Resourceful folks are always looking for ways to get the most out of their equipment. One way to do this is to repurpose tools whenever possible. One such tool is the trash pump. If you already have one and need to move fertilizer, it only makes sense to wonder, "Can I use my trash pump for fertilizer?".
The short answer is yes, in many cases, a trash pump can handle fertilizer. However, this is not always the case. Several factors affect a pump's ability to handle fertilizer, including the type of fertilizer, pump materials, horsepower, and more-all of which might impact the overall effectiveness and longevity of your trash pump.
Do not worry. In this article, we will explore not only whether repurposing a trash pump for fertilizer is a feasible option but also which situations make the most sense. We'll cover the basics of trash pumps, the properties of fertilizers, and how to know if your specific pump can handle the job.
What is a Trash Pump?
A trash pump is a type of centrifugal pump that is designed to move water that contains large pieces of debris, such as sand, gravel, sticks, etc. Generally, they are self-priming pumps that are constructed out of. Some are made from more durable metals like cast iron or ductile iron, while less expensive models are aluminum or other alloys.
Compared to other centrifugal pump types they are generally less efficient. This is because they are designed for versatility and not for efficiency. Most centrifugal pumps used for clear or "clean" fluids are more efficient because they have a smaller clearance between the impeller and the volute inside the pump housing.
Trash pumps have a smaller impeller diameter in relation to the volute size, which allows them to pass rocks or other debris more easily without scoring the internals of the pump. This capability makes them particularly useful in construction, agricultural, and dewatering/drainage scenarios.
Can Trash Pumps Handle Fertilizer?
Fertilizers come in various forms: liquid, granular, and soluble powder. Each type has different handling and application requirements. Liquid fertilizers are often preferred for their ease of application and rapid absorption by plants. However, they can be corrosive or abrasive, depending on their chemical composition, which can include nitrogen, phosphorus, potassium, and various micronutrients in different chemical forms.
The concept of using a trash pump for moving liquid fertilizer might seem viable. Trash pumps can handle slurries and fluids with solid particles, which theoretically could include liquid fertilizers. However, there are some things you need to consider, like material compatibility, efficiency, and reliability, before actually using your trash pump to transfer fertilizer.
Trash Pump Chemical Compatibility
Many trash pumps are designed to handle water and may not be compatible with the aggressive chemical nature of some fertilizers. Corrosion of the internal components, such as the impeller and the housing, can occur if the materials are not resistant to fertilizer chemicals.
Materials Typically Not Suited for Common Liquid Fertilizers:
Aluminum
Brass
Polycarbonate
PVC
Materials Recommended for Use with Liquid Fertilizer:
Cast Iron
Stainless Steel
Viton
Carbon Steel
Polypropylene
In addition to pitting, rust, and corrosion of the housing and impeller, the pump seal can suffer damage from an aggressive fertilizer. Trash pumps typically have a mechanical shaft seal that keeps liquid from leaking out during operation. This seal consists of two faces and an elastomer that rub together to form a barrier.
If the seal faces or elastomers are made from a material not compatible with the type of fertilizer you want to pump, the seal will fail. Abrasive fertilizers cause damage to the seal faces and the pump will leak around the shaft. This can happen gradually or quite quickly if the fertilizer and materials are not compatible.
A fertilizer's with your pump materials might be the most crucial deciding factor for whether you can utilize a trash pump over another type of pump . If you are new to fertilizer transfer pumps, this guide explains in detail the different options for high-volume fertilizer transfer pumps.
Trash Pump Efficiency
Let's say your trash pump is constructed of materials that will stand up relatively well to whatever type of fertilizer you need to pump. Good, you can check off that consideration. However, there is still the matter of efficiency to consider. Trash pumps are by nature less efficient than other centrifugal pumps typically used for fertilizer transfer. You'll therefore want to ensure that your trash pump will actually perform as you need or you'll have to start at square one finding another solution.
As mentioned earlier, trash pumps generally have more clearance inside them to pass solid material. This makes them less efficient. (If you want to fully understand centrifugal pump efficiency, then check our You may be able to live with this lower efficiency, especially if it means not having to spend the extra money buying another more expensive pump.
Even so, just because a trash pump may work, doesn't mean it will move the liquid at the same volume as other pumps designed specifically for the transfer of fertilizers. It's crucial then, that the prospective costs of that lower efficiency be weighed out for both the short-term and long-term benefits of your operation.
Conclusion: Should You Use a Trash Pump for Fertilizer?
While trash pumps are a versatile option in a pinch, there are better pumps available for the efficient transfer of fertilizer. Over a season the additional amount of time it takes you to move fertilizer could impact your bottom line. Not to mention trash pump built with metals not suited for your specific fertilizer could fail prematurely, costing you additional time and money than if you had opted for another pumping solution in the first place.
Dultmeier carries several different pump lines that are well-equipped for fertilizer transfer:
Whether you're dealing with weeds, insects, or applying fertilizer, selecting the right sprayer nozzle plays a crucial role in the effectiveness of your results. Nozzles affect the rate, coverage, drift potential, and other performance characteristics of your spray applications. But how do you choose the perfect nozzle for your needs? The answer lies in understanding spray nozzle charts.
Spray charts provide you with all the details you need to make an informed decision. However, if you are not familiar with them, all the information these charts provide can be hard to sift through. If you want to learn how to use a nozzle chart, stick around because in this guide we will walk through all the information these tools provide and how you can become more confident in reading these charts accurately.
Understanding the Information Included in a Spray Nozzle Chart
A spray nozzle chart is a detailed table that provides comprehensive performance data for a specific sprayer nozzle series. It displays essential information about the nozzle's performance characteristics, such as flow rate, droplet size, and pressure ranges. Understanding how to read a nozzle chart, therefore, is crucial for selecting the appropriate spray nozzle for your specific needs.
TeeJet Spray Nozzle Chart Example:
The primary purpose of spray nozzle charts is to guide applicators in making an informed decision when choosing a sprayer nozzle. To use the chart effectively, you must understand the information being presented.
So, let's look at the different pieces of data shown in nozzle charts.
Nozzle Capacity (GPM)
The most essential piece of information that a nozzle chart shows is the flow rate of a single nozzle in gallons per minute (GPM) at different pressures. It is important to note that regardless of which nozzle type you are looking at, the flow rate/capacity will be the same across all the different nozzle sizes.
This allows users to select the proper nozzle size according to their application parameters.For help sizing your nozzles, you can refer to our complete guide to properly sizing sprayer tips.
Spray Nozzle/Tip Numbers & Colors
Sprayer nozzles used for agricultural and turf spraying are color-coded and abide by an international standard. These standards set criteria so that nozzles across different brands and nozzle types/series can be compared equally.
In simple terms, a yellow-colored or "02" size nozzle in one series will have the same flow capacity as a yellow nozzle from another brand or spray nozzle series. You can find the different sizes/colors and their part numbers in the far-left column of a sprayer nozzle chart:
For additional details on how to understand spray nozzle sizing, refer to our guide to understanding sprayer nozzle numbers.
Operating Pressure
The operating pressure directly influences the flow rate of the nozzle, which is the amount of liquid that passes through the nozzle per unit of time, typically measured in gallons per minute (GPM). A range of operating pressures is displayed to show the capacity (flow rate) of each nozzle size at various PSI.
As pressure increases, the flow rate generally increases as well. A spray chart allows you to see how much liquid the nozzle will dispense at each specified pressure level. This is vital because two different nozzle sizes may deliver the overall GPM you need, but they will do so at different pressures. You must match the flow rate and operating pressure you prefer in order to maximize tip performance.
Droplets Size
Another significant factor influenced by operating pressure is droplet size. Just as flow rate changes with pressure so too can the droplet size also change. However, while the flow capacities remain the same across nozzle sizes, the droplet sizes produced by the different sizes at various pressures will vary between different types/families of sprayer nozzles.Spray nozzle charts provide the average droplet size a nozzle produces at different operating pressures.
Again, droplet size is one of the most vital aspects of a sprayer nozzle to get right because it impacts factors like spray coverage and drift which determine your application's effectiveness. For more details on how to understand this aspect of sprayer nozzles, be sure to read our full guide to spray nozzle droplet size.
Using a Spray Nozzle Chart to Identify the Right Nozzle
While understanding the information that is presented in a sprayer nozzle chart is vital, it is only half the equation. You also must understand how to use it to narrow in on the best nozzle for your needs. Here's a simple step-by-step guide to help you navigate the chart and select the perfect nozzle for your specific application.
Determine Your Application Requirements
The first step involves gathering the details of your application. Here is the information you need:
Application Rate: How many gallons per acre (GPA) you need to apply.
