Need to find the right nozzle size for your application? Sometimes a simple chart is the easiest way to figure things out. Print it and place it in your sprayer cab.
In this chart, identify your water volume along the top row, and follow the column until you encounter the travel speeds you’re interested in.
Once you’ve encountered your travel speed, move along the row to the left to identify the nozzle size and spray pressure.
Make sure that your travel speeds are achieved at a pressure that’s right for the nozzle you’re using. For most air-induced nozzles, this will be about 60 to 70 psi (highlighted).
Once you’ve decided on a nozzle size, the travel speed column for that size becomes the travel speed range at various pressures. Avoid operating a low-drift spray below 30 psi – its pattern will be too narrow and likely its spray quality will be too coarse for good results.
Click on the images or text below to download a high quality pdf version of each chart, starting from the top with US, 15″ spacing, then US, 20″, then US 30″, then metric, 50 cm. Print, laminate, and place them in your sprayer cab.
Canada, like most of the world, is officially Metric. Our American friends are US Imperial. It sounds very cut and dried, doesn’t it?
Anyone that’s tried to calibrate a sprayer in Canada quickly discovers that we’re really a horrible amalgam of the two systems. Our sprayers and nozzles often hail from the states, and that means US Imperial. Our pesticide labels hail from Health Canada’s Pest Management Regulatory Agency, and that means Metric
And so, when speaking with applicators about their sprayer practices, we’re often treated to mind-rending sentences like:
Well, I drive 12 mph, spraying about 150 L/ha and my pressure is about 40 psi. How many ml/min should my nozzles emit for a product that wants 6 oz/acre acid equivalent?
Cue the quiet sobbing…
Well, your smoking calculators are in for a treat! In a fit of frustration we created the ultimate set of conversion tables that should set you right for almost any Imperial/Metric emergency! Find one we missed -We DARE you! (update: Tip of the hat to D. Wiens of Saskatchewan, who found one! We added it.)
Simply find your current units in the left-hand column. Then find the units you are converting to in the upper row. Now multiply by the conversion figure where they intersect in the table.
Yes, they’re ugly, but they’re absolutely complete! If the tiny ones are too tiny to read, right click and download the image so you can zoom in. It’s a limitation of this website that we can’t make them larger.
We often write about how valuable water sensitive paper can be to visualize and assess the coverage we’re getting from a specific application method. A handy reference is this matrix that combines both factors. Print it and use it in the field to compare what your application method is doing to these relative standards. On average, you will want to see deposits similar to those in the middle of the matrix.
Undoubtedly, the number one question we get from operators is: “Which nozzle should I get”? Luckily there’s no simple answer, or we wouldn’t have jobs! The reason it’s not simple is because selecting the “right” nozzle for a sprayer is a process. It can be broken down into two steps:
identifying the right flow rate (aka nozzle size)
choosing a specific nozzle model (i.e. brand, spray pattern type, spray quality, etc.)
It’s a big question, so let’s tackle just the first bullet: identifying the right flow rate.
All sprayer nozzles come in standardized (ISO) sizes, and these sizes are usually identified by numbers stamped on the nozzle as well as the colour of the nozzle itself. The nozzle’s key characteristics (i.e. the fan angle and nominal flow rate), are identified in a format that looks like some version of this (Fig. 1):
Fig. 1: Typical information printed on modern nozzles.
The 110 refers to the fan angle (110°) and the 04 refers to the flow rate. 04 means 0.4 US gallons of water per minute (gpm) at 40 psi. Each nozzle brand has a slightly different convention, but no matter how the information is presented it ought to be on the nozzle somewhere.
Nozzle colour has an ISO standard across fan-style nozzles, and we have this table to match the nozzle colour to the flow rate:
Fig 3: ISO nozzle colours and flow rates
You’ll note that the nozzle we pictured earlier was “flame red”, matching the 0.4 gpm on the table. So how do we use the table to pick the right size nozzle?
Application rate (i.e. gallons per acre or L/ha) is a function of travel speed, nozzle spacing along the boom, and nozzle flow rate. Traditionally, this has been expressed as the following formula in US units:
This formula is famously represented in nozzle charts found in all sprayer catalogues (Fig 4). Along the left side are nozzle sizes and pressures. Along the top is sprayer speed. The body of the table contains application volume. Pick your speed, and look for your application volume in the columns. If you want to apply five gpa, you need to look for the number 5 (or as close as you can get to it), among these numbers.
Fig 4: Typical nozzle flow rate chart, with speed at top and volumes in body. Ugh.
The format of the chart can be confusing because it doesn’t follow a modern sprayer operator’s priorities. Usually, an operator decides on an application volume first, and this decision is not very flexible. Travel speed, decided second, has more flexibility.
