October 23, 2025

Spray Pattern Classifications: Flat Fan, Full Cone, Hollow Cone, Solid Stream & More (Industrial Guide)

In industrial spray applications, the spray pattern determines how liquid spreads across a surface or through a space. This directly affects coverage, droplet size, impact force, and overall process performance. Whether the goal is coating, cleaning, cooling, or humidification, the spray pattern is the starting point for getting good results.

Picking the wrong spray pattern can waste materials, create uneven results, and drive up costs. For example, using a full cone nozzle when a flat fan is needed might give spotty coverage. Choosing a hollow cone when a solid stream is required won't deliver enough punch for effective cleaning.

NozzlePro specializes in industrial spray technology and offers a wide range of nozzles built to handle tough jobs across many industries. The team brings real expertise in selecting the spray patterns, types of spray nozzles, and figuring out what works best for each application. Whether it's picking the right nozzle or troubleshooting an existing system, NozzlePro has the technical know-how and products to help get the best spray performance.

What Determines a Spray Pattern

The spray pattern a nozzle creates comes from several design and operating factors working together. Understanding these helps with both picking the right nozzle and fixing spray performance problems.

1. Outlet Geometry and Internal Design

The physical shape of the nozzle opening plays the biggest role in forming the pattern. The internal passages, vane angles, and opening shape directly control how liquid leaves the nozzle and spreads into its particular pattern.

2. Axial vs. Tangential Feed

Comparison chart of spray nozzle types showing axial and tangential designs with differences in spray pattern and liquid flow.

The direction liquid enters the nozzle chamber makes a big difference in the spray that comes out:

Axial feed sends liquid straight through the nozzle body, typically making a solid stream or certain flat fan patterns with less swirling inside.
Tangential feed directs liquid into a swirl chamber at an angle, creating spinning motion that makes circular patterns like full cone and hollow cone sprays.

This basic design choice determines whether the spray will be directional (flat fan, solid stream) or circular (cone patterns).

3. Flow Rate and Pressure

Operating pressure and the flow rate it creates affect spray features beyond just how much liquid comes out:

Higher pressure generally makes smaller droplets and can change the spray angle.
The relationship between pressure and flow follows specific curves that are unique to each nozzle design

Keeping pressure steady ensures the spray performs the same way every time with predictable pattern features.

4. Liquid Properties

Viscosity: Thicker liquids resist breaking into droplets, making larger drops and potentially narrower spray angles
Surface tension: Affects how droplets form and can influence how far from the opening they break apart
Density: Impacts momentum and how far the spray travels
Presence of solids or contaminants: Can change flow characteristics and cause nozzle wear

These factors work together, changing operating pressure might make up for higher viscosity, while picking the right nozzle material can handle corrosive or abrasive fluids.

Major Spray Pattern Types (with Industrial Applications)

Infographic of spray nozzle types including flat fan, full cone, hollow cone, solid stream, air atomizing, and tank cleaning patterns.

1. Flat Fan Spray Pattern

A flat fan nozzle creates a thin, stretched-out spray pattern that spreads liquid in an oval or rectangular shape. The pattern has tapered edges with the heaviest flow usually at the center, though some designs spread the liquid evenly across the width.

Characteristics:

Spray shape looks like a flat plane or fan
Available in spray angles typically from 15° to 110°
Impact varies by design (standard, even spray, or deflector)

Typical Applications:

Surface rinsing: Removing leftover materials, coolants, or dirt from metal, plastic, or glass surfaces
Coating and surface treatment: Applying protective coatings, adhesives, or chemical treatments with controlled thickness
Cleaning operations: Washing conveyor belts, parts, or continuous web materials
Cooling: Strip cooling in steel mills, plastic extrusion cooling, or equipment temperature control

NozzlePro offers various flat spray nozzles including standard flat fan nozzles for general use and specialized designs for tough industrial environments.

Flat fan spray nozzle showing uniform linear spray pattern used for industrial cleaning, coating, and surface rinsing.

2. Full Cone Spray Pattern

Full cone spray nozzles create a circular spray pattern with complete liquid coverage throughout the entire cone shape. The distribution can be uniform (where each ring gets equal flow) or center-weighted (with more flow in the middle).

