Dultmeier: Blog

Comprehensive Guide to Deicing Equipment: Storage Systems, Pumps, and Sprayers

There are several liquids used to effectively manage snow and ice on parking lots, streets, and highways. But effective deicing and anti-icing requires not only the right liquids, but also the proper equipment to store, transfer, and apply these solutions efficiently. 

In this guide we will cover the essential storage systems, pumps, plumbing, and sprayers needed for applying salt-brine, (sodium chloride and water), mag chloride, calcium chloride, and other de-icing liquids.

Common Deicing Liquids

Before we discuss the equipment, let's clarify the types of liquids we'll be storing and applying:

Salt Brine, Sodium Chloride (NaCl): Approx. 1.2 specific gravity (23.5-26.4 % solution).
Mag Chloride (MgCl₂): Approx. 1.34 specific gravity.
Calcium Chloride (CaCl₂): Approx. 1.33 (specific gravity).

Compatible materials:

Polypropylene
HDPE
PVC
Stainless
EPDM
Viton

De-Ice Storage

No matter what liquid deicer you are using, proper storage is essential to prevent waste and provide you with a convenient way to access and mix your batches. The type and size of your tank(s) is not the only factor to consider but also the lid, tank fittings, and plumbing. 

De-ice Storage Tanks

Poly tanks are the most popular storage solution for deicing liquids. Fiberglass and stainless steel can be used as well. All these tanks have an excellent lifespan and compatibility with the common de-icing fluids, although stainless and fiberglass are less common due to their cost. Carbon steel tanks are not recommended.

When storing de-ice or anti-ice fluid, we recommend polyethylene tanks strong enough to hold liquids that weigh up to 14 lbs. per gallon. This will cover the weight of any de-ice liquids. Common polyethylene tanks are a partially transparent “white” color with inhibitors to protect the tank from UV rays. Other color tanks can be used but the standard white tanks allow liquid level in the tank to be seen.

What size tank do I need for de-ice? 

Poly tanks come in a wide variety of sizes and shapes. The size of your tank depends a lot on your operation. However, there are some key things to consider:

If you purchase your liquids, is there a certain volume it is delivered in? Is there a quantity discount?
How much brine would you need to cover all of your territory in one application?
Do you make your own brine? If so, how fast can you make brine compared to how fast your trucks cany apply it? 
How long can your liquid be stored?

Fittings and Recirculation

Brine stratifies overtime so circulating your tanks is important. Typically, a tank will come standard with one fitting installed for load/unload. It is best to request or install multiple fittings so you can plumb a tank for recirculation.

It's best to use tanks with two 2-inch or 3-inch fittings to facilitate adequate suction & recirculation.
Polypropylene (polypropene) fittings are acceptable, but they can be easier to break, especially in cold temps. Stainless steel is recommended for its durability, despite the higher cost.

Tank Mixing Educators (TMEs)

Proper recirculation and mixing are enhanced with a tank mixing eductor. An eductor increases the agitation rate of liquid in the tank. It is both quicker and more effective than simply pumping the liquid out one tank port and into another.

Shop De-Ice Storage Tanks & Equipment

De-Ice Transfer Pumps

The next component needed for handling de-icing liquids is a transfer pump. As with the storage tanks, the best option is a pump constructed of polypropylene or stainless steel. Poly pumps are less costly, but stainless is more durable. 

In most cases a 2-inch transfer pump is adequate, depending on the specific pump and your plumbing, you can expect 80 or more gallons per minute from a 2-inch pump. A three-inch pump can be used if higher rates are desired, 250 GPM or more. 

A transfer pump for brine or other de-ice liquid should be rated to handle liquids up to a 1.4 S.G. This means that the horsepower is relatively higher than the same pump that is intended to handle water only. 

Plumbing for De-Ice Transfer Pumps

Plumbing is an aspect that you should not overlook. At the risk of sounding repetitive, the hose, pipe, valves, and fittings need to be made from materials compatible with the liquid you are using and sized properly. The size of those plumbing components is vital. Your pump may be capable of 200 GPM but your plumbing will have a huge impact on whether or not you actually can achieve that flow rate. 

The primary thing to ensure is that the suction pipe (the hose or pipe from the tank to the pump inlet) has an inner diameter at least the same size as the pump inlet. For example, a two-inch pump requires a two-inch inside diameter hose or pipe. If a hose is used, then it must be a suction hose that won’t collapse from the suction generated by the pump. 

Why is this essential? A centrifugal pump needs the right size fluid path on the suction side to avoid cavitation. Cavitation happens when the pump is starved of adequate liquid, which can damage the pump. You can learn more about centrifugal pump operation in our guide written by our in-house engineer Tom Hansen. 

Moving on to the discharge side of the pump, we still have some important guidelines to maximize your flow potential:

Use hose or pipe that won’t restrict flow, again 2-inch hose, fittings, valves for 2-inch pumps and 3-inch for 3-inch pumps. 
Note that not all “2-inch” valves have a 2-inch fluid path. Some 2-inch valves actually have only a 1-½ inch fluid path. Use full 2-inch port valves and fittings to reach the full potential of the pump.
Limit the number of restrictions in your plumbing. Elbows, valves, vertical pipe, strainers, etc. will potentially decrease your flow rate.
Install strainer after the pump to decrease chances of cavitation.

De-Ice/Anti-Ice Sprayers

When it comes to the actual machines that apply the liquid to the surface, there are several options. These different types of applicators work on the same basic principles with the primary difference between them being their size and the sophistication of the controls.

Skid Mount Sprayers

Sizes: 50, 100, 200, 300, and 500 gallons
These sprayers are designed for easy installation and removal, making them suitable for parking lots, side streets, driveways
Made to fit in pickup beds, smaller 50 and 100-gallon skids can fit in UTVs/side-by-sides. 
Basic pressure-based controls used to manually control the sprayers output. Automatic rate controllers and GPS can be incorporated if desired.

Deice Skid Options:

Larger Sprayers for Dump Trucks

For larger-scale deicing operations, dump truck-mounted sprayers are essential. These sprayers offer greater capacity and coverage, making them ideal for highways and extensive road networks. Specific models and configurations can be tailored to meet the needs of different municipalities and road maintenance departments.

The primary feature of Dultmeier Sales’ larger de-ice sprayers is the ability to “self-load”. These 1065 and 1800-gallon sprayers feature heavy-duty steel leg frames. The front legs swivel as the truck backs up and the skid slides into the truck.  

Self-Loading Sprayer Options:

De-ice Rate Control

Rate control refers to the method used to adjust the output of the sprayer. There are two primary rate control options: pressure based, and flow meter based. These systems help regulate the amount of deicer being applied, ensuring efficient use of the solution.

In a pressure-based control system, the output of the sprayer is controlled by changing the operating pressure of the sprayer. This can be done manually by adjusting a regulating valve or with an electronic regulating valve.

In a flowmeter-based system, you control the output of the sprayer with an electronic regulating valve. Typically, this is done automatically via a rate control console. Automatic rate control allows you to input your parameters and desired output per lane mile. The system will automatically adjust to maintain your application rate if it is within the flow capacity of your nozzles.

View Rate Control Options for De-Ice/Anti-Ice Sprayers

De-Ice/Anti-Ice Spray Nozzles

The nozzles used on a de-ice/anti-ice sprayer should be poly or stainless steel. Stainless steel is the most durable option. Nozzles are available in different spray patterns to accommodate various scenarios. The most common nozzles are solid stream nozzles, flat fan nozzles, and flood nozzles. 

Flat fan nozzles and flood nozzles are ideal when you want to completely cover a surface to prevent ice and snow buildup. Solid stream nozzles are used in de-ice applications. They do not cover the entire surface, rather they deliver a directed spray to penetrate ice/snow on the road. The idea is to get the liquid under the snow and ice to the road surface to melt from the bottom and allow sunlight to work on the top layer. 

Solid stream nozzles can also be effective for anti-ice or prewetting applications. When using these nozzles, there are gaps on the surface between treated areas. This method is a safety precaution in extremely cold temperatures to prevent the entire road surface from becoming a sheet of ice should the liquid solution freeze. The untreated strips provide dry, ice-free areas for drivers.

Nozzle Sizing

The rate control system is used to adjust your output, however the nozzles on the sprayer ultimately dictate the flow rate. Nozzles come in a wide range of sizes, and you must calculate the correct size based on the gallons of liquid you want to apply per lane mile, 1000 square feet, acre, etc. 

If you need help sizing your nozzles you can reach out to us with your application rate (gallons per lane mile, per 1000 sq ft, etc.) and we can help you. 

Brine Production System

An efficient brine production system is the backbone of any deicing operation. These systems are designed to produce large quantities of salt brine quickly in a cost-effective manner. Key components of a brine production system include:

High rate of production
Mechanism to ensure the correct concentration of the brine solution
Ability to clean out sand/debris easily so you can get up and running again 
Durable and reliable
Easy to operate controls

Dultmeier Sales manufactures a completely stainless steel brine production system that is extremely easy to operate and clean out. If you would like more information, please let us know, we would be glad to help!

Chemical Inductors Guide: Keys to Efficient Operation

Using a chemical inductor is an effective way to add chemicals into a mix load for a sprayer. At Dultmeier Sales, we assemble a variety of cone bottom inductor tanks with Venturi assemblies that ensure precise and efficient chemical mixing. 

