When it comes to sprayers, planters, and other liquid application equipment, choosing between automatic and manual rate control is one major aspect that has a massive impact on the convenience and efficiency of your system. Each option offers advantages depending on your operation's needs, equipment, and budget. This blog will break down the key differences between these systems, how each one works, and the pros and cons of both to help you make an informed choice between the two.
What is Rate Control?
At its core, rate control refers to how the system manages the volume of liquid applied per acre. Precise control ensures that chemicals are applied at the correct rate, avoiding under-application that could harm yields or over-application that could waste inputs and increase costs.
All rate control systems fit into two primary categories: manual and automatic control. The fundamental difference lies in how the system adjusts flow rates as ground speed changes. While automatic systems adjust the flow in real-time as you change speed, manual systems require you to adjust flow settings yourself. Let's dive deeper into each approach.
Manual Rate Control: Simplicity at a Lower Cost
Manual systems rely on the operator to adjust the application rate manually, either by changing the pressure in the system with a regulating valve or by controlling the speed of the pump motor/drive. This setup is typically much simpler and budget-friendly but requires more hands-on monitoring and manual adjustment during operation.
How Manual Rate Control Works
Manual rate control systems achieve the desired output primarily through two methods: varying pressure with a regulating valve or adjusting the speed of a pump motor/drive. Both approaches require hands-on operation and frequent adjustments to maintain accurate application rates.
The first method involves varying pressure using a manual regulating or bypass valve. In this setup, the operator sets the system’s pressure to match the desired application rate. For example, you might calculate that at 5 mph, 28 PSI is needed to deliver 10 gallons per acre (GPA). However, if your speed increases to 6 mph, you must manually increase the pressure to 33 PSI to maintain the same 10 GPA (these numbers are just examples). This method demands careful pre-calculation of operating pressures for different speeds, along with frequent adjustments throughout the application process.
The second approach involves using a mechanism to adjust the speed of the pump. Two common methods are using a rheostatic control to adjust the RPM of a 12-volt electric pump or a PWM valve to vary the flow of a hydraulic pump. These systems allow the operator to increase or decrease the pump’s speed to control flow rates.
While the flow can be adjusted in real-time, it still requires manual input based on changes in ground speed. If you speed up, you need to increase the pump RPM to keep the application rate consistent, and if you slow down, you must decrease the RPM to avoid over-application.
Lower upfront cost: Fewer components mean a more affordable setup.
Simplicity: Easier to install and maintain with fewer parts to troubleshoot.
Flexible with smaller operations: Suitable for fields where speed changes are minimal or predictable. Best option for skid sprayers or turf sprayers that utilize a spray gun rather than a boom.
Cons:
Labor-intensive: Requires constant monitoring and adjustment, which can be challenging when the operator has multiple things to monitor in the sprayer/tractor cab.
Inconsistent applications: Greater risk of over- or under-application due to human error
Less efficient: Not ideal for operations where speed frequently changes, like irregular terrain or fields with obstacles. Not ideal for prescription applications.
You can see more information about setting up simple and cost-effective manual rate control in this article about planter fertilizer systems.
Automatic Rate Control: Precision and Convenience
Unlike manual rate control systems where the operator constantly must monitor speed and adjust as best they can to changes in the field, automatic rate control systems take the guesswork out of fertilizer and chemical applications. These systems are designed to automatically adjust flow rates as ground speed changes. This type of control is especially necessary in larger operations requiring maximum efficiency.
How Automatic Rate Control Works
Automatic rate control systems rely on sensors, controllers, and flow meters to monitor both ground speed and flow rate in real-time. As the system detects changes in speed—whether from variations in terrain or adjustments made by the operator—it automatically adjusts an electronic regulating valve (or PWM valve/motor) to maintain a consistent application rate, typically measured in gallons per acre (GPA).
These systems remove the need for manual input during the application, which frees up the operator to check for plugged nozzles, monitor wind conditions, and obviously steer. Many automatic rate control systems are integrated with GPS or in-cab monitors to enhance precision further.
Highly accurate applications: Reduces waste and ensures nutrients or chemicals are applied at the correct rate across the entire field.
Increased efficiency: Operators can focus on other aspects of operation instead of manually adjusting settings.
Ideal for large-scale operations: Handles varying speeds and field conditions seamlessly.
Cons:
Higher cost: Advanced components like sensors, monitors, and GPS integration increase the upfront investment.
More complex setup: May require professional installation and calibration
Potential for downtime: Malfunctioning sensors or controllers can be more difficult to troubleshoot and halt operations until repaired.
Conclusion: Which System is Right for You?
Choosing between manual and automatic rate control depends on the specific needs of your operation. Manual systems offer a cost-effective solution for small farms, acreages, pastures, sports fields, etc. Basically, anywhere you can maintain a fairly constant speed on level terrain. On the other hand, automatic systems are ideal for large-scale or precision farming operations where efficiency and accuracy are paramount, though these systems come with higher upfront costs and more complex maintenance.
No matter which route you choose, Dultmeier Sales can help you identify the system that will meet your needs. Give us a call today and we’ll happily help you determine the best option for your operation.
Choosing the right pump can make all the difference in how smoothly your system runs, whether moving fertilizer, de-icing fluid, or pumping out a pit. One of the big questions people often ask is: which type of pump gives you the highest flow rate?
The type of pump designed to produce the highest flow rate is a centrifugal pump. These pumps are intended to handle large volumes of liquid at relatively low pressures. They work by converting rotational kinetic energy, often from a motor, into energy in a moving fluid, which creates a flow rate that can be very high.
If you're looking to move a lot of liquid quickly, the centrifugal pump is usually your best bet. Let's take a closer look at why these pumps are so good at handling large volumes with ease.
Why Centrifugal Pumps Excel in High-Flow Rate Applications
Centrifugal pumps are engineered to move as much liquid as possible in an efficient manner, making them the go-to choice when high flow rates are needed. Other pump types are designed to handle thicker liquids or to generate higher pressures, but a centrifugal pump's primary purpose is to transfer fluids that are relatively less viscous. Think water, fuels, fertilizers, and other flowable liquids.
How Centrifugal Pumps Work
Centrifugal pumps function by converting rotational energy into fluid flow, making them exceptionally efficient for high-volume transfer. You can read more on the specifics in our centrifugal pump guide. The short explanation is the heart of a centrifugal pump is the impeller. As the impeller spins, it imparts velocity to the fluid, pushing it outward from the center where the fluid enters, to the edges where it exits. This process creates a continuous, smooth flow of liquid.
High Speed Equals High Flow
The faster the impeller spins, the more kinetic energy is transferred to the fluid, resulting in a higher flow rate. This ability to maintain a steady, high-speed transfer of liquid makes centrifugal pumps ideal for applications that demand high flow rates.
Continuous Flow for High Efficiency
Unlike positive displacement pumps-such as gear pumps or piston pumps-that move liquid in cycles, centrifugal pumps deliver a continuous, non-pulsating flow. This is a significant advantage in applications where moving large volumes of liquid is essential, as it reduces turbulence and inefficiencies that can arise from intermittent flow. Because centrifugal pumps don't need to pause between cycles, they're more efficient for handling large volumes.
