Choosing the right spray nozzle is critical to achieving high performance, reducing waste, and improving the quality of applications across industries like dust suppression, evaporative cooling, washing, and chemical dosing.
At Synergy Spray Systems, we’ve engineered solutions for thousands of clients. This guide combines technical insights, practical charts, and real-world examples to help you make an informed nozzle selection.
Why Nozzle Selection Matters
- The right nozzle ensures:
- Uniform spray coverage
- Controlled droplet size
- Efficient fluid usage
- Lower operational costs
Whether you're setting up a dust control system for mining or a cooling process in manufacturing, nozzle selection plays a pivotal role.
Key Nozzle Parameters
1. Spray Pattern
Choose based on fluid distribution needs:
- Flat Fan – Linear spray (e.g., conveyor cleaning)
- Full Cone – Circular, even coverage (e.g., cooling towers)
- Hollow Cone – Edge-focused spray (e.g., coating)
- Solid Stream – Concentrated jet (e.g., high-pressure washing)
2. Flow Rate
Measured in LPM (liters per minute). Choose based on fluid delivery requirements:
| Tip Size | Flow Rate @ 3 bar | Spray Angle |
|---|---|---|
| 01 | 0.4 L/min | 80° |
| 03 | 1.2 L/min | 65° |
| 05 | 2.0 L/min | 40° |
| 10 | 4.0 L/min | 25° |
3. Operating Pressure
Higher pressure = finer mist.
- Low Pressure (10–40 bar): General washing
- High Pressure (80–200 bar): Dust control, fine mist cooling
4. Spray Angle
Select based on coverage:
- 15°–40° – High impact, narrow
- 65°–120° – Wide coverage, low impact
Application-Based Nozzle Selection
| Tip Size | Flow Rate @ 3 bar | Spray Angle |
|---|---|---|
| 01 | 0.4 L/min | 80° |
| 03 | 1.2 L/min | 65° |
| 05 | 2.0 L/min | 40° |
| 10 | 4.0 L/min | 25° |
Material Compatibility
Choose nozzle material based on fluid:
SS316 – Acids, chemicals, high-temp
Brass – Water, non-corrosive
PP/PVC – Lightweight, chemical-resistant, budget-friendly
Frequently Asked Questions
Q1: How do I determine the spray angle needed?
A: Use the formula: Width = 2 × height × tan(angle/2)
Q2: What pressure is ideal for misting?
A: 80–200 bar for finer atomization and wider coverage.
Q3: Can I mix nozzle types in one system?
A: Yes! For example, use a flat fan for cleaning and mist for cooling.
Q4: How often should I check nozzle performance?
A: Weekly for high-use environments. Look for clogs, uneven spray patterns, or reduced flow.