We’ve therefore re-worked the table to make more sense (Fig. 5). Along the top are common water volumes. The body of the table are travel speeds. Pick a water volume at the top and follow the column underneath this value to find a speed range you’re comfortable with. To the left, the nozzle size and corresponding operating pressures are now visible.
Fig. 5: Nozzle flow rate chart with volumes at top makes it user friendly.
Try to operate at a spray pressure that’s in the middle of the nozzle’s operating range. For an air-induced nozzle, the range is usually from 30 to 90 psi, so the middle is 60 to 70 psi. That should be the target pressure. Look for a nozzle size that delivers this pressure at your expected travel speed.
These columns can be used to work out a nozzle’s travel speed range. If a nozzle can be operated between 30 and 90 psi, for example, the corresponding speeds are listed in the same rows in the volume column.
For example, say you want to apply seven gpa and think that 13 mph would be a good average travel speed.
Fig 6: Five solutions for the question, “which nozzle to apply 7 gpa at 13 mph?”
Move down the seven gpa column, and you’ll encounter a value close to 13 mph five times – the yellow nozzle at 90 psi, the lilac nozzle at 60 psi, the blue nozzle at 40 psi, the dark red at 30 psi, and the red at about 25 psi. Now use the columns to see which of these three best matches your expected travel speed range.
The yellow nozzle would allow between seven and 12.5 mph from 30 and 90 psi, the lilac nozzle nine to 16 mph, the blue nozzle 11 to 19 mph, the dark red 13 to 22 mph, and the red 15 to 26 mph.
The best choice for a typical air-induced tip would be the lilac 025 size, since it would meet the target speed of 13 mph at a perfect 60 psi, about right for nozzles of that size, and allowing some travel speed flex on the slower side.
Some operators try to extend that range, but dropping below 30 psi will likely result in too narrow a pattern, or too coarse a spray quality, so it’s not advised.
Note that the three-fold change in pressure from 30 to 90 psi translates to only a 1.73-fold change in travel speed. That’s due to the square-root nature of the relationship, as illustrated by this formula:
This exercise applies to sprayers with rate controllers that adjust pressure to regulate flow rates. However, if you use pulse-width modulation (e.g. Case AIM Command, Capstan Sharpshooter, Raven Hawkeye, or TeeJet DynaJet) check out this article describing these systems.
There are a number of apps and websites, usually developed by nozzle manufacturers, which provide similar answers. These are also very useful, and all of them rely on the same formulas used in our new, simplified table. You can go here to download a high resolution version, suitable for framing, in both US and metric units.
Automatic rate controllers are standard equipment on almost all new sprayers. They ensure consistent application volumes, but they don’t do all the thinking for you. We explore how to make them work properly.
A rate controller needs to know the boom width (entered by the user), the total spray liquid flow rate (from a flow meter), and the sprayer speed (gps, radar). It controls the spray liquid pressure by opening or closing a bypass valve. More pressure equals more flow to the boom.
The rate controller allows the applicator to enter a desired application volume and the controller sets the spray pressure that gives the necessary flow for the application volume and sprayer travel speed being used. In practice, this means that higher travel speeds result in higher spray pressure, and vice versa.
But it’s not that simple. Rate controllers aren’t smart enough to know how pressure affects nozzle performance. Some nozzles don’t work well at low pressures. Others do a poor job at high pressures. Some sprayer pumps may even have a problem generating some of the higher pressures a rate controller calls for. What does that mean for the available travel speed range that’s possible with any given nozzle? To answer that question, we first have to have a closer look at how pressure affects nozzle performance.
Spray Pressure and Nozzle Performance
Nozzle performance depends on a number of factors. Of these, the most critical is spray pressure. Pressure affects the flow rate of the nozzle, the spray pattern (fan angle) and the spray quality (droplet size range). The last two of these affect coverage, overlap, and spray drift, so it’s important to get them right. Each nozzle model has a unique spray pressure range and unique spray qualities within that range, so one must obtain information that is specific to the nozzles on the spray boom from the nozzle manufacturer.
ASABE spray quality for the TeeJet AIXR nozzle.
Catalogues Contain Important Information
Nozzle manufacturer catalogues identify the pressure range over which the nozzle should be operated. At low pressures, engineers look for a uniform pattern that meets the advertised fan angle. The upper pressure limits are kept low enough to prevent the formation of excessively fine sprays. Manufacturers now publish tables containing “Spray Quality”, a broad categorization of droplet size, for their various nozzles and spray pressures in their product line. Common spray qualities for agricultural nozzles are Fine (orange), Medium (yellow), Coarse (blue), Very Coarse (green), and Extremely Coarse (white). An example table from a catalogue is shown in Figure 1. Note that for any given nozzle flow rate (left column), the spray quality changes with spray pressure. For example, the TT110025 nozzle can produce a Very Coarse or a Fine spray, depending on the pressure. Also note that for any given pressure, higher flow rate nozzles produce coarser sprays. At 40 psi, the TT nozzle can produce a Medium, Coarse, or Very Coarse spray, depending on its nominal flow. Both of these relationships depend on the nozzle model and manufacturer.