In this article, we'll provide a complete guide on how chemical inductor systems work, covering everything from the principles behind the Venturi effect to the detailed operation of these systems. Whether you're new to using chemical inductors or looking to optimize your current setup, this guide will equip you with the knowledge you need.

How a Chemical Inductor Works

The Venturi effect is the driving principle behind how a chemical inductor works. The Venturi effect occurs when a fluid flows through a narrow constriction, causing its velocity to increase and its pressure to decrease, creating a low-pressure zone that can generate suction. This happens in a chemical inductor when carrier from the transfer pump flows into the inductor assembly on the bottom of the cone bottom tank.

The suction effect draws the chemical from the inductor tank into the flowing water. As the chemical mixes with the water in the Venturi nozzle, the combined solution is then transferred into the main sprayer tank or nurse tank. 

This process not only requires a specific set of components but also the correct plumbing to work effectively. Let’s examine each component and how they work together.

Chemical Inductor Components

Whether a chemical inductor system is on-board a sprayer, mounted on a tender trailer, or stationed the ground, the core components are the same: 

Venturi/bypass assembly
Cone bottom tank
Hose/plumbing
Centrifugal transfer pump

There are variations of each component depending on the specifics of the application. 

Venturi/bypass Assembly

The venturi bypass assembly is the critical piece of any chemical inductor system and essential to drawing in agrochemicals, AMS, crop oil, etc. into your final mix load. This assembly includes the venturi, bypass valve, and all appropriate plumbing fittings. When the bypass valve is closed water is forced through the venturi. Then the tank valve can be opened, and the contents of the inductor tank are drained by the suction from the venturi. 

When the bypass valve is open, water avoids the venturi and the flow rate is faster, but there is no suction to pull any intended mix liquids or chemicals from the tank. 

If you are building an chemical inductor, you can add a venturi assembly to an existing cone bottom tank. 

Inductor Tank

A cone-bottom polyethylene tank is recommended for use with agrochemicals (pesticides, herbicides, fertilizers, etc.) because it offers a wide range of chemical compatibilities. They are available in various sizes, commonly 15 to 110 gallons. The size of your inductor tank does NOT affect the rate at which chemicals are drawn into your mainline. A larger tank simply holds more product. The tank opening on the bottom of the tank, however, is important to consider. A smaller tank opening can restrict the induction rate and make your overall operation less efficient. 

The size of the tank lid also matters. For starters, a larger lid opening makes it easier to add chemicals and reduces the risk of spillage outside the inductor system. A larger 16-inch lid also allows you to use a Chem-blade jug emptying and rinsing system. With this accessory you can quickly empty chemical jugs without opening them or pouring them.

On this page you can see all our available cone bottom inductor tanks.

Plumbing/Hose

Like the tank, it is recommended that the valves and fittings are also poly. Polypropylene not only works best with agrochemicals but is also suitable for other products such as salt-brine, fertilizers, acids, and cleaning solutions.

EPDM rubber suction and discharge hoses, such as these offerings from Kanaflex (link) and TigerFlex (link) work great for the suction and discharge sides of your inductor system pump. Two- and three-inch hoses are common plumbing sizes used with inductors.

Transfer Pump

Although the pump is not an integrated part of the inductor assembly, it is a critical component required to make the system function. The inductor system must be used with a centrifugal transfer pump that is capable of pushing enough flow through the venturi to generate adequate suction. A general rule of thumb is to use a pump that matches the same size as your inductor’s plumbing. So, use a two-inch pump with a two-inch inductor system, and a three-inch pump with a three-inch inductor system.

Additionally, you’ll need to ensure the pump has adequate horsepower to move the liquid through the inductor venturi. If the pump lacks enough horsepower, the pressure may be too low, which can limit the amount of suction created. For example, when pumping water, a two-inch pump with a five-horsepower gas-engine will suffice for a two-inch inductor setup. If you have a three-inch inductor assembly, then you typically need a three-inch pump with 8+ horsepower. 

If your carrier is fertilizer or some other liquid heavier than water, you will likely need more horsepower to drive the pump. You can learn more about the pump sizes in our fertilizer transfer pump guide. 

Pump Options for Chemical Inductors:

How to Install a Chemical Inductor System

Like the pump, the plumbing setup of an inductor tank is crucial. The most important aspect is the placement of the pump in relation to the inductor system. The inductor should be positioned on the discharge side of the pump. This placement is essential because it is the flow of the water pumped through the venturi that creates the vacuum effect.

Using the right hose and fittings is vital to proper plumbing for inductor tanks. It is important to match the inside diameter of the hose and fittings with that of the pump ports. For example, a two-inch inductor system should have two-inch plumbing throughout. Hose, fittings, pumps, valves, venturi, etc., likewise should be two-inch inside diameter. 

Any restriction in flow can disrupt the system’s effectiveness. Eliminating as many bends or slowdowns within your plumbing will ensure your flow rate remains strong enough to draw product down through the venturi. Try to limit the length of hose on the suction and discharge sides of the pump and avoid using too many 90-degree elbows and strainers. 

Furthermore, where you place your pump in relation to your system’s water supply tank and inductor can affect the performance of the overall system. You will want to keep the pump as close to the water tank as possible, because the shorter the distance the water must travel to the pump, the less pressure loss you'll have and the better your pump will perform. Proper pump placement means a more reliable and effective chemical mixing process.

Since plumbing plays such a large part in the overall performance of your inductor system, it’s important to consider how every part of the system works in tandem with one another. As referenced above, the hoses throughout your system need to be the proper size to the inductor unit.

This is also true for the inlet of the pump as well. A two-inch pump needs to be fed with at least a two-inch hose, a three-inch pump with three-inch hose, and so on. You do not want to starve the pump or run it dry. This will result in seal failure in addition to the inductor not functioning properly. 

Chemical Inductor Plumbing Diagram

Keys to Remember When Plumbing Your Inductor Tank:

Venturi Assembly: Must be on the discharge side of the pump.
Hose and Fittings: Match the inside diameter of your pump inlet and inductor.
Flow Optimization: Avoid 90-degree elbows and pumping great distances 100 ft +
Pump Placement: Keep the pump close to the supply tank for efficient operation.
Pump Operation: Never run the pump dry and ensure supply tank valves are fully open.

Using an Inductor Tank Without a Venturi Assembly

While most chemical inductors utilize a venturi assembly, you can use a cone-bottom tank without a venturi assembly by placing it on the suction side of the pump. However, this setup requires careful consideration to avoid starving the pump of liquid, which can cause pump cavitation and damage.

One of the risks by positioning the inductor tank upstream of the pump is the possibility of air bubbles entering the system. When you open the tank valve, liquid in the tank is drawn into your carrier line, but you are also introducing air into the line. Air bubbles passing through the pump can lead to damage over time. A large amount of air can starve the pump and lead to seal failure rather quickly.

Placing the inductor on the suction side of the pump also means you have chemicals passing through your pump rather than just water. Although many pumps are compatible with agrochemicals, this will inevitably lead to more wear and tear compared to water alone.

You also have the risk of contaminating your water supply or water tank, though using a check valve between the water tank/supply and the cone bottom tank to prevent chemical back flow can likely eliminate this contamination risk.

Conclusion

When set up properly, inductor tank systems are a highly effective way to introduce multiple chemicals or fertilizers into your spraying application. Following these guidelines will help you build or improve your current set-up, ensuring efficient and reliable chemical induction for your sprayer.

Dultmeier Sales offers a complete inductor systems in poly and stainless steel as well as all the components needed to operate them:

Complete Banjo Manifold Flange Guide: Fittings, Clamps, & Gasket Sizing

Banjo Corporation has a long history of creating innovative products. One of their biggest innovations came when they introduced manifold flange plumbing fittings into the agricultural spraying and industrial liquid handling industries. These flange fittings are designed to be used in place of threaded fittings. This advancement makes it much simpler and faster to assemble, disassemble, and re-plumb systems without the hassle of dealing with threaded connections.

With manifold clamps, you can quickly remove and inspect sprayer components like flow meters and strainers without disassembling the entire system. This is a stark contrast to threaded systems where you must start at one end and disassemble parts until you reach the desired component.

Anyone who has ever replaced a cracked strainer or valve knows how difficult and time consuming it can be to remove several hoses and fittings to replace your broken part, and then reassemble the entire thing. With manifold flanges the component can be removed and replaced by just removing the flange clamps. 

This guide will cover everything you might need to know when it comes to using manifold flanges, from the fittings themselves to how to correctly size a gasket for Banjo manifold flanges.

Understanding Manifold Flanges

A Banjo manifold flange is a type of connection used in sprayer systems to join various components such as pumps, valves, and hoses. These flanges are available in different sizes, and two flanges of the same size are connected with a manifold flange clamp. A gasket fits in between the two flanges to create a secure, leak-proof seal.

Banjo manifold flanges have been so widely adopted in the market that besides other different manifold fittings, these flanges have been integrated into the designs of pump housings, valves, strainers, flow meters, and more. 

For example, Banjo, Hypro, and John Blue offer many pumps with manifold flange connections in place of pipe thread. There are also line strainers that have flanged ports in place of threaded ports. To help with the installation of manifold flanges, there are also U-bolts specifically designed for the various manifold fitting sizes.

Other manufacturers have made compatible flanges that will work with the Banjo manifold fittings, but the key is making sure that you match up the correct corresponding sizes. 

