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SPRAY NOZZLE SYSTEMS FOR PRETREATMENT TUNNELS

Synergy Spray Systems proudly serves as the exclusive European distributor of Uni-Spray’s advanced spray nozzle systems—the global benchmark for performance and reliability in pretreatment tunnels. Our complete range includes spray nozzles, quick-change nozzle holders, nozzle tubes, pipe couplers, and mounting systems designed to deliver uniform, controlled spraying in metal surface treatment lines.

Overview of Pretreatment Spraying Systems

Spray nozzle systems for pretreatment tunnels must meet stringent demands
Precise spray pattern
Chemical resistance
Efficient changeovers
Long operational life
Uni-Spray systems have replaced traditional stainless-steel configurations with glass-filled polypropylene, PVC, CPVC, or PVDF—offering superior chemical resistance, reduced corrosion, and easier maintenance.
Pretreatment Spraying

Choosing the Right Pretreatment Spray Nozzles

Effective nozzle selection requires balancing several factors
Spray angle and coverage to suit tunnel dimensions
Flow rate and droplet size based on chemical type
Material compatibility with aggressive agents like phosphates
Maintenance ease through fast-change systems
Each nozzle’s purpose in the tunnel depends on its position and the type of chemical it sprays. Uni-Spray’s nozzles for phosphating tunnels are specifically designed to prevent reaction damage, ensuring long-term reliability.
Pretreatment Spray Nozzles

Material Engineering – Chemical Compatibility

Pretreatment processes often involve acidic or alkaline chemicals, especially during phosphate conversion coating. Using metal nozzles in this context is risky—they may corrode or react with the chemicals, compromising the process and increasing contamination risk.
Glass-filled Polypropylene
PVC / CPVC
PVDF
are preferred for their,
Resistance to most pretreatment chemicals
Affordability compared to stainless steel
Longevity in temperatures under 100°C
Material Engineering – Chemical Compatibility

Spray Pattern, Coverage & Optimization

Uniform and consistent spray coverage is crucial. Even minor inconsistencies in spray pattern or nozzle placement can lead to
Incomplete surface treatment
Overspray and chemical waste
Uneven coating adhesion
To address these challenges
Nozzles can be fine-tuned using adjustable mounts.
Spray angles, positions, and pressure settings can be customized.
Tunnel design may require trial-and-error adjustments to optimize spray zones—especially when treating diverse product shapes.

Nozzle Wear & Maintenance Challenges

All nozzle systems degrade over time due to wear, clogging, or chemical buildup. Worn nozzles can distort spray patterns, resulting in
Missed product zones
Off-angle sprays
Uneven treatment quality
Unfortunately, traditional systems require complete disassembly to inspect or clean. This process,
Is labor-intensive
Involves potential exposure to hazardous chemicals
Causes expensive downtime
Nozzle Wear & Maintenance Challenges

Fast Changeover with Uni-Spray Technology

To overcome these limitations, Synergy recommends Uni-Spray’s fast-change system
Nozzle tips can be snapped out and replaced instantly.
Nozzle bases stay fixed—avoiding re-alignment.
Changeover time is drastically reduced.
Tip sets are interchangeable—maintain one clean, one in use.
This system is ideal for high-throughput tunnels with hundreds or even thousands of nozzles. Replacement nozzle tips are inexpensive and can be cleaned and reused multiple times, keeping operational costs low.
Fast Changeover with Uni-Spray Technology

Best Practices for Pretreatment Spray Systems

To maximize uptime and treatment quality
Maintain two sets of nozzle tips to swap during cleaning cycles.
Perform routine inspections for spray distortion.
Use non-metallic nozzles where phosphating or acidic solutions are applied.
Align spray angle and flow to specific tunnel configurations.
A well-maintained pretreatment spray system minimizes chemical waste, ensures consistent product finish, and extends equipment life.
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