Speed-Pressure-Spray Quality Relationship
As we increase spray pressure, flow rate increases with a square-root relationship.
The square root relationship between travel speed (or flow rate) and spray pressure for hydraulic nozzles
This means that in order to double the flow rate, we need to increase spray pressure by a factor of four. Figure 2 shows three different flow rate tips, each applying 10 US gpa at a range of travel speeds. Assume the operator uses a AIXR11004 to apply 10 US gpa at 12 mph. The nozzle would operate at about 40 psi, producing an Extremely Coarse spray quality. If the sprayer slows down to 7 mph to initiate a turn, spray pressure will drop to 15 psi, producing an Ultra Coarse spray. The spray pattern would likely become noticeably narrower, and poor pest control performance is likely in this situation due to the coarseness of the spray.
Relationship between travel speed and spray pressure for three nozzles applying 10 US gpa
It would have been better to use the AIXR11003 nozzle. At 12 mph, this nozzle would have operated at about 70 psi, producing a Coarse spray. Slowing down to 7 mph would drop the pressure to 25 psi, producing an Extremely Coarse spray. If the pesticide being used is sensitive to spray quality, then perhaps such slow speeds should be avoided in order to maintain a higher pressure and finer spray.
The lesson from this exercise is three-fold: (a) size the nozzle to operate at a higher pressure at your target speed to avoid dropping the pressure too low when you slow down, (b) avoid going as slow as 7 mph to prevent the pressure from dropping too low (c) compromise by setting a minimum spray pressure on the rate controller, in which case you’d over-apply product somewhat when their speed dropped too low.
Spray Pattern Overlap
Flat fan nozzle patterns need the correct overlap in order to achieve a uniform spray pattern under the boom. Research has shown that the amount of overlap for low-drift nozzles needs to be at least 100% to achieve optimum nozzle performance. In other words, the edge of a fan should reach into the centre of the adjacent fan (Figure 3), with each fan covering twice the nozzle spacing at target height. This amount of overlap assures that not only the spray volume is uniformly distributed, but that the droplet density is equally uniform. Less overlap may result in fewer droplets depositing in the overlap region, resulting in poor coverage and reduced pesticide performance.
100% overlap means that all areas under the boom receive spray from two adjacent nozzles.
Adjust the boom height so that at the lowest expected spray pressure (slowest planned travel speed), the nozzles still achieve 100% overlap. There is no disadvantage with greater than 100% overlap, but higher booms will lead to greater drift. When a choice exists, choose 110º fan angle nozzles. Most air-induced nozzles are produced at one (usually wide) fan angle only, but actual angles often differ from those advertised. It is important to visually check the overlap before spraying.
Recommendations
What does this mean in practice? Spray operators need to know the right spray quality for the job, and should consult with the pesticide product manufacturer. They also need to use nozzle manufacturers’ charts to identify the spray quality their nozzle will likely produce at their expected application volume and travel speed. If it’s a poor match, a different nozzle may need to be found. Here are some rules of thumb:
Choose a nozzle that produces a Coarse spray over most of the operating pressures you expect to use. Although Very Coarse sprays can work in most situations, avoid them when using lower water volumes, controlling grassy weeds, or using contact modes of action.
Minimize spray drift by avoiding nozzles or pressures that produce Medium or Fine spray qualities.
Make your pressure gauge your speedometer. First, choose a pressure that is in the middle of the nozzle’s recommended operating range. If the range is 15 to 90 psi, select 50 psi. If it’s 40 to 100 psi, select 70 psi. This allows you slow down or speed up somewhat without breaching the nozzle’s capabilities.
Identify the travel speeds that are possible without creating spray qualities that could compromise your application goals.
Visually inspect the spray pattern at the pressure extremes you expect to spray at. At the lowest pressure, your nozzle should still produce 100% overlap (the edge of the spray fan should come to the middle of the next nozzle at target height). If it doesn’t, choose a wider fan angle nozzle, increase spray pressure or elevate the boom.
Make sure your pump can produce the higher spray pressures you expect to need. Pressure limitations are greatest at high flow rates (fast travel speeds applying large water volumes).
Be prepared to compromise. It’s rarely possible to travel at the exact speed, obtain the perfect pressure, and apply the desired water volume that’s been worked out in the office or using manufacturer’s charts. If in doubt, choose slower speeds or higher water volumes to make things work out.
Nozzle manufacturers are getting much better at producing information that helps applicators produce good spraying outcomes. Learning how to use this information is the first step.
