Spray Patterns & Nozzle Types

Understanding Spray Patterns and Nozzle Types

When it comes to industrial spraying systems, the spray pattern is just as important as the nozzle type that produces it. The spray pattern describes the shape, angle, and droplet distribution of the liquid as it leaves the nozzle, while the nozzle type refers to the design and mechanism that generates the pattern.

Choosing the right combination ensures efficient coverage, consistent results, and lower operating costs across industries like food & beverage, automotive, chemical, steel, and wastewater treatment.

Common Spray Patterns

Spray Pattern Description Best For Example Nozzle Types

Flat Fan

 Narrow, sheet-like spray with strong impact and even coverage Washing, rinsing, conveyor cleaning, pressure washing Flat fan nozzles, high-pressure fan nozzles

Hollow Cone

 Ring-shaped spray with fine droplets, hollow center Cooling, humidification, gas scrubbing, coating Axial-flow hollow cone, tangential-flow hollow cone

Full Cone

 Solid circular spray with evenly distributed droplets Chemical processing, dust suppression, fire protection Axial-flow full cone, tangential-flow full cone

Solid Stream

 Focused, high-impact jet with maximum force Cutting, descaling, tank cleaning, pressure washing Jet nozzles, high-pressure solid stream nozzles

Fog & Mist

 Ultra-fine droplets forming fog or mist Cooling, humidification, odor/dust suppression Hydraulic mist, high-pressure fog, air-assisted fog nozzles

Air Atomizing

 Uses compressed air + liquid for ultra-fine atomization Coating, sanitization, electronics, humidification Air atomizing spray nozzles, fine mist atomizers
Specialty Patterns Unique designs for niche needs (spiral, cluster, tank cleaning) Pollution control, dust suppression, tank cleaning Spiral nozzles, cluster nozzles, rotary tank cleaning nozzles

 

Specialty Nozzle Types

Some applications require unique nozzle designs to meet demanding conditions:

  • Spiral Nozzles: Compact design for high flow rates and clog resistance

  • Cluster Nozzles: Multiple orifices for high-volume sprays in dust suppression or chemical processes

  • Tank Cleaning Nozzles: Rotary, static, or fluid-driven designs for CIP (Clean-In-Place) systems

  • Quick-Connect Nozzles: Fast changeover for car wash, pressure wash, and maintenance operations

Why Spray Pattern Selection Matters

  • Process Efficiency: Right pattern = less liquid waste, better coverage

  • Product Quality: Consistent droplet size improves coating, cleaning, and cooling

  • Safety & Compliance: Optimized spray reduces overspray, airborne particles, and contamination risks

  • Cost Savings: Correct nozzle choice lowers water, chemical, and energy usage