Category: Boom Sprayers

Main category for sprayers with horizontal booms

  • The Challenges of Spraying by Drone

    The Challenges of Spraying by Drone

    Spray application by drone is here. It’s common practice in South East Asia, with a very significant proportion of ag areas now treated that way. Estimates from South Korea, for example, suggest about 30% of their ag area being sprayed by drone. It’s in the US, too. The Yamaha RMax and Fazer helicopters, which pioneered drone spraying in Japan dating back to the mid 1990s, have been approved for use in California since 2015.  DJI, the world’s largest drone manufacturer, introduced their ag model, the Agras MG-1, to North America in 2016. Many other spray drones are available or in development.

    As William Gibson, the author of Johnny Mnemonic, once said, “The future’s here, it’s just not widely distributed yet.”

    DJI Agras MG-1 spray drone (Source: DJI.com)

    Proponents of drone spraying cite a drone’s ability to access areas where topography is a problem, such as steep slopes, where productivity of manual application is much lower, or low areas where soil moisture prevents ground vehicles. Operator exposure is reduced compared to handheld application.

    Opponents talk about productivity and cost factors compared to manned aerial application, spray drift, and rogue use.

    Before drone spraying becomes commonplace, two important things need to happen.

    1. Federal laws need to be updated to accommodate the unique features of remotely piloted aircraft systems (RPAS), as they’re now called. Current laws make many assumptions unique to manned ships, and the process to correct that will require some patience. A thorough review for US laws, and their shortcomings, can be found here.
    2. Federal pesticide labels need to permit the use of drones for application. As of August, 2021, Canadian labels have no such registered use.

    There is no doubt that we need to prepare for a future that includes spraying by drones. Features such as topography adjustment for height consistency and autonomous swath control are already essentially standard, and the capabilities that improve control and safety will continue to develop.

    And yet I’ve been nervous about the prospect of pesticide application with drones. My primary concern is around – you guessed it – spray drift. Because a drone payload is relatively small (about 5 to 25 L, depending on the model), application volumes will need to be low to have any sort of productivity. How low? For manned aircraft with a 200 to 600 gallon hopper, 2 to 4 US gpa (18 to 36 L/ha) are the lowest commonplace volumes. The lower volumes require a Medium spray quality (among the finer sprays in modern boom spray practice) to achieve the required coverage.

    It’s a simple concept: the less water is used, the smaller the droplets need to be to provide the necessary droplet density on the target. Drift control with coarser sprays requires higher volumes, and true droplet-size-based low-drift spraying can’t really happen at volumes less then, say 5 to 7 US gpa.

    At 2 to 4 US gpa, a drone would be able to do perhaps 1 acre per load. While OK for spot spraying, it represents a serious productivity constraint for anything larger.  There will be a push toward lower volumes, perhaps 0.5 to 1 gpa (5 to 10 L/ha). The only way these will provide sufficient coverage is with finer sprays, ASABE Fine to Very Fine, with expected problematic effects on off-target movement and evaporation. These fine droplets are also more prone to the aerodynamic eccentricities of aircraft.

    Vortices from the rotor can create unpredictable droplet movement (Source: kasetforward.com)

    The current regulatory models for aerial drift assessment in North America, AgDISP and AgDRIFT, are not yet able to simulate drone application. But by entering finer sprays into these models for their conventional manned rotary wing aircraft, we can see that buffer zones will be higher. Much higher. And that outcome will give pause to regulators. Failure to control the movement of a spray is, and should be, a problem.

    Estimated Buffer Zones (calculated by AgDISP) for a reference rotary wing spray aircraft, using three pesticide toxicologies and two spray qualities.

    Furthermore, ultra-low volume (ULV) sprays can change the efficacy of some products, and these will require new performance studies. At this time, regulators are seeking information not just on spray drift, but on product efficacy, operator and bystander exposure, and crop residues.

    Regulators are currently collecting spray drift and efficacy data from drones. Since the drones available in today’s market do not conform to a common design standard like fixed or rotary winged manned aircraft, each model may have its own characteristics and need its own study. Some will have rotary atomizers, others will use hollow cone hydraulic sprays. Some will have electrostatic charging, others may propose special adjuvants.