Ground Speed: The speed at which you'll be operating the sprayer (MPH).
Spray Pattern Spacing: The spacing between your nozzles on the boom (most commonly 20" or 30").
Desired Droplet Size: Based on the type of chemical and drift potential as recommended by your chemical labels.
With this info, you can calculate the gallon per minute (GPM) flow rate you need out of a nozzle to achieve your desired application rate (GPA). Here is the formula to determine this:
You can see a full walkthrough of how to use this formula as well as a calculator that will do the work for you in our guide to calculating nozzle/orifice size.
Find Your GPM In the Chart
Once you have determined the flow rate you need out of each nozzle, you can search for that flow rate in the capacity column. The nozzles are listed from smallest to largest capacity, starting at the top. You'll simply follow the column down until you arrive at your flow rate.
Note, you may discover several different sizes of spray tip will work for your desired flow rate, but that doesn't necessarily mean each nozzle is equally right for your application. There are other factors to consider as discussed above that you'll want to check, too.
Identify the Corresponding Nozzle
Next, follow the row horizontally to the left to find out the PSI that will produce your flow rate with that nozzle. If that PSI is too low or high for your application, then look at the next nozzle size and find out what operating pressure will produce the GPM you need. Continue this step until you find a nozzle that matches both your desired flow rate and operating pressure.
Verify Droplet Size
Confirm the droplet size classification meets your requirements (e.g., Medium, Coarse) as recommended by the product label. Droplet size typically decreases as pressure increases, so this means that two different sized nozzles can potentially produce the same flow rate but create different droplet sizes.
Droplet size is a complex topic that can have a significant impact on the effectiveness of your pesticide/herbicide application. If you would like a full breakdown, please read our guide on
Example
Let's suppose you need to apply 15 GPA at a ground speed of 6 MPH with nozzles spaced 20 inches apart. If we enter these numbers into the GPM formula we get 0.30 GPM. This is the number we need to find in the nozzle chart.
In our example, we are using the chart for TeeJet Turbo TwinJet (TTJ60) nozzles, but this process is the same for most flat fan sprayer nozzles regardless of the brand:
You can see that our flow rate (0.30 GPM) can be produced by four different nozzle sizes albeit at different pressures. This is common. What you want to do is look at the pressure column just to the left to see what operating pressure would produce this flow rate. Typically, you would want to choose the nozzle that will deliver 0.30 GPM near the middle of the pressure range.
Choosing a nozzle size that delivers your flow rate in the center of the pressure range provides you room to speed up or slow down as you spray. You would just need to increase or decrease your pressure accordingly.In this example, you would likely settle on the 025 size (violet) or 03 size (blue) nozzle.
Depending on your application, you may opt for a nozzle size that can deliver 0.30 GPM while maintaining a certain droplet size. The blue nozzle will result in a spray pattern that will have most of the droplets fall into the Coarse size range. The violet-size nozzle also produces a coarse droplet, however, if you were to speed up and increase your pressure it is possible that most droplets would fall into the Fine category.Depending on the chemicals that you are spraying, this change in droplet size may not fall within the recommended and approved droplet range, increasing drift potential ineffectiveness or risk for your spray area (and those areas around it).
The various families/types of nozzles will produce a range of different droplet sizes. This specific type of nozzle produces a relatively small droplet across the different sizes compared to other nozzle types, such as air induction nozzles. It is important to consider your application and consult the label of any product you are using to find help deciding the appropriate droplet size.
Specific Scenarios
Many nozzle charts, such as the one referenced earlier, will display the specific flow rate of a spray nozzle across a range of speeds when used at certain spray nozzle widths. In the chart above, you can see the flow rates for each nozzle size when spaced at both 20 and 30 inches apart on a sprayer boom.
This can help you identify the nozzle sizes that will work for your application rate without having to calculate your GPM. Of course, this is only applicable if your nozzles are at that specific spacing and you travel within the provided speed range.
Conclusion
Understanding spray nozzle charts is key to making informed decisions and optimizing your spraying operations. By following the steps described today, you can use spray charts to identify the most suitable nozzle for your specific application requirements.
You can find charts for specific spray nozzles on our product pages for each nozzle type:
If you're still uncertain about which nozzle is right for your needs or want to explore more about spray nozzles, contact our agriculture sales team for assistance.
There are several liquids used to effectively manage snow and ice on parking lots, streets, and highways. But effective deicing and anti-icing requires not only the right liquids, but also the proper equipment to store, transfer, and apply these solutions efficiently.
In this guide we will cover the essential storage systems, pumps, plumbing, and sprayers needed for applying salt-brine, (sodium chloride and water), mag chloride, calcium chloride, and other de-icing liquids.
Common Deicing Liquids
Before we discuss the equipment, let's clarify the types of liquids we'll be storing and applying:
Salt Brine, Sodium Chloride (NaCl): Approx. 1.2 specific gravity (23.5-26.4 % solution).
Mag Chloride (MgCl2): Approx. 1.34 specific gravity.
No matter what liquid deicer you are using, proper storage is essential to prevent waste and provide you with a convenient way to access and mix your batches. The type and size of your tank(s) is not the only factor to consider but also the lid, tank fittings, and plumbing.
De-ice Storage Tanks
Poly tanks are the most popular storage solution for deicing liquids. Fiberglass and stainless steel can be used as well. All these tanks have an excellent lifespan and compatibility with the common de-icing fluids, although stainless and fiberglass are less common due to their cost.Carbon steel tanks are not recommended.
When storing de-ice or anti-ice fluid, we recommend polyethylene tanks strong enough to hold liquids that weigh up to 14 lbs. per gallon. This will cover the weight of any de-ice liquids. Common polyethylene tanks are a partially transparent "white" color with inhibitors to protect the tank from UV rays. Other color tanks can be used but the standard white tanks allow liquid level in the tank to be seen.
What size tank do I need for de-ice?
Poly tanks come in a wide variety of sizes and shapes. The size of your tank depends a lot on your operation. However, there are some key things to consider:
If you purchase your liquids, is there a certain volume it is delivered in? Is there a quantity discount?
How much brine would you need to cover all of your territory in one application?
Do you make your own brine? If so, how fast can you make brine compared to how fast your trucks can apply it?
How long can your liquid be stored?
Fittings and Recirculation
Brine stratifies overtime so circulating your tanks is important. Typically, a tank will come standard with one fitting installed for load/unload. It is best to request or install multiple fittings so you can plumb a tank for recirculation.
It's best to use tanks with two 2-inch or 3-inch fittings to facilitate adequate suction & recirculation.
Polypropylene (polypropene) fittings are acceptable, but they can be easier to break, especially in cold temps. Stainless steel is recommended for its durability, despite the higher cost.
Tank Mixing Educators (TMEs)
Proper recirculation and mixing are enhanced with a tank mixing eductor. An eductor increases the agitation rate of liquid in the tank. It is both quicker and more effective than simply pumping the liquid out of one tank port and into another.
The next component needed for handling de-icing liquids is a transfer pump. As with the storage tanks, the best option is a pump constructed of polypropylene or stainless steel. Poly pumps are less costly, but stainless is more durable.
In most cases a 2-inch transfer pump is adequate, depending on the specific pump and your plumbing, you can expect 80 or more gallons per minute from a 2-inch pump. A three-inch pump can be used if higher rates are desired, 250 GPM or more.
A transfer pump for brine or other de-ice liquid should be rated to handle liquids up to a 1.4 S.G. This means that the horsepower is relatively higher than the same pump that is intended to handle water only.
Plumbing is an aspect that you should not overlook. At the risk of sounding repetitive, the hose, pipe, valves, and fittings need to be made from materials compatible with the liquid you are using and sized properly. The size of those plumbing components is vital. Your pump may be capable of 200 GPM but your plumbing will have a huge impact on whether or not you actually can achieve that flow rate.
The primary thing to ensure is that the suction pipe (the hose or pipe from the tank to the pump inlet) has an inner diameter of at least the same size as the pump inlet. For example, a two-inch pump requires a two-inch inside diameter hose or pipe. If a hose is used, then it must be a suction hose that won't collapse from the suction generated by the pump.
Why is this essential? A centrifugal pump needs the right size fluid path on the suction side to avoid cavitation. Cavitation happens when the pump is starved of adequate liquid, which can damage the pump.You can learn more about centrifugal pump operation in our guide written by our in-house engineer Tom Hansen.
Moving on to the discharge side of the pump, we still have some important guidelines to maximize your flow potential:
Use a hose or pipe that won't restrict flow, again 2-inch hose, fittings, valves for 2-inch pumps and 3-inch for 3-inch pumps.
