In the world of cleaning, high-pressure nozzles play a crucial role in delivering the power and precision needed to tackle tough jobs. Whether pressure washing a driveway, detailing a car, or performing industrial cleaning, the right high-pressure nozzle can make all the difference.

 

 

These nozzles are designed to enhance the effectiveness of your cleaning equipment by focusing water pressure into a powerful stream, capable of removing dirt, grime, and stains that would be impossible to eliminate with ordinary nozzles. They are typically constructed from stainless or hardened stainless steel to withstand high pressures.

Here's a comprehensive look at what you need to know about high-pressure nozzles.

High-Pressure Nozzles Applications

Most nozzles are rated to working pressures up to 4,000 psi, but higher-rated nozzles (up to 10,000 psi) are also available for more intense cleaning needs. Different pressure ranges are required to tackle the various cleaning tasks. It is important to identify the proper operating pressure for your scenario and size the nozzle accordingly.

Here are some common applications and the general pressures required:

Pressure Washing

From driveways and sidewalks to commercial buildings and heavy equipment, pressure washing relies on high-pressure nozzles to deliver targeted cleaning power. These nozzles help remove stubborn dirt, mildew, and other contaminants.

• Pressure Range: 1000 - 4000 PSI, Nozzle Options: SS Quick Coupler Nozzles & Stainless NPT Nozzles

Car Wash

In the automotive industry, high-pressure nozzles are essential for achieving a spotless finish. They are used in both automatic car washes and self-serve bays to apply foam, rinse off detergents, and remove dirt without damaging the vehicle's surface.

• Pressure Range: 1200 PSI - 2200 PSI, Nozzle Options: SS Quick Coupler Nozzles & Stainless NPT Nozzles

Industrial Cleaning

Factories, warehouses, and other industrial settings require heavy-duty cleaning solutions. High-pressure nozzles are often used in automated cleaning. They can be fixed to a machine or apparatus that is part of an industrial process to clean, strip, or prepare surfaces. Ideal for cleaning machinery, floors, walls, and other surfaces that accumulate grease, oil, grime, and other residues.

• Machinery Cleaning: Typically, 2,000 to 5,000 PSI to remove grease and grime.

• Paint Stripping: Around 5,000 to 10,000 PSI to effectively remove paint from surfaces.

• Surface Preparation: Up to 10,000 PSI (or even more in some cases!) for tasks like removing coatings, rust, or other surface contaminants before applying new coatings or treatments.

• Nozzle Options: Rotating Nozzles & Stainless NPT Nozzles

Selecting the Proper High-Pressure Nozzle

The benefits of using the right high-pressure nozzle for specific tasks cannot be overstated. Selecting the appropriate nozzle ensures:

• Efficiency: The correct nozzle maximizes cleaning power and reduces the time needed to complete a task.

• Safety: Using the right nozzle minimizes the risk of damage to surfaces.

• Cost-Effectiveness: Proper nozzle selection can extend the life of your cleaning equipment and reduce the need for additional cleaning agents.

To identify the right nozzle for your needs there are several things to consider in addition to the pressure rating of the nozzle. These include the spray angle, pattern, material, flow rate, and other nozzle features such as stabilizing vanes and rotating turbines.

Understanding Spray Angles and Patterns of High-Pressure Nozzles

The spray angle of a nozzle determines the coverage pattern and effectiveness at various distances from the surface. Common spray angles include:

• Zero Degree: Provides a concentrated, powerful spray for tough cleaning tasks. All fluid is directed in a narrow stream that impacts the surface in a very small area. Excellent for cutting through surfaces.

• 15 Degree: Offers a narrow, but slightly wider spray pattern; common for pressure washing and industrial cleaning.

• 25 Degree: Delivers a wider spray pattern, ideal for car wash and truck wash operations.

• 40 Degree: Provides the widest common spray pattern, excellent for general cleaning tasks.

A nozzle with a narrower spray angle will deliver more impact than a wider fan. So it is important to identify a good balance between the impact you need and the fan angle desired. Often the best way to determine this is by testing some different angles in your application, but knowing this can provide a good starting point.

Sizing a High-Pressure Nozzle

In addition to the spray angle, you need to determine the nozzle size for your application. The orifice size of a nozzle affects the flow rate (measured in gallons per minute, GPM) through the nozzle.

Nozzles are sized based on their flow capacity at 4000 PSI. In other words, how many gallons will flow through the tip/orifice of the nozzle at 4000 PSI? For example, a #4 nozzle will flow 4 GPM at 4,000 PSI. A #3 nozzle will flow 3 GPM at 4000 PSI.

This chart shows the flow capacity of each orifice size at various pressures:

 

Identifying your nozzle size requires that you know the parameters of your system and size a nozzle accordingly. Let's look at an example: a pressure washer that delivers 3 GPM at 2000 PSI. Using the chart, you can find 2000 PSI at the top and follow the column down until we get to 3 GPM. Then we can follow the row left to the nozzle size column on the far left of the chart. This shows us that a 4.5 nozzle or orifice size will flow 3 GPM at 2000 PSI.

This nozzle will work for the system in our example, but it is a good rule of thumb to select a nozzle size slightly smaller than what you find in this chart. In this case a #4. This will provide some bypass and allow for nozzle wear over time without a decrease in pressure.

If you are unsure of any aspect of nozzle sizing, you can always get in touch with our high-pressure cleaning team!

Nozzle Features

While spray pattern and nozzle size are the two main factors you must consider, there are other nozzle features and attributes to keep in mind.

• Internal Stabilizer Vanes: Some nozzles come with internal stabilizer vanes which create a more defined spray pattern. These are particularly useful in industrial or process cleaning where precision is a necessity.

• Rotating Nozzles: High-pressure rotating nozzles or Turbo Nozzles have an internal turbine that creates a rotating stream that vastly improves efficiency when compared to flat fan nozzles.

• Pipe Thread Sizes: High-pressure nozzles are usually available in 1/8" or 1/4" male or female pipe thread sizes, making them compatible with existing wands, arches, or other cleaning equipment.

• Quick Coupler Nozzles: Designed to fit 1/4" quick coupler fittings, allowing for easy change out or removal.

By choosing the right nozzle, you can maximize cleaning efficiency and ensure that your equipment operates at peak performance.

Conclusion

High-pressure nozzles are a key component in effective cleaning systems. Understanding their types, features, spray angles, and orifice sizes can greatly enhance your cleaning results. Always ensure you're using the right nozzle for your specific application to achieve the best performance and longevity from your equipment.

 

We all know the key role fertilizer plays in crop production. Handling large volumes of these vital plant nutrients requires the right transfer equipment. At the heart of every fertilizer transportation system is the pump. Whether it is unloading rail cars or filling the tanks on your planter, the type of pump you use has an impact on your ability to run your operation smoothly.

In this guide, we'll dive into the various types of fertilizer pumps. We will also look at the specific characteristics and attributes that hold up to the rigorous nature of transferring fertilizer.

 

Understanding Fertilizer Transfer Pumps

The primary pump type used for high-volume transfer of fertilizers is a centrifugal pump. Known for their simplicity and effectiveness, They are ideal for any scenario where the goal is to transfer fluid as quickly as possible. In other words, high-volume transfer scenarios such as loading or unloading semi-tankers, emptying rail cars, loading sprayers, applying liquid on fields, etc.

 

 

Now, centrifugal pumps are not the only pump types used to handle fertilizer. There are many different positive displacement pumps used to apply fertilizers on planters or toolbars, and there are gear pumps used for some more viscous products, but centrifugal pumps are the primary choice for high-volume transfer.

 

Advantages of Centrifugal Pumps for Fertilizer:

• Simple
• High-flow
• Easy to repair
• Durable

 

Disadvantages of Centrifugal Pumps for Fertilizer:

• Low pressure relative to other pump types
• May not handle really heavy or viscous products
• Cannot be run dry unless they have a lubricated seal

 

How Fertilizer Transfer Pumps Work

Before we get to the dirty details of fertilizer pump selection, it is worth your time to get familiar with the basics of centrifugal pumps. Especially, if you aren't familiar with them or need a quick refresher. If you want to jump straight to the pump selection, click here to jump ahead.

In order to gain a thorough understanding of how a centrifugal pump works, we should first look at the main components. These are the housing, the impeller, the shaft, and the shaft seal. Depending on the specific type of pump and the design there may be other components like a pedestal, volute, bearings, etc., but these are the main pieces that make up all centrifugal pumps.

 

Basic Components of a Centrifugal Fertilizer Pump:

 

 

• Housing
• Volute
• Impeller
• Shaft
• Seal
• Gasket
• Pedestal/Adapter

A centrifugal pump operates by using centrifugal force to move liquid. The impeller, mounted on the shaft, is driven by a motor or engine. As the shaft rotates, the impeller also rotates. The rotation of the impeller creates centrifugal force, which pushes the liquid inside the pump away from the center (the eye of the impeller) towards the outer edges

 

Pump Curves

Variations in pump construction result in different capabilities, such as flow rate, head, horsepower, and efficiency points. These differences arise from the various pump sizes, the shapes of the pump volute, as well as the sizes and designs of impellers. These factors alter the pump curve, which represents the pump's performance based on discharge plumbing parameters.

All these different variations mean that it is important to look at a pump curve when choosing a pump and not just physical attributes such as the port size or horsepower. Those alone don't tell the whole story.

A pump curve is a graphical representation that shows the relationship between the flow rate and the head (pressure) of a pump. It illustrates how a pump performs under different conditions, helping users determine the best operating point for efficiency and effectiveness. By understanding the pump curve, you can select the right pump and the horsepower needed for your specific application, ensuring optimal performance and energy savings.

 

How to read pump curves

For more detailed information on centrifugal pump operation and pump curves, be sure to read this detailed guide on centrifugal pumps written by Tom Hansen, Head Engineer at Dultmeier Sales.

 

Selecting a Fertilizer Pump

Now that we have a solid understanding of how a centrifugal pump operates, Let's look at the different aspects you should consider when choosing the right one for your needs.

 

Straight Versus Self-Priming

While there are many variations and different designs, all centrifugal pumps fit into two main categories: straight and self-priming. Both of these types operate on the same basic principle, using centrifugal force to move liquid. They differ in their ability to maintain liquid inside the pump. This is an important factor to consider when you select a pump so let's examine this a bit further.

 

Self-priming pump

 

A self-priming centrifugal pump can pull liquid from a level that is below the pump inlet (assuming it is properly primed initially). This is achieved via a combination of the design of the volute and suction created by the pump. A self-priming pump is designed to store fluid in the housing even after it stops running. Thus keeping the pump seal protected when it is started again and it begins to prime.

 

Priming is important because a standard centrifugal pump requires liquid in it at all times to lubricate the shaft seal. I say standard because there are centrifugal pumps that can be run dry but more on that later.

 

This video thoroughly explains the principles of pump priming:

 

Self-priming pumps are often used as transfer pumps to load and unload sprayers or nurse tanks. They provide more flexibility in this scenario because they do not have to be installed lower than the tank outlet. This means they can be installed almost anywhere on a truck or trailer and pull liquid from the tank.

 

Straight centrifugal pump

 

A straight centrifugal pump will also create suction the same way that a self-priming pump does, however, due to the design of the pump volute, they do not store liquid. The inlet of the pump must be gravity-fed so that the pump is not operated without liquid. If the pump inlet is not gravity-fed (flooded suction), You can use a check valve or foot valve in the suction line to trap fluid in the pump. This will protect the seal from cavitation when it starts again.

