Low cost items still need care

Nozzles wear out quicker than many people think, particularly if the manufacturing quality of the nozzle is not to a high enough standard.However, according to BETE, it is often the case that the downtime and inconvenience associated with examining and replacing a nozzle deters some maintenance managers from checking this equipment

Poor, non-effective cleaning is occurring in a pre-treatment plant, resulting in quality control rejects or worse still, complaints. The root cause of the problem is worn, clogged or poorly aligned nozzles, but this is not known at the time.

Wrong diagnosis It is thought that the problem must be something to do with the chemicals being used. Perhaps it's a new batch? The problem is 'remedied' by increasing the flow rate or increasing the concentration of chemical cleaner used. This seems to solve the problem for while, but of course the nozzle continues to wear or becomes even more clogged, so the problem re-occurs. Operating costs increase as chemical use is increased, and money, quite literally, is being poured (or sprayed) away. Also, the chemical supplier is probably taking flak unfairly.

A solution While it may seem logical to blame a poor batch of chemicals, it would perhaps have been advisable to look at the spray setup/ nozzles as well. The main reason for a plant maintenance manager being dissuaded from carrying out a nozzle audit is the length of time and effort required. Nozzles need to be taken out, put back in and re-aligned, which, of course, means downtime.

Replacing nozzles in a pre-treatment tunnel is not the most pleasant way to spend a day. This being the case, it can be tempting to blame the chemicals for the problem instead of tackling the possible root cause. At the very least there is a temptation to put off investigating the condition of the nozzles.

If left unchecked, this situation can lead to the real cause of the problem going undiagnosed for a long time and possibly leading to more serious problems. If a problem with the chemicals is incorrectly suggested then increasing chemical flow rates or concentrations may be a temporary 'solution', even if it's actually a nozzle problem.

However, this 'solution' will provide false validation of the erroneous diagnosis and hence the real issue will remain unaddressed.

The reality may be that it is the sheer hassle and effort involved that is putting some maintenance managers off checking their nozzle array.

Colour coding Spotting the difference between a 45° spray and 55° spray tip is almost impossible at the best of times. If you have been sent the wrong product or they get mixed up in your store room, when would you spot the error? For most, the honest answer is 'When it's too late', ie when spraying starts. But what if the different spray tips and nozzles were made from different coloured plastics? It's a simple idea but one that can make a difference.

Quick release system Often it's just the nozzle tip that needs replacing, although most nozzles will then require re-aligning. For example, quick tip release system nozzles are available allowing nozzles tips to be snapped in and out at the exact same angle so there is no need for realignment.

This reduces the time needed for changing nozzles. Good practice is to have a complete spare set of tips and nozzle holders that are always maintained in top condition.

These can then be quickly snapped into place. The old set can be checked, cleaned and any necessary replacements re-ordered.

Expert help While it's unlikely that a nozzle supplier will be one of your key business relationships, it is still worth cultivating a good dialogue. The nozzle business is specialist and wide ranging and there is a large amount of expertise to be tapped into.

Quality matters Nozzles are a relatively low cost component but if they go wrong the knock-on costs can be high. Nozzle and spraying system specialists BETE offers more than 20,000 different nozzle products and has specialist technical knowledge. Investment in state-ofthe- art order processing and warehouse management technology means it can deliver the next day, or even the same day if it's urgent. As no minimum order values are required, if you only need one nozzle, one nozzle will be delivered.

BETE nozzles are used in a wide range of industries for various applications, for example in cleaning processing machinery, screen washing, cooling hot gases, extinguishing fires, neutralising micron-size pollutants, coating delicate electronics, and for applying colours and flavourings.