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Airless Precision Spray Systems

In manufacturing operations, fluids need to be applied in a distributed manner. One way of achieving this is to utilize an airless precision spray system. Sometimes referred to as a “Hydraulic atomizing” system, his type of product uses hydraulic pressure to break a liquid into droplets and form a spray. This differs from air-atomized spray systems which introduce compressed air to break apart a liquid into droplets. Both methods produce droplets and spray but each have their own advantages and disadvantages when it comes to fluid delivery.

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How airless spray systems work

Hydraulic (airless) spray systems work by utilizing the energy from a pressurized liquid to break that liquid intro droplets. In an airless spray nozzle, this is typically accomplished by forcing pressurized fluid through a reduced diameter orifice. As the fluid path narrows at the orifice, the potential energy in the liquid becomes kinetic energy and the fluid increases in velocity. The high-velocity fluid leaves the orifice and quickly encounters a difference in pressure as it interacts with the surrounding, slow moving air. If the difference in pressure across the orifice is high enough, the liquid breaks apart and forms droplets.

Advantages of airless spray systems

  • deliver more fluid faster than air-atomized systems (higher transfer efficiency)
  • create less fog and overspray than air-atomized spray systems
  • reduces material bounce back when spraying into cavities or recesses
  • Does not require compressed air
  • Provide better results for rinsing
  • Easier installation - No need to plumb for air

Disadvantages of airless spray systems

Atomization is coarse - this may be fine for certain less-demanding applications (open-air applications or applications with large spray areas). If a very fine spray is required an air-atomizing system should be used.

  • Less control over the spray pattern
  • Dependent on fluid pressure to work
  • Consumes more liquid than an air-atomized spray
  • Nozzles are more likely to drip when turned off
  • Nozzles can be more prone to clogging
  • Cannot properly atomize more viscous liquids

Airless Vs. Air-Atomized: Still a mystery? Contact us for more information!