These pumps are generally more efficient than self-priming pumps. They are simpler machines, with impellers and casings designed for hydraulic efficiency. Self-priming pumps, on the other hand, have additional features like a priming chamber that can create turbulence and energy loss, making them less efficient.

A straight centrifugal pump uses most of its energy for pumping, whereas self-priming pumps must expend some energy on the priming process, reducing their overall efficiency.

Straight centrifugal pumps are very common in scenarios where the pump is going to be permanently installed with a flooded suction port:

• Bulk transfer from large storage tanks
• rail unloading, etc.
• onboard sprayers
• planters
• fertilizer toolbars

Choosing between a straight centrifugal pump and a self-priming centrifugal pump depends largely on your specific application needs. Self-priming pumps are versatile and work for many applications, but if you want efficiency and the pump will have flooded suction, then a straight centrifugal pump is generally the best way to go.

 

Types of Fertilizer Pump Drives

Another aspect to consider when selecting a centrifugal fertilizer pump is the means you will use to drive it. A pump can be driven any way you want as long as you have enough horsepower to handle the application.

Common centrifugal pump drive types used for fertilizer transfer:

• Electric Motor
• Hydraulic Motor
• PTO Driven
• Gas-Engine

 

Electric Motor Units

Electric motor-driven units are the most common drive type in fertilizer facilities. There are two different pump and motor unit styles: close-coupled and long-coupled. As the name suggests, a close-coupled is where the pump is directly bolted to the electric motor. Long-coupled pump units are connected with a set of couplers.

 

Close Coupled Pump & Motor Units

SCLFE471

 

A close-coupled pump unit is a much simpler design that has many benefits. Both self-priming and straight centrifugal pumps can be coupled with a C-face motor. Pump manufacturers build pumps with motor adapters to mate with several different electric motor frame sizes.

Pros:

• Compact design
• less expensive
• easy to connect
• No alignment issues

Cons:

• Leaking around the pump seal can damage the motor

 

Long Coupled Units

 

DUVF4x3-20-SGL

 

Although they are more complex and expensive, long-coupled units have many benefits. They typically consist of a baseplate, a 3-piece flexible coupling, and the pump and motor. Pumps used for long coupled units are called pedestal pumps. This indicates that they have a bearing pedestal with a solid shaft.

Pros:

• Design protects motor bearings from leaks
• Flexibility for more pump and motor combinations

Cons:

• Requires precise alignment
• Can be more expensive due to the baseplates and couplers required

 

Engine-Driven Pumps

Pumping fertilizer on a nurse/tender trailer or a tanker limits the power sources, so typically we will use engine-driven pumps. For fertilizer, Banjo, MP, John Blue, and Scot offer engine-driven pump units fitted for fertilizer. The horsepower requirements are higher to move fertilizers that are heavier than water. For 2-inch pumps this general means an 8hp engine, and 3-inch pumps will need 13hp. 

Like electric motor pump units, there are a variety of variations available. From manifold flange pumps, poly, cast-iron, and stainless steel:

Engine Driven Pump Units:

John Blue 3-Inch Fertilizer Pump

 

View Other Engine-Driven Fertilizer Pump Options

 

Consider Chemical Compatibility

Compatibility is a crucial factor to consider. As you know, fertilizer is a broad term encompassing several different liquids used to improve plant growth. Most of these products possess properties that lead to rust, corrosion, and friction wear on pump components.

Centrifugal pumps can be constructed using various types of materials. Due to the wide variety of chemical properties of the different fertilizers, there isn't one material that works best for all of them. It is important to look at individual products to determine the best material to use.

 

Common Fertilizer Pump Materials

Although no material will handle all types of fertilizers, there are some that work with common fertilizers such as 10-34-0 or 32% nitrogen. For these products, we recommend polypropylene or cast iron pumps with Viton mechanical seals. Stainless steel is another material that will work with a broad range of fertilizers, but due to the cost, it is only used when necessary.

 

If you are not sure what materials are best suited for the type of fertilizer you use, you can refer to our chemical compatibility charts or call us for help. Our years of combined experience give us a good idea of what materials should be used with different products.

 

Regardless of pump type, it is recommended to drain corrosive liquid from the pump and fill it with a non-corrosive liquid such as crop oil or RV antifreeze. This will significantly prolong the life of cast iron pumps.

 

Choosing A Seal Type

No matter what type of centrifugal pump you are using, the shaft seal is the most important component to understand. The seal provides a barrier keeping liquid in the pump as the shaft rotates.

There are different types of seals used in centrifugal pumps, but the most common we see used with fertilizer is a mechanical seal. This type consists of two seal faces, an elastomer, and a spring:

• Rotating Seal Face: Attached to the pump shaft and rotates with it.
• Stationary Seal Face: Fixed to the pump housing and remains stationary.
• Elastomer: keeps the rotating pieces tight on the shaft.
• Spring: Pushes the two faces together to maintain a tight seal

Each seal face is smooth and consists of durable materials such as silicon carbide, carbon, or ceramic. The seal elastomers can be Buna, EPDM, Viton, or other material that is compatible with the fluid you are pumping. While the pump is operating a small amount of the fluid being pumped forms a barrier between these two seal faces. This lubricates the seal and provides a barrier that keeps the pump from leaking around the shaft.

 

Viton® mechanical seal assembly

 

Without liquid in the pump housing, a standard mechanical seal can fail because it is not lubricated. This is called "running a pump dry". The two faces rub together creating friction that will harm the seal face or crack it all together. Even slight damage to the seal face can result in a leak.

Using a pump with a lubricated seal or double seal assembly can prolong seal life. These mechanisms keep the shaft seal of the pump lubricated with antifreeze or grease. This adds protection in situations where the pump might run dry, like unloading trucks or storage tanks. Any situation where a tank is emptied or prime could be lost.

 

Pressurized wet seal assembly on fertilizer pump & motor unit.

 

If your pump will be installed in a scenario where it could be running dry or you don't want to risk seal failure in the middle of your busiest season, a double seal or lubricated seal is your best option.

 

Pump Size

When we say pump size, we are talking about flow rate. The amount of liquid you need your pump to move in a given amount of time is important, but determining what pump will deliver your needed flow rate can be tricky.

The flow rate in centrifugal pumps is closely tied to the discharge head. An increase in discharge head leads to a decrease in flow rate, and vice versa. Understanding this relationship is essential for selecting and operating these pumps, as it directly affects their performance in various scenarios.

Of course, no two scenarios are the same so let's explore how you can go about sizing a fertilizer pump for a specific application.

 

Sizing A Fertilizer Transfer Pump

First, you need to consider the specific fertilizer you are going to be moving as well as the plumbing layout. This process involves gathering some information, here are the basic steps:

1. Determine Desired Flow Rate: Calculate the required flow rate in gallons per minute (GPM). Consider the application, are you filling tanks? Unloading trailers? How quickly do you want the load/unload process to be completed?
2. Identify Your Fertilizer Properties: Determine the viscosity and density of the fertilizer.
3. Calculate Total Head (TDH): Determining the total discharge head of a pump involves calculating the total head or pressure that the pump needs to overcome to move the fluid through the entire system. If you have plumbing in place already, consider any restrictions such as elbows, valves, strainers, meters, vertical pipes, etc. For more details, you can read this guide that further explains total dynamic head.
4. Identify Pump: Once you know your flow rate and TDH, you can identify a pump that can achieve your desired GPM given your plumbing setup. This requires examining the pump curves of different models to find a suitable option. The pump curve will offer insights into the most efficient option and the required horsepower for your application.

 

The total dynamic head, the pump design, and the flow rate, combined with the viscosity and weight of the fertilizer will determine how much horsepower is required. Determining pump flow rates and horsepower requirements is a complex matter. If you have questions or just want us to walk through this process, you can give us a call any day and we can help you determine the pump and motor size you need.

 

Final Takeaways

Choosing the right fertilizer pump is crucial for efficient and smooth operations. By understanding the advantages and disadvantages of different pumps and the specific needs of your application, you can make an informed decision.

Remember to consider factors such as pump type, drive methods, material compatibility, seal types, and proper sizing to ensure optimal performance and longevity of your equipment. Investing time in selecting the appropriate pump will ultimately lead to better handling of fertilizers, increased productivity, and cost savings in the long run.

There are many, many different options for fertilizer pumps, so do not hesitate to reach out to us if you need some guidance selecting a pump!

 

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.

Learn More About Author

Selective catalytic reduction is an advanced process that is intended to minimize pollution from diesel engines and contribute to better air quality. Diesel exhaust fluid, or DEF, is central to this process.

If you use modern farm or construction equipment you are well aware of the regulations that require the use of DEF. Although DEF is a simple liquid, consisting of urea and water, it does have unique properties. So for those who need to fuel equipment, the question arises what kind of pump do I need for DEF?

In this guide, Will will be looking at the properties of DEF to understand what types of materials are compatible with it. We will also take a look at the different DEF pump options and accessories.

 

Understanding What Pump Types Are Suitable for DEF

The most important thing to consider when selecting a pump for DEF is material compatibility. There are other factors to consider such as flow rate and drive type, but this is most important. Let's look at the materials that work for pumping DEF and the types of pumps that will work.

 

Material Compatibility

Diesel Exhaust Fluid (DEF) is a solution made up of 32.5% urea and 67.5% deionized water. DEF is non-toxic, non-flammable, and non-hazardous under normal conditions. However, DEF is not compatible with most metals and some plastics. This limits the pumps that are suitable to be used with it.

How important is this really? What is the worst that can happen if you use just any old pump? Simply put, it may work for a very short period but it won't be long before you have issues. DEF decomposes into ammonia, which corrodes incompatible metals like copper, zinc, and aluminum. It causes pitting, erosion, oxidation, and galvanic corrosion, weakening metal and leading to rapid component damage.

So what materials do work with DEF? Stainless steel (grades 304 and 316), polyethylene, and polypropylene are resistant to the effects of DEF. Therefore manufacturers use these materials to construct pumps suitable for DEF. The seals and gaskets used for DEF pumps are EPDM or Viton.

 

Material suitable for handling DEF:

• Polypropylene
• Viton
• EPDM
• Stainless Steel

 

 

Pump Types for DEF

Although the materials suited for DEF are limited, there are several different types of pump that will work fine for DEF fluid. Centrifugal pumps, diaphragm pumps, gear pumps, and even submersible pumps. Again, the type is not as important as the materials and elastomers used to construct the pump.

Centrifugal pumps are most common for large volumes, and diaphragm pumps are used for dispensing into vehicles and equipment. Diaphragm pumps for DEF will generally come as a kit that includes the hoses, nozzles, and couplings needed for DEF barrels or other pre-packaged containers (more about this in a moment). 

• Centrifugal Pumps
• Diaphragm Pumps
• Submersible Pump

 

Pump Drive Types for DEF

A variety of drive options can be used for DEF Pumps. Electric motors, gas engines, hydraulic motors, air-driven pumps, and more. No matter what kind of power supply, you can find a pump that will work for you.

