case study

Wire Manufacturer Saves On Chemicals with AutoJet Spray System

AutoJet® Modular Spray System improves worker safety and achieves payback in just weeks by reducing lubricant consumption.

A wire manufacturer was using air atomizing nozzles to apply lubricant on cable, so it could be easily pulled through conduit. However, the nozzles clogged frequently, bringing production to a standstill. In addition, the nozzles produced excessive mist which was messy, wasteful and created worker safety issues. The manufacturer turned to Spraying Systems Co. for help.

Wire manufacturing spray application drawing

After testing different spray pressures and spray set-ups, we identified which of our nozzles could deliver the desired performance without misting. Our solution included two PulsaJet® air atomizing nozzles and an AutoJet 1550+ Modular Spray System. One nozzle is positioned above the cable, and the other is below to provide complete coverage of the cable. The spray controller cycles the nozzles on and off very quickly to control the flow rate and ensure the proper volume of lubricant is applied. Flow rate adjustments are automatic and made nearly instantly when operating conditions, such as line speed, change.

The precision application of lubricant using the AutoJet Modular Spray System has solved many problems for the wire manufacturer. Messy and costly misting and overspray have been eliminated, resulting in reduced maintenance time and an increase in production time. Unscheduled downtime due to clogged nozzles has also been eliminated enabling even more production capacity. In addition, lubricant use has decreased dramatically, saving the manufacturer US$83,000 annually and offsetting the cost of the spray system in less than two months. If the value of the reduced maintenance time and increased production time are factored in, the payback period for the system is just a matter of weeks.

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AutoJet 1550+ Controller

AutoJet Model 1550+ Modular Spray System

Ensures the proper volume of lubricant is applied even when line speed changes.

PulsaJet Nozzle

PulsaJet® Automatic Nozzles

Two PulsaJet nozzles provide precise lubricant coverage with minimal misting.

Precision Spray Control Savings

Precision Spray Control (PSC)

PSC involves turning nozzles on and off very quickly to control flow rate. This cycling is so fast that the flow often appears to be constant. Pressure remains constant enabling flow rate changes without changes in spray performance

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