Characteristics:

Circular spray coverage area
Solid distribution with no hollow center
Medium to large droplet sizes depending on design and pressure
Spray angles commonly available from 30° to 120°

Typical Applications:

Tank and vessel cleaning: Interior washing of storage tanks, mixing vessels, and processing equipment
Cooling towers: Spreading cooling water over fill media
Coating operations: Applying uniform liquid layers in chemical processing or agriculture
Humidification: Adding moisture to air in HVAC systems, textile manufacturing, or controlled environments
Fire protection: Water distribution in fire suppression systems

3. Hollow Cone Spray Pattern

Hollow cone nozzles produce a ring-shaped spray pattern where liquid concentrates around the outer edge of the cone, leaving the center mostly empty. This shape comes from liquid entering at an angle, creating a spinning force that pushes fluid to the pattern's outer ring.

Characteristics:

Ring-shaped distribution with very little center flow
Fine to very fine droplet sizes due to lots of internal swirling
Large surface area for efficient contact with air or gas
Spray angles typically ranging from 45° to 120°

Typical Applications:

Gas scrubbing and absorption: Removing pollutants, particles, or gases from air streams with maximum liquid-gas contact
Cooling applications: Evaporative cooling, quenching, or temperature control where fine droplets help transfer heat better
Chemical processing: Reactions needing large contact area between liquid and gas
Dust suppression: Creating a mist barrier to capture airborne particles
Spray drying: Breaking liquids into droplets for quick evaporation in powder production

The hollow cone's fine mist and high surface area make it especially good for jobs requiring maximum interaction between liquid and the surrounding air or gas.

4. Solid Stream / Jet Spray Pattern

Solid stream nozzles create a focused, concentrated jet of liquid with very little breakup over long distances. Rather than breaking into droplets right away, the stream stays in a cylinder shape.

Characteristics:

Focused, cylinder-shaped liquid jet
Very little mist at the jet nozzle, gradual breakup further away
High impact force concentrated in a small area
Can reach much farther than spray patterns

Typical Applications:

Descaling operations: Removing scale, rust, or mill scale from steel and metal surfaces
High-impact cleaning: Removing stubborn deposits, hardened materials, or heavy buildup
Tank washing: Reaching far surfaces in large storage tanks or vessels
Cutting and drilling: Using high-pressure water jets to cut soft materials or drill holes
Emergency cleaning: Clearing blockages or removing heavy buildup in industrial equipment

NozzlePro's solid stream nozzles are built tough for high-pressure conditions, using materials like hardened stainless steel to resist wear in these demanding jobs.

5. Air Atomizing and Mist/Fog Nozzle

Air atomizing nozzles use a two-fluid design, mixing compressed air with liquid to create extremely fine mist. This external mixing makes droplets much smaller than regular (single-fluid) nozzles can produce, resulting in fog or mist-like sprays.

Characteristics:

Needs both liquid and compressed air supply
Makes very fine droplets (often 10-100 microns)
Adjustable by changing air pressure, liquid flow, or both
Lower liquid pressure needed compared to regular atomization

Typical Applications of an Air Nozzle:

Precision coating: Applying thin, uniform coatings of paints, lubricants, or release agents
Humidification: Adding moisture with minimal wetting in paper mills, textile plants, or electronics manufacturing
Dust suppression: Creating fine mist barriers to capture tiny dust particles
Evaporative cooling: Quick temperature reduction through flash evaporation
Spray drying and chemical processes: Jobs requiring controlled, fine droplet distributions

Being able to adjust air and liquid flow separately provides flexibility that regular nozzles can't match– air atomizing designs are ideal for processes needing precise control over droplet size.

6. Tank Cleaning Nozzles

Tank cleaning nozzles are a specialized type designed specifically for cleaning the inside of tanks, vessels, reactors, and storage containers. These nozzles can be stationary (fixed spray pattern) or rotating (moving coverage).

Characteristics:

Stationary designs:

Multiple spray patterns from single nozzle body
No moving parts for reliability
Lower flow rates and pressure needs

Rotating designs:

Mechanical or fluid-driven rotation
360° coverage with stepped or continuous rotation
Stronger cleaning power
Self-cleaning in many designs

Typical Applications:

CIP (Clean-In-Place) systems: Automated cleaning of process equipment in food, beverage, pharmaceutical, and chemical industries
Storage tank maintenance: Removing leftover materials, sediment, or contamination from large storage vessels
Reactor cleaning: Preparing vessels for the next batch or keeping conditions sanitary
Transportation containers: Cleaning rail cars, tank trucks, and IBC totes

NozzlePro offers both stationary spray ball designs and rotating tank cleaning nozzles built for specific tank sizes, contamination types, and cleaning needs.

Spray Angle, Flow Rate, and Coverage

Table explaining spray nozzle types and spray angle ranges, showing how narrow, medium, and wide angles affect coverage and performance.