• Electric
• Gas-engine Driven
• Air Operated

 

DEF Pump Couplings

Many DEF tanks and containers utilize Micromatic RSV valves and couplings. These couplings are designed to prevent contamination of DEF. They have a dry-break mechanism that minimizes the exposure of DEF to the environment during connection and disconnection, maintaining the purity of the fluid

 

These couplings also help to eliminate drips or spills. Even a small amount of DEF fluid can corrode metals, so the dry-break feature is vital to protect any equipment around your DEF pump and tank.

RSV Coupler

RSV Drum/Tank Valve

 

RSV couplings are the same type of couplings used on beer kegs and other chemical containers. There is a valve in the tank or drum, and there is the coupler on your pump or suction hose.

There are two different types of Micromatic couplers: 3-key and 4-key. The reason for this difference is to prevent cross-contamination of equipment. For example, it prevents you from coupling a DEF pump to a tank containing some other chemical.

 

How to Connect the Micro Matic RSV Dispense Coupler

 

DEF Pump Options

Due to the specific applications and the limited materials that are compatible with it, manufacturers have designed pumps and pump units specifically for DEF. There are 12-volt options available for mobile applications as well as stainless steel centrifugal pumps for bulk transfer.

 

12-Volt DEF Pumps

• Flowserve: CT6-DEF
• Fill-rite: FRDF012-PO
• Piusi: PJ33102
• MP: MX35322
• Dura: DP6518-AE12

 

115-Volt DEF Pumps

• Piusi: PJ33101
• Flowserve: CT6-DEFA
• Fill-Rite: FRDF120-PO
• Dura: 6518-AE110

 

Air Operated DEF Pumps

• Fillrite: FRAP32V

 

DEF Pump Kits

Understanding that DEF is only compatible with certain materials, you must be careful when selecting a pump, but then you have to piece together a hose, nozzle, meter, and tank that is compatible. This is time-consuming and nerve-racking if you are not certain that an item will work with DEF.

DEF pump manufacturers understand this and offer comprehensive solutions. There are several DEF pump kits that include a pump, hose, RSV coupler, and all the other appropriate fittings needed. These kits are often designed to hang off an IBC tote or 275-gallon shuttle. Some of these kits will even include a tank.

 

DEF Pump Kits for Cage Tanks/IBC Totes

12-Volt Kits:

• Dura: DP6518-AE12
• Fill-Rite: FRDF012
• Piusi: PUF101A1A
• Flowserve: SICT6-DEFD

 

110-Volt Kits:

• Dura: DP6518-AE110
• Piusi: PUF101AOH
• Fill-Rite: FRDF120
• Flowserve: SICT6-DEFE

 

DEF Pump Kits with Tank

58 Gallon Tank Kit: PUPPT58

116 Gallon Tank Kit: PUPPT116

135 Gallon Tank Kit: DP2512-AE-135

 

DEF Pumping Accessories

Your pump's compatibility with DEF is vital, as are the accessories you use to handle it. Here are some essential accessories to consider and the types that work with DEF:

 

DEF Tanks

Polyethylene and stainless steel are the best materials for DEF storage. Poly is much more affordable. You can use just about any poly tank but you will want to ensure that the tank is properly sealed up and equipped with dry-break couplers to preserve the purity of your DEF.

As mentioned earlier RSV couplers are the common method to ensure closed system transfer. These can be added to a tank if you do not have them. The RSV tank valves are made to fit into different thread types. If you use a 275-gallon IBC tote/Cage tank, you can replace the lid with one that will fit an RSV coupler.

 

DEF Tank Options:

• 275 IBC Tote/Cage Tank
• Mini Bulk Tanks
• RSV Couplers & Valves

 

DEF Hose

EPDM rubber is the preferred hose to use for DEF. Hose fittings should be either polypropylene or stainless steel. There are also poly and stainless hose reels designed to handle DEF.

• EPDM Bulk Hose
• DEF Hose Assys
• DEF Hose Reels

 

Other DEF Accessories:

• DEF Meters
• Filters
• DEF Nozzles

 

Let Us Know if You Need Help

DEF is a uniquid fluid with properties that dictate that you use the right type of pump and accessories to handle it safely. Fortunately, the pumps that work with DEF are clearly designed to do so. If you have questions about whether or not a specific product will work for DEF let us know.

 

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.

Learn More About Author

Injecting a liquid into a center pivot is an effective way to deliver nutrients to crops later in the growing season. Getting a fertigation or chemigation system setup is pretty straightforward, but there are some key aspects that you must get right to avoid any issues.

So if you are not familiar with the type of pump you need, not to mention the other components that make it all work, this article will give you the information you need. Let's get to it.

 

Components Needed for Injecting Fertilizer or Chemical into a Center Pivot Irrigation System

The main components needed to inject fertilizer are the pump, check valves, hose, strainer, and tank. Several types will work as long as they meet the necessary size, flow, and compatibility requirements.

• Positive Displacement Pump
• Check Valve
• Tank
• Hose/Plumbing
• Strainer

 

It is important to note that in addition to the fertilizer components we discuss in this guide, you also need a chemigation backflow preventer or check valve on the well. The fertilizer is injected downstream from this valve. The specifics are dictated by local regulations. This chemigation check valve prevents chemicals or fertilizer from getting into the well and contaminating groundwater.

These chemigation check valves are not sold by Dultmeier sales. For more information, you can check out this article from North Dakota State University. You can also check with your pivot dealer.

 

Injection Pump for Fertigation or Chemigation

If you want to apply fertilizer or chemicals through a center pivot you need a pump. That may be obvious, but you cannot use just any type of pump. While centrifugal pumps are commonly used to transfer fertilizer they will not be effective when it comes to injecting fertilizer into a pivot or any other irrigation pipe.

You need a positive displacement pump to inject liquids into the center pivot or irrigation pipe. This is a type of pump that uses mechanical means to physically move it fixed amount of fluid with each stroke or rotation. These pumps create higher pressure and central pumps and they can overcome the existing pressure in the irrigation line.

There are different types of positive displacement pumps. Piston pumps are commonly used when injecting into an irrigation line but a diaphragm pump can also be used. These injection pumps are rated in gallons per hour. In addition to moving the liquid, the pump also serves as the metering device.

These pumps can deliver a precise amount of liquid into the irrigation pipe, consistently with each stroke. The rate can be adjusted according to the amount of liquid you need to apply.

 

Irrigation Injection Pump Options

EZ Meter Piston Pumps

• Available in 5-30 GPH or 10-100 GPH
• Up to 150 PSI
• Wettable parts made of stainless steel and polypropylene, Teflon available
• Motors available in 12-volt, single-phase 110-220 volt, and three-phase 220-440 volt
• Easily repairable

View all the options EZ Meter pump options here.

 

Check Valve

We already talked about the chemigation check valve in the irrigation line to prevent backflow into the well. There is another check valve that is needed for the fertigation system. This is installed in the injection port. They ensure fertilizer is released in the center of the pipe, providing even dispersion. 

These ensure only fertilizer gets in and nothing leaks when the pump is not running. They also provide back pressure to ensure the pump meters are accurate.

 

Storage Tank

The tank is pretty straightforward whether you are using a stationary tank or you have a nurse trailer, you must have a vessel to hold your fertilizer. Flat-bottom vertical storage tanks are very common and they are rated to handle heavy fertilizers.

Poly Vertical Tanks Tanks for Fertigation:

• 500 Gal
• 1000 Gal
• 1500 Gal

 

Hose/Plumbing

The hose that you use might seem like an afterthought, but the wrong hose could give you a lot of trouble. Just like with the pump, the hose needs to be constructed of material compatible with the fertilizer you are using. For nitrogen fertilizers, EPDM rubber hose works great. 

You will need a reinforced suction hose on the inlet side of your pump. This means that from the supply tank to the pump. This hose should also have an inside diameter that is at least the size of the pump inlet. Using a smaller diameter hose can restrict the flow to the pump, damaging the pump and keeping you from hitting your application rate.

The discharge hose does not need to be rated for suction. It should be rated to handle some pressure, the EZ Meter pumps from John Blue can produce 150 PSI. The nature of how these pumps operate does create pulsing. This means that your discharge hose will jump around a bit.  So be sure it won't rub on anything that could wear a hole in it during operation.

This is a typical plumbing diagram for injecting metering pumps.

 

Rinsing the pump is important. You can make it easier to do this by installing a 3-way valve somewhere in the suction line. This would allow you to switch from the fertilizer tank to a freshwater source. You can also use a three-way valve in the outlet of the tank so you can both withdraw and fill the tank without disconnecting the pump.

 

Filters

It is also vital to use a strainer in the suction line. This strainer should also be at least the size of the inlet port on the pump. A piston pump does not handle solid particles well, so the screen should have a fine mesh. The manufacturer of our piston pumps, John Blue, recommends an 80 mesh screen size to protect the pump.

80 Mesh Line Strainer

 

Final Thought

With the right equipment and setup, you can deliver the nutrients your crops need through your irrigation system. Remember that the correct pump is vital to achieving the accurate results you want. Plumbing things correctly will help prolong the life of the pump and save you time.

 

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.

Learn More About Author

Whether it's farming, construction, or mining, the seamless supply of fuel to your equipment is vital to maintaining productivity. Using the right diesel transfer pump can keep refueling from becoming a bottleneck in your operation.

Several options are available for refilling equipment and bulk transfer of diesel fuel. I have been working with customers to identify efficient ways to refuel equipment for several years. Using that experience and customer feedback, I will break down the options and lay out the best diesel transfer units for several scenarios.

 

Getting Started: Diesel Transfer Pump Options

Diesel transfer pumps come in many forms to suit various needs. Two common types used for refueling and bulk transfer are rotary vane pumps and centrifugal Pumps. Because diesel is not as volatile as gasoline, there are typically different pumps or safety features required when pumping gasoline. In this article, we are solely talking about diesel fuel pumps and systems.

 

Mobile Fueling Options

When you are in the middle of a harvest or a construction project, you need to get fuel onsite. This calls for mobile fuel transfer options that run off the power available. Typically this means 12-volt batteries, hydraulic motors, or gas/diesel engines.

 

12-Volt Rotary Vane Pump Units

You are probably familiar with the 12-volt rotary vane pumps used for mobile fueling. These are the 12-volt pumps that are installed right on top of a fuel tank. Often the pump manufacturer such as GPI or Fill-Rite, will package their pumps as kits. These kits generally include a suction pipe that fits into the pump inlet, a 3/4" or 1" discharge hose, a fuel nozzle, and an optional meter. These pumps feature a 2-inch male NPT inlet that easily attaches to standard 2" tank bung threads.

 

12-Volt Fuel Pump Specs:

• Flow rate: Up to 25 gallons per minute (GPM)
• Manufacturers: GPI, Fill-rite, Piusi
• Inlet: 2-inch male NPT
• Discharge Hose: 3/4" or 1"
• Features: Fuel nozzle, optional meter, suction pipe

 

High-Flow 12-Volt Fuel Pump Options:

GPI Model: GIV25-012AD

Filrite Model: FRNX25-12V

Piusi Model: PUEX100-PO

 

RELATED: Mechanical Vs Digital Meter: Which One is Best for My Application (not yet written)

These 12-volt pump units are relied on a lot for mobile refueling applications. These pumps are reliable and can last for years. One downside to this type of pump is the flow rate. The highest flow 12-volt fuel pumps are rated to about 25 gallons per minute.

That is pretty good for most scenarios but it does not take into account the loss of flow from the hose, nozzle, fuel filters, and any elevation you are trying to overcome. (Think pumping fuel up into a combine or a large excavator.) When all of this is taken into account, your flow may be greatly reduced.