Scalability
One of the key benefits of centrifugal pumps is their scalability. These pumps can easily be adjusted to handle higher flow rates by increasing the impeller size or the speed at which the pump operates. This scalability is more straightforward compared to other types of pumps, where increasing the flow rate might involve more complex changes.
High Flow at Lower Pressure
Centrifugal pumps shine in applications where high flow rates are needed at relatively low pressures. While they might not be the best choice for high-pressure needs, their design is optimized to move large amounts of liquid with minimal energy input.
Flow Rate Capabilities of Centrifugal Pumps
The flow rate of a centrifugal pump can vary widely depending on the size of the pump, the speed of the impeller, and the specific design of the system. These pumps can achieve flow rates ranging from a few gallons per minute (GPM) to several thousand GPM. For instance, centrifugal pumps used in large-scale agriculture can easily move hundreds of gallons in a minute
Common High-Flow Centrifugal Pump Applications
Railcar Unloading
Centrifugal pumps are ideal for transferring liquid fertilizer from railcars to storage tanks. In many scenarios flow rates of over 1000 gallons per minute are possible.
Centrifugal and submersible (a type of centrifugal pump) are ideal for moving water from construction sites, drainage pits, or any location where excess water accumulation could interfere with operations.
In cooling towers, the volume of water that needs to be circulated is immense. Centrifugal pumps are ideal for this purpose due to their ability to handle high flow rates. These pumps ensure a continuous and reliable flow of water through the cooling tower.
Industrial and Manufacturing Processes
Centrifugal pumps are essential for the precise and reliable transfer of raw materials, intermediates, and finished products. Additionally, when precise flow control is needed, these pumps can be paired with variable frequency drives (VFDs) to adjust the flow rate accurately.
Dultmeier engineers have several combined years of experience sizing pumps according to the specific needs of several high-volume applications.Be sure to contact us if you have any questions.
Factors Affecting Flow Rate
Several factors affect the flow rate of a centrifugal pump, including:
Pump Size: Larger pumps with bigger impellers can move more liquid per rotation, increasing the overall flow rate.
Impeller Design: The shape and size of the impeller blades, along with the speed at which the impeller rotates, play a crucial role in determining the pump's efficiency and flow rate.
System Head: The height and resistance the liquid must overcome (referred to as 'head') can impact the pump's performance. Centrifugal pumps are more efficient at lower heads, making them ideal for applications requiring high flow but not high pressure.
If you would like a more detailed explanation of system head and flow rates, be sure to read our guide on centrifugal pumps written by in-house engineer Tom Hansen.
Selecting the Right High-Flow Pump for Specific Applications
Although a centrifugal pump is the best pump type for high-volume transfer of several fluids, in some scenarios a centrifugal pump may not be the best option. Thicker fluids may require a gear or diaphragm pump. Applications that require high-flow and higher pressures such as hydro excavating or sewer jetting, will need a different type of pump.
Here are some common applications where a centrifugal pump may not be the best option and which pump types can offer the highest flow rate in each scenario:
Tree Spraying: While a centrifugal pump offers enough volume, spraying tall trees requires more pressure than they can deliver. This is where high-flow diaphragm pumps come into play. They can deliver flow rates ranging from a few gallons per minute to over 100 while producing pressures from 250 psi and more.
Liquid Feed Transfer: The combined viscosities and occasional cold temperatures of many liquid applications require a gear pump for high-volume transfer. Centrifugal pumps work in some scenarios but are limited when handling thicker, more viscous liquids like molasses.
NH3: Vane pumps are used for high-volume transfer of anhydrous ammonia. Centrifugal pumps can struggle with the low viscosity and high vapor pressure of NH3, leading to issues like cavitation, reduced efficiency, and potential pump damage.
High-Pressure: Applications requiring higher pressures (think 1000 PSI+), and large volumes of fluid typically require plunger pumps or piston pumps. Pumps producing high-pressure and high flow rates do have significant horsepower requirements.
12-Volt Power:12-volt motor pumps are available for applications where only 12-volt power is available. The flow rates that can be achieved by these pumps are limited to a maximum of about 20-25 gallons per minute. This is only achieved at very low pressures, about 5 PSI. There are 12-volt pumps that produce 1-5 GPM at much higher pressures, typically 40-60 PSI, making them much more versatile for low-volume applications.
Final Thought
Centrifugal pumps are the top choice for high-flow applications, efficiently moving large volumes of low-viscosity fluids at lower pressures. Their scalability and continuous, smooth flow make them ideal for industries requiring reliable, high-volume liquid transfer.
If you need help selecting and sizing a centrifugal pump you can reach out to our team. Our engineering department can provide flow analysis and expert guidance!
Resourceful folks are always looking for ways to get the most out of their equipment. One way to do this is to repurpose tools whenever possible. One such tool is the trash pump. If you already have one and need to move fertilizer, it only makes sense to wonder, "Can I use my trash pump for fertilizer?".
The short answer is yes, in many cases, a trash pump can handle fertilizer. However, this is not always the case. Several factors affect a pump's ability to handle fertilizer, including the type of fertilizer, pump materials, horsepower, and more-all of which might impact the overall effectiveness and longevity of your trash pump.
Do not worry. In this article, we will explore not only whether repurposing a trash pump for fertilizer is a feasible option but also which situations make the most sense. We'll cover the basics of trash pumps, the properties of fertilizers, and how to know if your specific pump can handle the job.
What is a Trash Pump?
A trash pump is a type of centrifugal pump that is designed to move water that contains large pieces of debris, such as sand, gravel, sticks, etc. Generally, they are self-priming pumps that are constructed out of. Some are made from more durable metals like cast iron or ductile iron, while less expensive models are aluminum or other alloys.
Compared to other centrifugal pump types they are generally less efficient. This is because they are designed for versatility and not for efficiency. Most centrifugal pumps used for clear or "clean" fluids are more efficient because they have a smaller clearance between the impeller and the volute inside the pump housing.
Trash pumps have a smaller impeller diameter in relation to the volute size, which allows them to pass rocks or other debris more easily without scoring the internals of the pump. This capability makes them particularly useful in construction, agricultural, and dewatering/drainage scenarios.
Can Trash Pumps Handle Fertilizer?
Fertilizers come in various forms: liquid, granular, and soluble powder. Each type has different handling and application requirements. Liquid fertilizers are often preferred for their ease of application and rapid absorption by plants. However, they can be corrosive or abrasive, depending on their chemical composition, which can include nitrogen, phosphorus, potassium, and various micronutrients in different chemical forms.
The concept of using a trash pump for moving liquid fertilizer might seem viable. Trash pumps can handle slurries and fluids with solid particles, which theoretically could include liquid fertilizers. However, there are some things you need to consider, like material compatibility, efficiency, and reliability, before actually using your trash pump to transfer fertilizer.
Trash Pump Chemical Compatibility
Many trash pumps are designed to handle water and may not be compatible with the aggressive chemical nature of some fertilizers. Corrosion of the internal components, such as the impeller and the housing, can occur if the materials are not resistant to fertilizer chemicals.