Note that not all "2-inch" valves have a 2-inch fluid path. Some 2-inch valves actually have only a 1-1/2 inch fluid path. Use full 2-inch port valves and fittings to reach the full potential of the pump.
Limit the number of restrictions in your plumbing. Elbows, valves, vertical pipes, strainers, etc. will potentially decrease your flow rate.
Install a strainer after the pump to decrease the chances of cavitation.
De-Ice/Anti-Ice Sprayers
When it comes to the actual machines that apply the liquid to the surface, there are several options. These different types of applicators work on the same basic principles with the primary difference between them being their size and the sophistication of the controls.
Skid Mount Sprayers
Sizes: 50, 100, 200, 300, and 500 gallons
These sprayers are designed for easy installation and removal, making them suitable for parking lots, side streets, driveways
Made to fit in pickup beds, smaller 50 and 100-gallon skids can fit in UTVs/side-by-sides.
Basic pressure-based controls are used to manually control the sprayer's output. Automatic rate controllers and GPS can be incorporated if desired.
For larger-scale deicing operations, dump truck-mounted sprayers are essential. These sprayers offer greater capacity and coverage, making them ideal for highways and extensive road networks. Specific models and configurations can be tailored to meet the needs of different municipalities and road maintenance departments.
The primary feature of Dultmeier Sales' larger de-ice sprayers is the ability to "self-load". These 1065 and 1800-gallon sprayers feature heavy-duty steel leg frames. The front legs swivel as the truck backs up and the skid slides into the truck.
Rate control refers to the method used to adjust the output of the sprayer. There are two primary rate control options: pressure-based, and flow meter-based. These systems help regulate the amount of deicer being applied, ensuring efficient use of the solution.
In a pressure-based control system, the output of the sprayer is controlled by changing the operating pressure of the sprayer. This can be done manually by adjusting a regulating valve or with an electronic regulating valve.
In a flowmeter-based system, you control the output of the sprayer with an electronic regulating valve. Typically, this is done automatically via a rate control console. Automatic rate control allows you to input your parameters and desired output per lane mile. The system will automatically adjust to maintain your application rate if it is within the flow capacity of your nozzles.
The nozzles used on a de-ice/anti-ice sprayer should be poly or stainless steel. Stainless steel is the most durable option. Nozzles are available in different spray patterns to accommodate various scenarios. The most common nozzles are solid stream nozzles, flat fan nozzles, and flood nozzles.
Flat fan nozzles and flood nozzles are ideal when you want to completely cover a surface to prevent ice and snow buildup. Solid stream nozzles are used in de-icing applications. They do not cover the entire surface, rather they deliver a directed spray to penetrate ice/snow on the road. The idea is to get the liquid under the snow and ice to the road surface to melt from the bottom and allow sunlight to work on the top layer.
Solid stream nozzles can also be effective for anti-ice or prewetting applications. When using these nozzles, there are gaps on the surface between treated areas. This method is a safety precaution in extremely cold temperatures to prevent the entire road surface from becoming a sheet of ice should the liquid solution freeze. The untreated strips provide dry, ice-free areas for drivers.
Nozzle Sizing
The rate control system is used to adjust your output, however the nozzles on the sprayer ultimately dictate the flow rate. Nozzles come in a wide range of sizes, and you must calculate the correct size based on the gallons of liquid you want to apply per lane mile, 1000 square feet, acre, etc.
If you need help sizing your nozzles you can reach out to us with your application rate (gallons per lane mile, per 1000 sq ft, etc.) and we can help you.
Brine Production System
An efficient brine production system is the backbone of any deicing operation. These systems are designed to produce large quantities of salt brine quickly in a cost-effective manner. Key components of a brine production system include:
High rate of production
Mechanism to ensure the correct concentration of the brine solution
Ability to clean out sand/debris easily so you can get up and running again
Durable and reliable
Easy-to-operate controls
Dultmeier Sales manufactures a completely stainless steel brine production system that is extremely easy to operate and clean out. If you would like more information, please let us know, we would be glad to help!
Tech Ag & Industrial Sales
Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.
Using a chemical inductor is an effective way to add chemicals into a mix load for a sprayer. At Dultmeier Sales, we assemble a variety of cone bottom inductor tanks with Venturi assemblies that ensure precise and efficient chemical mixing.
In this article, we'll provide a complete guide on how chemical inductor systems work, covering everything from the principles behind the Venturi effect to the detailed operation of these systems. Whether you're new to using chemical inductors or looking to optimize your current setup, this guide will equip you with the knowledge you need.
How a Chemical Inductor Works
The Venturi effect is the driving principle behind how a chemical inductor works. The Venturi effect occurs when a fluid flows through a narrow constriction, causing its velocity to increase and its pressure to decrease, creating a low-pressure zone that can generate suction. This happens in a chemical inductor when the carrier from the transfer pump flows into the inductor assembly on the bottom of the inductor tank.
The suction effect draws the chemical from the inductor tank into the flowing water. As the chemical mixes with the water in the Venturi nozzle, the combined solution is then transferred into the main sprayer tank or nurse tank.
This process not only requires a specific set of components but also the correct plumbing to work effectively. Let's examine each component and how they work together.
Chemical Inductor Components
Whether a chemical inductor system is on-board a sprayer, mounted on a tender trailer, or stationed on the ground, the core components are the same:
Venturi/bypass assembly
Cone bottom tank
Hose/plumbing
Centrifugal transfer pump
There are variations of each component depending on the specifics of the application.
Venturi/bypass Assembly
The venturi bypass assembly is the critical piece of any chemical inductor system and essential to drawing in agrochemicals, AMS, crop oil, etc. into your final mix load. This assembly includes the venturi, bypass valve, and all appropriate plumbing fittings. When the bypass valve is closed water is forced through the venturi. Then the tank valve can be opened, and the contents of the inductor tank are drained by the suction from the venturi.
When the bypass valve is open, water avoids the venturi and the flow rate is faster, but there is no suction to pull any mix of liquids or chemicals from the tank.
If you are building a chemical inductor, you can add a venturi assembly to an existing cone bottom tank. You can also use a venturi/bypass assembly to pull chemicals directly into a carrier line without the cone bottom tank. For more information be sure to read this guide to mixing chemicals without 12-volt pumps.
Inductor Tank
A cone-bottom polyethylene tank is recommended for use with agrochemicals (pesticides, herbicides, fertilizers, etc.) because it offers a wide range of chemical compatibilities. They are available in various sizes, commonly 15 to 110 gallons. The size of your inductor tank does NOT affect the rate at which chemicals are drawn into your mainline. A larger tank simply holds more product. The tank opening on the bottom of the tank, however, is important to consider. A smaller tank opening can restrict the induction rate and make your overall operation less efficient.
The size of the tank lid also matters. For starters, a larger lid opening makes it easier to add chemicals and reduces the risk of spillage outside the inductor system. A larger 16-inch lid also allows you to use a Chem-blade jug emptying and rinsing system. With this accessory, you can quickly empty chemical jugs without opening them or pouring them.
Like the tank, it is recommended that the valves and fittings are also poly. Polypropylene not only works best with agrochemicals but is also suitable for other products such as salt-brine, fertilizers, acids, and cleaning solutions.
EPDM rubber suction and discharge hoses, such as these offerings from Kanaflex (link) and TigerFlex (link) work great for the suction and discharge sides of your inductor system pump. Two- and three-inch hoses are common plumbing sizes used with inductors.
Transfer Pump
Although the pump is not an integrated part of the inductor assembly, it is a critical component required to make the system function. The inductor system must be used with a centrifugal transfer pump that is capable of pushing enough flow through the venturi to generate adequate suction. A general rule of thumb is to use a pump that matches the same size as your inductor's plumbing. So, use a two-inch pump with a two-inch inductor system, and a three-inch pump with a three-inch inductor system.
Additionally, you'll need to ensure the pump has adequate horsepower to move the liquid through the inductor venturi. If the pump lacks enough horsepower, the pressure may be too low, which can limit the amount of suction created. For example, when pumping water, a two-inch pump with a five-horsepower gas engine will suffice for a two-inch inductor setup. If you have a three-inch inductor assembly, then you typically need a three-inch pump with 8+ horsepower.
If your carrier is fertilizer or some other liquid heavier than water, you will likely need more horsepower to drive the pump. You can learn more about the pump sizes in our fertilizer transfer pump guide.