Pressure loss is a tricky thing to determine, but you can see charts on this page that will help know the pressure loss in your plumbing setup. We will get to ways to get the most flow out of your pump in a moment, but first, let's look at some other high-flow pump options.

 

Engine Driven Diesel Pump Units

So what if these 12-volt pumps won't cut it? I mean, If you are filling a 300-gallon fuel tank at 15 gallons per minute, it is going to take some time. That is where engine-driven centrifugal pump units come into play. These units offer more flow potential than the smaller 12-volt pumps. That is why we have built diesel fuel pump units to offer a more efficient refueling option for large equipment.

 

High Volume Diesel Fuel Transfer Systems

 

Dultmeier High-Flow Diesel Unit Specs:

• Flow rate: Up to 60 GPM
• Pump Type: Centrifugal pump units
• Inlet Hose: 1-inch or 1-1/2 inch
• Flow Rate (Assembled):
• 1-inch version: 30 GPM
• 1-1/2 inch version: 60 GPM
• Additional Features: Shut-off nozzle, filter, hose, reel, meter (optional)

 

On its own, a two-inch diesel pump driven by a gas engine is capable of moving over 150 gallons per minute. The cost of these pump and engine units is often comparable to the 12-volt pumps that can move 25 gallons per minute. Now, that may sound too good to be true, so let me explain.

When you are filling equipment you will likely need all of these things in addition to your pump: a shut-off nozzle, a filter, plenty of hose, a reel, and possibly even a meter. The 150 gallons per minute flow from a gas-engine driven centrifugal pump is only achievable with the right size hose. For a flow rate of 150 gallons, you would not want to use anything less than a 2-inch hose (inside diameter). Smaller hoses will restrict flow and so will a fuel filter, auto nozzle, meter, and hose reel.

Even though these items reduce the overall flow rate you are still getting a lot more flow from one of these units compared to the 12-volt rotary vane pumps. Especially when pumping vertically into a combine or other large piece of equipment.

We build a 1-inch version and a 1-1/2-inch version. Assembled with filters, nozzles, hose reels, etc., they will still deliver a flow rate of 30 and 60 gallons per minute respectively. This flow rate is at the nozzle and after pushing through 35 ft of hose. The primary limiting factor is the fuel filters used on each unit.

30 Gpm Unit: DUFPU1P

60 Gpm Unit: DUFPU1.5P

These units are available in various configurations. Base units have recoil start engines and no meters, but you can upgrade to an electric start gas engine and add a meter. Contact one of our team members to learn more.

 

Stationary/Bulk Storage Tank Pumps

If you have a tanker truck to unload or want to fill your fuel trailers from bulk storage tanks, then you probably need more than a 30 or even 60-gallon flow rate. Well, as we discussed earlier, centrifugal diesel transfer pumps can achieve much higher flow rates than this, you just need the right plumbing. Let's examine the bulk diesel transfer pump options.

 

Electric Motor Driven Centrifugal Pump Units for Diesel

As referenced above, a two-inch centrifugal pump is capable of well over 150 gallons per minute. But you don't have to limit yourself, for bulk transfer you can use larger pumps. Three-inch pumps can potentially move 300-500 gallons per minute or more. There are also plenty of larger diesel transfer options if your scenario requires it.

Options:

• Flow rate: 50 gallons per minute and up
• Explosion-proof motors available
• Common 2-3 inch port sizes

 

Popular Electric Motor Diesel Pump Units:

Diesel Unit: DUMP3030C

Explosion Proof Motors GR81-1/2-3P

 

How to Choose a Diesel Transfer Pump for Bulk/Storage Tank

When you are looking for a high-flow transfer pump to handle bulk diesel transfer or truck unloading, here are the main things to consider:

• Flow Rate: Decide how quickly you need to move your fuel. For example, if you want to fill a 1000-gallon fuel trailer in 10 minutes, you'll need a pump with a flow rate of at least 100 gallons per minute (GPM).

• Power Source: Determine what pump drive type will work best for you depending on available power sources and site conditions.

• Self-priming vs Straight: Choose self-priming If the pump needs to lift fuel from a lower level, such as from an underground tank. Use a straight centrifugal pump when the pump inlet is permanently lower than the liquid level of the tank.

• Material Compatibility: Select materials that are compatible with diesel to prevent corrosion and ensure longevity. Metals: stainless, cast iron, aluminum, ductile iron, Rubbers: nitrile, buna, Viton®.

 

You might be asking, "But what about filters or fuel nozzles, won't those limit the flow rate?". They certainly can if they are not rated to accommodate higher flow rates. Fortunately, there are high-volume filters and nozzles available for these applications.

Viking series filters are designed for high-volume fuel transfer. There are different models and they will handle 120-300 gallons per minute.

 

Viking Filters:

Viking 2

Viking 3F

There are also high-flow fuel nozzles for flow of 100 gpm or more. Of course, you can always use a brass or stainless steel ball valve as well.

2-inch Fuel Nozzles: Morrison 2-Inch 75 Degree Nozzle

 

How to Maximize Your Diesel Pump Flow Rate

To maximize the flow rate from a diesel pump, it's essential to consider several factors that can influence performance, including hose size, fitting size, filters, nozzle, and vents. Let's break down each component and how they contribute to optimizing flow rate.

 

Hose Size

The flow rate of fuel through a hose depends on the size of the hose's inside diameter. If you double the diameter of the hose, the flow rate can increase significantly. Bigger hoses reduce friction inside the hose. Smaller hoses create more resistance, which slows down the flow of fuel. A larger hose allows the fuel to flow more freely and quickly.

Tips to Maximize Flow:

• For discharge hose, use the largest hose diameter possible to minimize friction loss. Example: for a 2-inch pump, use a 2-inch or larger inside diameter hose.
• Ensure the hose length is only as long as necessary; longer hoses can reduce the flow rate.
• Ensure the suction hose or pipe (this is any pipe or hose prior to the pump inlet) is large enough for the pump. Again, for a 2-inch pump, you need at least a 2-inch (inside diameter) suction hose or pipe. Same for 3-inch, 4-inch, etc.

 

Fitting Size

Similar to hose size, the diameter of the fittings used in the diesel pump system must be adequate to handle the desired flow rate without creating bottlenecks. You might have a 2-inch discharge hose, but if you use a 1-1/2 inch elbow or swivel, that will result in a flow reduction. If you have multiple points where there is a smaller fluid path, this really adds up.

Tips to Maximize Flow:

• Select fittings that match or exceed the inner diameter of your hoses.
• Avoid unnecessary bends, elbows, and reducers that can increase friction and reduce flow.

 

Filters

Filters are crucial for maintaining fuel quality but can introduce resistance and reduce flow rate if not appropriately sized or maintained. There are two size dimensions to consider with a fuel filter: port size and filter size.

Filter port size refers to the inlet and outlet on the filter. As a rule of thumb use a filter head with ports that match your hose size and pump outlet. Not all filters flow the same even if they have the same port size. One filter may allow a max flow of 18 GPM while another may be designed for 25 GPM. We can provide the flow rate of various filter types to find the best fit for your operation.

The reason for the different flow capabilities is due to the type of filter element inside the filter housing. These are available in various levels of filtration. Often this is measured in micron size. The smaller the number, the smaller the particles it will filter. 2, 10, and 30 microns are common filter sizes for fuel. While finer filtration is good, it can significantly affect your flow rate.

 

Tips to Maximize Flow:

• Choose filters with a flow rating that matches or exceeds your pump's flow rate.
• Regularly maintain and clean filters to prevent clogging and flow restriction.
• Use 10 microns for most applications, and 30 microns for heavier fuels like diesel fuel.

Shop Fuel Filters

 

Nozzle

Discharge nozzles are necessary to stop flow when filing is complete, but these nozzles, especially automatic nozzles, can restrict flow. It is important to know that not all nozzles will flow the same even if they appear the same size.

You can see high-flow fuel nozzles here. There are typical nozzles that will handle 15-20 GPM, but also larger auto nozzles that can handle flows of 75 and even 100 GPM.

Tips to Maximize Flow:

Only use automatic or "service station" style nozzles when needed. For bulk transfer use ball valves instead as your shut-off. These have higher flow rates.

 

Vents

Proper tank venting is essential to maximize your flow. You must be able to remove air from your tank to add fuel, and you must allow air into your tank to withdraw fuel.

Venting is not just about flow rates, it is also a safety issue (see what can happen here). Diesel fumes can be flammable. Ventilation allows these fumes to escape safely, reducing the flammable vapors inside the tank. This minimizes the risk of fire or explosion.

• Tips to Maximize Flow: Ask tank manufacturers/retailers to help size vents
• Check the vent regularly for clogs or damage

 

Time & Money Saving Diesel Pump Accessories

Hose swivels are a great tool that makes handling your fuel nozzle easier, but they also keep your hose from wearing out at the ends from the natural twisting and bending that occurs over time when the hose is handled.

View fuel swivel options and other petroleum accessories here.

 

Similar to a swivel, but these fittings are not "live" swivels. Pipe unions allow for the quick disconnection of pipes without the need to rotate them. This is particularly useful in tight spaces where turning a long pipe might be impractical. You can see the different size unions for fuel here.

 

Hose Reels

How a hose is handled and stored has a profound effect on its lifespan. For example, a hose rolled up and hung on a hook can wear at the pressure point over time. A hose drug on gravel or rough concrete will suffer from abrasion and be prone to potential leaks.

A hose reel helps to avoid these issues. It also removes the hard labor of rolling up and unraveling a hose. You will also avoid the potential safety hazards from a hose lying on the ground.

Electronic rewind and spring rewind hose reels are available to work with fuel and they come in sizes that can handle up to three-inch hoses:

 

1 Inch Spring Rewind Fuel Hose Reels:

• HNN818-25-26BTR 1 inch x 35 ft of hose

• RFFD84050OLP 1 inch x 50 ft of hose

 

1-1/2 Inch Spring Rewind Fuel Hose Reel:

• HN922-30-3115.5 1-1/2 inch x 50 ft of hose

 

Conclusion

In the world of demanding industries like farming and construction, the efficiency of refueling operations is crucial. The right diesel transfer pump can transform refueling from a logistical headache into a smooth, efficient process that keeps your equipment running without delays.

There are many options, understanding the specific needs of your operation and the technical aspects of these pumps will help you make an informed choice. Always consider flow rates, power sources, and additional features like filters and nozzles to optimize your setup for maximum productivity.

You can reach out to one of our sales team directly via email or phone if you have any more questions!

 

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.

Learn More About Author

It is no secret that there are quite a few options when it comes to sprayer tips. In fact, our Liquid Handling Catalog has over 30 pages dedicated to different spray nozzles! Fortunately, there is an international standard in place to ensure the consistency and performance of sprayer nozzles used in agriculture. This is crucial because nozzles need to perform reliably to apply pesticides, herbicides, and fertilizers effectively.

This standard, specifically known as ISO 10625, defines these specific nozzle characteristics: spray pattern, flow rate, and droplet size. The standard achieves this by implementing a numbering system that helps identify and categorize nozzles based on their performance characteristics and specifications.

 

Numbering System for Spray Nozzles

Now that we have the reasoning behind the numbers out of the way, we can examine what these numbers tell us.