Materials Typically Not Suited for Common Liquid Fertilizers:
Aluminum
Brass
Polycarbonate
PVC
Materials Recommended for Use with Liquid Fertilizer:
Cast Iron
Stainless Steel
Viton
Carbon Steel
Polypropylene
In addition to pitting, rust, and corrosion of the housing and impeller, the pump seal can suffer damage from an aggressive fertilizer. Trash pumps typically have a mechanical shaft seal that keeps liquid from leaking out during operation. This seal consists of two faces and an elastomer that rub together to form a barrier.
If the seal faces or elastomers are made from a material not compatible with the type of fertilizer you want to pump, the seal will fail. Abrasive fertilizers cause damage to the seal faces and the pump will leak around the shaft. This can happen gradually or quite quickly if the fertilizer and materials are not compatible.
A fertilizer's with your pump materials might be the most crucial deciding factor for whether you can utilize a trash pump over another type of pump . If you are new to fertilizer transfer pumps, this guide explains in detail the different options for high-volume fertilizer transfer pumps.
Trash Pump Efficiency
Let's say your trash pump is constructed of materials that will stand up relatively well to whatever type of fertilizer you need to pump. Good, you can check off that consideration. However, there is still the matter of efficiency to consider. Trash pumps are by nature less efficient than other centrifugal pumps typically used for fertilizer transfer. You'll therefore want to ensure that your trash pump will actually perform as you need or you'll have to start at square one finding another solution.
As mentioned earlier, trash pumps generally have more clearance inside them to pass solid material. This makes them less efficient. (If you want to fully understand centrifugal pump efficiency, then check our You may be able to live with this lower efficiency, especially if it means not having to spend the extra money buying another more expensive pump.
Even so, just because a trash pump may work, doesn't mean it will move the liquid at the same volume as other pumps designed specifically for the transfer of fertilizers. It's crucial then, that the prospective costs of that lower efficiency be weighed out for both the short-term and long-term benefits of your operation.
Conclusion: Should You Use a Trash Pump for Fertilizer?
While trash pumps are a versatile option in a pinch, there are better pumps available for the efficient transfer of fertilizer. Over a season the additional amount of time it takes you to move fertilizer could impact your bottom line. Not to mention trash pump built with metals not suited for your specific fertilizer could fail prematurely, costing you additional time and money than if you had opted for another pumping solution in the first place.
Dultmeier carries several different pump lines that are well-equipped for fertilizer transfer:
MP Pumps has been manufacturing quality centrifugal pumps for more than 80 years. Over this time, they have developed and improved upon their designs to offer reliable and affordable fluid-handling options for a variety of industries and applications.
There is almost certainly an MP pump that will work for you, but sorting through the various types can be tough. As a master MP Pumps distributor, Dultmeier Sales can help you pinpoint the right one. Here's a detailed look at the different MP Pumps available, their common uses, and the advantages and disadvantages of each type.
MP Pumps Company Overview
MP Pumps has been around since 1942, proudly crafting high-quality centrifugal pumps from their home base in Fraser, Michigan. They've got a pump for just about everything from making sure your fertilizer and ag chemical system runs without a hitch to keeping industrial processes flowing smoothly, to moving petroleum products efficiently.
MP Pumps has an extensive product line. They manufacture self-priming pumps, straight centrifugal pumps, chemical pumps, circulator pumps, petroleum pumps, and more.
Dultmeier Sales can supply just about any MP pump but we focus primarily on the ag, industrial, and petroleum pumps. These industries rely on the MP Flomax, Chemflo, and Petrolmaxx lines. One of the most common is the Flomax self-priming pump series, so let's start there.
MP Flomax
Description: These are self-priming centrifugal pumps. Available in materials like cast iron and stainless steel. Versatile, and capable of handling a wide variety of fluids. Many parts are interchangeable with other Flomax models.
Common Uses: The MP Flomax pump can be implemented in countless situations. Dultmeier Sales has been selling the Flomax series pump for use in agriculture for several years. Specifically, nurse trailer and sprayer tender truck transfer pumps, as well as fertilizer and agrochemical bulk plant pumps. They are excellent at handling water, agrochemicals, and fertilizer but they can be used with other liquids as well.
Key Features:
Capable of flows up to 750 GPM.
Handles pressures up to 230 head feet.
Stainless steel shaft sleeve for durability and corrosion resistance.
Self-Priming
Viton seals standard
Removable bolt-on FNPT flanges means your piping remains in place when servicing the pump
Wear plate can be replaced to extend the life of the pump
Suction check-valve holds liquid, protecting the pump seal when it re-primes
When it comes to connecting the pump to an engine or motor, MP offers the Flomax pump in two basic configurations. The pedestal version and the PumpPak version.
Pedestal: A pedestal pump is designed to be long-coupled to motors, or other drives. It features a bearing pedestal and solid shaft.
PumpPAK: This version of the Flomax pump is designed to be mounted directly to an engine or motor. There are versions to mount on gas-enines, hydraulic motors, and C-face electric motors.
Flomax Pump Sizes
Flow rate is always key for any pump type. There are Flomax pumps made to deliver up to 750 GPM:
The Flomax line is available in several materials. Pumps constructed with cast iron housings and impellers, stainless shafts, and Viton seals are most common. All stainless pumps are available for more corrosive applications.
Pump Drives
An MP Flomax pump can be driven a number of ways. Whether you require an electric motor, engine, or hydraulic motor. The pedestal pump version can be assembled on a baseplate with motor and long-coupled together. The PumpPak version can be mated directly or close-coupled to C-face electric motors or gas engines.
Various shaft sleeve sizes and bolt patterns are available so you can easily connect an MP pump to almost any C-face motor or gas engine.
If you would like a more detailed explanation of close-coupled and long-coupled pump units, be sure to read this guide to the best fertilizer pump options.
Chemflo Series
Description: Some liquids are more harsh on pumps than others. The MP Chemflo stainless steel pump family is built to withstand more severe applications and corrosive liquids. There are several different variations within this family to be compatible with different types of liquids.
Common Uses: Agricultural chemical mixing, fertilizer transfer, water treatment, de-icing liquids, and other industrial fluid transfer.
The Chemflo pump family is made up of more than 30 unique models. These different models are designed to be used in many different applications. They vary in flowrate, drive type, port size (flanged & NPT), etc.
Sizes
Chemflo pumps come in very low to high-flow options. Their CFX pumps have 1/2 to 1-inch ports with flow rates ranging from 10-40 GPM. The larger versions are available with 1-1/2 up to 3-inch ports and these pumps will provide maximum flow rates of 150-395 GPM.
Materials
One of the primary features of this pump series is the cast 316 stainless steel components used to construct the pump. While stainless is not an answer for 100% of liquids, it does offer resistance to the effects of a much wider range of liquids when compared to cast iron.
While the housing, impeller, and other components are made from stainless steel, the mechanical seal is available with a variety of options including Viton, EPDM, and Teflon. You can always refer to our chemical compatibility charts to evaluate which materials and elastomers will be compatible with the liquid you need to pump.
Drive Options
Like other MP pumps, the Chemflo series comes in a variety of setups included long-coupled pump and motor units, close-coupled pump and motor units, and hydraulic-driven units.
For more details and an explanation of close-coupled and long-coupled pump units, be sure to read this guide to the best fertilizer pump options.