Sizing Manifold Flanges

Banjo manifold flange fittings come in four standard sizes: 1-inch, 1.5-inch (also referred to as a 2-inch standard port), 2-inch full port, and 3-inch. Understanding their inside diameter is crucial for determining flow capacity and ensuring effective use of these fittings. Despite the varying naming conventions across different manufacturers like Banjo, Hypro, and TeeJet, compatibility is straightforward if the correct sizes are identified.

A common source of confusion is that Banjo labels their 1.5-inch inside diameter flange as a 2-inch “standard port” flange, while their 2-inch inside diameter flange is called a 2-inch “full port” flange. Banjo uses M200 and M220 as the part numbers for their 2-inch standard port and 2-inch full port flanges. Hypro refers to their 1.5-inch diameter flange fittings as 150 series flanges. This means a Hypro 150 series clamp will fit a Banjo M200 series flange. The same is true for the gaskets.

These part numbering systems are confusing. This charts below shows the different flange sizes and what part number from each manufacturer will work with each size.

Compatible Part Numbers for Each Manifold Flange Size

Manifold Flange Size	Inside Diameter Measurement	Banjo Part Number	Hypro Part Number	TeeJet Part Number
1-inch	1-inch	M100	100	50
1.5-inches (2-inch standard port)	1.5-inches	M200	150	75
2-inch full port	2-inches	M220	200	na
3-inch	3-inches	M300	300	na

Compatible Manifold Flange Gasket Part Numbers 

Manifold Flange Size	Banjo	Banjo Viton	Banjo Skirted Gaskets	Hypro EPDM	Hypro Viton
1-inch	TKM100G	TKM100GV	TKM102G	HYUFG0100E	HYUFG0100V
1.5-inches (2-inch standard port)	TKM201G	TKM150GV	TKM202G	HYUFG0150E	HYUFG0150V
2-inch full port	TKM221G	TKM200GV	TKM222G	HYUFG0200E	HYUFG0200V
3-inch	TKM301G	TKM300GV	TKM302G	HYUFG0300E	HYUFG0300V

Skirted Gaskets

Both Hypro and Banjo offer “skirted” gaskets. These gaskets are designed to stay in place when installed in a manifold. This allows you to install flange clamps without worrying if the gasket is seated correctly. 

Shop Manifold Flange Gaskets

Compatible Clamps for Each Manifold Flange Size

Clamp Part Numbers	Standard Clamp	T-Bolt Clamps	Bolted Heavy Duty Clamps	Hypro Clamp
1-inch	FC100	na	na	HYC100
1.5-inches (2-inch standard port)	FC200	na	na	HYC150
2-inch full port	FC220	TKFC220TB	TKFC220B	HYC200
3-inch	FC300	TKTC300TB	TKFC300B	HYC300

Banjo offers three different types of clamps for their manifold flanges. The first type is a standard worm gear clamp. This is the most economical and works well when there isn’t too much weight or movement from the adjacent components. 

T-bolt flange clamps are another clamp option, and these clamps are ideal for use with larger, heavier hoses or pipes. Finally, the heavy-duty bolted clamp is best suited for applications where significant weight may be applied to the clamp.

For example, if you have a 3-inch hose connected to a manifold flange outlet on a pump and you will move the hose around, it can put strain on the flange clamp. The heavy duty bolted clamp is the best option in this case as it is designed to withstand this frequent stress, ensuring the integrity of your connections.

Hypro manifold flange clamps are made of poly, and they are also T-bolt style clamps. The big advantage of the Hypro clamp, however, is the hinged design. This makes it even easier to get the clamp around the flange after your fittings are in place. 

You can view all the different flange clamps and gaskets on this page.

Different Types of Flange Fittings

The manifold flange fittings are primarily available in polypropylene, but some stainless-steel fittings are also available. There is a poly manifold fitting to replace just about any standard pipe thread plumbing fitting you can think of, though some of the most common are:

Elbows
Couplings
lugs/Caps
Hose Barbs
Reducers
Crosses
Tees

You can see the full selection of poly manifold fittings here. 

Final Word

Flange fittings have been incorporated into about every type of sprayer component used today, from pumps and valves to flow meters and strainers.

Banjo Corporation's manifold flange fittings simplify assembly, disassembly, and re-plumbing in ag spraying and industrial systems. These fittings are compatible with many other manufacturers components, and so long as you are comfortable identifying the correct corresponding size needed, you’re unlikely to encounter many issues using these flange fittings. If you have any questions about manifold flange fittings, please contact us. 

Comprehensive Guide to Cam-Lock Couplers: Selecting the Right Fitting for Your Needs

Cam lever couplings, or cam and groove couplings, are essential plumbing fittings used widely in agricultural and industrial liquid handling. These couplings provide an efficient means of quickly connecting and disconnecting hoses from tanks, tanker trailers, sprayers, pumps, and more.

While manufacturers typically refer to these fittings as cam-lever or cam and groove couplings, they are also known by other names such as cam locks (couplers), cam levers, quick couplers, and lever locks.

Despite the varied terminology, these terms generally refer to the same type of fitting – though not every camlock coupler works for every application. In this article, we’ll detail the key features and differences of various cam and groove couplings to help you decide which style of fitting works best for your unique needs.

Types of Cam-Lock Couplers

Nomenclature is important when discussing cam-lock couplers (or any coupling device for that matter). Understanding the different jargon used to refer to specific fittings ensures that you identify the correct item you need.

There are six main types of cam-lever couplings, each made from different combinations of male adapters (male ends) and female couplers (female ends) with either male pipe thread (MPT), female pipe thread (FPT), or hose shank connections. The types are labeled A, B, C, D, E, and F depending on the end connection type they feature and generally range in sizes from ¾ to 6 inches. There are also dust caps (DC) and dust plugs (DP) available for each size.

Part A

Male adapter with female pipe thread, typically National pipe thread (NPT).

Part B

Female coupler with male pipe thread (MPT).

Part C

Female coupler with a hose shank.

Part D

Female coupler with female pipe thread.

Part E

Male adapter with a hose shank.

Part F

Male adapter with male pipe thread.

Dust Plug (DP)

Fits into the female coupler to prevent dust and debris entry.

Dust Cap, Female Coupler (DC)

Fits onto the male adapter to prevent dust and debris entry.

Non-Standard Cam Lever Fittings

Beyond these standard fittings, there are additional non-standard types available for specific applications.

Jump Sizes, for transitioning between two sizes of cam couplings
Elbows
Flange Ends
Couplers with Gauge Ports
Locking couplers
Swivels

Even these specialty camlock fittings aren’t the last of the available options. You can shop all our cam lever couplings and accessories , and if you are looking for something specific, please let us know.

Materials and Compatibility

Cam and groove couplings are manufactured in a variety of materials including stainless steel, aluminum, polypropylene, nylon, and more.

The couplers (female) have a rubber gasket inside to seal up the connection. There are different gasket materials available as well to offer compatibility with different types of liquids:

EPDM: Agrochemicals, fertilizers, salt brines, DEF, acetone, acetic acid
Viton: Acids, bleach, agrochemicals, fertilizers, salt brine, DEF, xylene, biofuels
Buna: Fuels, oil, hydraulic fluid

*These are general guidelines. Always check compatibility before selecting materials.

Common Cam-Lock Coupler Applications

A cam-lock coupling offers users a way to couple and uncouple hoses from tanks, trailers, pumps, etc., while still providing a secure seal. The couplers are suitable for a variety of applications including but not limited to:

Agriculture
De-icing
DEF (Diesel Exhaust Fluid)
Petroleum
Mining
Manufacturing
General Water Transfer
Waste Management
Brewing & Distilling
Industrial Cleaning

Connecting and Disconnecting Cam-Lock Fittings

Connecting cam-lock fittings is straightforward but a little difficult to describe in words alone. This video provides a live look at the simple process:

Insert the Adapter: The adapter is the “male” end. You insert this end into the coupler side (“female”) with the cams/levers in the open position or levers “up”.
Lock the Levers: Push the levers down to the closed position to lock the connection.
Disconnect: Lift the cam arms/levers to the open position and pull the adapter out.

Are Cam-Lock Couplings Interchangeable?

One key advantage of cam-lock couplings is their standardized sizing. Cam-lever couplings are manufactured according to a standard, so regardless of the manufacturer or material, they will connect seamlessly. For instance, a polypropylene male end will fit a stainless-steel female coupler so long as they are both the same size.

Preventing Leaks and Ensuring Security

Cam-lock couplings are designed to seal completely when the levers are properly closed. If there are leaks, it may be due to improper connection, worn-out gaskets, or damage to the coupling itself.

Installing cam couplings vertically or at a 45-degree angle can help reduce wear on the gasket. This takes the weight off the fitting, so it is not pinching the gasket on the bottom of the coupler. If needed, though, replacement gaskets and shims are available.

Camlock Coupler Accessories

Safety Bumps: These “bumps” replace standard cam-lock dust plugs and caps. They feature a handle for convenience, and they provide protection to the cam-lock coupler in case it is dropped.
Safety Locks: To prevent accidental opening of the levers, you can use safety locks. These accessories help secure the levers and prevent spills or leaks in demanding industrial environments. Another option is to use locking-style lever couplings which feature a locking mechanism built into the camlock arm.
Extra Thick Gaskets: These cam-lock coupler gaskets are thicker than the standard gaskets and provide a tighter seal and extend the life of your gaskets.
Shims: A shim can be installed under the cam-lock gasket. This helps create a seal when the couplers or gaskets get worn.