Understanding how spray angle, flow rate, and coverage distance relate to each other is essential for picking the right nozzle and positioning it correctly.

1. Spray Angle Basics

Spray angle describes how wide the spray pattern is, measured in degrees from the nozzle opening. Common spray angles include:

Narrow angles (25°-40°): Give focused coverage over longer distances with stronger impact force. Great for reaching distant surfaces or when concentrated flow is needed.
Medium angles (40°-65°): Balance between reach and coverage area. Good for general-purpose jobs with moderate mounting distances.
Wide angles (65°-110°): Cover the biggest area from close mounting positions. Used when nozzles must be positioned near the target surface or when broad distribution is needed.

2. Coverage vs. Impact Trade-offs

Picking a spray angle involves natural trade-offs:

Wider angles increase coverage area but decrease impact force and how far the spray reaches effectively. The same flow rate spreads over a larger area, reducing liquid amount per square inch.
Narrower angles concentrate flow into a smaller area, increasing impact force and throw distance but needing more nozzles or multiple passes for complete coverage.

3. Flow Rate Influence

Flow rate, determined by nozzle opening size and operating pressure, directly affects:

Coverage intensity: Higher flow rates put down more liquid per unit of time
Droplet size: At the same opening size, higher pressure makes smaller droplets
Pattern fill: Enough flow is necessary to keep the pattern shape without gaps

For example, at a mounting height of 12 inches (30 cm):

A 25° flat fan nozzle covers about 5.5 inches (14 cm) width
A 65° flat fan nozzle covers about 15 inches (38 cm) width
A 110° flat fan nozzle covers about 26 inches (66 cm) width

This relationship scales up evenly with mounting distance—doubling the distance doubles the coverage width but reduces the impact force and liquid density by four times.

Selecting the Right Spray Pattern for Your Application

A step-by-step approach to nozzle selection ensures the best spray performance while avoiding costly trial-and-error:

Step 1: Define the Process Objective

Clearly identify what the spray system needs to do:

Cleaning (light rinsing vs. heavy deposit removal)
Coating (thickness, how even it needs to be)
Cooling (temperature reduction targets, evaporation vs. convective cooling)
Humidification (moisture addition rate, droplet size needs)
Dust suppression, fire protection, or chemical processing

Step 2: Determine Coverage and Droplet Requirements

Specify the physical needs:

Coverage area: Linear (flat fan), circular (cone), or point-focused (solid stream)
Droplet size: Fine mist, medium spray, or large drops/solid stream
Impact force: Light contact vs. aggressive mechanical action
Distribution uniformity: Strict evenness vs. center-weighted acceptable

Step 3: Consider Fluid Properties and Pressure Limitations

Look at the liquid characteristics and system limits:

Viscosity and surface tension: May need specialized nozzle designs or higher pressure
Temperature: Affects material choice and may influence spray characteristics
Corrosiveness or abrasiveness: Dictates material selection (stainless steel, hardened alloys, ceramic)
Available pressure range: Some patterns need minimum pressure to form properly
Flow rate capacity: System pump capacity and required throughput

Step 4: Match Pattern Type to Application

Based on the factors above, select the right pattern:

Flat fan Nozzles: Linear surface treatment, rinsing, strip coating
Full cone Nozzles: Circular area coverage, tank washing, fire protection
Hollow cone Nozzles: Fine mist, gas contact, cooling
Solid stream Nozzles: High-impact cleaning, descaling, long-throw applications
Air atomizing Nozzles: Ultra-fine droplets, precision coating, controlled humidification

Step 5: Select Appropriate Nozzle Material

Material choice ensures the nozzle lasts and keeps working well:

Brass: Budget-friendly for water and non-corrosive fluids at moderate temperatures
Stainless steel (303, 316): Resists corrosion for most industrial chemicals and food applications
Hardened stainless steel: For abrasive or high-pressure jobs needing wear resistance
Ceramic or carbide inserts: Maximum wear resistance for extremely abrasive fluids or high-pressure solid streams

NozzlePro's engineering team can help with material selection based on specific fluid properties and operating conditions.