    Once data are assessed, there will likely be restrictions in flight height, flight speed, wind speed, spray quality, water volume, perhaps air temperature and relative humidity (or Delta T). This is not new to spraying, as current labels already constrain use for both ground and aerial spray application, more so for aerial.

    The obvious question is how these proper application practices can possibly be assured. Operators will need more than just regulatory approval to use a drone, they will require proper training, similar to what a commercial aerial applicator now receives prior to operating a business.

    Recall that our aerial applicators are governed by national organizations, the NAAA in the US and the CAAA in Canada. These organizations are in regular contact with federal regulators to assure compliance. They also help fund research into application efficacy and safety. They organize conferences in the off-season and calibration clinics in the growing season. At these, flow rates are confirmed and deposited droplet size is measured. Spray pattern uniformity is assessed and corrected as necessary.

    Should drone applications be exempt from these controls? I don’t think that would be wise. Are we ready to implement them? Absolutely not.

    These requirements would change the drones’ economic model. And despite these precautions, a drone may still leave the control of a pilot due to unforeseen technical or human events.

    In the US, Yamaha does not sell their drone helicopters. Instead, they deploy their own teams to make the applications. This way, they have assurance that only trained and experienced pilots use the technology.

    As the industry gears up for the first registrations, we see drone service companies take a leading role in testing. Much is being learned via legal applications of liquid micronutrients, for example, or limited use of pesticides under approved research permits. And I’m pleased to see the recognition of drift management in these efforts through the use of low-drift nozzles. We are off to a promising start.

    Requests for drone use are in progress at our regulatory agencies. The outcomes of their risk assessments will provide important initial guidance, and food for thought and discussion. In the meantime, the drone development continues at a rapid pace, with new features and greater capacity at each iteration.

  • New Use for Bourgault 1460 Field Sprayer

    New Use for Bourgault 1460 Field Sprayer

    This week I spoke with Gerry Bell, a producer from near Gravelbourg in southern Saskatchewan (a beautiful town with a historic downtown, church and school, also, home of the Gravelbourger at the local diner). He told me about a project he recently completed, converting his older pull-type sprayer to a granular spreader. It’s a great project, worth sharing.

    The concept was first popularized by Manitoba farmer Kyle Holman in 2012, who uses the #SprayMar hashtag on Twitter to promote it.

    Gerry wrote his project up for us and I’ve posted his description below.

    Bourgault 1460 Field Sprayer

    The sprayer sat in a machine shed from 2011 when we purchased a Patriot 4420 sprayer. For many years we wondered if we couldn’t find a use for the sprayer as Bourgault had build a very rugged unit. So, in 2017 we decided to mount a Valmar tank (now owned by Salford) on the sprayer frame to be used for granular herbicides and granular fertilizer applications.

    Bourgault 1460 (Source: Bourgault.com)

    The liquid tank and plumbing were removed as well as the secondary boom with the wet boom. A few modifications to frame were made but for the most part the frame was left as is. The unit was painted with the Salford colours. (Case IH red)

    The Valmar/Salford unit is a ST8 which is used lots in Eastern Canada and the States for strip tilling for applying granular products. We purchased the tank, hoses, splitters and deflectors from Salford.

     The unit as purchased had the following features:

    • 8 imperial tons (16,000 lbs)
    • Stainless steel tank and duct systems
    • Mueller Hydraulic metering system with two sets of rollers – one pair for granular herbicides and one pair for granular fertilizers
    • Two hydraulic driven air fans – usually just one fan but we chose two fans – one for each boom
    • Weight scales for tank
    • ISOBus system with mapping, auto on off, sectional control (one for each boom)
    • 18 outlets – 9 outlets on each side of tank

    We designed unit in consultation with Salford engineers:

    • Each of the 18 outlets has a 2” flexible hose from the tank going to 2” stainless steel tubing stacked on the boom frame
    • Just prior to the deflectors each 2’ tubing is split into two 1-1/4 streams with special splitters supplied by Salford (according to Salford these are commonly used and have an accuracy of less than 2-3 % variation if mounted properly). Need to be horizontal.
    • The deflectors are mounted every 30” along the length of the boom (36 deflectors)
    • The sprayer boom was cut down from 110’ to 90’ to give the correct spacing

    Comments on use of the unit

    • Functionality seems to work very well as designed
    • Weigh scales, GPS, mapping, auto on/off, sectional control a real plus compared to original field sprayer with none of these features
    • Accuracy of product metering seems very good
    • Distribution across length of unit seems very good
    • Travel speeds of 10 mph
    • Product takes 2.5 seconds from time meter starts turning until product reaches far end of boom

    There is a difference of about thirty feet in travel distance with start and stop of product on the ground between inner side of boom and outer end of boom. Therefore, we have set look ahead time at 3.3 seconds and shut of time at 0.3 seconds.