Each spray nozzle is assigned an identification code. This code may consist of letters and numbers. It provides the nozzle type, orifice size, spray pattern/spray angle, and material of construction.

• Nozzle Type: Manufacturer nozzle type/name. Denotes specific designs or features specific to this nozzle series such as extended range (psi), twin fans, droplet size, etc.

• Spray Angle: The numbering system specifies the angle of the fan produced by the nozzle. Nozzle spray patterns have a vital role in effective coverage. For more details, take a look at this chart that shows the theoretical coverage of nozzles at different angles and spray heights.

• Nozzle Size: The numbering system classifies nozzles based on their flow rate at a standard pressure (40 psi). This helps in selecting nozzles that deliver the correct amount of chemical per unit area.

• Material/Features: The final part of the code will include information about the nozzle material (e.g., brass, stainless steel, plastic). It can also note other nozzle features such as a specific shape or characteristic of the spray pattern.

 

Let's look at an example of nozzle numbering using an "XR 110-04 VK" spray tip:

 

Here is the breakdown of what each section of this sprayer nozzle number/code means for this specific nozzle:

• XR: This indicates the type or series of nozzle, in this case, the XR TeeJet, which stands for "extended range". Extended range refers to the wide range of PSI the nozzle will operate at.

• 110: Represents the spray angle in degrees. This particular spray tip, therefore, will spray at a 110-degree angle.

• 04: Indicates the flow rate. In this case, it signifies a flow rate of 0.4 GPM at 40 PSI.

• VK: Describes the material of the nozzle. "VK" stands for VisiFlo ceramic. This indicates that the nozzle tip is made of ceramic and follows the VisiFlo* color code.

*Just a quick note, VisiFlo was the color coding system started by Teejet to categorize different-size nozzles. This system was adopted by the ISO standard that is used today. The code assigns a color to each nozzle side:

 

 

Not all spray tips make it this easy. In some cases, spray tip numbers are not displayed as clearly on the nozzle face but instead may be labeled on the side or base of the nozzle. This variance in numbering location is because manufacturers often offer numerous nozzle types that vary in design, which of course further differs for each manufacturer.

Further complicating matters, some spray nozzle brands do not adhere to the ISO color coding system. To illustrate these differences, let's take a look at a few examples.

 

Example Sprayer Nozzle Numbers & Comparisons

First, lets look at two nozzles from the same manufacturer and family/type. The only difference between the two is the sizes or flow rate:

 

The red nozzle is an 04 size and the yellow nozzle is an 02 nozzle.

 

Now, sometimes the numbers are not this clearly displayed. Both of these are Teejet nozzles, but they are different types. You can clearly see the numbers on the XR spray tip but this other nozzle does not have the numbers listed in this form.

You can see that the nozzle does have an 04 on the tip, this along with the color indicates the size, as all red nozzles are going to be an 04 size. It does say Turbo and Teejet on the side but it is hard to see.

You will notice that there is no indication of the spray angle or the material. But, if we look up a TT nozzle in our catalog you can see that a Turbo TeeJet is going to have a 110-degree tapered flat fan and is made of polymer. This is an example where the manufacturer, because of the unique design of their spray tip, has only labeled the nozzle with the nozzle series (Turbo Teejet/TT) and the size (04).

Since all sizes within this family of nozzles share the same spray angle and material, the nozzle type is understood to stand in for this information without it having to be shown directly on the tip as with the XR nozzle. If you are uncertain or have a nozzle that lacks numbers clearly displayed on it, call us, we can help you!

 

In our next photo, we have two nearly identical nozzles. Same brand, same type, same size, and color; however, there is a significant difference in the spray pattern produced by each one. Once more, the numbers tell the story.

 

First Number: We know the first set of numbers is the spray angle. So here, the nozzle on the left produces an 80-degree fan, while the nozzle on the right will produce a 110-degree fan.

Second Number: We know this portion of the number signifies the size of the nozzle, which in this instance is 04 for both. We know this from the number as well as the color.

Letters: This is where things start to get interesting. The nozzle on the left does not have any prefix numbers (More on this in a bit). Conversely, the nozzle on the right is an XR tip. As we explained earlier, this means it is an extended-range flat fan tip. The final set of letters indicates the material of the tip, which for the nozzle on the left is VS (stainless) and on the right is VK (ceramic).

 

But what about that "E" before the VS on our first nozzle? This notes that the nozzle has a special spray fan. It is not the standard tapered flat fan found on most ag sprayer nozzles. Instead the "E" tells us that the nozzle produces an even spray pattern.

This one little letter makes these two nozzles very different. The XR nozzle will give you a tapered flan fan pattern. It applies the most spray in the center of the pattern, with less towards the edges. This is designed to overlap with other nozzles on a boom. An even fan spray nozzle, on the other hand, produces a uniform spray pattern across its entire width. This type is ideal for band spraying, where a consistent amount of spray is needed over a specific strip or band. Unlike the tapered flat fan nozzle, it does not taper off at the edges.

Image from Teejet.com

 

For our last comparison, let's look at Greenleaf TurboDrop nozzles. These nozzles all consist of two pieces that each have different numbers on them. This can lead to some confusion. The reason for the two sets of numbers is that they are made up of two sections: a venturi pre-orifice and a tip/cap.

 

Below we have a TDXL11004 TurboDrop series nozzle. The venturi, which is the red portion, has a size number on the side. For the TDXL11004, that number is TD 04. This follows the same color code and size code as other flat fan nozzles.

 

The tip/cap, which is white for this particular nozzle, will also have a number. You will notice that our number is 110-08 and the color is white. If you remember, a nozzle with 04 in the number will have a flow of 0.4 GPM. So what is this 08 tip doing on a nozzle that says it is rated for 0.4 GPM?

 

Greenleaf TurboDrop nozzles are designed to reduce drift and still offer excellent coverage. Their two-piece design pulls air into the droplets to create a consistent droplet size. The venturi or pre-orifice controls the rate while the tip/cap produces the fan. Consider the TDXL11004, On its own the white 08 tip/cap could be used as a standard 11008 spray tip that will produce finer droplets.

When combined with the venturi, though, it becomes an effective air-induction nozzle. The tip is double the size of the pre-orifice and this difference is what helps pull air into the nozzle resulting in larger air-filled droplets.

 

Using These Numbers: Spray Nozzle Charts

Once you understand spray nozzle numbering, you'll be able to better choose the right nozzle for your specific application. Identifying the number on the nozzle is just half the battle. You will also need to know how to read a spray nozzle chart to compare nozzles and examine the different characteristics of each type.

A spray nozzle chart provides all the necessary information you need to determine how a nozzle will perform under various operating pressures. These charts are provided by the nozzle manufacturers, TeeJet, Wilger, Hypro, Greenleaf, etc. Nearly all spray charts will display the following information:

1. Flow Rate: The amount of liquid delivered per minute at a specified pressure, usually measured in gallons per minute (GPM) at 40 psi.
2. Spray Angle: The width of the spray pattern produced by the nozzle, measured in degrees.
3. Droplet Size: Classification of the droplet size produced, which can range from very fine to extremely coarse.
4. Operating Pressure: The range of pressure that the nozzle will perform as intended, usually measured in pounds per square inch (PSI).
5. Application Rate: The amount of liquid applied per unit area, expressed in gallons per acre (GPA).

 

Sprayer Nozzle Chart Example

This is a nozzle chart for the Air Induction Turbo TwinJet Nozzles. You can see that the nozzle capacity (flow rate), droplet size, and GPA is displayed at various pressures:

Spray nozzle charts warrant a more detailed discussion to thoroughly understand them. While we won't get into those details in this guide, for more information check out this article on how to use sprayer nozzle charts.

 

Spray Nozzle Selection Tools

Many spray nozzle manufacturers now also offer electronic spray tip selection tools that offer nozzle recommendations based on your specific application inputs. These tools make nozzle selection easy, but a basic understanding of the numbers behind the nozzle is still important when using these tools:

• TeeJet Spray Select
• GreenLeaf
• Wilger Tip Wizard
• Hypro Spray It

 

Conclusion

Understanding the numbering system for spray nozzles is crucial for selecting the right one for your application. The ISO 10625 standard provides a clear and consistent method to identify and categorize nozzles based on their performance characteristics.

Dultmeier handles a large quantity of TeeJet, Wilger, Greenleaf, and Hypro sprayer nozzles in stock and ready to ship. If you need assistance sizing and selecting a nozzle, don't hesitate to reach out for expert 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.

Learn More About Author

Use this simple GPM calculator to help size your sprayer nozzle flow rate!

Sprayer nozzle or fertilizer orifice selection requires that you determine the flow rate or size that you need. This tool will help you quickly and accurately calculate the flow rate required per sprayer nozzle to apply your desired application rate.

 

 

Using This Information

With this information, you can use a sprayer nozzle chart to find a nozzle that will apply this flow rate. For more information, refer to this complete guide to finding a nozzle size, that breaks down using a spray nozzle nozzle chart. If you need help sizing nozzles for a PWM system then refer to this guide.

 

Understanding The Formula In This Calculator

We use the GPM formula to determine the spray nozzle or orifice size needed for your specific sprayer and application requirements. The formula looks like this:

And here is what each value in the equation represents:

• GPM (Gallons Per Minute): This is the flow rate of each nozzle on the sprayer. It tells you how many gallons of liquid are being sprayed out of each nozzle every minute.
• GPA (Gallons Per Acre): This is the amount of liquid you want to apply per acre. Your target application rate.
• mph (Miles Per Hour): This is the speed at which you're driving the sprayer, tractor, UTV, etc.
• W (Width in Inches): This is the nozzle spacing from center to center of each nozzle.
• 5,940: This is a constant number used to convert the units back into a number that is easy to work with. It is a derivative of the different units involved in this formula. The important part is that you know you need to use 5940 in this formula.

 

Example Calculation:

You want to apply a rate of 20 gallons per acre. The average speed you will spray at is 5 mph. The distance between each spray nozzle is 20 inches (center to center).

In this case, you would Input these values into the calculator:

1. GPA: 20
2. Speed: 5
3. Nozzle Spacing: 20

Click "Calculate GPM" and you get:

GPM: Approximately 0.34

This means each nozzle should deliver 0.34 gallons per minute to apply 20 gallons per acre at a speed of 5 mph with nozzles spaced 20 inches apart.

This formula works for broadband spraying applications with overlapping flat fan nozzles as well as solid stream nozzles used on fertilizer bars and applicators.

 

Finding a Spray Nozzle

Nozzle size is a major factor when selecting a spray nozzle but it is not the only thing to consider. You also should consult the label on the product you apply for guidance on the specific spray nozzle requirements for your application.

Dultmeier Sales carries a wide range of sprayer nozzles for nearly any application:

• Broadcast
• PWM
• Drift-control
• Pre or Post-emergent
• Contact or systemic
• Soil applied
• Insecticides
• Fungicides
• Herbicides
• Fertilizer

If you are looking for guidance, get in touch with us and we can help you with sizing and finding a sprayer nozzle.

 

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.

Learn More About Author

 

 

This guide focuses on the unique needs and challenges of row crop farming, emphasizing efficient use of resources, technology integration, and sustainable practices to enhance productivity and profitability.

 

1. Soil Testing and Field Preparation

Conduct Detailed Soil Tests: Test each field for pH, nutrient levels, and soil composition to guide precise fertilizer and lime applications. Soil sample analysis can be done by your local soil laboratory or extension service.