PetrolMaxx Series
Description: Pumping fuels in high-volume applications requires the right type of pump for efficiency, compatibility, and safety. MP's PetrolMaxx series is a self-priming pump similar in design to the Flomax family but constructed with materials compatible with fuels. There are variations to ensure compatibility with diesel, biodiesel, gasoline, E85, and more.
Common Uses: High-volume fuel transfer. Loading and unloading bulk fuel trailers and trucks. Filling large equipment for construction and agriculture.
Key Features:
Self-priming
Available to mate directly to engines/motors or with a bearing pedestal for long coupling
Flow rates of 150-700 GPM
Options for Ethanol, Biodiesel, Gasoline, Diesel, and More
MP PetrolMaxx Options
For safety and compatibility, it's crucial to use the right pump for each type of fuel. That's why MP has created a variety of pump models designed specifically for different fuels. Each model is built with materials that match the unique properties of the fuel it's meant to handle, ensuring safe and reliable operation.
One of the most popular versions is made to handle diesel. Dultmeier sells hundreds of two-inch PetrolMaxx pumps driven by gas-engines for high-volume diesel fuel transfer. These pump units help fill equipment much faster than the common 12-volt fuel pumps. You can get flow rates well over 100 GPM with the right size hose and fuel filters.
As mentioned earlier, the PetrolMaxx family of pumps consists of several pumps fitted for specific fuels. The materials used include: steel, aluminum, cast iron, ductile iron, nitrile, 316 SS, Viton, Ni-resist, and more.
Drive Options
You can fit a PetrolMaxx pump to a gas-engine, electric motor, or hydraulic motor. It is important to note that some fuel types may require the use of an explosion-proof motor or gas-engine.
Dultmeier sales builds pump units on baseplates for easy installation. The units are available close coupled to electric motors or engines, and long coupled to electric motors. There is also a complete fuel unit with a hose reel, pump, fuel filters, fuel nozzle, and base plate.
MP Pumps has been a reliable supplier for years offering a wide range of pump solutions. Dultmeier sales has relied on MP as a competitively priced and durable pump for the rigors of the primary industries we have served. Including the fertilizer and ag chemical world as well as for de-icing, industrial, and fuel transfer.
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.
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.
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
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 likeMosmatic, 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!
The commercial spraying industry continues to improve technology. At this point, incremental gains can make a tremendous impact and that incremental gain can be as smaller than a 60 micron droplet. If you have a new spray rig, you're probably not alone. Favorable grain prices paired with government payouts related to COVID-19 have allowed many operations to afford asset upgrades this past year. Maybe that asset upgrade came with Pulse Width Modulation technology? If so, this post is a must read for you prior to sizing your spray nozzles this season.
Speak at length with anyone involved in the ag sprayer industry about the new advances in sprayer technology, and there is a solid chance you'll hear the phrase "pulse-width modulation" mentioned. Although the technology isn't exactly new, advancements in spray nozzle design and overall efficiency of pulse-width modulation (PWM) spray systems arrive on the market every year, along with a slew of new PWM spray nozzles.
Following up on our article on sprayer nozzle sizing, we'll focus on explaining how PWM systems work and provide you example-based guidance for how to size a PWM spray nozzle on your own. We'll also explore the benefits of PWM spraying and why it may be time to consider making the switch from a conventional sprayer system to one outfitted with PWM spray nozzles and accessory components. Read on for all the details and be sure to use the table of contents to help you get around.
Pulse-width modulation was first developed for the agriculture industry in the 1990s by Dr. Ken Giles, a professor of Biological and Agricultural Engineering at the University of California, Davis, and Capstan Ag Systems. For many farmers and agronomists today, however, pulse-width modulation still presents considerable degrees of uncertainty and understanding. So, let's clear up the confusion.
Pulse-width modulation, in ag-related terms, refers to how liquid flow rates are controlled via an electronic signal and shut off valve. Unlike conventional sprayer booms, a PWM system features nozzle bodies each equipped with an electric solenoid. As this solenoid turns on and off-typically an average of 10 times a second-an intermittent, pulsed spray is created through the nozzle. The proportion of time that the solenoid is open is known as the pulse width or duty cycle. It's this percentage of time the nozzle is open vs. closed that ultimately dictates your rate of application.
Because duty cycle plays such a significant role in determining proper sprayer calibration for PWM operation and PWM nozzle sizing, it's best we dive a little deeper into how this concept works. That way, you will know exactly how to choose the proper size spray nozzle for your specific agricultural operation.
Duty Cycle - The Driving Force Behind PWM
One of the limitations of conventional sprayer systems is that nozzle flow varies indirectly with sprayer pressure. As the sprayer speeds up, the system must adjust pressure to also adjust flow rate to deliver the same application rate per acre. Generally, a device called a rate controller automatically recalculates the necessary adjustments for you. So, when the sprayer increases speed, the rate controller causes spray pressure to increase as well until the flow rate sensor shows that the nozzle flow is enough to maintain the target application rate desired.
There are two related problems with these conventional spray systems. First, pressure must be increased significantly in order to increase flow rate as speed is increased. For instance, nozzle pressure must be doubled for nozzle flow to increase by just 41%. Moreover, pressure must be tripled to increase flow by 73%. Most sprayer pumps cannot achieve this doubling or tripling of their output while increasing flowrate.
Secondly, sprayer tips are very sensitive to changes in spray pressure. Go too slow and the lower pressure can cause the spray pattern to collapse. The result is poor, inconsistent coverage. Drive too fast, though, and your droplet size becomes finer, creating drift problems. This delicate balance means traditional sprayers must remain within a very specific, narrow speed range, which is not always possible given field conditions or with variable rate applications.
A key aspect in PWM systems is that spray nozzle output is no longer tied solely to sprayer pressure. Instead, PWM systems focus on duty cycle. Again, duty cycle is the proportion of time that the solenoid is open/on, meaning the percentage of time that your spray nozzles are actually spraying.
Typical duty cycle ranges are between 20-100%. Although lower duty cycles are possible, they are not recommended since droplet size and spray pattern can become inconsistent.
During operation, every nozzle can spray at its maximum flow (100% duty cycle) or a fraction of its flow capability. That means a nozzle operating at a 20% duty cycle will deliver about one-fifth of the flow of a spray nozzle spraying 100% of the time. Even so, the pulses occur so quickly that spray pattern and droplet size won't be adversely affected.
What does this mean in practice? For one, while duty cycle is still linked to changes in sprayer speed, the spray pressure remains constant. This enables a sprayer operator to make pressure adjustments to maximize coverage or drift control independent of speed and the rate of application. The end result is a spray application that is not only more accurate but also more consistent across diverse field conditions.
Calculating Duty Cycle
Duty cycle directly correlates to ground speed. When calculating duty cycle to correctly size your PWM spray nozzles, you want to aim for an average speed around 75% duty cycle. For example, if you figure you'll travel between 10 and 20 MPH while spraying, you'll want to choose your spray nozzle for an average speed of 15 MPH-or 75% of your maximum speed. This gives you plenty of flexibility to adjust the duty cycle up or down if you experience unexpected changes in speed without compromising your droplet size or spray pattern integrity.