    • Load products with a belt conveyor in yard
    • Apply 100 lbs of elemental sulphur (0-0-90) on 25% of the crop land each year

    (Tank does 160 acres)

    • Applied Avadex at 12.5 lbs per acre last fall on some acres prior to snow.
    • Apply Edge at 20 lbs per acre each fall just prior to snowfall  (for pulses)

    Tanks holds 10 minibulk bags – 12,000 lbs, and does 600 acres. On a long day have put out 1200 acres of Edge.

    We did extend the axles and also put on new hubs and new tires which were a bigger size. A Bourgault 1850 with 1600 gallons would have worked better but it is hard to find them. Plus they would probably have needed new tires anyways.

    It took a lot more time than we had imagined to build but that is true of most building projects. But I would say that we are very happy with the results. It is a pleasure to operate and appears to serve our needs very well.

    Thank you, Gerry, for sharing this with us!

  • How Low Can You Go?

    How Low Can You Go?

    Listen to an audio recording of this article by clicking here

    There’s a lot of talk about lowering the boom to reduce drift and make twin fan nozzles more effective. But how low can we actually go with a boom before striping becomes a problem?

    We’ve done some calculating and have come up with answers.

    First, a few guidelines. Tapered flat fan nozzles require overlap to generate a uniform volume distribution under the boom. Traditionally, we’ve recommended 30 to 50% overlap with fine flat fan sprays. The small droplets tended to redistribute to fill in any gaps that might occur.

    Overlap from fine sprays is less critical than from coarser sprays because the small droplets redistribute readily.

    The advent of low-drift nozzles changed that advice. This nozzle type produces fewer droplets overall, and, like all fan-style nozzles, puts the coarser ones towards the outside edges of the fan. These don’t redistribute.

    A typical flat fan spray places the coarser droplets at its periphery, and the smaller ones in the middle. When only the outed edges overlap, that can creates a band of poor coverage.

    When we had 30% overlap and these two edges met, a region of relatively few, coarse droplets was formed, and this region contained almost no small droplets. On a patternator, the volume distribution was still good. But when we measured the droplet density, we saw a deficit in coverage at the overlap.

    With low-drift nozzles, we need 100% overlap to distribute both small and large droplets uniformly under the spray swath. Too little overlap and we create bands of relatively few but large droplets that can cause striping.

    Since then, we’ve been recommending 100% overlap for low-drift sprays. This means that the pattern width at the target will be twice the nozzle spacing, and all regions under the boom receive droplets from two adjacent nozzles.

    With this adjustment, small droplets appeared throughout the spray swath, and striping was eliminated.

    That leaves the question, just how low can a boom be set without creating this problem? The following tables provide some theoretical numbers.

    Minimum boom heights for achieving 50% and 100% overlap of flat fan spray nozzles (US units)

    Minimum boom heights for achieving 50% and 100% overlap of flat fan spray nozzles (metric units)

    A word of caution: The advertised fan angle on a sprayer nozzle often differs in practice. Not only will it be slightly different by design, it also depends on spray pressure and tank mix. As a result, it’s best to do a visual check. Set the spray pressure to the minimum you expect to use. Inspect the spray patterns and set the boom height so that the edge of each nozzle pattern reaches to the middle of the next nozzle. That means your pattern width is twice the spacing and will give 100% overlap. No tape measure required.