Industry Applications

Proper maintenance extends nozzle life, keeps process quality high, and prevents unexpected failures that can disrupt production schedules. Different industries use specific spray patterns to meet their unique process needs:

1. Automotive and Metal Processing

Flat fan nozzles: Parts washing, paint stripping, surface prep before coating
Solid stream nozzles: Descaling during steel production, removing mill scale
Full cone nozzles: Phosphate coating application, rust prevention treatments
Hollow cone nozzles: Quenching heat-treated parts, cooling during machining

2. Chemical and Energy Industries

Hollow cone nozzles: Gas scrubbing, absorbing acid gases, cooling tower applications
Full cone nozzles: Reactor vessel cleaning, tank washing between batches
Air atomizing nozzles: Precise chemical dosing, humidification for static control
Solid stream nozzles: High-pressure equipment cleaning, removing hardened deposits

3. Food & Beverage and Agriculture

NP9520 - TC – High Pressure Spray Nozzle, Tungsten Carbide Insert - NozzlePro

Stationary and rotating tank cleaning nozzles: CIP systems for sanitary equipment, brewery vessel cleaning
Flat fan nozzles: Conveyor cleaning, produce washing, surface sanitizing
Hollow cone nozzles: Spray drying milk or coffee, agricultural pesticide application
Full cone nozzles: Humidification in fermentation areas, cooling of packaged products

4. Fire Protection and Dust Suppression

Full cone nozzles: Fire sprinkler systems, deluge systems for industrial protection
Hollow cone and fogging nozzles: Dust suppression in mining, demolition, material handling
Air atomizing nozzles: Creating fine mist barriers for tiny dust control
Solid stream nozzles: Monitor nozzles for firefighting, high-volume water delivery

Maintenance and Optimization Tips

Regular maintenance keeps spray patterns working well and prevents process problems:

1. Inspection and Monitoring

Regularly watch spray patterns during operation to spot uneven spray, streaking, or reduced coverage that signals wear or clogging
Compare actual flow rates against manufacturer specs to identify wear
Track operating pressure over time; increasing pressure for the same flow suggests partial blockage

2. Cleaning Procedures

Remove nozzles and clean using appropriate solvents or ultrasonic cleaning for precision openings
Install filters upstream of nozzles to prevent debris from reaching openings

3. Replacement Intervals

Set up replacement schedules based on:

Fluid characteristics: Abrasive or corrosive fluids speed up wear
Operating hours: High-use applications need more frequent replacement
Performance drop: Replace when flow rate increases beyond spec (typically 10-15% means significant wear)
Pattern distortion: When spray pattern no longer keeps its proper shape or coverage

4. Optimization Through Testing

Keep records comparing design flow rates to actual measurements
Use test setups with impact surfaces to check distribution evenness
Test different pressures to find the best balance between droplet size, coverage, and system efficiency

Conclusion

Spray pattern selection is the foundation of effective industrial spray nozzles’ design. Each pattern type, flat fan, full cone, hollow cone, solid stream, air atomizing, and specialized tank cleaning setups, offers distinct characteristics suited to specific jobs.

The step-by-step approach to nozzle selection, considering process goals, coverage needs, fluid characteristics, and pressure limits, ensures the best performance while avoiding costly mistakes.

Need to select spray pattern, nozzle recommendations tailored to your applications. Our experienced engineering team can provide detailed application analysis and product solutions.

Contact NozzlePro for expert guidance

Frequently Asked Questions

Full cone patterns spread liquid throughout the entire circular spray area with solid coverage, while hollow cone patterns concentrate liquid around the outer ring with very little flow in the center. Full cone patterns work best when even coverage over a circular area is needed, whereas hollow cone patterns work great for jobs requiring fine mist and maximum liquid-gas contact, such as cooling or gas scrubbing.
Spray angle directly determines the coverage width at a given mounting distance—wider angles cover more area from close positions, while narrow angles provide focused coverage over longer distances. Doubling the mounting distance doubles the coverage width but significantly reduces impact force and liquid density.
While some nozzle designs offer versatility, the best performance typically needs pattern-specific selection. A nozzle great for high-impact cleaning (solid stream) will perform poorly for humidification (requiring fine mist), and a hollow cone designed for gas scrubbing won't provide the uniform distribution needed for coating.
Pattern problems mainly result from nozzle wear, which enlarges openings and erodes internal surfaces, changing flow characteristics. Abrasive fluids, high operating pressures, and corrosive chemicals speed up wear. Partial clogging from debris or chemical deposits can distort patterns. Regular inspection, filtration, and scheduled replacement based on flow rate measurements prevent performance issues before they impact process quality.
Using the wrong pattern can lead to uneven coverage, wasted materials, and poor results like trying to paint a wall with a garden hose. It's worth taking the time to match the pattern to your specific needs, or consulting with experts to avoid costly do-overs.
Watch for telltale signs like distorted spray patterns, uneven coverage, or a flow rate that's increased by 10-15% from the original spec. These changes mean the nozzle has worn enough to affect your process quality, so it's time for a fresh one.