide compares all three with duty examples.

Flow through a nozzle follows the square root of pressure: double the pressure and flow rises by about 41%, not 100%. That is why published flow tables quote a flow at a reference pressure. For a different pressure, scale by √(P2/P1). Angle and droplet size also shift with pressure, so sizing at your real line pressure matters. The flow rate calculation guide shows the full formula.

Brass is cheap and easy to machine, fine for clean water and light duty, but it wears and corrodes faster, and dezincification is a real risk with aggressive water. Stainless steel (316L as standard) resists corrosion and erosion much better, which is why it dominates food, chemical and high-pressure duties. For most industrial lines, the stainless upgrade pays for itself in replacement cost. See the stainless vs brass comparison.

Polypropylene (PP) suits many mild acids and alkalis up to moderate temperatures. PVDF (polyvinylidene fluoride) handles stronger acids, halogens and higher temperatures. PTFE (Teflon) resists almost the full chemical table but is softer and pricier. When steel fails on a corrosive line, the right plastic outlasts it at a fraction of the cost: the plastic nozzle range covers the options.

Clogging usually comes from particles larger than the orifice, scale build-up, or dry residue after shutdown. Fixes in order: filter to below orifice size, choose a clog-resistant design (spiral nozzles have no internal vanes to trap debris), and flush lines after use. If particles are unavoidable, a spiral or a larger-orifice flat fan with the same flow will hold up far longer than a fine misting tip.

Tank cleaning needs the right coverage, not just pressure. Static spray balls suit gentle, full-surface rinsing of smaller vessels. Rotary and fluid-driven cleaners concentrate the flow into a jet that strips residues, covering the shell and heads with fewer nozzles and less water. The choice depends on tank size, residue type and whether you run a CIP cycle: the tank cleaning range and the selection guide cover both.

Air atomizing nozzles use compressed air to shatter liquid into a fine, controlled spray: droplets far smaller than pressure atomization can reach. Typical duties: coating and release-agent spraying, humidification, oil mist lubrication, evaporative cooling and dust suppression. Internal-mix versions atomize inside the body for viscous fluids; external-mix versions keep air and liquid separate until the tip. See the air atomizing range.

Drift is controlled at the nozzle, not after the fact. Air-induction (AI) tips draw air into the spray, producing larger droplets that fall faster and stay out of the wind. Match the tip to the target crop and application rate, keep pressure in the recommended band, and avoid spraying in high wind. The herbicide drift guide explains the droplet classes and selection logic.

Standard ranges ship from stock with no fixed MOQ. One piece is fine. Custom nozzles to drawing are quoted per part: tooling, prototype and production on one line, with the lead time confirmed before you commit. Tell us the annual volume and duty and we come back with a number, not a maybe.

Yes, OEM to drawing is our standard mode. Send a drawing, STEP file or sample with the material, flow and pressure requirements, and we handle tooling, prototype and production. Material, surface finish and tolerances are matched to your drawing. The OEM page explains the process.

Send your duty conditions: fluid, flow rate, pressure, temperature and the coverage or target you need. For tank cleaning include tank size and residue type; for coating include line speed and wet film target. We come back with nozzle options, figures and a quotation, typically within one business day. Use the contact form or email us directly.