Ultrasonic Spray Nozzles
Synergy Spray Systems supplies advanced ultrasonic spray nozzles in India, designed for ultra-fine coating, humidification, and precision chemical application. These high-performance ultrasonic nozzles—also known as electrically actuated spray nozzles—use high-frequency vibrations to convert liquids into a uniform mist of micron-sized droplets.
Our systems are widely used where controlled, low-flow, and highly accurate spraying is essential.
How Ultrasonic Spray Nozzles Work
An ultrasonic sprayer operates by converting high-frequency sound waves into mechanical energy. This energy forms standing waves in the liquid, and as the fluid exits the atomizing surface, it breaks into a fine, consistent mist. Because droplet size is controlled by resonant frequency, ultrasonic atomizer nozzles produce a very narrow droplet distribution.
For example, a 120 kHz ultrasonic atomising nozzle generates droplets around 18 microns—ideal for precision coating and moisture-sensitive applications.
These nozzles are manufactured using high-strength titanium alloy and corrosion-resistant materials, ensuring long life, excellent acoustical performance, and safe operation in industrial environments.
Variable flows (pulse width modulation)
With such fast and reactive on/off cycle times the Electric Hydropulse can achieve vary the flow from the nozzle without varying the fluid pressure. This is achieved by pulsing the nozzle very rapidly, (pulse width modulation – PWM). So, for example, a half flow could be achieved by having a 0.05 second on to 0.05 second off cycle time. This would halve the overall flow rate at any given pressure. Because the on-off cycle is so fast the resulting spray remains very evenly distributed even when targeting fast-moving conveyors.
With a normal hydraulic nozzle flow rates could only be controlled by varying the fluid pressure. This, however, will alter other important spray characteristics such as droplet size. When variable flow rates are required due to, say, different product lines, it might not be possible to achieve the required variance with a hydraulic nozzle. This would mean a nozzle change between production runs. The HydroPulse Electric will mean the same nozzles can be used despite variable dosing requirements.
- Additionally, rapid pulse modulation allows for lower flow rates to be achieved when compared to traditional hydraulic nozzles. This can be important in some very low flow rate applications.
How Ultrasonic Spray Nozzles Work
- Control a wide range of flow rates
- Reduce consumption of expensive coatings
- Reduce overspray waste and improve product quality
- Guarantee an even and uniform application rate that connects with conveyor line for automated speed adjustments
- Exact target coatings secure a clean and safe environment
- Promote increased production
- Reduce maintenance and downtime
- Reliable spray dosing.
Applications of ultrasonic nozzle
Our ultrasonic atomizing nozzles are used across food processing, pharma, packaging, and industrial sectors, including:
- Antimicrobial agents for food safety
- Preservatives and mold inhibitors to help
- extend shelf life & Egg wash
- Coat bottles to minimize scuff damage
- Apply water to balance moisture loss from the freezing process
- Apply viscous coatings like syrups, glazes, and chocolate
- Coatings and release agents to pans, cookie sheets, and conveyors to prevent sticking
- Flavorings, oil, and butter to enhance the appearance and improve the taste of products
How Ultrasonic Spray Nozzles Work
Specialized Expertise in Ultrasonic Technology
We supply industry-grade ultrasonic spray nozzles built for precision applications, ensuring accurate droplet control and long-term performance.
Customized Droplet Size & Frequency Options
Whether you need fine misting, micro-coating, or fogging, we offer custom frequency ultrasonic atomizer nozzles to match your exact process requirements.
High-Quality Titanium & SS Construction
Our nozzles are manufactured using premium titanium alloys and corrosion-resistant components for superior durability and acoustic efficiency.
Advanced PWM Control for Variable Flow Rates
Our electrically actuated systems allow precise dosing and stable spray patterns even at very low flow rates—perfect for pharma, food, and electronics industries.
Proven Solutions Across Multiple Industries
Trusted by manufacturers in food processing, pharmaceuticals, packaging, electronics, and specialty coating sectors.
Energy-Efficient & Low-Maintenance Systems
Ultrasonic nozzles operate without compressed air, reducing energy consumption and lowering maintenance costs.
Technical Support & Application Guidance
We provide end-to-end support—nozzle selection, system integration, installation guidance, and troubleshooting—to ensure optimal performance.
Made in India with Global-Standard Engineering
All products are developed to meet international quality expectations while offering competitive pricing for Indian industries.
Products
FAQs About High-Pressure Fogging Systems
What factors affect ultrasonic spray nozzle price?
Price depends on frequency, droplet size requirement, material (titanium or stainless steel), spray width, and whether you need a standalone ultrasonic atomizer nozzle or a complete controller + power module.
Can ultrasonic nozzles handle viscous liquids?
Yes, ultrasonic nozzles can spray moderately viscous liquids like syrup, oils, glue, and coatings, but droplet size may change based on fluid thickness.
What is the difference between an ultrasonic nozzle and a normal spray nozzle?
A normal spray nozzle relies on pressure to atomize liquids, while an ultrasonic nozzle uses sound-wave vibration. This gives ultrasonic nozzles better droplet control, lower flow rates, reduced overspray, and much finer droplet sizes.
What droplet size does an ultrasonic atomizing nozzle produce?
Depending on frequency, an ultrasonic atomizing nozzle typically produces droplets from 5 to 50 microns, making it suitable for delicate and controlled coating applications.
Where are ultrasonic fogging nozzles used?
Ultrasonic fogging nozzles are used in humidification systems, cleanrooms, plant nurseries, electronics cooling, food storage rooms, and odor-control systems that require ultra-fine fog.
Are ultrasonic spray nozzles energy efficient?
Yes. Ultrasonic nozzles operate with low power consumption and do not require compressed air, making them significantly more energy-efficient than traditional atomizing nozzles.
Does water quality affect ultrasonic spray performance?
Yes, ultrasonic nozzles work best with filtered or low-mineral water to avoid mineral buildup on the vibrating surface and maintain consistent droplet size.
Do ultrasonic nozzles require compressed air?
No. Most ultrasonic spray nozzles can atomize liquid without compressed air, though some air-assist hybrid models exist for directional control.
Do ultrasonic nozzles clog easily?
Clogging is minimal because ultrasonic systems operate at low flow rates, but using filtered/liquid with minimal particulates is recommended to extend lifespan.
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