Recommended Cam-lock/Lever-Coupling Brands

Banjo Corporation is a leading manufacturer of cam-lock couplers. They specialize in injection molded glass filled polypropylene fittings and manufacture extremely durable cam-lock couplings in the USA.
Dixon has an extensive selection of cam-lever couplings. They offer different styles, accessories, sizes, materials, and other features.
Kuriyama is a leading manufacturer of industrial and agricultural hose. They also offer a wide array of quality stainless-steel and aluminum couplers.
Green Leaf cam-lever couplings feature an innovative locking design. The levers are locked in place automatically and you simply push the buttons on each lever to release.

Before You Go

Cam-lock fittings follow industry standards, ensuring compatibility across different sizes and materials. They offer a versatile and reliable solution for fluid transfer in various industries. By selecting the right type and material for your application, you can maintain a secure and efficient connection, prolonging the life of your fittings.

For more information or to purchase cam-lock couplers, contact our sales team.

275 Gallon IBC Cage Tank FAQs

Intermediate bulk containers (IBCs) are common chemical containers used in a variety of industries. Also known as “cage tanks”, IBCs are available in several sizes, though one of the most common is the 275-gallon cage tank. The availability and chemical compatibility of these 275-gallon cage tanks makes them an obvious low-cost option for several small-scale chemical-handling applications.

275 Gallon IBC/Cage Tank 

If you are looking at using one an IBC to store or transfer chemicals, you’ll first need details on the tank’s dimensions, lid size, and how to connect to the tank. Understanding these specifications is crucial for ensuring the compatibility and safety of your chemical storage and transfer operations. This guide will walk you through the essential aspects of these common 275-gallon cage tanks.

275 Gallon Cage Tank Dimensions

Standard dimensions of a 275-gallon tote:

Height: 46 inches
Width: 48 inches
Depth: 40 inches

These dimensions can vary slightly depending on the manufacturer and the specific design of the tote, but they generally fall within these measurements. 

IBC Cage Tank Features

IBC cage tanks have a metal cage that encases a high-density polyethylene (HDPE) plastic tank. The cage is required, as it protects the tank from any equipment that may bump into it and helps maintain the integrity of the tank walls while filled. 

When empty, you can stack these tanks on top of one another, although it is not advised to stack more than three. Even with a cage, IBC totes are not strong enough to stack when they have liquid inside. The base of the tank, a galvanized pallet integrated in the cage frame, is designed to be moved using standard pallet jacks and forklifts.

Empty Weight of 275 Gallon IBC/Cage Tank

Depending on the manufacturer these 275-gallon cage tanks can weigh between150-170 lbs. pounds when empty.  The weight varies slightly due to small variations in the cage design, type of outlet valve, and number of lids/vents on the top of the tank.

Rated Weight per Gallon

IBC shuttles have a 1.9 S.G. rating. This means they are rated for liquids that weigh up to about 15 pounds per gallon. For reference, water is 8.345 lbs./gal.

IBC Tank Lids 

The 275-gallon IBC tanks sold at Dultmeier Sales feature one six-inch lid positioned on the top center of the tank. The lid features a vent in the center. The vent is essential to prevent the collapse of the tank when using a pump to withdraw liquid. There are many different lid variations that can accommodate different types of pipe thread or Micro Matic valves. 

There are several types of lids options. They feature single ports, multiple ports, vents, etc.:

There are also a wide range of cage tank accessories to accommodate different applications:

NPT Adapters
Butress Adapters
RPV Valves for Micro Matic Couplers

You can view more IBC tote accessories here.

Tamper Evident 

The lid, vent, and the outlet valve also feature spots for tamper evident seals to be installed. These seals lock the lid in place and ensure that a the liquid contents are not tampered with or compromised during use or transport from place to place. The tank lid cannot be opened without the wire seal being broken.

How to connect to a 275 Gallon Cage Tank

The outlet at the bottom of the standard IBC cage tank is generally a 2-inch valve. The valve will typically feature a built-in check-valve that allows liquid to flow out of the tank but will not allow anything to be pumped into it. This tank outlet will often feature a 2-inch male cam-lock adapter, and the end of this adapter is threaded for a dust cap. It is advised that this thread not be used to attach any accessories/pumps, use only for the dust cap.

If you need to connect a hose to a standard IBC cage tank you just need a 2-inch female cam-lock coupler. This could be a part C, part B, or part D coupling. If you are not familiar with the different cam-lock coupler types, you can see a complete explanation in this guide to cam-lock couplers.   

Common Uses for 275 Gallon IBC/Cage Tanks

The uses for IBC containers are many and varied. Some of the most common liquids and applications include, but are not limited to:

Water Collection
Agricultural Chemicals & Fertilizer
DEF
Waste oil
Brine
Cleaning products
Aquaponics and Hydroponics
Industrial Processes
Brewing and Winemaking
Construction

Dultmeier Sales keeps 275-Gallon IBC Tanks on hand with all the accessories you might need, including pumps for handling a wide variety of different liquids. Contact our sales team for more information, availability, and freight estimates on 275 Gallon IBC Cage Tanks.

High-Pressure Cleaning: Volume vs Pressure

When it comes to using a pressure washer for cleaning, the debate often centers around two critical metrics: volume and pressure. Whether you are using a power washer to clean cars, trailers, concrete, or sewer lines, both volume and pressure play significant roles in the effectiveness of your cleaning efforts.

Higher flow rates are associated with more efficient rinsing and moving of dirt/debris. High-pressure is important when you need to cut through grime or film on a surface. However, the most important thing to consider is the specific job requirements and then determine the cleaning method that will be most effective.

There are several factors. Let's dive into the details to understand which is more important and how to balance these two metrics for optimal cleaning.

What’s More Important for Cleaning: Volume or Pressure? 

It is difficult to say whether you should prioritize volume or pressure without knowing the specific application. The needs of cleaning tasks vary so the answer will differ depending on the nature of your job. There are several cleaning tasks where flow rate is often more critical than PSI, but there are also tasks where higher pressures should be prioritized.

Volume and pressure provide different benefits in the cleaning process. Volume is most beneficial when there is a large amount of debris which needs to be rinsed away. This is commonly needed when cleaning out stock trailers that contain manure or rinsing out tanks that had sediment left behind.

To illustrate the effect of larger volumes of water when cleaning, consider a flat surface with a small pile of dirt spilled on it. If you were to pour a few ounces of water onto the pile of dirt, you would have very little cleaning effect. In fact, this would likely just make things worse. However, if you were to pour a five-gallon bucket of water on the pile it would have a drastic effect on the dirt. The more water used the more it will rinse and push away the dirt.

Pressure is also vital, especially in scenarios requiring concentrated cleaning. Pressure is most beneficial when the cleaning process involves material that is difficult to remove. This is typically needed in scenarios such as preparing surfaces for painting which often requires removal of old paint or grime.

Let’s look at some specific examples:

Tank Washout

Requirement: High flow, medium pressure

Reasoning: The goal of tank washout is to move and remove material efficiently. This task requires a large volume of water (high flow) to carry away debris and residues. The pressure does not need to be extremely high, as the primary objective is volume movement rather than breaking up tough deposits.

This video shows high-flow, medium pressure cleaning in action:

Concrete Cleaning

Requirement: Low flow, high pressure

Reasoning: Cleaning concrete surfaces, such as driveways or industrial floors, requires breaking up tough, stuck-on dirt, and stains. This task benefits from high pressure (3,000 to 4,000 psi) to effectively dislodge and remove stubborn grime, while a moderate flow rate (3-4 gallons per minute) may be sufficient to carry the debris away.

Cleaning Units: A Practical Comparison Tool

To compare the effectiveness of different pressure washers, we can combine the flow rate and pressure output of each using a metric known as cleaning units. This is calculated as:

Cleaning Units = Pressure (PSI) × Flow (GPM)

Example 1:

Pressure washer with 4 GPM and 3,000 psi
Cleaning units: 4 × 3,000 = 12,000

Example 2:

Pressure washer with 3.5 GPM and 3,500 psi
Cleaning units: 3.5 × 3,500 = 12,250

These examples show that despite different flow rates and pressures, the cleaning units are quite comparable (12,000 vs. 12,250). Another important aspect of comparing pressure washer is the horsepower (HP) needed to operate the pressure washer. This is a topic that is covered in this guide to horsepower sizing.

Compare Pressure Washer Options Here

Understanding Flow Rate & Pressure 

Flow Rate measures the flow rate of water coming out of your pressure washer. Essentially, it indicates how much water is being used per minute. This is typically measured in GPM (Gallons Per Minute). A higher GPM means more water flow, which can help rinse away dirt and debris more effectively.

Pros of High Flow

Faster cleaning by covering a larger area with more water.
More effective rinsing action, removing debris efficiently.

Cons of High Flow

Higher cost for machines with higher GPM ratings.

Pressure (Pounds per Square Inch) measures the pressure of the water coming out of the nozzle. Higher PSI means more forceful water, which is crucial for breaking up tough grime, stains, and dirt on surfaces. PSI helps in dislodging dirt but may not be as effective alone without sufficient water flow to wash the dirt away.