Field Preparation: Implement tillage practices suited to your soil type and crop needs. Minimum tillage can preserve soil structure and moisture, while conventional tillage may be necessary in certain conditions to prepare a seedbed, control weeds, or incorporate amendments.

 

2. Crop Selection and Rotation

Select Adapted Varieties: Choose crop varieties with high yield potential, disease resistance, and adaptability to your climate. Consider traits such as drought tolerance or herbicide resistance as applicable.

Implement Crop Rotation: Rotate crops to break pest and disease cycles, improve soil health, and optimize nutrient use. Plan rotations to include legumes to fix nitrogen, reducing the need for synthetic fertilizers.

 

3. Seed Treatment and Planting

Use Treated Seeds: Opt for seeds treated with fungicides and insecticides to protect against early-season pests and diseases. Consider seed treatments that enhance germination under cold or wet periods or seed varieties which tolerate drought or high-wind conditions.

Precision Planting: Use precision planting equipment to ensure uniform seed depth and spacing. Calibrate planters for specific seed sizes and adjust planting rates based on germination tests and field conditions.

 

4. Water Management

Irrigation Efficiency: For irrigated fields, optimize irrigation schedules and methods (pivot, drip, or furrow) based on soil moisture monitoring and crop water needs. Consider technology like soil moisture sensors and weather-based irrigation scheduling.

Drainage: Ensure proper field drainage to prevent waterlogging and enhance root development. Install or maintain drainage systems where necessary.

 

5. Integrated Pest Management (IPM)

Scouting and Monitoring: Regularly scout fields for pest and weed pressure. Use thresholds to make informed decisions about the need for interventions.

Chemical and Biological Controls: Use targeted chemical controls when necessary and consider biological controls like beneficial insects for sustainable pest management.

 

6. Machinery Maintenance and Calibration

Equipment Readiness: Ensure all planting, tillage, and spraying equipment is in good working order before the season starts. Perform necessary maintenance and repairs during the off-season.

Planter Calibration: Precisely calibrate planting equipment to match seed size, type, and desired planting rate. Check and adjust downforce, seed tubes, and closing wheels to ensure optimal seed placement. Perform a short test swath of planted seeds to ensure all settings are correct before planting entire fields.

 

7. Technology in Farming

Adopt Precision Agriculture: Utilize GPS-guided equipment for precise planting, fertilizing, and spraying. Consider variable rate technology (VRT) for applying inputs based on soil and yield data.

Data Management: Use farm management software to track field operations, input applications, and crop performance. Analyze data to make informed decisions for future seasons.

 

8. Weather and Climate Adaptation

Weather Tracking: Use weather forecasts and climate data to plan field operations and mitigate risks from extreme weather events.

Resilience Practices: Implement practices to increase crop resilience against climate variability, such as cover cropping, diversified cropping systems, and conservation tillage.

 

9. Economic Planning and Risk Management

Cost Analysis: Conduct detailed cost analyses for each crop, considering input costs, projected yields, and market trends.

Risk Management: Utilize crop insurance and marketing strategies (futures, options, contracts) to manage price and yield risks.

 

10. Professional Development and Networking

Continuous Learning: Stay updated on agronomic research, crop protection products, and new technologies through extension services, agricultural publications, and professional associations.

Collaboration: Engage with local farming groups, cooperatives, and research institutions for shared learning, market opportunities, and collaborative projects. 

 

Flow meters are some of the most versatile and integral components in any fluid handling system. From agriculture chemical production to water treatment facilities, meters offer a reliable means to monitor how efficient your operation is and provide a tangible reading to identify potential issues within the plumbing system. This makes choosing the right flow meter for your application even more important. Selecting the wrong meter causes inaccuracies within your flow monitoring processes and creates inefficiencies throughout the rest of the system, not to mention significant unintended costs.

Dultmeier Sales is here to ensure that doesn't happen.

In this guide to flow meter selection, we'll take a look at several common meter types and the various applications in which they are used. We will also highlight some key considerations to keep in mind so that you always choose the best flow meter for your application needs. So, without further ado, let's get started.

 

Understanding What a Flow Meter Does

Simply put, a flow meter is a device that measures the flow of material-typically either liquids or gases-through a pipe. It determines how much material passes through the pipe (or hose) in a given period. It typically provides this measurement in units like gallons per minute (GPM), liters per second (L/s), or cubic feet per minute (CFM).

While this concept is straightforward, selecting the right flow meter for your specific task, however, can be more complicated.

 

Fill-Rite mechanical flow meters & digital flow meters

 

How to Choose the Right Flow Meter

First off, It is important to note that no two meters are exactly alike. Depending on application and metering needs, you may have several meter options or a single very specific one from which to choose. Complicating things further are the many external considerations your meter must satisfy in order to accomplish its intended purpose. As they say, the "devil is in the details," and the same goes for choosing the best flow meter for your application.

Below are some key characteristics to keep in mind when selecting the proper flow meter:

• Accuracy & Repeatability
• Type of Fluid (liquid, gas, slurry, steam)
• Density
• Viscosity
• Conductivity
• Temperature
• Pressure
• Flammable/Oxidizer
• Corrosiveness/Toxicity
• Flow Range/Turndown
• Materials of Construction
• Environment/Location & System Configuration
• Hygiene Requirements (pharmaceutical, food processing, etc.)
• Costs
  • Initial Investment
  • Installation
  • Long-term Maintenance

While the meter you ultimately select should ideally meet every factor above, ensuring it meets the most important ones for your operation will help guarantee you receive the best results. Let's dive into a few of the main ones on which you should focus.

Accuracy & Repeatability

Near the top of the list when evaluating flow meter specs is flow meter accuracy. Accuracy is how close a measurement is to the actual true value passing through a system. Expressed as a percentage (i.e. +/- 1%) accuracy represents how close the meter's output is to its calibrated parameters. Generally, the lower the percentage, the more accurate a meter is.

However, accuracy is not the only side of the coin. Repeatability, or the production of like outcomes under the same conditions, is perhaps even more important when evaluating which flow meter to choose. This is because accuracy is only reliable so far as its consistency. As you can see below, repeatability is possible without high accuracy, but high accuracy is not achievable without repeatability.

Flow meter accuracy & repeatability

If your flow readouts are unreliable-meaning you receive inconsistent results despite the same conditions-then you aren't gaining any value. Likewise, if your flow volume falls short of or exceeds your meter's rated flow range (also known as turndown), you won't receive accurate readings either.

Precision readings go hand in hand with any well-tuned operation. Choosing the best flow meter accuracy and repeatability percentages that meet your application requirements ensures your system maintains the precision readings you desire.

Liquid, Gas, or Semi-Liquid?

The type of fluid you work with is another big factor when choosing which flow meter best fits your application. Fluid type breaks into four categories: gas, liquid, slurry, and vapor-each with its own unique characteristics.

Properties such as fluid density, temperature, viscosity, and corrosiveness/acidity all must be determined before a final selection. This ensures you avoid choosing a flow meter incompatible with the fluid type you are attempting to measure. Electromagnetic flow meters, for example, won't work with non-conductive fluids like hydrocarbons. Likewise, few meter types are capable of measuring slurries because of their unique semi-liquid characteristics.

Illustration of how slurry particles behave between homogenous & heterogeneous mixtures

Here is a short list of flow meter types commonly used for the four fluid categories:

• Gas: Coriolis, Thermal Mass, Positive Displacement, Turbine, Variable Differential Pressure, Ultrasonic
• Liquid: Coriolis. Thermal Mass, Positive Displacement, Variable Flow, Paddlewheel, Turbine, Variable Differential Pressure, Ultrasonic, Electromagnetic
• Slurry: Coriolis, Electromagnetic, some subsets of Differential Pressure
• Vapor: Vortex, Ultrasonic, Floating Element

While not comprehensive, this list should offer a good starting point. That said, not every meter listed may work for your specific setup or needs. For instance, if your operation handles multiple fluids, you'll want to ensure that the meter you go with is compatible with all fluids-not just one. Otherwise, you likely spend valuable time calibrating your flow meter each time you handle a different product or troubleshooting why your inventories are off from your readouts.

Location & System Configuration

Meter location, as in real estate, is another major consideration. Will the flow meter be installed inside a controlled environment or outdoors in the elements? Is space a non-factor, or must size be considered? Certain flow meters even require stretches of straight pipe before and after the meter to generate accurate flow readings.

As a rule of thumb, pipe lengths of 10X (where X = pipe diameter) are needed before and after a meter for straight runs of pipe. So, if your plumbing's diameter is 2" you would need 20" or approximately 2 feet of pipe before and after the flow meter. This goes for just about any meter type, but it is always best to check the manufacturer's specs.

Also, keep in mind horizontal or vertical mounting. Some meters can be mounted in either orientation while others must be in one orientation or the other. Variable flow meters, for example, rely primarily on gravity in order to measure flow rate. Thus, they must be installed vertically to work. Determining how and where a meter will be installed while choosing a meter saves installation time and avoids costs related to unintended system reconfiguring.

Differentiating Between Volumetric vs. Mass Flow

Before we break down various flow meters, it is important to say a word on flow measurement. While there are many types of flow meters, most used today fall under two primary categories according to how they calculate flow: volumetric and mass.

As their name suggests, volumetric flow meters measure flow by calculating the volume of a fluid. Flow is often directed through an intrusion metering device such as a turbine or orifice plate, which then measures fluid velocity proportionally to the volume of matter passing by. Volumetric flowmeters make up the majority of meter types today and include turbine, magnetic, positive displacement, ultrasonic, and vortex meters to name a few.

Volume flow vs. mass flow within a cylinder

Mass flow meters, meanwhile, calculate flow rate by measuring the mass of a fluid. Mass meters have become increasingly popular due to their precision performance and truer reading of product flow compared to older metering technologies. In the diagram above, for instance, the product volume significantly changes depending on the position of the piston-even as mass remains the same. Today, mass meters have more or less become synonymous with Coriolis mass meters, but other types do exist. We'll discuss how mass meters work later in the article.

Whether you choose volumetric meters and mass meters depends on your application and metering needs, as well as your operational preferences and cost differences. In the end, you can still calculate volume to mass or mass to volume so long as the fluid density, surrounding temperature effects, and other conversion factors are all understood.

Comparing Flow Meter Types

There is, unfortunately, no such thing as a universal flow meter. Each flow meter type has fluids and applications for which it is well suited, and similarly, ones for which they are not. The following is a breakdown of some of the most common types of flow meters and the pros and cons of using each one.

Positive Displacement Flow Meters

Pros

• Accurate across wide flow ranges
• *Can handle very viscous fluids
• Versatile applications-simple, reliable design
• Require no power supply
• Cost-effective

*Thicker viscosity fluids create larger pressure losses & reductions in flow rates

Cons

• Requires medium to high-flow applications
• Experience greater pressure drops
• Larger/heavier than other meters
• Not recommended for dirty fluids or gases
• Some subsets require constant lubrication
• Many moving components need regular maintenance and replacement

Positive displacement (PD) meters consist of chambers featuring mechanical components that rotate in relation to volume flow. As fluid passes through, the reciprocating components-generally a type of gear, vane, or diaphragm-divides the fluid into fixed, metered volumetric units. The number of units rotated through within a specified time frame directly correlates to flow rate. Subtypes include screw meters, rotary vane meters, diaphragm meters, reciprocating or oscillating piston meters, and helical or oval gear meters.