Selecting the Appropriate Spray Nozzle for PWM Systems
Since the means of controlling nozzle flow rate is different between traditional sprayer setups and those with pulse-modulation, sizing PWM nozzles likewise differs a bit from conventional spray tips. This means that you won't necessarily be able to use traditional flow rate tabulation charts to size your nozzles. No need to fear, though. The PWM spray nozzle sizing process is still easy to understand.
There are three things to remember when selecting PWM nozzles. For starters, you want to always choose wider angle spray nozzles for pulse-width systems. One of the biggest concerns regarding PWM spraying is the risk of application "skips" as you move through the field. Wider angle nozzles such as 110° flat fans ensure you'll produce enough overlap in your spray coverage to eliminate skipping.
Additionally, you'll want to avoid using air-inducted spray nozzles for PWM spraying. The introduction of air can compromise the spray pattern and droplet size as the nozzle pulses off and on. As shown in the video below (at 3:18), this deterioration of droplet size is especially obvious upon the valve pulsing off, where residual air causes the application to dribble out from the air inlets-thus rendering the spray nozzle ineffective.
Now, new advancements have been made regarding air-induced nozzles regarding pulse-width modulation. TeeJet, for example, has several air-induced nozzles that have been approved for PWM use. However, your best bet is still to use non-air-inducted nozzles such as the Turbo TeeJet and Turbo TwinJet. The Greenleaf Soft Drop or Blended Pulse Dual Fan (BPDF) series or Wilger ComboJet series are good options, too.
Finally, an important point to remember when using PWM systems is that nozzle pressure is different than boom pressure. This is because nozzle pressure/flow is now controlled by the solenoids which are independent of your overall system's pressure reading. As the solenoids turn off and on, a pressure drop needs to be accounted for with higher boom pressure.
Difference between gauge pressure and nozzle pressure for an 0.8 nozzle.
For example, for a 110-04 spray tip, the average drop is only about 3 PSI. A larger 110-08 tip, however, will push the limits of the solenoid even further, creating a greater decrease in pressure. This can be anywhere from 6 PSI at 30 PSI gauge pressure to 13 PSI at 60 PSI gauge pressure! If the pressure drops too low, the nozzle won't be able to form a uniform spray pattern and droplet size. Therefore, the larger the nozzle orifice, the greater the boom pressure required to compensate.
PWM charts calculate against this pressure drop and offer speed ranges for operating specific nozzles at a given gauge pressure.
Sizing PWM Sprayer Nozzles
Alright, let's size some spray nozzles. A few things you'll need to know ahead of time:
Target application rate
Typical average speed
Desired droplet size
Using these three components, you'll be able to quickly find the correct spray nozzle size for your PWM application.
Once you start looking at the charts, just like with conventional spray tips, you want to select a PWM nozzle which falls near the center of the pressure range for your desired droplet size. In most cases, this will be between 40 and 70 PSI for the best pattern and droplet size retention. However, it's difficult to suggest the proper droplet size and nozzle type for every application. As always, check your chemical labels for proper application droplet size before beginning.
Sizing Greenleaf PWM Nozzles
For this first example, we're going to find a nozzle within the Greenleaf line of spray nozzles using their PWM tabulation chart. To start, we take our target application rate, let's say 12.5 GPA on 20" spacing, and set our average speed at 15 MPH. Keep in mind we want to maintain a 75% duty cycle through the field. This means we can go as fast as 20 MPH (100%) or as slow as 5 MPH (25%) without exceeding our chosen nozzle's pressure rating or compromising our droplet size or application rate. Our droplet size for this example is Coarse to Very Coarse.
Next, moving down the 75% duty cycle column, we find where our average speed of 15 MPH falls within the 40 to 60 PSI gauge pressure range. Looking left, we see that the best fit is a 0.8 nozzle. We can also readily see that only one nozzle, the BPDF, will provide our desired droplet size.
We could've chosen an 0.7 nozzle, but we're already pushing the pressure limits of that nozzle at our speed. If our average speed was to increase by even one mile to 16 MPH, our droplet size would decrease to Medium. Choosing an 0.8 nozzle still retains our Course-Very Course droplet size even if we were to decrease pressure or speed.
Sizing TeeJet PWM Nozzles
TeeJet has a similar approach to sizing PWM nozzles, though their tabulation chart works a bit differently. Instead of providing you with the duty cycle columns, they simply display your minimum/maximum speed range. This means you have to calculate what the 75% duty cycle speed would be on your own. Once you have that however, you can quickly find your ideal spray nozzle.
In the example below, we chose to apply a 15 GPA at 10 MPH with a desired Ultra Coarse or Extremely Course droplet size. We actually have two nozzle options to choose from in this case-the Turbo TeeJet Induction (TTI) and TTI TwinJet (TTI60). Both are again in the 0.8 size.
We also have the Air-Inducted Turbo TwinJet (green box) with an XC droplet size if we wanted. However, the larger UC droplet size of the other two nozzles and the fact that they aren't air induction nozzles makes them better options.
Sizing Wilger PWM Nozzles Using the Wilger Tip Wizard
Wilger has made selecting their Combo-Jet nozzles for PWM systems even easier via their online Tip Wizard. Here, simply enter your GPA, speed, and target droplet size into the specific fields. You'll also enter nozzle spacing, spray tip angle, and which PWM system you're operating on. Many PWM systems, from Capstan PinPoint to Case AimCommand, Raven Hawkeye to John Deere ExactApply have different actuation speeds. The Tip Wizard will then provide you a list of the best nozzle options given your specifications.
For a complete guide to using Wilger's Tip Wizard and understanding results when sizing nozzles for PWM, click here. They even have a video walkthrough if you prefer that option.
Advantages of Using Pulse Width Modulation Nozzles
Although there is no indication that conventional spray nozzles will become obsolete in the near future, the rise of PWM nozzles will undoubtedly continue to assume an increasing share of the industry. And for good reason.
First, PWM spray nozzles allow you to maintain constant pressure across a wide range of speeds. Having a wider range of travel speeds means that even when speeding up or slowing down through the field, you retain the necessary pressure-and therefore droplet size-to correctly apply your desired chemical rate without sacrificing coverage.
Drift control is another benefit of using PWM nozzles. While PWM systems do not significantly improve drift control alone, they do make it easier. This is because they offer a wider speed range to work with, meaning you can use larger sprayer nozzles designed for coarser spray patterns. Even if you tweaked your pressure higher or lower, your duty cycle would internally adjust to apply the same application regardless of speed. The larger droplet sizes then allow you optimal drift control.
Illustration of turn application rates for conventional spray system with rate controller only (left) vs. a PWM system with nozzle-by-nozzle turn compensation capability (right)
Finally, greater precision. The consistency across numerous speeds means PWM spray nozzles provide incredible application accuracy. Reduction in chemical costs, fewer over- or underapplications, and less drift potential gives PWM operators much more control over their spray operation. Many systems today even have the capability of controlling individual nozzle flows. This nozzle-by-nozzle sectional control enables greater turn compensation and more accurate, site-specific application through the field.
This feature is especially important when turning around at the end of the row. When turning in a conventional sprayer system, the inner boom nozzles become effectively stationary and substantially over apply chemical. Meanwhile, the outside boom nozzles move faster than the application rate can be accurately applied. PWM systems featuring turn compensation such as Capstan's PinPoint overcome this by individually controlling each nozzle, maximizing efficiency and accuracy.