    The tables were generated from a spreadsheet which can be downloaded here:

    • The values are theoretical and assume the fan angles are accurate. Some nozzles don’t produce the advertised fan angle. Enter your actual angle in the spreadsheet if you know it.
    • The theory assumes that the droplets at the edge of the fan always move in their projected direction. In fact, after some distance, say 50 to 75 cm, gravity pulls the droplets down and the pattern no longer widens at the same rate. The rate of pattern collapse depends on the droplet sizes.
    • Use the 0% overlap column to help with banding nozzle pattern width. Simply use the nozzle spacing column to enter your desired band width.
    • Note that angling the nozzles forward or backward decreases your minimum boom height, but depending on the deflection of the spray in the wind, this too has limits.
    • Too high a boom obviously increases drift. But patternation from overlap isn’t affected that much, largely because the pattern is now subject to aerodynamics and that becomes more important.

    Pro Tip: Attach a length of plastic hose or a large zip tie to the boom, cut to your minimum boom height. This makes it easier to see what your boom height is, from the cab or the ground.

    The bottom line is that a boom can be quite low and still allow excellent overlap and pattern uniformity from the nozzles. Yet we all know that most sprayer booms can’t reliably operate that low because they don’t control sway well enough. The ball’s in your court, sprayer manufacturers!

  • Boom Heights at Fan Angles Worksheet

    Boom Heights at Fan Angles Worksheet

    Use this spreadsheet to calculate the minimum boom heights needed for various applications.

    Some caution:

    • The values are theoretical and assume the fan angles are accurate. Some nozzles don’t produce the advertised fan angle. Enter your actual angle in the spreadsheet
    • The theory assumes that the droplets at the edge of the fan always move in their projected direction. In fact, after some distance (say 50 to 75 cm, gravity pulls the droplets down and the pattern no longer widens at the same rate. The rate of pattern collapse depends on the droplet sizes.
    • Use the 0% overlap column to help with banding nozzle pattern width. Simply use the nozzle spacing column to enter your desired band width.
    • Note that angling the nozzles forward or backward decreases your minimum boom height, but depending on the deflection of the spray in the wind, this too has limits.
    • Too high a boom obviously increases drift. But patternation from overlap isn’t affected that much, largely because the pattern is now subject to aerodynamics.
  • Six Spray Technology Skills for Agronomists

    Six Spray Technology Skills for Agronomists

    Press play to listen to an audio version of this article

    Agronomists help farmers manage their crop with advice on everything from crop cultivars to fertilizer rates to marketing. It’s challenging to be an expert on everything, but a few core competencies can go a long way to improving the level of service.

    Agronomists are also responsible for communicating environmental best practices. Along with fertilizer rates come messages of source, time, and place, the 4R principles. The same is true for spraying, with messages of spray drift, resistance management, and economic thresholds part of the consultation. Let’s remember that we should not be indifferent to the potential consequences of our recommendations.

    Here are six skills that an agronomist should know about spray technology.

    1. Recognizing major nozzle models and their spray quality and pressure requirements.

    Application technologists are often asked to identify nozzles and recommend spray pressures for clients. It’s a skill that anyone can develop with just a bit of homework.

    First, learn the colour-coding of nozzles – colours identify flow rates and follow an international standard that all manufacturers have adopted.

    ISO Colour coding of major nozzle sizes, as well as application volumes at benchmark speeds.

    Next, focus on the common nozzles on the major sprayers. John Deere sprayers will typically have three main air-induced nozzles, made for John Deere by Hypro, the Low-Drift Air (LDA), the Ultra Low-Drift (ULD), and the GuardianAIR Twin (GAT). Those with ExactApply, John Deere’s PWM system, will see the non air-induced 3D, the Guardian (LDX), and the Low-Drift Max (LDM). Recall that PWM flow control should not be used with air-induction tips.

    Almost all Case sprayers have PWM, called AIM Command. Case uses Wilger ComboJet bodies and nozzles, with the ComboJet ER, SR, and MR most common, sometimes the DR or UR for dicamba.

    New Holland/Miller with PWM (called IntelliSpray) are also likely to have these tips, but because these brands have TeeJet bodies on their booms, they require an adaptor for the proprietary ComboJet caps.

    Otherwise, PWM units often use TeeJet’s TurboTeeJet (TT), Turbo TwinJet (TTJ60), and Air-Induced TurboTwinJet (AITTJ60), the only air-induced tip approved for PWM use by TeeJet.