Like the pump, the plumbing setup of an inductor tank is crucial. The most important aspect is the placement of the pump in relation to the inductor system. The inductor should be positioned on the discharge side of the pump. This placement is essential because the flow of the water pumped through the venturi creates the vacuum effect.
Using the right hose and fittings is vital to proper plumbing for inductor tanks. It is important to match the inside diameter of the hose and fittings with that of the pump ports. For example, a two-inch inductor system should have two-inch plumbing throughout. Hose, fittings, pumps, valves, venturi, etc., should also be two inches in diameter.
Any restriction in flow can disrupt the system's effectiveness. Eliminating as many bends or slowdowns within your plumbing will ensure your flow rate remains strong enough to draw product down through the venturi. Try to limit the length of hose on the suction and discharge sides of the pump and avoid using too many 90-degree elbows and strainers.
Furthermore, where you place your pump in relation to your system's water supply tank and inductor can affect the performance of the overall system. You will want to keep the pump as close to the water tank as possible, because the shorter the distance the water must travel to the pump, the less pressure loss you'll have and the better your pump will perform. Proper pump placement means a more reliable and effective chemical mixing process.
Since plumbing plays such a large part in the overall performance of your inductor system, it's important to consider how every part of the system works in tandem with one another. As referenced above, the hoses throughout your system need to be the proper size to the inductor unit.
This is also true for the pump inlet. A two-inch pump needs to be fed with at least a two-inch hose, a three-inch pump with a three-inch hose, and so on. You do not want to starve the pump or run it dry. This will result in seal failure in addition to the inductor not functioning properly.
Chemical Inductor Plumbing Diagram
Keys to Remember When Plumbing Your Inductor Tank:
Venturi Assembly: Must be on the discharge side of the pump.
Hose and Fittings: Match the inside diameter of your pump inlet and inductor.
Flow Optimization: Avoid 90-degree elbows and pumping great distances 100 ft +
Pump Placement: Keep the pump close to the supply tank for efficient operation.
Pump Operation: Never run the pump dry and ensure supply tank valves are fully open.
Using an Inductor Tank Without a Venturi Assembly
While most chemical inductors utilize a venturi assembly, you can use a cone-bottom tank without a venturi assembly by placing it on the suction side of the pump. However, this setup requires careful consideration to avoid starving the pump of liquid, which can cause pump cavitation and damage.
One of the risks of positioning the inductor tank upstream of the pump is the possibility of air bubbles entering the system. When you open the tank valve, liquid in the tank is drawn into your carrier line, but you are also introducing air into the line. Air bubbles passing through the pump can lead to damage over time. A large amount of air can starve the pump and lead to seal failure rather quickly.
Placing the inductor on the suction side of the pump also means you have chemicals passing through your pump rather than just water. Although many pumps are compatible with agrochemicals, this will inevitably lead to more wear and tear compared to water alone.
You also have the risk of contaminating your water supply or water tank, though using a check valve between the water tank/supply and the cone bottom tank to prevent chemical backflow can likely eliminate this contamination risk.
Conclusion
When set up properly, inductor tank systems are a highly effective way to introduce multiple chemicals or fertilizers into your spraying application. Following these guidelines will help you build or improve your current set-up, ensuring efficient and reliable chemical induction for your sprayer.
Dultmeier Sales offers a complete inductor system in poly and stainless steel as well as all the components needed to operate them:
Banjo Corporation has a long history of creating innovative products. One of their biggest innovations came when they introduced manifold flange plumbing fittings into the agricultural spraying and industrial liquid handling industries. These flange fittings are designed to be used in place of threaded fittings. This advancement makes it much simpler and faster to assemble, disassemble and re-plumb systems without the hassle of dealing with threaded connections.
With manifold clamps, you can quickly remove and inspect sprayer components like flow meters and strainers without disassembling the entire system. This is a stark contrast to threaded systems where you must start at one end and disassemble parts until you reach the desired component.
Anyone who has ever replaced a cracked strainer or valve knows how difficult and time-consuming it can be to remove several hoses and fittings to replace your broken part, and then reassemble the entire thing. With manifold flanges, the component can be removed and replaced by just removing the flange clamps.
This guide will cover everything you might need to know when it comes to using manifold flanges, from the fittings themselves to how to correctly size a gasket for Banjo manifold flanges.
Understanding Manifold Flanges
A Banjo manifold flange is a type of connection used in sprayer systems to join various components such as pumps, valves, and hoses. These flanges are available in different sizes, and two flanges of the same size are connected with a manifold flange clamp. A gasket fits in between the two flanges to create a secure, leak-proof seal.
Banjo manifold flanges have been so widely adopted in the market that besides other different manifold fittings, these flanges have been integrated into the designs of pump housings, valves, strainers, flow meters, and more.
For example, Banjo, Hypro, and John Blue offer many pumps with manifold flange connections in place of pipe thread. There are also line strainers that have flanged ports in place of threaded ports. To help with the installation of manifold flanges, there are also U-bolts specifically designed for the various manifold fitting sizes.
Other manufacturers have made compatible flanges that will work with the Banjo manifold fittings, but the key is making sure that you match up the correct corresponding sizes.
Sizing Manifold Flanges
Banjo manifold flange fittings come in four standard sizes: 1-inch, 1.5-inch (also referred to as a 2-inch standard port), 2-inch full port, and 3-inch. Understanding their inside diameter is crucial for determining flow capacity and ensuring effective use of these fittings. Despite the varying naming conventions across different manufacturers like Banjo, Hypro, and TeeJet, compatibility is straightforward if the correct sizes are identified.
A common source of confusion is that Banjo labels their 1.5-inch inside diameter flange as a 2-inch "standard port" flange, while their 2-inch inside diameter flange is called a 2-inch "full port" flange. Banjo uses M200 and M220 as the part numbers for their 2-inch standard port and 2-inch full port flanges. Hypro refers to their 1.5-inch diameter flange fittings as 150-series flanges. This means a Hypro 150 series clamp will fit a Banjo M200 series flange. The same is true for the gaskets.
These part numbering systems are confusing. The chart below shows the different flange sizes and what part number from each manufacturer will work with each size.
Compatible Part Numbers for Each Manifold Flange Size
Manifold Flange Size
Inside Diameter Measurement
Banjo Part Number
Hypro Part Number
TeeJet Part Number
1-inch
1-inch
M100
100
50
1.5-inches (2-inch standard port)
1.5-inches
M200
150
75
2-inch full port
2-inches
M220
200
na
3-inch
3-inches
M300
300
na
Compatible Manifold Flange Gasket Part Numbers
Manifold Flange Size
Banjo
Banjo Viton
Banjo Skirted Gaskets
Hypro EPDM
Hypro Viton
1-inch
TKM100G
TKM100GV
TKM102G
HYUFG0100E
HYUFG0100V
1.5-inches (2-inch standard port)
TKM201G
TKM150GV
TKM202G
HYUFG0150E
HYUFG0150V
2-inch full port
TKM221G
TKM200GV
TKM222G
HYUFG0200E
HYUFG0200V
3-inch
TKM301G
TKM300GV
TKM302G
HYUFG0300E
HYUFG0300V
Skirted Gaskets
Both Hypro and Banjo offer "skirted" gaskets. These gaskets are designed to stay in place when installed in a manifold. This allows you to install flange clamps without worrying if the gasket is seated correctly.
Banjo offers three different types of clamps for their manifold flanges. The first type is a standard worm gear clamp. This is the most economical and works well when there isn't too much weight or movement from the adjacent components.
T-bolt flange clamps are another clamp option, and these clamps are ideal for use with larger, heavier hoses or pipes. Finally, the heavy-duty bolted clamp is best suited for applications where significant weight may be applied to the clamp.
For example, if you have a 3-inch hose connected to a manifold flange outlet on a pump and you move the hose around, it can put strain on the flange clamp. The heavy-duty bolted clamp is the best option in this case as it is designed to withstand this frequent stress, ensuring the integrity of your connections.
Hypro manifold flange clamps are made of poly, and they are also T-bolt-style clamps. The big advantage of the Hypro clamp, however, is the hinged design. This makes it even easier to get the clamp around the flange after your fittings are in place.
You can view all the different flange clamps and gaskets on this page.
Different Types of Flange Fittings
The manifold flange fittings are primarily available in polypropylene, but some stainless-steel fittings are also available. There is a poly manifold fitting to replace just about any standard pipe thread plumbing fitting you can think of, though some of the most common are:
Flange fittings have been incorporated into about every type of sprayer component used today, from pumps and valves to flow meters and strainers.