 

TCS 700 Series Rotary Fuel Meter with Register

Since PD meters only measure flow while fluid passes through, they're ideal for applications where metering is crucial to calculate fluid usage. The TCS 700 series rotary vane meters, for example, are widely used in oil and gas custody transfer industries, while diaphragm meters are commonly installed on residential or municipal water and gas lines. Their fluid-driven design additionally makes positive displacement flow meters one of the more cost-effective options since they require no outside power supply to operate. However, these meters are ill-suited for impure fluids such as wastewater or slurries, as the suspended soils can clog or slow the reciprocating elements and create inaccurate readings.

Electromagnetic Flow Meters

Pros

• Obstruction-less/No moving components
• Highly accurate-unaffected by density, viscosity, turbulence, or pipe configuration
• Can handle wide flow ranges & multiple fluid types
• Zero pressure drop
• Bi-directional
• Cost-effective

Cons

• Cannot measure gases, vapors, or non-conductive liquids
• Limited fluid temperature range
• Interference possible with certain suspended fluids
• Specialized subsets can be expensive

 

Electromagnetic flow meters, also known as magnetic flow meters or magmeters, are rather unique in the technology they use to measure flow. Magmeters feature two parts, a transmitter and an inline sensor, the latter of which features coils that generate a magnetic field. When a conductive fluid passes through the field, a voltage is produced proportional to flow. This flow principle is known as Faraday's Law.

 

 

Unlike other meters, magnetic flow meters can measure fluids regardless of fluid density, viscosity, or flow turbulence. This makes mag meters highly accurate and reliable across a wide range of solutions. Additionally, their design features no obstructions in the pipe, making these meters ideal for a wide spectrum of applications, from highly sanitary liquids to slurries and highly corrosive fluids. Electromagnetic meters can be found in industries such as pulp and paper, metals and mining, food and beverage, water and wastewater, chemical transfer, and many more.

 

Magnetic meters, however, only work with conductive fluids. This means hydrocarbons such as oils, gasoline, or deionized liquids are not recommended with mag meters. Suspended solids, such as those found in various ag chemicals and fertilizers, can also sometimes pose a problem. The suspended soils, which may not be conductive, can interrupt the magnetic field and throw off the reading's accuracy. Newer, specialized magmeters such as slurry magmeters are engineered to counteract this magnetic interference. However, these units generally feature heftier price tags compared to standard models.

Turbine Flow Meters

Pros

• Highly accurate
• Cost-effective
• Capable of measuring low flow rates
• Versatile applications-simple, reliable design

Cons

• Not recommended for dirty or suspended liquids
• Require straight pipe runs for best results
• Limited to certain pipe sizes
• High flow rates can cause damage or inaccuracies
• Moving components need regular maintenance and replacement

Like paddlewheel or propeller flow meters, turbine meters feature a multi-bladed rotor mounted inline to fluid flow. Sensors attached to one or more of the turbine blades transmit the number of revolutions the turbine makes. The speed at which these revolutions happen is proportional to volumetric flow rate. Similar to positive displacement meters, turbine and paddlewheel meters only measure flow when fluid mechanically acts upon their metering components.

 

 

Because turbine meters provide accurate readouts in relation to linear flow-even at low flow rates-they are widely used in the oil and natural gas, custody transfer, and petrochemical industries. In fact, turbine meters are often used to help verify the accuracy of other meter types.

Turbine meters aren't without their limitations, though. For starters, turbine meters are not well suited to handle dirty or highly viscous fluids, as the turbines can be easily fouled by the soils. These meters also require straight runs of pipe before and after the meter to stabilize flow for the most accurate results. Additionally, larger pipe diameters are incompatible from an engineering standpoint. This limits where and for what applications turbine meters can be installed. Finally, as with any technology with moving components, regular maintenance is necessary to keep these meters in peak-performing condition.

Coriolis Flow Meters

Pros

• Extremely accurate
• Low maintenance
• Can handle a wide spectrum of flow ranges
• Compatible with many dirty, corrosive & difficult to handle fluid types
• Versatile installation-no straight pipe runs required
• Serviceable without removing from the pipeline
• Easy in-field calibration
• Capable of measuring gases

Cons

• Expensive initial investment
• Not suited for low-pressure gases
• Limited to certain pipe sizes

Coriolis meters, more commonly known as mass meters, differ from other meter types in that they measure mass flow instead of volume flow. These meters also feature a unique means of calculating flow rate based upon the Coriolis Principle. Check out the video below for a quick look at Coriolis meter technology.

 

Advantages of Mass Meters

Mass meters generally hold an NTEP certification and are widely used in legal-for-trade (resale) applications. In the Dultmeier Sales world, this generally means fertilizers or chemicals with respect to the agricultural industry. Back in the 1990s, Dultmeier Sales partnered with Kahler Automation to offer some of the first automated solutions for fertilizer/chemical plant automation.

The mass meter was at the heart of the system because it was new technology that allowed end-users to sell using the real-time density of the product - a truer way to meter liquids. For example, water is known to be 8.34 lbs. per gallon at 70°F. However, as temperature drops, the weight of water increases. Thus, the solution of water becomes denser as the ambient temperature drops. This would mean static volumetric calculations would be off if one pumped 1000 gallons of water and converted to 834 lbs. (using 8.34lbs/gal as the constant conversion factor) if the water were only 50°F.

This same principle happens with fertilizer and chemicals - as they are generally water-based solutions. Volumetric meters of the time; however, were unable to account for this change in density in relation to volume flow. Take this scenario for example, which was quite common in the 1990s and early 2000s:

Let's say that it's 40° F. and we're loading a 10,000 gallon tender trailer, running 32% Nitrogen into the vessel. We're using a paddlewheel meter as our measuring device and pumping the product into the vessel. Once we reach our hit point of 10,000 gallons - the automated equipment shuts down and we send our trucker to the scale. The scale breaks in 20 lb. increments.

Our potential for error:

• Paddlewheel meter runs at approx. +/- 2% accuracy (mass meter is +/- .3% accuracy)
• Paddlewheel cannot determine density reading, so we have a static calibration factor that was calibrated at 70° F. (or another temperature) and we are using that static factor to now calibrate pounds to gallons at 40° F.
• Scale breaks in 20 lb. increments vs. mass meter measuring in increments of 1/10th of a pound
• Scale cannot account for "slosh" or movement of liquid as truck stops abruptly on the scale

Considering these many variables and the potential for error, it's no wonder why inventories could, and often would, be way off come year-end. We know that a solution's density changes constantly if in an ambient environment. For this reason alone, mass meter technology is the preferred method of measurement in many instances. By using a mass meter that can continually read this fluctuation in density on the fly, we offer our customers a better method to dispense and record inventory.

Today, Dultmeier works with Easy Automation Inc. to provide automated plant solutions using mass meters in addition to other state-of-the-art meters, controls, and equipment.

Flow Meter Price, Performance & Popularity

Unfortunately, there is no universal flow meter that works for every application. Depending on how diversified your operation is, that could mean multiple types of flow meters are needed. While it is fair to research the most popular meters for your industry, don't buy the first meter you think will work.

Price, quality, and other key factors do play a significant role in a flow meter's overall performance. Simply because everyone else uses a certain meter does not mean you should be. Low purchase cost, for instance, shouldn't be the deciding factor in choosing the best flow meter for your application. When choosing a flow meter, you have to consider not only the initial purchase price, but the overall lifetime costs and long-term returns on investment, too.

 

For instance, while a Coriolis meter boasts a hefty price tag at initial investment, it provides a great ROI because less maintenance and greater product savings are realized over the long run. Mass meters' exceptional accuracy, versatile flow ranges, and fluid compatibilities, minimal wearable parts, and the ability to recalibrate without removing the meter from the pipeline all translate to fewer dollars spent overall. When it comes to the bottom line, spending more money upfront can outweigh years of hemorrhaging dollars spent repairing or replacing inefficient meters.

That said, not every operation needs an expensive, high-end flow meter. It's a good idea to run a cost assessment evaluating application needs against initial investment costs and long-term cost savings. This way you have the best picture of whether a certain meter is practical or worth the price tag over the long haul. If you need help assessing meter options and determining what is best for your application(s), we are always just a phone call away at 1-888-677-5054.

Final Words

We hope this article has provided some insight into the world of flow meter solutions. Although we covered some of the most common types, these are by no means the only flow meters out there. Choosing the best type of flow meter for your application all starts with knowing what you need and researching your best options. Compare all associated costs-both short and long-term-and avoid making a decision based on price tags alone. Ultimately; however, the manner in which you choose to meter is entirely up to you.

If you have any questions regarding flowmeter selection, give us a call at 888-667-5054 or dultmeier.com. Dultmeier Sales carries a diverse inventory of chemical and water flow meters, flow meter repair parts, and flow meter accessories. No matter what meter your operation requires, our experience and technical expertise will help make sure you select the right one.

We speak a lot about sanitation and disinfection these days. From the office and classroom to our own personal spaces, we are focused on cleaner, safer areas more than ever. And while many businesses are just now taking a closer look at how they clean their facilities, disinfecting in food processing has long been serious business. That doesn't mean all disinfectants for food processing cleaning are made equal.

Disinfectants come in a variety of forms, each with its distinct advantages and disadvantages. In fact, which disinfectant you choose for your application is just as important as the why and how you disinfect. As we'll cover in this article, understanding the basics of each disinfectant type and the general rules behind applying them ensures a more comprehensive and cost-effective cleaning regimen. Read on for our breakdown of disinfection basics for more effective disinfecting.

Why Disinfecting in Food Processing is So Important

While commercial processing facilities spend the majority of their time up and running, their most important activity occurs when the production floor is empty and silent. Maintaining clean, sanitary workstations and equipment, particularly in food processing, is integral to public health and safety. In the United States, such standards are overseen by government agencies such as the EPA, CDC, and USDA.

But why disinfect at all?

E. coli, a common bacterial target of disinfecting food processing facilities

Well, for starters, food processing plants are not the cleanest places once production gets going. Soils, in the form of fats, oils, blood, and other animal protein and production byproducts, quickly collect on equipment and surrounding surfaces. Such deposits, if left unaddressed, make these surface areas ideal breeding grounds for countless hosts of bacteria, viruses, and other potentially harmful microorganisms.

Proper cleaning removes these unwanted soils and contaminants, providing significant benefits downstream. Maximized production efficiency, increased product shelf life, safer work conditions, and fewer mechanical failures and delays are but a few positive outcomes to attentive housekeeping. Scheduled cleaning and disinfection also significantly decrease the chances of costly product recalls due to food hazard risks such as food poisoning or foreign body contamination.

A processing plant's commitment to a culture of health and food safety can easily be seen by how devoutly they approach the cleaning and disinfecting processes. And yes, there is a difference between the two.

Cleaning vs. Disinfecting

For most of us, cleaning, sanitizing, and disinfecting are all one and the same concept. They are, however, three distinct steps within the larger cleaning process. Cleaning is the process of physically removing unwanted substances and contaminants from a given surface. The cleaning stage, sometimes referred to as the detergent stage, is often characterized by the removal of common soils such as dirt, grease, or oils via manual scrubbing with brushes or wipes or washing with a high-pressure spray wand. Cleaning a surface in this manner alone; however, will not kill germs present.