Pros of High Pressure

Better at breaking up tough dirt and grime.

Cons of High Pressure

Splatter
inefficiency 
may damage delicate surfaces

The Relationship Between GPM, PSI, & Nozzle Size

It’s important to note that GPM, PSI, and your nozzle size are interrelated. The relationship between pressure and flow rate in a pressure washer system is inversely proportional when other factors like the nozzle size and pump capacity remain constant:

Increasing Flow Rate (by enlarging the nozzle or enhancing pump capacity) leads to a decrease in Pressure.
Decreasing Flow Rate (by reducing the nozzle size or lowering pump capacity) leads to an increase in Pressure.

Understanding this relationship is crucial for optimizing the performance of a pressure washer to match the specific cleaning tasks and ensuring efficient and effective cleaning results.

Balancing GPM and PSI: Spray Nozzle Orifice Size Matters

If we compare two machines that produce 3000 PSI but one delivers 8 GPM and the other only 2 GPM, the one with the higher flow will provide more efficiency. This is provided that you use the proper size spray gun and nozzle to accommodate the flow of the machine. 

While both a 2 GPM and an 8 GPM machine can produce the same PSI, the water output volume makes a significant difference in cleaning efficiency. The orifice size in the nozzle adjusts to maintain the PSI:

A 2 GPM machine requires a smaller orifice to build up pressure with less water.
An 8 GPM machine has a larger orifice, allowing more water to flow while maintaining the same pressure.

This means that an 8 GPM machine can clean surfaces much faster and more thoroughly than a 2 GPM machine, even if both are rated at 3000 PSI.

What to Consider When Selecting a Pressure Washer:

Focus more on GPM for general cleaning efficiency.
Ensure PSI is adequate for the types of surfaces and dirt being cleaned.
Higher GPM models are ideal for professionals and large cleaning tasks.
Higher GPM means faster cleaning times and better rinsing.
Adequate PSI ensures dirt and grime are effectively broken up.

Shop High-Volume Pressure Washer Units:

Conclusion

When choosing a pressure washer, it's essential to consider both GPM and PSI. However, for most cleaning tasks, prioritizing GPM over PSI can lead to faster, more efficient cleaning. By understanding and adjusting these metrics, you can optimize your pressure washer’s performance for any cleaning job.

Buyer's Guide for Selecting the Best Nozzle for Fungicides

No two growing seasons are the same. Every year brings unique fluctuations in temperature, varying amounts of precipitation, and different pests which thrive in these various conditions. These many variables make the choice of when to apply fungicides – and which one you should use – a complex decision. Expert guidance is often required to ensure you get the most out of fungicide treatment on your crops. 

The type of sprayer nozzle you use to apply fungicides is just as important as the choice of fungicide itself. The right type of nozzle can significantly enhance the effectiveness of your application, thereby reducing the likelihood of reapplication or subpar results. While I cannot help you decide the best time to apply, I can help you identify the sprayer nozzles that are excellent for use with fungicides.

Understanding Nozzle Requirements for Fungicide Application

Nozzles play a crucial role in how successful a fungicide treatment can be, including determining the amount of chemical applied, the uniformity of the application, and the potential drift. Different nozzles produce varying droplet size ranges and spray angles. These attributes provide benefits like improved drift reduction, greater canopy penetration, and more precise spray direction. 

In this guide we are going to be referring to the droplet size classification and spray patterns of several different nozzles. If you are not familiar with how spray nozzle droplets are classified, be sure to read this guide to nozzle droplets first. 

As with other spray nozzle applications, the nozzle type you need will depend on your specific fungicide, target pest, crop type, etc. Spray nozzles are not specifically designed for a certain pesticide or fungicide. Instead, they are manufactured to provide specific performance traits. These include GPM, droplet size, spray pattern shape, spray angles, etc. 

Finding the best nozzle requires examining the mode of action (or the means a fungicide uses to eliminate the pest) of fungicide you are using and then identifying a nozzle that can most effectively deliver the liquid to the target surface. It is recommended to always consult an agronomist or local crop care specialist when choosing a fungicide for your unique needs. Here, though, are general guidelines for different types of fungicides:

Contact Fungicides

Contact fungicides require thorough coverage of the leaf surfaces to be effective. These fungicides stay on the surface of the foliage and need to cover the entire leaf area to prevent or control the disease. Therefore, it is essential to use nozzles that produce fine to medium droplets. Fine droplets provide a larger number of droplets per unit area, enhancing the coverage and ensuring that all leaf surfaces are uniformly coated.

Systemic Fungicides

Systemic fungicides need to reach the lower canopy or soil surface, where they can be absorbed by the plant and translocated to the site of action. These fungicides are typically taken up by the roots, making it important to ensure that the droplets can penetrate the plant canopy and reach these areas. Coarse to very coarse droplets are suitable for systemic fungicides as they are less likely to drift and can more effectively deposit the fungicide at the base of the plant.

Recommended Spray Nozzles for Fungicides

When you have identified all the aspects of your scenario, fungicide type, crop type, etc., you can then look at the various nozzles that are recommended for fungicides. Nozzle manufacturers can provide guidance on which of their nozzles will produce the needed coverage and droplet size.

Wilger Spray Nozzles for Fungicides

To provide expert insight into the effectiveness of spray applications, I reached out to Chris Bartel from Wilger Inc. Chris shared his expertise and emphasized the importance of achieving optimal coverage in fungicide and insecticide applications.

“The goal of a fungicide/insecticide contact application is to have complete coverage in the application zone. The more droplets that are in the spray application, the more effective it will be in providing complete coverage. This is done with higher gallons per acre rates coupled with nozzles that are more focused on providing coverage than drift control with a medium or coarse droplet spectrum.”

Chris continued, noting the different options operators have for achieving the best coverage possible. “Combining nozzles in a double down (2 nozzles side-by-side in a straight down orientation) or dual angle (nozzles oriented at an angle forward and backward) application can also allow for better coverage in dense canopy applications by combining tips with different droplet spectrums to get deeper canopy penetration and complete coverage of the entire plant top to bottom.”

Wilger offers a wide range of spray nozzles, but these two series they offer provide optimal performance when fungicides are involved.

ER Series

Droplet Size: Fine to Extremely Coarse
Excellent for Fungicides
Provides fine droplet for excellent coverage in applications where drift is not a concern.

Wilger ER Series Nozzles

SR Series

Droplet Size: Fine to Ultra Coarse
Excellent for contact fungicides
Provides about 50% fewer driftable fines compared to the ER series.

Greenleaf Technologies Spray Nozzles for Fungicides

"Fungicide application is coverage critical, so we would recommend using a DualFan nozzle of some sort” said Clay DeGruy, a spray nozzle specialist with Greenleaf Technologies. Clay’s statement reinforces the importance of coverage in fungicide applications, and Greenleaf offers several nozzles that fit that objective.

TurboDrop XL (TDXL), Turbo Drop XL-D (TDXL-D)

Droplet Size: Medium to Extremely Coarse (Very Coarse to Ultra Coarse produced by TDXL-D)
Excellent with contact fungicides and systemic fungicides
Advantages: Designed for higher pressures (60-120 psi), providing excellent drift control and coverage. Ideal for penetrating dense crop canopies.

AirMix (AM)

Droplet Size: Medium to Coarse
Excellent with contact and systemic fungicides
Advantages: Operates effectively at lower pressures (15-30 psi), reduces drift while maintaining good coverage.

TurboDrop DualFan (TADF)

Droplet Size: Fine to Extremely Coarse
Excellent for Systemic and Contact Fungicides
Advantages: Suitable for a wide pressure range (30-120 psi), featuring dual spray fans for improved coverage and reduced drift.

Greenleaf DualFan Nozzle

TeeJet Spray Nozzles for Fungicides

Turbo TeeJet Wide Angle Flat Spray Tips (TT)

Droplet Size: Fine to Coarse
Excellent for contact fungicides and very good for systemic fungicides.
Advantages: Fine droplets provide best coverage in conditions where drift is not a concern.

Extended-Range Flat-Fan Nozzles (XR)

Droplet Size: Fine to Coarse
Excellent for contact fungicides and good for systemic fungicides
Advantages: Provides excellent spray distribution over a wide range of pressures, making them versatile and effective for various applications.

Turbo TwinJet (TTJ60)

Droplet Size: Medium to Very Coarse
Excellent for contact fungicides, very good for systemic. Superior leaf coverage and canopy penetration
Advantages: Dual spray fans provide two passes in one application, hitting the target from two different spray angles increasing the chances of reaching plant surface.

Turbo TwinJet Nozzle

AI Turbo TwinJet (AITTJ)

Droplet Size: Medium to Ultra Coarse
Excellent for systemic fungicides. Very good for contact fungicides
Advantages: Dual fans to provide increased number droplets and coverage while still creating coarser droplets to mitigate drift.

AI3070 Air-Induction Dual Pattern 

Droplet Size: Medium to Ultra Coarse
Excellent for fungicide application in wheat and other cereal grains
Advantages: The 30° forward-tilted spray effectively penetrates dense crop canopies, while the 70° backward-tilted spray effectively targets the spike or head of grain.

Hypro Spray Nozzles for Fungicide

Guardian Spray Nozzles

Droplet Size: Fine to Very Coarse
Excellent for fungicide
Advantages: Wide 120-degree pattern and tilted fan allows user to spray forward or rearward to suit your application.