Banjo Corporation's manifold flange fittings simplify assembly, disassembly, and re-plumbing in ag spraying and industrial systems. These fittings are compatible with many other manufacturers components, and so long as you are comfortable identifying the correct corresponding size needed, you're unlikely to encounter many issues using these flange fittings. If you have any questions about manifold flange fittings, please contact us.
Tech Ag & Industrial Sales
Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.
Cam lever couplings, or cam and groove couplings, are essential plumbing fittings used widely in agricultural and industrial liquid handling. These couplings provide an efficient means of quickly connecting and disconnecting hoses from tanks, tanker trailers, sprayers, pumps, and more.
While manufacturers typically refer to these fittings as cam-lever or cam and groove couplings, they are also known by other names such as cam locks (couplers), cam levers, quick couplers, and lever locks.
Despite the varied terminology, these terms generally refer to the same type of fitting - though not every camlock coupler works for every application. In this article, we'll detail the key features and differences of various cam and groove couplings to help you decide which style of fitting works best for your unique needs.
Types of Cam-Lock Couplers
Nomenclature is important when discussing cam-lock couplers (or any coupling device for that matter). Understanding the different jargon used to refer to specific fittings ensures that you identify the correct item you need.
There are six main types of cam-lever couplings, each made from different combinations of male adapters (male ends) and female couplers (female ends) with either male pipe thread (MPT), female pipe thread (FPT), or hose shank connections. The types are labeled A, B, C, D, E, and F depending on the end connection type they feature and generally range in sizes from ¾ to 6 inches. There are also dust caps (DC) and dust plugs (DP) available for each size.
Part A
Male adapter with female pipe thread, typically National pipe thread (NPT).
Part B
Female coupler with male pipe thread (MPT).
Part C
Female coupler with a hose shank.
Part D
Female coupler with female pipe thread.
Part E
Male adapter with a hose shank.
Part F
Male adapter with male pipe thread.
Dust Plug (DP)
Fits into the female coupler to prevent dust and debris entry.
Dust Cap, Female Coupler (DC)
Fits onto the male adapter to prevent dust and debris entry.
Non-Standard Cam Lever Fittings
Beyond these standard fittings, there are additional non-standard types available for specific applications.
Jump Sizes, for transitioning between two sizes of cam couplings
Elbows
Flange Ends
Couplers with Gauge Ports
Locking couplers
Swivels
Even these specialty camlock fittings aren't the last of the available options. You can shop all our cam lever couplings and accessories , and if you are looking for something specific, please let us know.
Materials and Compatibility
Cam and groove couplings are manufactured in a variety of materials including stainless steel, aluminum, polypropylene, nylon, and more.
The couplers (female) have a rubber gasket inside to seal up the connection. There are different gasket materials available as well to offer compatibility with different types of liquids:
EPDM: Agrochemicals, fertilizers, salt brines, DEF, acetone, acetic acid
Viton: Acids, bleach, agrochemicals, fertilizers, salt brine, DEF, xylene, biofuels
Buna: Fuels, oil, hydraulic fluid
*These are general guidelines. Always check compatibility before selecting materials.
Common Cam-Lock Coupler Applications
A cam-lock coupling offers users a way to couple and uncouple hoses from tanks, trailers, pumps, etc., while still providing a secure seal. The couplers are suitable for a variety of applications including but not limited to:
Agriculture
De-icing
DEF (Diesel Exhaust Fluid)
Petroleum
Mining
Manufacturing
General Water Transfer
Waste Management
Brewing & Distilling
Industrial Cleaning
Connecting and Disconnecting Cam-Lock Fittings
Connecting cam-lock fittings is straightforward but a little difficult to describe in words alone. This video provides a live look at the simple process:
Insert the Adapter: The adapter is the "male" end. You insert this end into the coupler side ("female") with the cams/levers in the open position or levers "up".
Lock the Levers: Push the levers down to the closed position to lock the connection.
Disconnect: Lift the cam arms/levers to the open position and pull the adapter out.
Are Cam-Lock Couplings Interchangeable?
One key advantage of cam-lock couplings is their standardized sizing. Cam-lever couplings are manufactured according to a standard, so regardless of the manufacturer or material, they will connect seamlessly. For instance, a polypropylene male end will fit a stainless-steel female coupler so long as they are both the same size.
Preventing Leaks and Ensuring Security
Cam-lock couplings are designed to seal completely when the levers are properly closed. If there are leaks, it may be due to improper connection, worn-out gaskets, or damage to the coupling itself.
Installing cam couplings vertically or at a 45-degree angle can help reduce wear on the gasket. This takes the weight off the fitting, so it is not pinching the gasket on the bottom of the coupler. If needed, though, replacement gaskets and shims are available.
Camlock Coupler Accessories
Safety Bumps: These "bumps" replace standard cam-lock dust plugs and caps. They feature a handle for convenience, and they provide protection to the cam-lock coupler in case it is dropped.
Safety Locks: To prevent accidental opening of the levers, you can use safety locks. These accessories help secure the levers and prevent spills or leaks in demanding industrial environments. Another option is to use locking-style lever couplings which feature a locking mechanism built into the camlock arm.
Extra Thick Gaskets: These cam-lock coupler gaskets are thicker than the standard gaskets and provide a tighter seal and extend the life of your gaskets.
Shims: A shim can be installed under the cam-lock gasket. This helps create a seal when the couplers or gaskets get worn.
Recommended Cam-lock/Lever-Coupling Brands
Banjo Corporation is a leading manufacturer of cam-lock couplers. They specialize in injection molded glass filled polypropylene fittings and manufacture extremely durable cam-lock couplings in the USA.
Dixon has an extensive selection of cam-lever couplings. They offer different styles, accessories, sizes, materials, and other features.
Kuriyama is a leading manufacturer of industrial and agricultural hose. They also offer a wide array of quality stainless-steel and aluminum couplers.
Green Leaf cam-lever couplings feature an innovative locking design. The levers are locked in place automatically and you simply push the buttons on each lever to release.
Before You Go
Cam-lock fittings follow industry standards, ensuring compatibility across different sizes and materials. They offer a versatile and reliable solution for fluid transfer in various industries. By selecting the right type and material for your application, you can maintain a secure and efficient connection, prolonging the life of your fittings.
Intermediate bulk containers (IBCs) are common chemical containers used in a variety of industries. Also known as "cage tanks", IBCs are available in several sizes, though one of the most common is the 275-gallon cage tank. The availability and chemical compatibility of these 275-gallon cage tanks make them an obvious low-cost option for several small-scale chemical-handling applications.
If you are looking at using one an IBC to store or transfer chemicals, you'll first need details on the tank's dimensions, lid size, and how to connect to the tank. Understanding these specifications is crucial for ensuring the compatibility and safety of your chemical storage and transfer operations. This guide will walk you through the essential aspects of these common 275-gallon cage tanks.
275 Gallon Cage Tank Dimensions
Standard dimensions of a 275-gallon tote:
Height: 46 inches
Width: 48 inches
Depth: 40 inches
These dimensions can vary slightly depending on the manufacturer and the specific design of the tote, but they generally fall within these measurements.
IBC Cage Tank Features
IBC cage tanks have a metal cage that encases a high-density polyethylene (HDPE) plastic tank. The cage is required, as it protects the tank from any equipment that may bump into it and helps maintain the integrity of the tank walls while filled.
When empty, you can stack these tanks on top of one another, although it is not advised to stack more than three. Even with a cage, IBC totes are not strong enough to stack when they have liquid inside. The base of the tank, a galvanized pallet integrated in the cage frame, is designed to be moved using standard pallet jacks and forklifts.
Empty Weight of 275 Gallon IBC/Cage Tank
Depending on the manufacturer these 275-gallon cage tanks can weigh between150-170 lbs. pounds when empty. The weight varies slightly due to small variations in the cage design, type of outlet valve, and number of lids/vents on the top of the tank.
Rated Weight per Gallon
IBC shuttles have a 1.9 S.G. rating. This means they are rated for liquids that weigh up to about 15 pounds per gallon. For reference, water is 8.345 lbs./gal.
IBC Tank Lids
The 275-gallon IBC tanks sold at Dultmeier Sales feature one six-inch lid positioned on the top center of the tank. The lid features a vent in the center. The vent is essential to prevent the collapse of the tank when using a pump to withdraw liquid. There are many different lid variations that can accommodate different types of pipe thread or Micro Matic valves.
There are several types of lids options. They feature single ports, multiple ports, vents, etc.:
The lid, vent, and the outlet valve also feature spots for tamper evident seals to be installed.These seals lock the lid in place and ensure that a the liquid contents are not tampered with or compromised during use or transport from place to place. The tank lid cannot be opened without the wire seal being broken.