Heavy Duty Cleaning Wipes for removing difficult soils

Disinfecting on the other hand, does kill bacteria and other microorganisms left behind following the cleaning stage. While similar to sanitizing agents, which merely reduce the number of bacteria and other germs to acceptable levels of health safety, surface disinfectants make a surface truly contaminant-free. Their high bactericide concentrations of chlorine or bleach eliminates the ideal growing conditions bacteria and other microorganisms thrive on.

Every cleaning application will follow a distinct set of variables, generally known as TACT. The four aspects of this cleaning/disinfection concept are time, temperature, action, and concentration. How prominently each phase is in the disinfecting cycle depends specifically upon your unique needs, including the soils you're wanting to destroy, and the chemicals being used. Followed properly, the combination of them all will achieve the desired result of a clean, disinfected space.

It's important to understand that cleaning must take place before the disinfecting stage. Since disinfectants do not break through heavy soils on surfaces, removing such deposits ahead of time ensures the disinfectants are able to work with the greatest efficacy.

Choosing the Right Disinfectant for the Environment & Application

Today, disinfectants cover a wide spectrum of chemical concentrations and applications. Choosing the right disinfectant for a specific environment, therefore, can be a task in and of itself. A few things to consider.

First, the choice of disinfectants depends foremost on a user's requirements. In other words, where are they disinfecting and what type of contaminants are they trying to eliminate. After that, the type of processing and cleaning equipment used, the application method, and, to some degree, the personal preference of the user all play a role in selecting a disinfectant.

Also, review a disinfectant's toxicity, leftover residues, and any possible chemical reactions related to water hardness and various surface types. This is particularly important within the food processing industry. Any residual chemical compounds left behind after disinfecting can adversely affect product taste, curing, and shelf life. In the brewing industry, for example, certain disinfectant cleaners are avoided because they linger on glass surfaces. (Soapy beer anyone?) Understanding a disinfectant's proper application process and any residue properties it has helps prevent product quality from suffering.

Once a disinfectant is chosen, the most important thing to remember is to always read your disinfectant product labels! Always. With effective cleaning practices, disinfectants will kill 100% of germs listed by the label-when used properly.

Ignoring what's detailed on the label-or choosing not to read it altogether-is a great way to undermine a disinfectant's effectiveness and cause mechanical failure of your disinfecting systems. It's also quite dangerous. Later in this article, we'll cover some of the safety considerations and equipment needed when dealing with disinfectants. For now, just remember that the label is the law. By following the label, you keep you, your cleaning staff, and anyone who comes in contact with the disinfected area, directly or indirectly, safe.

Disinfectant Type Comparison: Foam, Spray & Steam

Most of the food processing industry today relies on three common disinfectant application types: foam, spray (aerosol), and steam. Since no two environments are exactly alike, no two disinfectants will perform equally across the board either. Below we've provided some comparisons for these three disinfectant types and some general considerations to have before choosing the right disinfectant for your situation.

Foam Disinfectants

Pros:

• Better coverage of surfaces
• Greater visibility of coverage
• Lower pressure application
• Less product needed to work
• More cost-effective than other disinfectants

Cons:

• More challenging mix ratios
• Added costs if needing separate surfactant agent
• Greater attention to spray nozzle orifice size
• Greater flow needed to apply

Foam disinfectants are quite common in most food processing and industrial operations. Why? For starters, foam disinfectants can offer up to 50% more coverage than sprays. This is because foam expands as it comes in contact with a surface, greatly increasing coverage and disinfecting performance. In large production spaces, such as production floors or livestock barns, this helps keep cleaning costs down. Users can realize up to 50% cost savings on chemical alone, with additional savings possible in application time as well. Foaming is also a great option for disinfecting ceilings and vertical surfaces since the foam adheres better than sprays and therefore extends disinfection dwell time.

One challenge with foam disinfectants, however, is the need to include a surfactant. A surfactant is a foaming agent that chemically reacts with your disinfectant chemicals. Surfactants also lower the surface tension between two materials, such as water and dirt, making the soil easier to remove. Without a surfactant, your disinfecting solution will not foam properly, making it less effective. While some disinfectants include a surfactant already, most do not. Be sure to read your labels prior to starting your cleaning process to ensure proper solution effectiveness.

Additionally, check that your application equipment is compatible with foam solutions. Using a high-pressure pump without the appropriate chemically compatible elastomers is a great way to ruin an expensive pump. It is imperative, therefore, to check the chemical compatibility of ALL components throughout your entire cleaning systems. That includes examining the largest pump to the tiniest o-ring. In doing so, you not only avoid costly equipment damages or failures, but also prevent ineffective treatment from taking place.

Opt for chemical spray foamers and accessories that feature downstream injectors that bypass incompatible seals and components. Better still, invest in a complete foaming system like the Hydro FoamMaster. Available in multiple mounting styles, the FoamMaster is ideal for larger industrial cleaning applications, from washdown facilities and meatpacking plants to animal production buildings, such as the dairy barns shown in the video above. These compressed air units allow a user to set the desired dilution rate for their specific application. From there, the system mixes the chemical and surfactant with the carrier agent (generally water) to create rich, clinging foam.

Dultmeier has even helped develop custom disinfecting systems. Check out our work on the JBI Poultry Disinfectant Foaming Trailer here.

Spray Disinfectants

User disinfecting with spray in an industrial kitchen

Pros:

• Fewer chemical compatibility issues
• Quick-and-easy to apply
• Wide variety of disinfectant types
• Usable for almost any application/environment

Cons:

• More chemical usage to achieve adequate coverage
• Generally higher pressures applications
• Greater health concerns due to aerosol emissions

Dultmeier's DC1 Air-Driven Disinfectant Applicator

Aerosols are the most widely used disinfectants used for industrial cleaning tanks to their incredible versatility and ease-of-application. You can find disinfectant sprays for nearly every circumstance and apply them using a commercial pressure washer, handheld or backpack sprayer, or similar system without any chemical compatibility issues. Dultmeier's DC1 disinfectant applicator system, for instance, features an air-powered diaphragm pump, a 25 gallon storage tank with an automatic mixing valve, and a trigger spray wand that can easily store and apply most disinfectant products without a problem.

Complete Plant Washdown/Industrial Clean System

The thing about spray disinfectants is that they can be costly. For one, most disinfectant sprays require a high-pressure system to be applied well. These systems; while effective, can be expensive to fund. Furthermore, since so much energy goes into turning a disinfecting solution into spray, an operator may have to use more product to disinfect an area compared to if he used foam.

Steam Disinfectants

Dry steam disinfecting for food processing sanitation

Pros:

• Effective against a wide range of microorganisms
• Not affected by soils or hard water
• Non-corrosive or chemically reactive
• Leaves behind zero residue

Cons:

• Cannot be used on heat-sensitive equipment or surfaces
• Does not remove large soil deposits
• Dangerous high temperatures to human contact
• Difficult to maintain consistent temperature and exposure

As their name suggests, steam disinfectants work using steam to kill bacteria, spores, and other contaminants. The prolonged exposure to the moist high heat destroys microorganisms, leaving surfaces truly decontaminated.

Although a viable disinfectant method, we recommend using either foam or spray detergents for most applications. The main drawback to steam is that high temperatures, generally either 250° F or 270° F (or greater), must be maintained throughout the disinfection process to ensure microbial death. Such high temperatures can also damage certain components and surfaces. Foams and sprays have much wider applications, which simply makes them better and more-cost effective options for most operations.

Disinfecting Scope - Know Before You Go

No two areas are created equal when it comes to cleaning and disinfecting. Case in point, you don't clean and disinfect an office space in the same way you do a meat packing processing floor. That makes understanding your scope of disinfection all the more important before ever beginning the cleaning process.

Product Needs

Purehard surface disinfectant; ideal for food processing & food preparation

For instance, the size of the area you're disinfecting will greatly influence the amount of product needed. Do you need a 5-gallon bucket of disinfectant or a 55-gallon drum? Maybe you need more. This is where foam disinfectants really have the advantage. Their enhanced coverage and prolonged contact time with the applied surface allow less product usage.

Make note of the GPM flow of your system. If you have a pump that produces 3 GPM of flow attached to a 50 gallon tank, you effectively have 16.5 minutes of continuous application time. Time is money, so how much time will be spent mixing solution is an extremely important thing to remember when disinfecting large areas.

Disinfectant Systems

Your style of disinfectant system is something else to keep in mind. Most operations have some level of clean-in-place (CIP) process. However; for a vast majority of the disinfecting process, mobile cleaning units are necessary to leave an area truly decontaminated. Portable disinfectant systems equipped with powerful pumps and spray wands allow an operator to spray disinfectant at a variety of angles, speeds, and tailored quantities. This versatility ensures every hard-to-clean space can be adequately decontaminated.

Portable Sani-Mister disinfectant unit

Ventilation

Finally, take a minute to evaluate your space's ventilation. Taking the office vs. processing floor scenario, ventilation is likely very different between the two spaces. On the processing floor, the larger area means aerosols and vapors have more room to dissipate or be dispersed by exhaust fans. In the smaller office space, however, chemical fumes become more of a hazard. Respirator masks may be required based upon the chemicals used and/or size and ventilation capabilities of the application area.

Always be cognizant of how to enter a space for disinfection and understand how your solutions react when in use. Evaluating how to approach an enclosed space for disinfecting and how long someone should be exposed to that environment once they start keeps everyone healthy and safe.

Safety First: Personal Protective Equipment (PPE) for Disinfecting

Regardless of the style of disinfecting you ultimately use, you need to wear personal protective equipment, also known as PPE. This protective equipment ranges from nitrile chemical gloves and safety goggles to full body TYVEK coveralls. These products protect you from spills, splashes, and unexpected contact with the disinfectants which can cause serious chemical burns.

Certain aerosol disinfectants may even require a respirator mask to protect you from harmful chemical vapors. Even if the disinfectant label doesn't list a respirator as required PPE, you may still choose to wear one if working in a small, poorly ventilated space. Each chemical application is different.

Read your product labels for the proper PPE required to handle specific disinfectants safely. Regularly inspect PPE for wear or damages and replace if needed. Also, ensure your facility has clearly marked eyewash stations and safety showers in case of an emergency. Whether you need gloves, eye protection, or water-resistant clothing, we can help you find the gear you need to be best equipped for the tasks at hand.

Conclusion

Proper cleaning and disinfecting procedures will always be a serious focus in the industrial and food processing industries. In fact, one of the most important activities that occurs in any industrial processing facility is their disinfectant regimen. Even so, disinfection practices and policies will continue to change with new health research, product development, and societal perceptions. With that in mind, having a reliable, knowledgeable company you can trust to support you is imperative to your business's success.

Dultmeier is that company you can trust. We carry an extensive catalog of disinfectants, personal protective gear, and cleaning equipment and supplies from trusted brands like Mosmatic, DEMA, Suttner, General Pump, Hydro Systems, Boss, and others. While we cannot ultimately tell you how to disinfect, we can share with you the many different methods and assist your operation regardless of your choice of application. We'll happily help answer all your questions about various disinfecting types and work to get you the equipment and products you need to ensure your workspaces are cleaner than ever.

Reach us at dultmeier.com or give us a call at 888-667-5054. Your Experts in Delivering Fluid Handling Solutions - WE KNOW FLOW!