    Conventional spray systems (i.e., no PWM), will commonly have (in alphabetical order) the Air Bubble Jet (ABJ, actually labelled BFS for their manufacturer, Billericay Farm Systems), the Greenleaf AirMix (AM), the Hypro GuardianAIR (GA), and the TeeJet AIXR.

    Many sprayers will have a twin fan for fungicides, primarily for fusarium headblight (FHB) management. The Greenleaf Turbo Asymmetric Dual Fan (TADF), the Hypro GuardianAIR Twin (GAT), and the TeeJet AI3070 dominate, as well as a number of custom configurations using splitters and twincaps.

    Where dicamba is applied on Xtend trait soybeans, some special nozzles may be used to meet label requirements for coarseness. The TeeJet TTI is very common, but Greenleaf developed a special set of tips called the TurboDrop XL-D and the TADF-D. Wilger’s version, mentioned earlier, is the UR. John Deere has just announced their new ULDM.

    That covers 95% of what you’ll encounter in the North American market. In Europe, add some Lechler nozzles (ID3, IDTA, IDK, IDKT) to the mix. In Australia, Arag is gaining ground.

    Identifying the nozzles on sight is the prerequisite to finding out their average droplet size, called spray quality. Often, the inscriptions are worn off, so visual recognition is required to get there.

    We’ve published a visual identification guide with pictures of the major nozzles here.

    Knowing the relative spray qualities produced by these various nozzles will get you bonus points, but you’ll need to do some extra research to get there.

    2. Using a spray calibration chart

    This skill will make you popular on the farm and at the office. A very frequent question is “what size nozzle do I need for this new sprayer?”. The best way to approach the answer is to ask several questions.

    • Does the sprayer have 20” nozzle spacing? (90% of sprayers do).
    • What is the desired water volume?
    • What is the expected average travel speed?

    The first question guides you to the appropriate calibration chart, which can be downloaded here or can also be found in all sprayer catalogues.  We explain how to use these charts here. 

    Calibration chart for 20: spacing, in US units.

    If you don’t have a chart handy, use this shortcut: on a boom with 20” spacing, at 5 mph, every 0.1 US gpm capacity at 40 psi delivers 6 US gpa. So if you need to apply 12 gpa at 15 mph, an 06 size will get you there at 40 psi. That’s ballpark.

    In metric, with 50 cm spacing, at 10 km/h every 400 mL/min (01 size) at 3 bar delivers about 50 L/ha. To deliver 200 L/ha at 20 km/h would require an 08 (white) tip.

    Of course, if the tip is air-induced, make adjustments to speed or size to accommodate the higher pressure requirement of these types of nozzles.

    Remember that spray pressure is key to performance, therefore the operator needs to drive at a speed, or use a volume, that results in the correct spray pressure.

    3. Understanding Pulse Width Modulation

    PWM technology has been on the North American and Australian market for two decades, but it remains poorly understood by those who do not use it. PWM will continue to gain popularity and has implications for nozzle selection and sizing.

    Traditional rate control in the field involves the use of spray pressure to match liquid flow rates to travel speed. The rate controller knows the width of the boom (entered by the user), the travel speed (from gps), and the desired application volume (entered by the user). It does some math to identify the flow rate it needs, and compares that to the sprayer’s current flow meter reading. If the current flow is less than what’s needed, the sprayer increases pressure to increase flow. This happens continuously in the background.

    When an operator speeds up, the pressure increases, and vice versa. As a result, the pressure (and therefore droplet size) will fluctuate with travel speed, and that can result in inconsistent spray patterns, coverage and drift.

    PWM involves the installation of electronic solenoid valves at each nozzle body. These valves pulse on and off at 10, 15, 50, or 100 Hz, depending on the manufacturer. Each pulse contains a brief, complete shutoff of the flow. The proportion of the time the valve is open during a pulse is called the Duty Cycle (DC), and this is proportional to the flow through the nozzle.

    Capstan PWM solenoid on Case AIM Command

    When the system requires more flow, it no longer increases pressure. Instead, it increases the DC. The advantage of this approach is that nozzle pressure can now stay constant, ensuring consistent coverage and drift.