How to connect to a 275 Gallon Cage Tank
The outlet at the bottom of the standard IBC cage tank is generally a 2-inch valve. The valve will typically feature a built-in check valve that allows liquid to flow out of the tank but will not allow anything to be pumped into it. This tank outlet will often feature a 2-inch male cam-lock adapter, and the end of this adapter is threaded for a dust cap. It is advised that this thread not be used to attach any accessories/pumps, use only for the dust cap.
If you need to connect a hose to a standard IBC cage tank you just need a 2-inch female cam-lock coupler. This could be a part C, part B, or part D coupling. If you are not familiar with the different cam-lock coupler types, you can see a complete explanation in this guide to cam-lock couplers.
Common Uses for 275 Gallon IBC/Cage Tanks
The uses for IBC containers are many and varied. Some of the most common liquids and applications include, but are not limited to:
Water Collection
Agricultural Chemicals & Fertilizer
DEF
Waste oil
Brine
Cleaning products
Aquaponics and Hydroponics
Industrial Processes
Brewing and Winemaking
Construction
Dultmeier Sales keeps 275-Gallon IBC Tanks on hand with all the accessories you might need, including pumps for handling a wide variety of different liquids. Contact our sales team for more information, availability, and freight estimates on 275 Gallon IBC Cage Tanks.
When it comes to using a pressure washer for cleaning, the debate often centers around two critical metrics: volume and pressure. Whether you are using a power washer to clean cars, trailers, concrete, or sewer lines, both volume and pressure play significant roles in the effectiveness of your cleaning efforts.
Higher flow rates are associated with more efficient rinsing and moving of dirt/debris. High-pressure is important when you need to cut through grime or film on a surface. However, the most important thing to consider is the specific job requirements and then determine the cleaning method that will be most effective.
There are several factors. Let's dive into the details to understand which is more important and how to balance these two metrics for optimal cleaning.
What's More Important for Cleaning: Volume or Pressure?
It is difficult to say whether you should prioritize volume or pressure without knowing the specific application. The needs of cleaning tasks vary so the answer will differ depending on the nature of your job. There are several cleaning tasks where flow rate is often more critical than PSI, but there are also tasks where higher pressures should be prioritized.
Volume and pressure provide different benefits in the cleaning process. Volume is most beneficial when there is a large amount of debris which needs to be rinsed away. This is commonly needed when cleaning out stock trailers that contain manure or rinsing out tanks that had sediment left behind.
To illustrate the effect of larger volumes of water when cleaning, consider a flat surface with a small pile of dirt spilled on it. If you were to pour a few ounces of water onto the pile of dirt, you would have very little cleaning effect. In fact, this would likely just make things worse. However, if you were to pour a five-gallon bucket of water on the pile it would have a drastic effect on the dirt. The more water used the more it will rinse and push away the dirt.
Pressure is also vital, especially in scenarios requiring concentrated cleaning. Pressure is most beneficial when the cleaning process involves material that is difficult to remove. This is typically needed in scenarios such as preparing surfaces for painting which often requires removal of old paint or grime.
Let's look at some specific examples:
Tank Washout
Requirement: High flow, medium pressure
Reasoning: The goal of tank washout is to move and remove material efficiently. This task requires a large volume of water (high flow) to carry away debris and residues. The pressure does not need to be extremely high, as the primary objective is volume movement rather than breaking up tough deposits.
This video shows high-flow, medium pressure cleaning in action:
Concrete Cleaning
Requirement: Low flow, high pressure
Reasoning: Cleaning concrete surfaces, such as driveways or industrial floors, requires breaking up tough, stuck-on dirt, and stains. This task benefits from high pressure (3,000 to 4,000 psi) to effectively dislodge and remove stubborn grime, while a moderate flow rate (3-4 gallons per minute) may be sufficient to carry the debris away.
Cleaning Units: A Practical Comparison Tool
To compare the effectiveness of different pressure washers, we can combine the flow rate and pressure output of each using a metric known as cleaning units. This is calculated as:
Cleaning Units = Pressure (PSI) x Flow (GPM)
Example 1:
Pressure washer with 4 GPM and 3,000 psi
Cleaning units: 4 x 3,000 = 12,000
Example 2:
Pressure washer with 3.5 GPM and 3,500 psi
Cleaning units: 3.5 x 3,500 = 12,250
These examples show that despite different flow rates and pressures, the cleaning units are quite comparable (12,000 vs. 12,250). Another important aspect of comparing pressure washer is the horsepower (HP) needed to operate the pressure washer. This is a topic that is covered in this guide to horsepower sizing.
Flow Rate measures the flow rate of water coming out of your pressure washer. Essentially, it indicates how much water is being used per minute. This is typically measured in GPM (Gallons Per Minute). A higher GPM means more water flow, which can help rinse away dirt and debris more effectively.
Pros of High Flow
Faster cleaning by covering a larger area with more water.
More effective rinsing action, removing debris efficiently.
Cons of High Flow
Higher cost for machines with higher GPM ratings.
Pressure (Pounds per Square Inch) measures the pressure of the water coming out of the nozzle. Higher PSI means more forceful water, which is crucial for breaking up tough grime, stains, and dirt on surfaces. PSI helps in dislodging dirt but may not be as effective alone without sufficient water flow to wash the dirt away.
Pros of High Pressure
Better at breaking up tough dirt and grime.
Cons of High Pressure
Splatter inefficiency may damage delicate surfaces
The Relationship Between GPM, PSI, & Nozzle Size
It's important to note that GPM, PSI, and your nozzle size are interrelated. The relationship between pressure and flow rate in a pressure washer system is inversely proportional when other factors like the nozzle size and pump capacity remain constant:
Increasing Flow Rate (by enlarging the nozzle or enhancing pump capacity) leads to a decrease in Pressure.
Decreasing Flow Rate (by reducing the nozzle size or lowering pump capacity) leads to an increase in Pressure.
Understanding this relationship is crucial for optimizing the performance of a pressure washer to match the specific cleaning tasks and ensuring efficient and effective cleaning results.
Balancing GPM and PSI: Spray Nozzle Orifice Size Matters
If we compare two machines that produce 3000 PSI but one delivers 8 GPM and the other only 2 GPM, the one with the higher flow will provide more efficiency. This is provided that you use the proper size spray gun and nozzle to accommodate the flow of the machine.
While both a 2 GPM and an 8 GPM machine can produce the same PSI, the water output volume makes a significant difference in cleaning efficiency. The orifice size in the nozzle adjusts to maintain the PSI:
A 2 GPM machine requires a smaller orifice to build up pressure with less water.
An 8 GPM machine has a larger orifice, allowing more water to flow while maintaining the same pressure.
This means that an 8 GPM machine can clean surfaces much faster and more thoroughly than a 2 GPM machine, even if both are rated at 3000 PSI.
What to Consider When Selecting a Pressure Washer:
Focus more on GPM for general cleaning efficiency.
Ensure PSI is adequate for the types of surfaces and dirt being cleaned.
Higher GPM models are ideal for professionals and large cleaning tasks.
Higher GPM means faster cleaning times and better rinsing.
Adequate PSI ensures dirt and grime are effectively broken up.
When choosing a pressure washer, it's essential to consider both GPM and PSI. However, for most cleaning tasks, prioritizing GPM over PSI can lead to faster, more efficient cleaning. By understanding and adjusting these metrics, you can optimize your pressure washer's performance for any cleaning job.
No two growing seasons are the same. Every year brings unique fluctuations in temperature, varying amounts of precipitation, and different pests which thrive in these various conditions. These many variables make the choice of when to apply fungicides - and which one you should use - a complex decision. Expert guidance is often required to ensure you get the most out of fungicide treatment on your crops.
The type of sprayer nozzle you use to apply fungicides is just as important as the choice of fungicide itself. The right type of nozzle can significantly enhance the effectiveness of your application, thereby reducing the likelihood of reapplication or subpar results. While I cannot help you decide the best time to apply, I can help you identify the sprayer nozzles that are excellent for use with fungicides.
Understanding Nozzle Requirements for Fungicide Application
Nozzles play a crucial role in how successful a fungicide treatment can be, including determining the amount of chemical applied, the uniformity of the application, and the potential drift. Different nozzles produce varying droplet size ranges and spray angles. These attributes provide benefits like improved drift reduction, greater canopy penetration, and more precise spray direction.
In this guide we are going to be referring to the droplet size classification and spray patterns of several different nozzles. If you are not familiar with how spray nozzle droplets are classified, be sure to read this guide to nozzle droplets first.