GuardianAir Twin Nozzles

Droplet Size: Medium to Very Coarse
Excellent for fungicide application
Advantages: More droplets per gallon produced by dual fan pattern.

Keys to Remember When Selecting Spray Nozzles for Fungicides

Whenever you are selecting a spray nozzle, it is important to follow the label on the product you are using. Also, there may be more than one type of nozzle that can give you excellent results. The key is to consider the needs of your specific application and then identify a nozzle that will provide the necessary spray pattern, droplet size, etc.  Whatever type of fungicide you decide to apply you know you can identify a nozzle that will give you effective results.

For help finding or sizing a sprayer nozzle contact our sales team. You can also read our other resources on sprayer nozzles: 

Tech Ag & Industrial Sales

Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.

Learn More About Author

Understanding Droplet Sizes Produced by Agricultural Sprayer Nozzles

Despite all the expensive and sophisticated components on a sprayer, the tiny nozzles on your boom are still the number one factor impacting your sprayer's performance. You may have a high-volume pump, state of the art GPS guidance system, and stainless-steel boom, but the nozzle ultimately has the greatest influence on a sprayer’s effectiveness.

One of the main factors a sprayer nozzle dictates is the droplet size that is dispersed over the target. Droplet size is important because it affects several aspects:

Drift: Larger droplets are less prone to drifting to areas you don’t want sprayed, such as your neighbor’s field 
Coverage: Smaller droplets can typically provide better coverage, giving you the best chance to eliminate targeted weeds or pests
Penetration: Droplet size affects ability to penetrate dense canopies, ensuring that pests or weeds are effectively targeted
Adherence: Smaller droplets tend to adhere better to plant surfaces
Evaporation: Affects amount of liquid deposited on the target area rather than being lost to the surrounding environment or evaporation

When selecting a nozzle for your sprayer, it is vital to not only consider the droplet size but also the entire droplet size range a nozzle produces. In the rest of this guide, we will look at what droplet size means, what affects droplet size, and how different nozzles compare.  

Understanding Droplet Size

Droplet size refers to how big each droplet of sprayed liquid is. Their size is measured in microns. A micron (1 µm) is a very tiny unit equal to 1/25,000 of an inch or about 0.001 millimeters. So, when we talk about droplet size, we’re talking about the diameter, or width, of each droplet.

Just like sprayer nozzle sizes, droplet size classification is defined by international standards (ISO 25358 and ASABE S572.3). This classification system divides droplet sizes into specific categories so different nozzle types and brands can be compared. The categories are as follows:

Droplet Size	Abbreviation	Color Code	Approx Micron Range
Extremely Fine	XF	Purple	Less than 60
Very Fine	VF	Red	60 to 145
Fine	F	Orange	146 to 225
Medium	M	Yellow	226 to 325
Coarse	C	Blue	326 to 400
Very Coarse	VC	Green	401 to 500
Extremely Coarse	XC	White	501 to 650
Ultra Coarse	UC	Black	Greater than 650

These categories help in identifying and selecting the appropriate droplet size for different agricultural spraying applications. Each category is defined by specific droplet size ranges measured in microns (µm).

Spray nozzle charts show the droplet size produced by a nozzle at various pressures. It will be displayed with the abbreviation and color code shown above. It is important to note that this indicates the size of the majority of the droplets and not all the droplets dispersed by that particular nozzle. 

Example: If a nozzle chart indicates that a sprayer tip will produce Coarse (C) droplets, that nozzle can still produce finer droplets, but the majority will be Coarse. The image below shows the droplet size produced by the different sizes of a nozzle at various pressures:

You can see in the chart that a red nozzle (04 size) will most often produce Medium (M) droplets within the pressure range of 20-40 PSI. If the operating pressure is below 20 PSI, however, then the size of droplets produced changes from Medium to Coarse (C). Conversely, if the pressure increases to 60 PSI the majority of the droplets will be Fine (F). 

How Droplet Size Impacts Spray Quality

Drift: When it comes to spraying, drift is a major concern. Not only does drift reduce the effectiveness of your spray, but it can pose a potential threat to neighboring crops, waterways, wildlife, and people. Larger droplets are less prone to drift because they are heavier and fall more directly onto the target. This means they are less likely to be carried away by the wind. ensuring that your herbicide lands where it’s intended and not on neighboring crops or non-spray areas.

Another important concept to understand when discussing drift and considering nozzle selection is driftable fines. These are the very small droplets that are extremely susceptible to drift. Any droplet under 150 microns (µm) is considered a draftable fine. Nozzle literature typically indicates the percentage of the droplets produced by that specific nozzle that fall into the category of driftable fines.  

Here are two videos illustrating the importance of selecting the proper sprayer nozzle and the effect that droplet size has on drift reduction:

You can see there is a clear difference between the amount of liquid affected by wind, highlighting the importance of nozzle selection.

Coverage: Smaller droplets generally provide better coverage. They can spread more evenly over the target surface, which is essential for effective pest and weed control. However, this also means they are more susceptible to drift, so it’s a balancing act to achieve the right droplet size for your specific needs.

As the videos above show, even though smaller droplets provide better coverage in ideal conditions, you can potentially get better coverage from larger droplets because more liquid is getting to the target.

Penetration: Droplet size significantly affects the ability to penetrate dense canopies. Smaller droplets can move more easily through thick foliage, ensuring that the herbicide reaches the inner parts of the plant where pests or weeds might be hiding. This thorough coverage is vital for effective treatment.

Adherence: Smaller droplets tend to adhere better to plant surfaces. Their lightweight nature allows them to stick more easily to leaves and stems, providing a more uniform application and treatment. This is particularly important for contact herbicides, which need to stay on the plant surface for a period of time to be effective.

Deposition/Evaporation: The size of the droplets also influences the amount of liquid deposited on the target area versus what is lost to the surrounding environment or through evaporation. Larger droplets deposit more liquid on the target, reducing the amount lost to evaporation. This means more of the herbicide remains on the plants, enhancing its effectiveness and reducing waste.

How a Sprayer Nozzle Impacts Droplet Size

The importance of choosing the proper spray nozzle cannot be understated, because it is the very design of a nozzle that has the greatest impact on droplet size. As the liquid comes out of the sprayer nozzle, it doesn't just flow smoothly; instead, it breaks up from a solid “sheet” to smaller sheets (also called ligaments), and then finally droplets. The size and spread (spray pattern) of the droplets depends heavily in how the spray tip was engineered but can also change depending on the viscosity of the liquid, -, the flow rate of the nozzle, and the pressure at which the nozzle/liquid is being sprayed.  

The size and distribution of the nozzles throughout the width of the spray pattern varies depending on the nozzle type. Nozzles have precise, intricate internal fluid paths designed to generate a specific range of droplet sizes. Some herbicides require that you use a nozzle with larger droplets. Typically, in the extremely coarse range or larger. One of the common means used by nozzle manufacturers to create larger droplets is air induction. 

This is the process of pulling air into the nozzle to fill the droplets with air, resulting in an overall larger sized droplet. There are several different nozzle types that accomplish this, and different manufacturers utilize different designs. 

It’s important to note that not all nozzles that produce extremely coarse or ultra coarse droplets use air-induction technology. As more sophisticated spray methods are developed, nozzle technology will continue to adapt to increase efficiency and precision.

Selecting the Right Droplet Size for Your Application

The details behind droplet size creation and classification are important but ultimately the most important question is, “What droplet size do I need for my application and which nozzle will produce it for me?” 

Answering that question requires that we consider all the factors involved in your specific scenario. The first and most important guideline is the pesticide label. If specific instructions are provided in the product label in terms of droplet size required, then that guideline is the law. Following the label ensures you have the best chance at avoiding any unintended consequences during or after spraying. In addition to this, there are several other aspects of spraying that might indicate you should use a droplet size that is finer or coarser. 

Here are several factors to consider and why they would potentially affect which size droplets you need:

Crop Type: The foliage and leaves of various crops can present obstacles. For example, if you need to penetrate a dense canopy you may want nozzles that produce smaller droplets for better penetration.
Pesticide Type: The type of pesticide—whether it's a herbicide, insecticide, or fungicide—affects nozzle choice. Contact pesticides generally need smaller droplets for thorough coverage, whereas systemic pesticides can use larger droplets.
Target Pest or Disease: The specific pest or disease being targeted dictates the required droplet size. For instance, pests on the underside of leaves or deep within the canopy might require smaller droplets that can navigate through the foliage, whereas surface pests can be controlled with larger droplets.
Weather Conditions: Wind, temperature, and humidity significantly impact spray applications. Windy conditions necessitate nozzles that produce larger droplets to reduce drift, while calm conditions allow for finer droplets. High temperatures and low humidity increase evaporation rates, so larger droplets may be needed to ensure adequate deposition.
Drift Tolerance: Areas with sensitive neighboring crops or habitats require nozzles that minimize drift. Air induction nozzles producing very coarse droplets are often used in such scenarios to keep the spray on target and prevent damage to surrounding areas.
Spraying Speed: The speed at which you spray affects droplet size and distribution. Faster speeds can cause smaller droplets to drift, so selecting nozzles that produce larger droplets at higher speeds can help maintain effective coverage and reduce drift. When spraying across a range of speeds, you need a nozzle that will maintain your desired droplet size range at both lower and higher pressures. 
Operating Pressure: The pressure at which the spray system operates impacts droplet size. Higher pressure generally produces finer droplets, while lower pressure produces coarser droplets. Choosing nozzles compatible with your operating pressure ensures consistent and effective spray patterns.
Boom Height: The height of the spray boom above the crop affects coverage and drift. Lower boom heights reduce drift but require nozzles that can maintain a uniform spray pattern at closer range. Higher boom heights need nozzles that produce larger droplets to ensure they reach the target without drifting.