Final Thoughts
As industry leaders continue developing new, better PWM spray equipment systems, understanding PWM technology and how to apply it to your own operation becomes increasingly important. Not unlike sizing conventional sprayer tips, choosing the correct PWM spray nozzle plays an integral role in ensuring the accuracy and efficiency of your sprayer system. After all, your application is only as good as your spray tip.
For any questions regarding sprayer tip sizing and PWM spray systems, be sure to check us out at dultmeier.com or give us a call at 888-667-5054. We're happy to assist you with whatever questions you may have and provide you the technical expertise and diverse products necessary to get you back in the field. Let us help you find what you're after today so that you get the best sprayer performance possible.
Your Experts in Delivering Fluid Handling Solutions - WE KNOW FLOW!
Whether it's 1980 or 2021 - Dultmeier Sales fields thousands of calls each spring on this topic alone. How do I size my spray nozzles? We don't help you select the type of spray tip for your application(s) - we advise you to consult your agronomist in this instance so they can get eyes on the crop situation to help develop a custom plan for your operation. That being said, once you've identified which type of nozzle(s) you need, we can absolutely assist in the sizing of said nozzles. This post is a great resource to use that helps to outline what we do just about every day during spring.
It's spring, and with the frenzy of field preparation, fertilizing, and putting seed in the ground on everyone's mind, the height of the planting season is nearly upon us. This time of the year also signals, if you haven't started already, that the time for you to begin readying your sprayer for your early season spraying is fast approaching.
Between calibrating your sprayer pump and checking all your hoses, you already have a lot to get done in order for your sprayer to be ready for the field. One of the most important parts of your sprayer prep; however, is ensuring that you have the correct sprayer nozzles appropriately sized for the chemical and fertilizer solutions you're looking to apply.
Without serious attention to detail, improper nozzle sizing can lead to a multitude of mistakes and delays when you can least afford them, not to mention the increased costs. In this article, we'll examine the proper approaches for how to size nozzles for various spray application types and how to attain ideal nozzle coverage and drift control. We'll also share why correct sprayer nozzle sizing is so important to your sprayer and crop performance. Read on at your leisure or use our table of contents to help you navigate through the article to find the answers you're looking for.
Nozzle Sizing Information to Know Before You Begin
Sprayer nozzle sizing can often be a confusing bit of business, especially with new tips and nozzles being designed every season. Pulse width modulation anyone? Luckily, the way you decide which nozzles you need has remained essentially the same for years. The first step is ensuring you have three pieces of critical information:
Rate of application - in gallons per acre (GPA)
Average sprayer speed - in miles per hour (MPH)
Nozzle spacing - in inches (W)
Once you have those pieces of information nailed down, you can then plug them into a standardized formula and calculate how many gallons per minute (GPM) that you need to apply. Here's the formula:
GPA x MPH x W / 5,940 = GPM (per nozzle)
Knowing the number of gallons per minute you need to spray then allows you to reference a sprayer nozzle sizing chart that you can use to locate the ideal nozzle size for your specific sprayer setup. There are also plenty of tip sizing tools available online that calculate the best tip size for you. You can try our GPM calculator or use these from the nozzle manufacturers:
In the next section, we'll put this formula into practice and walk you through a few examples of how to size your sprayer nozzles for different chemical and fertilizer applications so you have a better idea of how to approach it on your own.
Sprayer Nozzle Sizing for Different Applications
Although sizing spray nozzles is largely uniform across the board, there are a few slight differences in how to size a sprayer tip depending on the type of liquid solution you're applying. Here, we've included the two most common application types when sizing broadcast nozzles: chemical/water solutions and liquids heavier than water.
Sizing for Ag Chemicals and Water Solutions
A vast majority of your sprayer applications will fall under this category since it includes most of your herbicides, insecticides, fungicides, and other common ag chemicals. Sizing nozzles for this type of application is also the most straightforward since you're using water as the base agent and aren't having to adjust for a higher relative density.
Relative density, also commonly referred to as specific gravity (SG), is the ratio of density-or mass of a unit volume-of a substance to the density of a standard reference material. For liquids, specific gravity is almost always measured against water since water has a specific gravity of 1.0. When calculating the application rate of liquids heavier than water, you must use a conversion factor to compensate for the higher solution density. We'll cover more on these conversion factors when we discuss sizing sprayer nozzles for liquids heavier than water a bit later. For now, though, assume that our examples are calculated with the SG of water.
Now, many sprayer nozzle sizing charts will display a wide selection of common spraying speeds. If your speed is already in the table, simply cross-reference your nozzle spacing and speed and locate the GPA you want to apply. But what if the speed you want to spray at isn't shown on the table? This is where the formula plays such an important role.
Shows how to find nozzle size for 8 GPA at 6 MPH for 20" nozzle spacing when all information is listed in the chart.
So, example time.
Let's say we want to spray 20 gallons per acre of 2,4-D. Our average sprayer speed in the field is 12 miles per hour (not shown in the table), and we are operating on 20-inch nozzle spacing. Our formula would look something like this:
20 x 12 x 20 / 5940 = 0.808 GPM (per nozzle)
Let's also say that we want a course droplet size and are looking to use a Turbo Teejet wide-angle spray tip. Taking our 0.808 gallons per nozzle rate and using the Teejet sizing chart for this model of spray tip, we scroll down the Capacity in One Nozzle column to the nozzle size most closely matching our desired specifications. In this example, that would be the white tip nozzle.
It's best practice to find a nozzle that meets the GPM rate as close to the middle of the PSI range as possible. This is important in relation to your speed. Most spraying systems rely on largely consistent speeds across the entire field for the optimal performance. As a result, slow down too much, such as at the end rows, and you compromise your spray pattern and improperly apply your chemicals. Go too fast, and your sprayer pump may not be able to match your new pressure rate for the nozzles you have, setting off system alarms.
Even if your sprayer pump can match the higher speed, your droplet size then becomes much smaller, increasing your risk of drift. Neither case is what you want. Having a spray nozzle in the middle of the range ensures that you're able to maintain spray pattern, solution density, and droplet size-even with slight rises and drops in speed.
Sizing for Ag Liquids Heavier Than Water
When sizing your spray nozzles for liquid solutions heavier than water, such as liquid fertilizer, you'll follow a very similar process as sizing nozzles for your water-based ag chemicals. The difference in sizing for this type of application; however, is that you need to adjust for the higher density of your solution. You accomplish this by using a density conversion factor seen in the chart below.
So, let's say we wanted to apply some liquid nitrogen fertilizer. Using the conversion chart above with our previous example, our formula would look like this:
20 GPA x 12 MPH x 20 W / 5940 = (0.808 x 1.13 Con. ) = 0.91 GPM
In this case, you'd still use the white nozzle tip from our previous example since the 0.91 GPM still falls near the middle of the pressure range for the course droplet size desired. If your speed is shown in the chart, simply take your intended GPA multiplied by your conversion factor to locate your nozzle size.
The key in either case is to factor in the conversion factor before you reference the sizing chart. Otherwise, you'll select the wrong spray nozzle and wind up with improper droplet size and inaccurate application. In the next sections we'll examine why these two ideas, spray coverage and droplet size, are tied so closely to the idea of proper nozzle sizing.