As with other spray nozzle applications, the nozzle type you need will depend on your specific fungicide, target pest, crop type, etc. Spray nozzles are not specifically designed for a certain pesticide or fungicide. Instead, they are manufactured to provide specific performance traits. These include GPM, droplet size, spray pattern shape, spray angles, etc.
Finding the best nozzle requires examining the mode of action (or the means a fungicide uses to eliminate the pest) of fungicide you are using and then identifying a nozzle that can most effectively deliver the liquid to the target surface. It is recommended to always consult an agronomist or local crop care specialist when choosing a fungicide for your unique needs. Here, though, are general guidelines for different types of fungicides:
Contact Fungicides
Contact fungicides require thorough coverage of the leaf surfaces to be effective. These fungicides stay on the surface of the foliage and need to cover the entire leaf area to prevent or control the disease. Therefore, it is essential to use nozzles that produce fine to medium droplets. Fine droplets provide a larger number of droplets per unit area, enhancing the coverage and ensuring that all leaf surfaces are uniformly coated.
Systemic Fungicides
Systemic fungicides need to reach the lower canopy or soil surface, where they can be absorbed by the plant and translocated to the site of action. These fungicides are typically taken up by the roots, making it important to ensure that the droplets can penetrate the plant canopy and reach these areas. Coarse to very coarse droplets are suitable for systemic fungicides as they are less likely to drift and can more effectively deposit the fungicide at the base of the plant.
Recommended Spray Nozzles for Fungicides
When you have identified all the aspects of your scenario, fungicide type, crop type, etc., you can then look at the various nozzles that are recommended for fungicides. Nozzle manufacturers can provide guidance on which of their nozzles will produce the needed coverage and droplet size.
Wilger Spray Nozzles for Fungicides
To provide expert insight into the effectiveness of spray applications, I reached out to Chris Bartel from Wilger Inc. Chris shared his expertise and emphasized the importance of achieving optimal coverage in fungicide and insecticide applications.
"The goal of a fungicide/insecticide contact application is to have complete coverage in the application zone. The more droplets that are in the spray application, the more effective it will be in providing complete coverage. This is done with higher gallons per acre rates coupled with nozzles that are more focused on providing coverage than drift control with a medium or coarse droplet spectrum."
Chris continued, noting the different options operators have for achieving the best coverage possible. "Combining nozzles in a double down (2 nozzles side-by-side in a straight down orientation) or dual angle (nozzles oriented at an angle forward and backward) application can also allow for better coverage in dense canopy applications by combining tips with different droplet spectrums to get deeper canopy penetration and complete coverage of the entire plant top to bottom."
Wilger offers a wide range of spray nozzles, but these two series they offer provide optimal performance when fungicides are involved.
Provides about 50% fewer driftable fines compared to the ER series.
Greenleaf Technologies Spray Nozzles for Fungicides
"Fungicide application is coverage critical, so we would recommend using a DualFan nozzle of some sort" said Clay DeGruy, a spray nozzle specialist with Greenleaf Technologies. Clay's statement reinforces the importance of coverage in fungicide applications, and Greenleaf offers several nozzles that fit that objective.
Excellent for contact fungicides, very good for systemic. Superior leaf coverage and canopy penetration
Advantages: Dual spray fans provide two passes in one application, hitting the target from two different spray angles increasing the chances of reaching plant surface.
Excellent for fungicide application in wheat and other cereal grains
Advantages: The 30° forward-tilted spray effectively penetrates dense crop canopies, while the 70° backward-tilted spray effectively targets the spike or head of grain.
Advantages: More droplets per gallon produced by dual fan pattern.
Keys to Remember When Selecting Spray Nozzles for Fungicides
Whenever you are selecting a spray nozzle, it is important to follow the label on the product you are using. Also, there may be more than one type of nozzle that can give you excellent results. The key is to consider the needs of your specific application and then identify a nozzle that will provide the necessary spray pattern, droplet size, etc. Whatever type of fungicide you decide to apply you know you can identify a nozzle that will give you effective results.
For help finding or sizing a sprayer nozzle contact our sales team. You can also read our other resources on sprayer nozzles:
Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.
Despite all the expensive and sophisticated components on a sprayer, the tiny nozzles on your boom are still the number one factor impacting your sprayer's performance. You may have a high-volume pump, state of the art GPS guidance system, and stainless-steel boom, but the nozzle ultimately has the greatest influence on a sprayer's effectiveness.
One of the main factors a sprayer nozzle dictates is the droplet size that is dispersed over the target. Droplet size is important because it affects several aspects:
Drift: Larger droplets are less prone to drifting to areas you don't want sprayed, such as your neighbor's field
Coverage: Smaller droplets can typically provide better coverage, giving you the best chance to eliminate targeted weeds or pests
Penetration: Droplet size affects ability to penetrate dense canopies, ensuring that pests or weeds are effectively targeted
Adherence: Smaller droplets tend to adhere better to plant surfaces
Evaporation: Affects amount of liquid deposited on the target area rather than being lost to the surrounding environment or evaporation
When selecting a nozzle for your sprayer, it is vital to not only consider the droplet size but also the entire droplet size range a nozzle produces. In the rest of this guide, we will look at what droplet size means, what affects droplet size, and how different nozzles compare.
Understanding Droplet Size
Droplet size refers to how big each droplet of sprayed liquid is. Their size is measured in microns. A micron (1 µ) is a very tiny unit equal to 1/25,000 of an inch or about 0.001 millimeters. So, when we talk about droplet size, we're talking about the diameter, or width, of each droplet.
Just like sprayer nozzle sizes, droplet size classification is defined by international standards (ISO 25358 and ASABE S572.3). This classification system divides droplet sizes into specific categories so different nozzle types and brands can be compared. The categories are as follows:
Droplet Size
Abbreviation
Color Code
Approx Micron Range
Extremely Fine
XF
Purple
Less than 60
Very Fine
VF
Red
60 to 145
Fine
F
Orange
146 to 225
Medium
M
Yellow
226 to 325
Coarse
C
Blue
326 to 400
Very Coarse
VC
Green
401 to 500
Extremely Coarse
XC
White
501 to 650
Ultra Coarse
UC
Black
Greater than 650
These categories help in identifying and selecting the appropriate droplet size for different agricultural spraying applications. Each category is defined by specific droplet size ranges measured in microns (µ).
Spray nozzle charts show the droplet size produced by a nozzle at various pressures. It will be displayed with the abbreviation and color code shown above. It is important to note that this indicates the size of the majority of the droplets and not all the droplets dispersed by that particular nozzle.
Example: If a nozzle chart indicates that a sprayer tip will produce Coarse (C) droplets, that nozzle can still produce finer droplets, but the majority will be Coarse. The image below shows the droplet size produced by the different sizes of a nozzle at various pressures:
You can see in the chart that a red nozzle (04 size) will most often produce Medium (M) droplets within the pressure range of 20-40 PSI. If the operating pressure is below 20 PSI, however, then the size of droplets produced changes from Medium to Coarse (C). Conversely, if the pressure increases to 60 PSI the majority of the droplets will be Fine (F).
How Droplet Size Impacts Spray Quality
Drift: When it comes to spraying, drift is a major concern. Not only does drift reduce the effectiveness of your spray, but it can pose a potential threat to neighboring crops, waterways, wildlife, and people. Larger droplets are less prone to drift because they are heavier and fall more directly onto the target. This means they are less likely to be carried away by the wind. ensuring that your herbicide lands where it's intended and not on neighboring crops or non-spray areas.
Another important concept to understand when discussing drift and considering nozzle selection is driftable fines. These are the very small droplets that are extremely susceptible to drift. Any droplet under 150 microns (µ) is considered a draftable fine. Nozzle literature typically indicates the percentage of the droplets produced by that specific nozzle that fall into the category of driftable fines.
Here are two videos illustrating the importance of selecting the proper sprayer nozzle and the effect that droplet size has on drift reduction:
You can see there is a clear difference between the amount of liquid affected by wind, highlighting the importance of nozzle selection.
Coverage: Smaller droplets generally provide better coverage. They can spread more evenly over the target surface, which is essential for effective pest and weed control. However, this also means they are more susceptible to drift, so it's a balancing act to achieve the right droplet size for your specific needs.
As the videos above show, even though smaller droplets provide better coverage in ideal conditions, you can potentially get better coverage from larger droplets because more liquid is getting to the target.
Penetration: Droplet size significantly affects the ability to penetrate dense canopies. Smaller droplets can move more easily through thick foliage, ensuring that the herbicide reaches the inner parts of the plant where pests or weeds might be hiding. This thorough coverage is vital for effective treatment.