Note: These are guidelines, no two applications are going to be the same and there may be more factors you need to consider. End users should always speak with their local crop consultant for specific application requirements/nozzle selection.

With so many different things to keep in mind, landing on one specific spray nozzle can be quite the task. The good news is that there are likely several nozzle types across the different manufacturers that will work in your scenario. The key is trying to zero in on one that will provide the best results based on all the variables involved. 

Nozzle selection may involve some trial and error, but we can get you off to a good start. The nozzle manufacturers offer extensive resources that detail the droplets sizes and other performance factors of a given type of nozzle family. 

They also provide nozzle selection tools to walk you through the process:

TeeJet Spray Select Tool

Greenleaf Nozzle Recommendation Tool

Wilger Tip Wizard

Hypro Nozzle Decision Tool

Selecting a sprayer nozzle also involves calculating the correct nozzle size for your application rate. For more information on this, be sure to examine this guide to sizing sprayer nozzles as well as the complete guide to sprayer nozzle numbers. 

Recommended Sprayer Nozzles for Various Droplet Size Requirements

Dultmeier sales carries a wide selection of sprayer nozzles that deliver a wide range of droplet sizes. Whether you need fine droplets for thorough coverage of plant tissue, need larger droplets to follow herbicide label requirements, or you require a nozzle that is approved for use with a PWM system:

Broadcast Sprayer Nozzles - Nozzles for reduced drift, insecticides, fertilizer, contact herbicides, soil applied, etc.

Approved Nozzles for 2, 4-D Based Product & DiCamba Product

PWM Approved Sprayer Nozzles

Sizing Nozzles for a PWM system is a bit different than for standard spray nozzles. Learn more in this article on properly sizing nozzles for PWM.

Maximize Coverage with Coarser Droplets

One of the natural concerns when using a nozzle that produces larger droplets is “Will I still get good coverage?”. With all things being equal, traditional flat fan nozzles like the Turbo Teejet or XR Teejet, which produce droplets in the Coarse, Medium, and Fine categories, offer better coverage. However, when we add in higher spraying speeds (10+ MPH), consistent wind (no one ever deals with wind while spraying, right?), and significant evaporation conditions, larger droplets can deliver more spray on target because they are more resistant to these factors.

When Extremely Coarse and Ultra Coarse droplet sizes are required but you are still concerned about adequate coverage, there are some options. For one, you can utilize dual fan nozzles instead of single flat fan nozzles.

Dual fan nozzles still produce the same size droplet as a single fan nozzle, but there are two separate spray fans directed at the target, at two different angles. Two fans allow you to retain desired droplet size while also increasing the number of spray angles at which to spray your target. More spray angles equals better coverage.

TTI TwinJet Nozzles Provides 2 fans at a 60-degree angle from one another.

GreenLeaf Dual Fan Nozzles alternatively offer a 10-degree forward angle and a 50-degree rear angle. These nozzles can be alternated on your nozzle bodies, and by pointing one “forward” then the next one “backward”, you are able to produce four different angles of spray directed toward your target.

(h3) Best Practices for Managing Droplet Size

In addition to the nozzle type there are different techniques that you can employ to help manage the droplet size dispersed from your sprayer:

Control the Pressure: Adjust the operating pressure to influence droplet size. Higher pressure creates finer droplets, while lower pressure produces coarser droplets.

Mind the Weather: Pay attention to weather conditions. Spray on calm days to minimize drift and avoid spraying during high temperatures or low humidity to reduce evaporation.

Boom Height: A higher boom level can increase the overlap and coverage, but it can also lead to more drift. A lower boom height reduces the chance of droplets drifting off target.

Spraying Speed: Adjust your spraying speed as needed. Finer droplets may be less prone to drift at slower speeds, faster speeds might require larger droplets to stay on target.

Regular Cleaning: Clean your nozzles regularly to prevent clogging and ensure consistent spray patterns. Use soft brushes or compressed air to avoid damaging the nozzle.

Check for Wear: Inspect nozzles for wear and tear. Worn nozzles can produce uneven droplet sizes and poor spray patterns, reducing effectiveness. You can use spray pattern test paper or an electronic sprayer calibrator to evaluate your nozzles and identify any that are worn and not delivering a consistent spray pattern. Nozzles that overspray by 20% or more are considered worn and should be replaced.

Conclusion

Precision spraying entails a lot of complexity, and it all begins with choosing the right tip to achieve your desired droplet size. Understanding droplet size is crucial for successful spray application. The right nozzle can make all the difference when it comes to coverage, drift, and overall effectiveness. Navigating the complexities of droplet size and spray nozzle selection can be daunting. However, with some time and expert guidance, choosing the right nozzle for your specific needs can become a straightforward and stress-free process.

If you have questions or would like help identifying a sprayer nozzle to meet your needs, please reach out to our agriculture sales team!

Tech Ag & Industrial Sales

Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.

Learn More About Author

Car Wash Wiper Bag Guide

Whether you are in the car wash industry or not, you may have noticed those plastic bags covering the windshield wipers of a car driving past you on the road. This may seem like an odd sight but there is a valid reason behind this anomaly.

What is a Wiper Bag?

A wiper bag is a protective covering specifically designed to shield windshield wipers during the car wash process. These bags are typically made from durable, water-resistant materials such as plastic or heavy-duty vinyl. They are easy to slip on and off and come in various sizes to fit different types of windshield wipers.

Why Put Bags on Wipers?

There are several key reasons why car wash operators and vehicle owners use wiper bags:

Protection of Wipers

Wiper bags protect the delicate rubber blades of the wipers from harsh chemicals, high-pressure water jets, and mechanical parts within the car wash. This ensures that the wipers are not damaged or worn out prematurely.

This is especially needed on rear wipers of vehicles. Soft cloth material in conveyor type car washes can get caught in the wipers and cause damage to the wiper and the brushes.

Prevent Streaking

Unprotected wipers can sometimes leave streaks or marks on the windshield after a wash. Wiper bags help avoid this by keeping the wipers clean and free from chemical residues.

Ensure Thorough Cleaning

By covering the wipers, the car wash system can focus on cleaning the windshield and the rest of the vehicle without interference, resulting in a more thorough and even wash.

Customer Satisfaction

For car wash businesses, using wiper bags demonstrates a commitment to quality and customer satisfaction. It shows that the business takes extra steps to protect the customer’s vehicle, leading to higher customer trust and repeat business.

What Is the Most Common Wiper Bag Size?

Dultmeier Sales offers two different sizes of wiper bags in rolls of 500:

3 Inch: DUWWB50, 3" Wide x 27" Long, 1.5 Mil

5 Inch: DUWWB75, 5" Wide x 27" Long, 1.5 Mil

The 3-inch wiper bags are by far the most common size we sell.

Choosing the Right Pump for Soft Wash Systems

When setting up a soft wash system, you have lots of options when it comes to equipment. Selecting the right pump is one aspect that can make or break your entire setup. Softwash jobs require a balance of power to reach tall heights and low pressure to be gentle on surfaces. 

The good news is that there are many options. The bad news is that all these options might have you feeling overwhelmed. Ultimately, any of these softwash pump options work. It comes down to your personal preferences and budget. So how about we get into the various softwash pump types and examine their pros and cons? 

Pump Types Used for Softwash

A diaphragm pump is the most common pump type used in the softwash industry. The are different varieties in terms of the amount of flow and pressure they will achieve as well as the means used to power them. 

12-volt and gas-engine-driven pumps are extremely common due to the mobile nature of the business. 110-volt, hydraulic, or air-driven can also be used if you have the means available, however, these often require more investment in additional equipment or access to electricity at the job site. In this guide, we are going to focus on the 12-volt and gas-engine pump options.

Another important factor is the material construction of the pump. Soft wash pumps need to be compatible with sodium hypochlorite solutions. The best materials for this application are polypropylene, Viton, Santoprene, and polyethylene1.

12 & 24-Volt Soft Wash Pumps

Even if you are new to the softwash world, you will probably recognize this type of pump. 12-volt diaphragm pumps are extremely versatile and user-friendly. They are used in many different industries from RV’s, marine, pest control, automotive, and more. 

12-volt pumps come in a range of sizes. There are 12-volt pumps that can produce a maximum flow rate of about 7 GPM. The maximum PSI you can get from a 12-volt pump is about 700. However, you won’t find one that delivers 7 GPM at 700 psi because 12 volts doesn’t provide enough power to do so. 

At higher pressure, these pumps are only capable of delivering a low flow rate, usually less than one gallon per minute. A 12-volt pump delivering 7 GPM will do so only at very low PSI. (We will get into the flow and pressure requirements needed for different jobs in the next section.) 

24-volt diaphragm pumps operate the same as 12-volt diaphragm pumps but they generally offer higher flow rates and pressure, which means greater spray distance or reach.