Nozzle Spacing and Spray Heights for Proper Coverage and Overlap
It should come as no surprise that sizing your spray tips correctly is just as important as where you put them on your sprayer. In fact, nozzle spacing and sprayer boom height are two aspects you mustn't ignore when choosing the size of the spray tip that you need.
For starters, nozzle placement-both width between nozzles on the boom and the height of the nozzles above the ground-determines how well your spray coverage theoretically performs based upon the fan angle a nozzle has. Most setups will use some type of nozzle which creates a fan-shaped spray pattern. This means that the heaviest concentration of spray is at its center and tapers off to nothing at the edges. Common sprayer systems operate on 20, 30, or 40-inch nozzle spacing, and the arrangement of nozzles at these spacings determines how uniformly your application is ultimately applied.
To achieve uniform application; however, you'll need to create a pattern overlap in your spray coverage. Overlap-or the combining of spray patterns-is necessary, particularly in broadcast spraying, because the outer edges of spray patterns don't have uniform volume distribution. Without overlapping coverage, you risk leaving portions of your field under-treated or even skipped. That means you'll likely spend more time and money correcting the mistake.
Illustration of spray pattern overlap.
Factors that affect spray nozzle overlap
Three factors affect overlap in relation to sprayer nozzle sizing. First of all, your nozzle fan angle determines the total width of the spray pattern. The wider the fan angle, the wider the spray pattern. Today, 80-degree and 110-degree fan angles are the most used nozzle angles in agriculture applications, though others are available. Second, spray tip spacing. The closer the nozzles are to one another, the more the patterns will overlap. Farther apart, and the amount of overlap is lessened.
Finally, adjusting your spray tip height will further affect how much overlap you have. The higher the boom, the more overlapping because each pattern has more room to spread out. Another good thing to remember regarding the height of your spray tips is that the higher above the row your boom/tips are, the more susceptible to wind and drift your solutions are. We'll touch on this a bit more in relation to droplet sizing in the next section, but for now keep it in mind.
Now, unsurprisingly, not all spray nozzles are the same. Finding the proper height in relation to your nozzle spacing then is imperative. In the table below for example, you can see the height recommendations of various TeeJet nozzle series based upon nozzle fan angle and boom spacing.
In most cases, your ideal overlap for broadcast spray nozzles is approximately 30%. Adjusting your nozzle spacing and boom height accordingly will give you the best chance to maintain adequate, uniform coverage across the entirety of your system, even when other variables such as wind speed and pressure decreases occur.
Maintaining Droplet Size for Optimal Drift Control
Finally, we want to share a few words on droplet size. Namely, follow your labels.
After all, the label is the law! Not following how a specific chemical or pesticide is meant to be applied can create serious damage to not only your crops, but your fellow farmers' as well. This has become especially important when dealing with volatile chemicals like Dicamba.
Burn damage caused by Dicamba drift.
Make sure that you've chosen and sized a sprayer nozzle capable of producing the appropriate droplet size recommended for the chemical you're applying. If the label lists a specific nozzle or droplet size to use, follow those listings to a T. Furthermore, install your spray tips at the proper boom height and operate at the required pressure range to achieve the stated recommended droplet size of a given chemical. This will significantly reduce the likelihood you experience issues with 'hanging' droplets and drifting.
Consulting the spray label is just smart practice. It can determine whether or not you need to make any additional adjustments to your spray equipment or need to purchase additional nozzle accessories to attain the right nozzle spacing and droplet size specifications.
Importance of Proper Sprayer Nozzle Sizing
We don't have to tell you that your time is money. When it's time for you to be spraying in the field, you can't afford troubleshooting on the fly or stopping to recalibrate your sprayer a second or third time.
Which is the exact reason why you should take the time well in advance of spraying season to research the agricultural chemicals and fertilizers you intend to apply. Running long or short of chemical means your solutions were not applied efficiently and may not work as effectively as intended.
In fact, overapplication due to poorly sized or worn out sprayer nozzles is a serious problem if left unaddressed. Ag chemicals are very expensive, and if you're over applying it, you're wasting money. All the major manufacturers that we represent recommend replacing any spray tip if it's overapplying by 10% of the rate of a new nozzle. That includes TeeJet and Hypro to Wilger, Greenleaf, and Delavan.
If you find that at least two of your nozzles are overapplying by this rate anywhere across your boom, replace every nozzle in the system. Using a sprayer nozzle calibration tool, like the one shown below, will give you the fastest and most accurate reading of how your nozzles are performing and if you need to swap them out for new ones.
SpotOn Electronic Sprayer Calibrator, 0-1.0 GPM
Incorrect spray tip sizing has ramifications on your other sprayer components as well. Your sprayer pump especially may struggle to operate at its ideal performance. This can substantially increase the wear and tear on your pump components and lead to an inability of your pump to create or hold the spray patterns and proper application density.
Conversely, your pump outperforming your spray nozzles at higher speeds can change the droplet size. Higher pressures create smaller droplet particles and lead to increased risk of drifting that can cause serious damage to you or your neighbor's crops when dealing with many of the volatile chemicals used today. Be sure to routinely examine your sprayer tips for wear of the nozzle orifice for the reason that you ensure they aren't in need of replacement in order to maintain the correct droplet size you're after.
In the end, understanding how your agriculture chemicals and fertilizers are meant to be used and their proper droplet size ensures both appropriate solution application and adequate drift prevention. Once you have that information, the rest is relatively easy.
Conclusion
Although the science behind sizing sprayer nozzles has become more dynamic in recent years, the process doesn't have to be complicated for you. Following the guidelines in this article will give you a great start to your spraying season and ensure you aren't left reworking your sprayer when you should be in the field.
Be sure to check us out at dultmeier.com or give us a call if you have additional questions regarding sprayer nozzle sizing. We offer a huge selection of TeeJet, Hypro, Greenleaf, Wilger and Delavan spray nozzles to suit your unique sprayer setups. Our team of experts will be glad to assist you with any concerns or questions you may have and discuss how to ensure you're getting the best performance from your spray nozzles.
After all, we're your Experts in Delivering Fluid Handling Solutions - WE KNOW FLOW! ®
Is it to merely kill weeds? How well does a certain sprayer kill weeds? The size - is bigger necessarily better? Or, do we also need to assess the value of that sprayer against how long it spends in each field? All these questions should be carefully considered when making a large investment into a piece of equipment that drastically affects the yield of your crop(s).
After all, a sprayer is one of your most important asset management tools when maintaining and ensuring your crop health - thus effectively ensuring that you get the most out of your yields - regardless of the crop you're raising. Therefore, I think the answer to the questions above is that we must absolutely consider each question when determining a true Return on Investment (ROI) for a sprayer - regardless of the operation size or scope.
In this write-up we will assess the four questions above. To start, let's dissect each question at a high, strategic level.
How Well Does a Certain Sprayer Kill Weeds?