Adherence: Smaller droplets tend to adhere better to plant surfaces. Their lightweight nature allows them to stick more easily to leaves and stems, providing a more uniform application and treatment. This is particularly important for contact herbicides, which need to stay on the plant surface for a period of time to be effective.
Deposition/Evaporation: The size of the droplets also influences the amount of liquid deposited on the target area versus what is lost to the surrounding environment or through evaporation. Larger droplets deposit more liquid on the target, reducing the amount lost to evaporation. This means more of the herbicide remains on the plants, enhancing its effectiveness and reducing waste.
How a Sprayer Nozzle Impacts Droplet Size
The importance of choosing the proper spray nozzle cannot be understated, because it is the very design of a nozzle that has the greatest impact on droplet size. As the liquid comes out of the sprayer nozzle, it doesn't just flow smoothly; instead, it breaks up from a solid "sheet" to smaller sheets (also called ligaments), and then finally droplets. The size and spread (spray pattern) of the droplets depends heavily in how the spray tip was engineered but can also change depending on the viscosity of the liquid, the flow rate of the nozzle, and the pressure at which the nozzle/liquid is being sprayed/p>
The size and distribution of the nozzles throughout the width of the spray pattern varies depending on the nozzle type. Nozzles have precise, intricate internal fluid paths designed to generate a specific range of droplet sizes.Some herbicides require that you use a nozzle with larger droplets. Typically, in the extremely coarse range or larger. One of the common means used by nozzle manufacturers to create larger droplets is air induction.
This is the process of pulling air into the nozzle to fill the droplets with air, resulting in an overall larger sized droplet. There are several different nozzle types that accomplish this, and different manufacturers utilize different designs.
It's important to note that not all nozzles that produce extremely coarse or ultra coarse droplets use air-induction technology. As more sophisticated spray methods are developed, nozzle technology will continue to adapt to increase efficiency and precision.
Selecting the Right Droplet Size for Your Application
The details behind droplet size creation and classification are important but ultimately the most important question is, "What droplet size do I need for my application and which nozzle will produce it for me?"
Answering that question requires that we consider all the factors involved in your specific scenarioThe first and most important guideline is the pesticide label. If specific instructions are provided in the product label in terms of droplet size required, then that guideline is the lawFollowing the label ensures you have the best chance at avoiding any unintended consequences during or after spraying. In addition to this, there are several other aspects of spraying that might indicate you should use a droplet size that is finer or coarser.
Here are several factors to consider and why they would potentially affect which size droplets you need:
Crop Type: The foliage and leaves of various crops can present obstacles. For example, if you need to penetrate a dense canopy you may want nozzles that produce smaller droplets for better penetration.
Pesticide Type: The type of pesticide-whether it's a herbicide, insecticide, or fungicide-affects nozzle choice. Contact pesticides generally need smaller droplets for thorough coverage, whereas systemic pesticides can use larger droplets.
Target Pest or Disease: The specific pest or disease being targeted dictates the required droplet size. For instance, pests on the underside of leaves or deep within the canopy might require smaller droplets that can navigate through the foliage, whereas surface pests can be controlled with larger droplets.
Weather Conditions: Wind, temperature, and humidity significantly impact spray applications. Windy conditions necessitate nozzles that produce larger droplets to reduce drift, while calm conditions allow for finer droplets. High temperatures and low humidity increase evaporation rates, so larger droplets may be needed to ensure adequate deposition.
Drift Tolerance: Areas with sensitive neighboring crops or habitats require nozzles that minimize drift. Air induction nozzles producing very coarse droplets are often used in such scenarios to keep the spray on target and prevent damage to surrounding areas.
Spraying Speed: The speed at which you spray affects droplet size and distribution. Faster speeds can cause smaller droplets to drift, so selecting nozzles that produce larger droplets at higher speeds can help maintain effective coverage and reduce drift. When spraying across a range of speeds, you need a nozzle that will maintain your desired droplet size range at both lower and higher pressures.
Operating Pressure: The pressure at which the spray system operates impacts droplet size. Higher pressure generally produces finer droplets, while lower pressure produces coarser droplets. Choosing nozzles compatible with your operating pressure ensures consistent and effective spray patterns.
Boom Height: The height of the spray boom above the crop affects coverage and drift. Lower boom heights reduce drift but require nozzles that can maintain a uniform spray pattern at closer range. Higher boom heights need nozzles that produce larger droplets to ensure they reach the target without drifting.
Note: These are guidelines, no two applications are going to be the same and there may be more factors you need to consider.End users should always speak with their local crop consultant for specific application requirements/nozzle selection.
With so many different things to keep in mind, landing on one specific spray nozzle can be quite the task. The good news is that there are likely several nozzle types across the different manufacturers that will work in your scenario. The key is trying to zero in on one that will provide the best results based on all the variables involved.
Nozzle selection may involve some trial and error, but we can get you off to a good start. The nozzle manufacturers offer extensive resources that detail the droplets sizes and other performance factors of a given type of nozzle family.
They also provide nozzle selection tools to walk you through the process:
Recommended Sprayer Nozzles for Various Droplet Size Requirements
Dultmeier sales carries a wide selection of sprayer nozzles that deliver a wide range of droplet sizes. Whether you need fine droplets for thorough coverage of plant tissue, need larger droplets to follow herbicide label requirements, or you require a nozzle that is approved for use with a PWM system:
Broadcast Sprayer Nozzles - Nozzles for reduced drift, insecticides, fertilizer, contact herbicides, soil applied, etc.
Sizing Nozzles for a PWM system is a bit different than for standard spray nozzles. Learn more in this article on properly sizing nozzles for PWM.
Maximize Coverage with Coarser Droplets
One of the natural concerns when using a nozzle that produces larger droplets is "Will I still get good coverage?". With all things being equal, traditional flat fan nozzles like the Turbo Teejet or XR Teejet, which produce droplets in the Coarse, Medium, and Fine categories, offer better coverage. However, when we add in higher spraying speeds (10+ MPH), consistent wind (no one ever deals with wind while spraying, right?), and significant evaporation conditions, larger droplets can deliver more spray on target because they are more resistant to these factors.
When Extremely Coarse and Ultra Coarse droplet sizes are required but you are still concerned about adequate coverage, there are some options. For one, you can utilize dual fan nozzles instead of single flat fan nozzles.
Dual fan nozzles still produce the same size droplet as a single fan nozzle, but there are two separate spray fans directed at the target, at two different angles. Two fans allow you to retain desired droplet size while also increasing the number of spray angles at which to spray your target. More spray angles equals better coverage.
GreenLeaf Dual Fan Nozzles alternatively offer a 10-degree forward angle and a 50-degree rear angle. These nozzles can be alternated on your nozzle bodies, and by pointing one "forward" then the next one "backward", you are able to produce four different angles of spray directed toward your target.
(h3) Best Practices for Managing Droplet Size
In addition to the nozzle type there are different techniques that you can employ to help manage the droplet size dispersed from your sprayer:
Control the Pressure: Adjust the operating pressure to influence droplet size. Higher pressure creates finer droplets, while lower pressure produces coarser droplets.
Mind the Weather: Pay attention to weather conditions. Spray on calm days to minimize drift and avoid spraying during high temperatures or low humidity to reduce evaporation.
Boom Height: A higher boom level can increase the overlap and coverage, but it can also lead to more drift. A lower boom height reduces the chance of droplets drifting off target.
Spraying Speed: Adjust your spraying speed as needed. Finer droplets may be less prone to drift at slower speeds, faster speeds might require larger droplets to stay on target.
Regular Cleaning: Clean your nozzles regularly to prevent clogging and ensure consistent spray patterns. Use soft brushes or compressed air to avoid damaging the nozzle.
Check for Wear: Inspect nozzles for wear and tear. Worn nozzles can produce uneven droplet sizes and poor spray patterns, reducing effectiveness. You can use spray pattern test paper or an electronic sprayer calibrator to evaluate your nozzles and identify any that are worn and not delivering a consistent spray pattern.Nozzles that overspray by 20% or more are considered worn and should be replaced.
Conclusion
Precision spraying entails a lot of complexity, and it all begins with choosing the right tip to achieve your desired droplet size. Understanding droplet size is crucial for successful spray application. The right nozzle can make all the difference when it comes to coverage, drift, and overall effectiveness. Navigating the complexities of droplet size and spray nozzle selection can be daunting. However, with some time and expert guidance, choosing the right nozzle for your specific needs can become a straightforward and stress-free process.
If you have questions or would like help identifying a sprayer nozzle to meet your needs, please reach out to our agriculture sales team!
Tech Ag & Industrial Sales
Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.
