Over time, all nozzles will eventually wear out or become clogged. It is strongly recommended to regularly clean and check for wear, as worn nozzles are often the root cause of insufficient spraying. Given that the cost of chemicals and water usually exceeds that of the nozzle, it may not be cost-effective to avoid replacing worn nozzles. Although replacing nozzles for cleaning and inspection can cause downtime, particularly for a large pre-treatment line with 1,000 nozzles, there are solutions to speed up this process.
Even slight wear or blockage can alter the spray pattern, as nozzles work by forcing fluid through a precisely machined opening. The shape of the opening determines the spray pattern and angle of the liquid. Even a small amount of particle buildup can significantly alter the resulting pattern, which can lead to areas being missed or undertreated, over-treatment of certain areas, or chemicals being sprayed at an incorrect angle. All of these can adversely affect the quality of the process and ultimately cost money.
SPRAY AREA COVERAGE
Designing the tunnel to spray only in the necessary areas can be challenging, and the optimal setup often requires trial and error. Minor adjustments to nozzle angles, spray points, individual nozzles, and nozzle positioning on pipelines are often necessary, and this can be a time-consuming process. The challenge is compounded when multiple items are being treated in the same tunnel.