    There are other advantages of these systems. Each nozzle can be controlled independently, offering high resolution sectional control and turn compensation.

    Nozzle selection and sizing are both affected by this technology. Nozzles need to be sized larger, with about 30 to 40% more flow capacity ideal. The DC will therefore run at 60 to 70%, optimal for speed fluctuations and turn compensation. Air-Induced tips are not usually recommended because their pattern deteriorates with pulsing.

    We’ve written about PWM here, here and here to get you started.

    4. Validating coverage of the target

    A very useful indicator of the success of a spray operation is an assessment of “coverage”. This term refers to a qualitative combination of droplet density and percent area covered, and can be quickly assessed using water sensitive paper. We’ve explained the use of WSP here and here.

    It’s very useful to have some of this paper on hand (available from any retailer that sells TeeJet or Hypro products, or on-line from Sprayer Parts Warehouse in Winnipeg or Nozzle Ninja in Stettler, AB). The coverage can be assessed in four different ways:

    Water-sensitive paper being used to assess spray coverage.
    • using the “SnapCard” app (gives % coverage only);
    • using the “DropScope” scanner (gives a comprehensive assessment of coverage, density, size, plus image editing tools);
    • using a template of coverage examples;
    • using experience built on years of doing this.

    Water-sensitive paper is also useful as a record, for quality assurance. A spray application is conducted and part of the record is an image of the deposit. Should a performance issue arise, this will help settle it.

    5. Understand basic sprayer plumbing

    Often, a sprayer problem can be traced back to an issue with its plumbing. There could be mysterious sources of contamination. The pump might not be building pressure. The agitation isn’t running. Or you need to drain all the remaining liquid from the tank.

    Sprayer plumbing seems intimidating for a number of reasons. It’s become complex on most modern sprayers. It’s hidden under the sprayer belly. All the lines are the same black colour, so they’re hard to tell apart.

    But it’s not as bad as it seems. Basic plumbing is the same on all sprayers. The pump draws the spray mix from the bottom of the tank, the sump. It may also have options to draw clean water from an external supply, or from the clean water tank for wash-down.

    The pressurized supply goes to three places:

    • to the booms, via sectional valves;
    • back to the tank, via a control valve that can be used to adjust the spray pressure;
    • to the wash-down nozzles.
    Typical sprayer plumbing for a centrifugal pump (Courtesy TeeJet).

    When spraying, the less is returned to the tank, the higher the boom pressure. There may be several ways back to the tank, via agitation, via bypass (sparge), or via wash-down (used only when the pump draws water from the wash-down tank). Usually engineers can’t help themselves and introduce several what-if features that complicate the situation. But with a bit of know-how, and a flashlight, the plumbing system can be deciphered.

    Pro tip: A centrifugal pump’s inlet (suction) is always the centre of the pump, its outlet (pressure) is at the periphery.

    6. Matching a pesticide recommendation with application advice

    It’s commonplace to recommend a specific crop protection product that matches the crop and pest situation. Recommending an ideal crop or pest stage improves the recommendation. But a truly successful outcome requires one additional step, advice on the application method. The customer may need to know if product performance depends on water volume and droplet size. Some products are more sensitive to this than others. Perhaps there is a specific nozzle type that may be helpful.

    The classic example for application method is Fusarium headblight in wheat. The basics are straightforward. An agronomist recommends the fungicide, and guides the tight application window with a field visit to stage the crop, plus a look at the disease risk forecast map. But true application success requires an angled spray, with a coarser spray quality plus relatively low boom height to make it all worthwhile. That’s a full-featured recommendation. 

    Common herbicide applications also benefit from additional information. Some tank mixes and weed spectra allow for coarser sprays than others, and the ability to spray coarser means a wider application window and therefore more accurate timing. Other tank mixes may pose a significant risk to drift damage, requiring special measures to prevent a problem. Identifying those opportunities adds value.

    Water volume and spray quality recommendations for major herbicide mode of action groups.

    Newer labels for dicamba (Xtendimax, Engenia, Fexapan) and 2,4-D (Enlist Duo) have very specific instructions for drift prevention. This information must be shared with customers to ensure that their drift liability is covered.

    Are there other skills that you feel agronomists should have? Please share them with us by contacting us at the bottom of this page.