This is a somewhat loaded question as chemical types, brands, and mix rates are involved. But if your accessory products/equipment, which are used to move the solutions onto the plants are lacking, then your sprayer effectiveness will undoubtedly be lacking, as well. Therefore, we must consider year-end maintenance programs. Boom-end flow rates, line obstructions in accessory products such as strainers and valves. Leaking pump seals, poor shaft alignment, and worn spray tips all factor into the efficiency and productivity of your sprayer. Neglect these important features of your sprayer and your operation, and your crop yields will undoubtedly suffer. So, to answer the question outlined in the opening paragraph - your accessory products, that are used to help move solutions, - are just as important to your operation as the sprayer itself.
Year-End Maintenance
It is necessary that a season-end maintenance program is followed to ensure your operation sees success in the ensuing season. Follow our recommended winterization process. Hoses, pumps, motors/engines, valves, strainers, and spray tips should all be inspected to help create a post-season inventory/repair list, in preparation of the upcoming season.
Spray Tip Selection
Have the proper spray tips been selected for the job(s)? Consult your local agronomist for specific details on the product(s) you will be spraying for the upcoming season. When spraying Dicamba products, only specific spray tips are approved for each product - and at specific pressure ranges. You can read another post related to Dicamba. Undoubtedly, always check the label of the product you are spraying to ensure you are spraying "on label". You can have all bases covered in preparation for an upcoming season. However, if you choose incorrectly on spray tips - or size your spray tip orifices incorrectly based upon the rates you intend to apply - the consequences could be catastrophic to your operation - or your neighbors' operations. Here is a tip sizing tool from TeeJet.
Sprayer Size
Does bigger necessarily mean better? It depends. If you're out in western Nebraska and have straight runs for a mile plus, then you may want to consider 120-foot booms with auto steer functionality. However, if you're in Western Iowa and you have many fields that are 75 acres or less, you probably want to opt into a smaller, more agile spray package. Regardless of your choice, one question should drive your purchasing decision - what is the potential ROI?
Speed and Efficiency
How long does it take to spray each field and how many acres do you anticipate covering daily? This should be one of the largest focal points when assessing your operation. Don't focus on non-productive time in an operational day (i.e. travel from field to field, rinse-out, rain/wind delays). These are variables that we have little to no control over.
However, a large area in which we do have control over is nursing, or fill, times. If you can cut your fill times, regarding both fuel and chemical, how much more productive can you make your operation? Let's look at some products that can help you achieve this task. First, let's look at a study done by Praxidyn's Doug Applegate, regarding average sprayer price in comparison with cost per acre/hour. The numbers displayed reflect average prices/costs from various suppliers/operators in a regional area in Western Iowa.
Conclusions:
Slower loading times increase the cost per acre/hour of productivity. Increased cost ranges from 26 to 42 percent.
Spending 10% more for larger capacity/coverage in a sprayer will increase productivity roughly 8%.
Spending 7% more for an automated mixing system can increase productivity by 20% to 30%.
Smaller sprayers are actually more cost effective for their capacity.
The main takeaway here is that, in general, an operation can lower operating costs by, roughly, 20%. Let me repeat….20%. And by simply shaving off 10 minutes from fill times. It's important to note, as the sprayer size increases, the cost savings are reduced. For instance, a sprayer with a 600-gallon tank and 90-foot boom can effectively realize over 29% savings by reducing fill times down to 5 minutes. Consequently, when looking at a sprayer with a 1200-gallon tank and 120-foot boom, we see about 20% cost savings.
Praxidyn MixMate
The Praxidyn system allows users to automate loads. You can prepare loads the night before from your living room while watching TV or from an office chair. Send the loads to the operator in the field. No math needs to be done by the operator. The biggest change the operator would make to the load is regarding weed height. Upon arrival to the field, if the operator notices weed height on the order calls for six inches, and the weed height is actually 10 inches - the operator can make that adjustment to the order and the software will recalculate input quantities on the fly - no math is needed.
Another value-added feature to the MixMate system is the ability to track and record data. Through the cloud-based software, a user can record exactly how much product was applied to each field - and the exact time of the load or batch. This will continue to be ever-more important as regulations continue to tighten.
MixMate Fusion - New for 2019
We hope that you enjoyed this write-up on increasing sprayer efficiencies. Should you have any questions or feedback don't hesitate to get in touch with us at www.dultmeier.com!
If you have had your finger anywhere close to the agricultural market in the past few years you know it is somewhat depressed. Especially, since we hit highs for corn around $7/bu back in 2013. This was such a rapid incline in grain prices that it somewhat threw the markets out of balance. Anyone that has remotely studied markets is familiar with the pendulum effect. If a market swings drastically in one direction, it is bound to swing back just as hard - if not harder - in the opposite direction.
This market effect could be potentially unfolding before our eyes this summer. Heat waves around the world are driving the price of wheat higher. Europe and Asia are seeing abnormal heat, which is burning up the wheat crop on these geographical regions. While the United States has seen heat as well - it hasn't necessarily been in wheat country. We live in a tremendously global market environment. The prices we see daily, are affected by what happens across the pond and all over the world.
European & Asian Wheat Farmers
Therefore, the distress that European and Asian farmers are currently experiencing is positively impacting the US wheat farmer. Simple supply and demand is causing this increase in the wheat market. Because there is less supply going into the market place from our European and Asian competitors, their 2018 wheat crop is expected to be less than the forecast. Whenever there is a shortage in a market, the commodity begins to increase in price. The less you have of something the more valuable it becomes.
Russia, Ukraine, France, and Great Britain are all European countries which have wheat farmers that are being negatively impacted by the 2018 heat waves. On August 2nd, Chicago wheat futures hit three-year highs to around $5.50/bu (The Wall Street Journal).
A Look Back into History
Looking at an aggregate chart of wheat prices since 1960, we can see fairly large market clips occurring about every seven to ten years. On average, these pullbacks are about 50% down from the high. The most recent high was back in December of 2007 at just under $12/bu. We seem to have found a level of support at roughly $4/bu. Currently, we are sitting at a $5/bu.
Wheat Prices Since 1960, Source: www.macrotrends.net
Looking at historical trends it appears as though wheat prices are on the up-and-up. It seems that the market has found a much more agreeable level of support. I say 'agreeable' since one can clearly see the higher lows met with higher highs in 2016-2018. We did not see this back in 2010-2012 failed rally. The market wasn't ready to correct and thus we were sent into a further recession.
Now, it seems the market is posed to regain the losses from 2012. Where we have seen about a 57% clip in the price of wheat - to the low in August of 2016.
Sometimes markets require a little extra push or catalyst to take off. A shortage in supply can absolutely be that catalyst. The US is positioned well in the current global wheat market and pose to reap the rewards of healthy crops.
Is an Increase in Wheat Futures a Certainty?
Now, we must acknowledge the tariff war and how that could potentially affect US wheat farmers. China has imposed tariffs on American grain and oil-seed imports. If we could look at wheat prices in a vacuum, one would say the US wheat farmer is posed to prosper over the next few years. The global supply and demand issues we addressed above, along with the technical analysis of the chart presented above both suggest this is the case. However, trade wars generally don't impact the farm market in a beneficial manner. It's difficult to say what is going to happen but all things aside - wheat looks posed to make a run.
As always we hope you find this post to be informative and educational. You may ask yourself how Dultmeier Salescomes into play in the wheat market. We offer a wide product selection to help enable producers plant, fertilize, and protect their crops through herbicide/fungicide applications. Check out our Agricultural Division page here. Stop back soon!
