Precision spray control reduces material costs by 50–80% in manufacturing
THE performance of any spraying operation, depends on a variety of system components working seamlessly to optimise production processes. From simple on/off control to real-time monitoring and automatic adjustments, advanced spray control technologies give manufacturers greater control over product quality, operating costs, and workplace conditions.
Spray nozzles can only perform effectively when the entire system is operating efficiently. Pumps, sensors, and other hydraulic and pneumatic devices can influence performance.
An established specialist in this field, Monitor Engineering has represented Spraying Systems Co. in Southern Africa for over seven decades. The company has helped manufacturers optimise operations through precision spray control technology that features electrically-actuated nozzles and controllers.
Managing Director Grant Orsmond explains, “Precision spray systems deliver precise fluid volumes with uniform coverage, eliminating overspraying, misting and dripping. This significantly reduces waste across applications such as coatings, flavourings, oils, release agents, lubricants, resins and waxes.”
Precision Spray Control improves efficiency in food manufacturing
In food manufacturing, precision spraying systems can extend the shelf life for products such as baked goods and cheese while reducing production costs. The consistent application of mould inhibitors at the correct volume ensures complete and reliable coverage.
Automation further enhances efficiency by reducing labour requirements, eliminating scrap caused by uneven application, and minimising cleaning time – all while improving product quality and maintaining food safety standards. Replacing manual rollers or air-atomised sprays, can significantly reduce the waste of costly coatings, oils, lubricants and chemicals.
Electrostatic nozzles for lubrication systems
Single-point electrostatic nozzles are particularly effective in lubrication applications. These nozzles enable precise application of low- or high-viscosity oils, release agents, and corrosion fluids to coils, sheets, stamping tools, and pipes.
Chain lubrication, for example, can be applied with exceptionally high transfer efficiency. This reduces oil consumption, minimises chain wear and breakages, and limits the downtime associated with chain-driven conveyors. By providing accurate placement and on/off control, lubricant consumption can be reduced by 70-80%.
Precise control of gas temperature and volume
AutoJet Gas Cooling Systems provide closed-loop control of all nozzles, pumps, sensors and other system components, simplifying the gas cooling process for effective emission control. This is ideal for cement plants, paper mills, power plants, steel mills, and waste incineration plants, among others.
In petrochemical processing, gas cooling systems and precision injectors support applications such as NOx control, feed injection, desuperheating, steam quenching, and chemical injection in off-gas streams and thermal oxidisers.
Precision spraying systems save time and money
Across all sectors of industry, precision spray systems make every drop count, reducing material costs by 50-80%, boosting line speeds, and eliminating hours of manual labour and maintenance.
Customers report quick payback through waste prevention, higher yields, and safer, more sustainable operations, thereby transforming precision spraying into measurable time and money savings.
For more info and for expert advice, contact Grant Orsmond at Monitor Engineering at email grant@monitorspray.co.za.
https://www.spray-nozzles.co.za/
