How long will a spray bar and nozzles last?

A spray bar itself is a durable piece of equipment that can provide a decade or more of service.

However, the nozzles in the spray bar are wear parts, and even small amounts of wear on precision components like nozzles can cause significant changes in spray performance.

As nozzles wear, the following issues may arise:

• Gradual increase in flow rates, leading to overspraying and waste.
• Degradation of the spray pattern, resulting in uneven coverage.

Factors Affecting Nozzle Lifespan

The rate of nozzle wear depends on several factors:

• Daily usage: The number of hours the nozzles are in use each day.
• Abrasiveness of the liquid: Liquids with high particle content will cause quicker wear.
• Environmental and liquid temperature: Higher temperatures can accelerate wear.
• Chemical erosion: Certain chemicals can erode the nozzle material over time.

Mitigating Nozzle Wear

Nozzle wear can be reduced by using wear-resistant materials. It is common for spray nozzles to be made from very hard materials, while the spray bar and nozzle body are made from standard stainless steel. For example, with certain nozzle types like the BJ series, only the spray tips are made from hard-wearing materials such as tungsten carbide, while the nozzle body is made from stainless steel. This approach reduces costs, as only the wear-prone parts are made from more expensive, durable materials.

Regular Maintenance and Best Practices

Nozzles should be inspected for wear on a regular basis. The best practice is to have a complete spare set of spray nozzles or tips and to swap them out periodically. Once an active set has been replaced, it can be inspected and tested for wear, and new nozzles can be ordered as needed. With this method, the spare set ensures there is no downtime or degradation in service, allowing the spray bar to continue operating at peak efficiency.