Demand Pump

The specific style of 12 & 24-volt pump used for softwash applications is a demand-style pump. A demand pump is designed to provide flow "on demand." This type of pump uses a pressure switch to automatically control the motor based on the pressure in the system. 

When your spray wand trigger or valve is closed, the pressure builds up, and the demand switch shuts off the motor. When the trigger or valve is opened, the pressure drops, the switch deactivates, and the motor restarts, allowing liquid to flow again. This mechanism is used to help you conveniently operate your system without wasting battery or overheating your motor. 

12/24-Volt Pump Pros & Cons

Pros

Inexpensive
Easy to replace
Quiet
No oil changes or re-fueling

Cons

Shorter lifespan relative to other diaphragm pump types
Repair costs often justify replacing the entire pump
Cycling pressure switch can burn out the motor and relay

12-Volt Pump Options:

24 -Volt Soft Wash Pumps:

MVEFSW10000

You can see more 12 & 24-Volt options here.

Engine-Driven Diaphragm Pumps for Softwash

When it comes to mobile softwash options, 12V, and 24V pumps are handy but have limitations in flow and pressure. This is where gas engine-driven pumps step in. Thanks to the increased horsepower of a gas engine, these pumps can deliver a much higher volume per minute and significantly greater PSI.

The enhanced volume and pressure mean you can achieve spray distances and heights far beyond what a 12V pump can offer. With the right plumbing and spray gun/nozzle combination, you can easily reach distances over 50 feet. This capability makes tackling larger jobs such as commercial buildings a breeze. You can effortlessly spray buildings over two stories high and reach rooftops.

Moreover, gas engine-driven pumps are more durable. They can be rebuilt and will last several years if properly maintained. They are a long-term solution for extensive softwash needs.

Engine-Driven Diaphragm Pump Pros & Cons:

Pros

Greater reach due to higher volume and pressure
More volume for larger jobs and taller buildings
Durable and repairable, equalling a longer lifespan

Cons

Requires regular oil changes for both the pump and engine
Diaphragms need periodic replacement
More expensive to repair
Additional cost of fuel to run the engine
Significantly more expensive than 12-volt pumps

Engine-driven soft wash pump options

Sizing Your Softwash Pump

Probably the number one question you have is “What pump will help me spray two-story buildings, roofs, etc.”. In other words, what is the spray distance of these different pumps? 

It is crucial to understand that spray distance is not just a matter of your pump's size. The pump’s flow and pressure specifications are the starting point. We can identify the potential reach from a particular pump, but the pump is not the only factor determining spray distance.  The nozzle size, nozzle type, inside diameter of your hose, etc., will contribute to or detract from the effective spray distance of your softwash system.  

There are two aspects of “pump size” to consider: the flow rate and the pressure it will produce. A pump needs to deliver enough flow that will allow you to cover an area quickly, but you don’t want to overspend on a large pump if you don’t need it. You also need the right combination of flow and pressure to propel your cleaning solution high enough to reach second-story walls and roofs.

With this in mind, we can pinpoint some common applications and the pumps that will work in those scenarios assuming you pair them with the proper equipment.

For more information on the accessories needed for effective softwash, you can view these pages on softwash spray guns and nozzles:

Recommended Pump Sizes for Common Soft Wash Applications 

Residential Cleaning

Cleaning a two-story home requires a system to spray at least 20 feet in the air. And if you want to clean the roof as well, you’re going to need more spray height than that. For these applications, you can rely on the 12-volt family of pumps that flow 5 GPM and reach pressures up to 100 PSI. Paired with the right nozzles and spray gun this pump will have no trouble reaching 30 feet or higher.

The Everflow SW5500 pump is specifically designed to be used with bleach and other types of disinfectant solutions. In addition to bleach-resistant materials, It features a motor shield that will shut off the pump if a leak is detected. 

Of course, there are other 12-volt options available that work great: 12-Volt Softwash Pump Options

Commercial and Larger Projects

If you plan to do buildings that are taller than two stories and larger than a typical house, you may want to consider a gas engine-driven pump.  

Large Surfaces: For cleaning large commercial buildings, parking lots, or extensive residential properties, a pump producing more than 5 GPM is recommended. The increased flow rate can significantly reduce cleaning time.
Multiple Users: If your setup involves multiple users cleaning different areas simultaneously, a higher flow rate pump will ensure that both operators receive sufficient solution pressure.

Example of Gas-Engine Driven Softwash Pump:

MVP40GRCBPE

Conclusion

Selecting the right pump for your softwash system depends on your specific needs and the scale of your projects. 12-volt pumps are inexpensive and effective for residential jobs. If you plan to clean larger commercial buildings a gas-engine unit offers more flow and reliability but they are more expensive. 

If you have questions or want to talk with someone about the softwash pump options available, give us a call

https://www.coleparmer.com/chemical-resistance

Tech Ag & Industrial Sales

Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.

Learn More About Author

MP Pumps: Ag, Petroleum, & Industrial Fluid Transfer Solutions

MP pumps has been manufacturing quality centrifugal pumps for more than 80 years. Over this time, they have developed and improved upon their designs to offer reliable and affordable fluid handling options for a variety of industries and applications.  

There is almost certainly an MP pump that will work for you, but sorting through the various types can be tough. As a master MP Pumps distributor, Dultmeier Sales can help you pinpoint the right one. Here’s a detailed look at the different MP Pumps available, their common uses, and the advantages and disadvantages of each type. 

MP Pumps Company Overview

MP Pumps has been around since 1942, proudly crafting high-quality centrifugal pumps from their home base in Fraser, Michigan. They’ve got a pump for just about everything—from making sure your fertilizer and ag chemical system runs without a hitch to keeping industrial processes flowing smoothly, to moving petroleum products efficiently.

MP Pumps Company Info:

Founding: 1942
Location: Fraser, Michigan.
Phone Number: (800) 563-8006
Parent Company: Ingersoll Rand
Website: MP Pumps

Industries Covered:

Agriculture
Fuel
Transportation
Irrigation
Marine
Industrial

MP Pump Types

MP Pumps has an extensive product line. They manufacture self-priming pumps, straight centrifugal pumps, chemical pumps, circulator pumps, petroleum pumps, and more. 

Dultmeier Sales can supply just about any MP pump but we focus primarily on the ag, industrial, and petroleum pumps. These industries rely on the MP Flomax, Chemflo, and Petrolmaxx lines. One of the most common is the Flomax self-priming pump series, so let’s start there.

MP Flomax

Description: These are self-priming centrifugal pumps. Available in materials like cast iron and stainless steel. Versatile, and capable of handling a wide variety of fluids. Many parts are interchangeable with other Flomax models.

Common Uses: The MP Flomax pump can be implemented in countless situations. Dultmeier Sales has been selling the Flomax series pump for use in agriculture for several years. Specifically, nurse trailer and sprayer tender truck transfer pumps, as well as fertilizer and agrochemical bulk plant pumps. They are excellent at handling water, agrochemicals, and fertilizer but they can be used with other liquids as well. 

Key Features: 

Capable of flows up to 750 GPM.
Handles pressures up to 230 head feet.
Stainless steel shaft sleeve for durability and corrosion resistance.
Self-Priming
Viton seals standard
Removable bolt-on FNPT flanges means your piping remains in place when servicing the pump
Wear plate can be replaced to extend the life of the pump
Suction check-valve holds liquid, protecting the pump seal when it re-primes

Find Flomax Pumps Ready to Ship Today!

Flomax Pump Options

When it comes to connecting the pump to an engine or motor, MP offers the Flomax pump in two basic configurations. The pedestal version and the PumpPak version. 

Pedestal: A pedestal pump is designed to be long-coupled to motors, or other drives. It features a bearing pedestal and solid shaft. 

PumpPAK: This version of the Flomax pump is designed to be mounted directly to an engine or motor. There are versions to mount on gas-enines, hydraulic motors, and C-face electric motors. 

Flomax Pump Sizes

Flow rate is always key for any pump type. There are Flomax pumps made to deliver up to 750 GPM:

Flomax 5 - 1-½ inch ports, Up to 145 GPM
Flomax 8 - 2 inch ports, Up to 170 GPM
Flomax 10 -  2 inch ports, Up to 225 GPM
Flomax 15 - 3 inch ports, Up to 320 GPM
Flomax 30 - 3 inch ports, Up to 500 GPM
Flomax 40 - 4 inch ports, Up to 750 GPM

Find Flomax Pumps Ready to Ship Today!

Materials

The Flomax line is available in several materials. Pumps constructed with cast iron housings and impellers, stainless shafts, and Viton seals are most common. All stainless pumps are available for more corrosive applications.

Pump Drives 

An MP Flomax pump can be driven a number of ways. Whether you require an electric motor, engine, or hydraulic motor. The pedestal pump version can be assembled on a baseplate with motor and long-coupled together. The PumpPak version can be mated directly or close-coupled to C-face electric motors or gas engines. 

Various shaft sleeve sizes and bolt patterns are available so you can easily connect an MP pump to almost any C-face motor or gas engine. 

If you would like a more detailed explanation of close-coupled and long-coupled pump units, be sure to read this guide to the best fertilizer pump options. 

Chemflo Series

Description: Some liquids are more harsh on pumps than others. The MP Chemflo stainless steel pump family is built to withstand more severe applications and corrosive liquids. There are several different variations within this family to be compatible with different types of liquids. 

Common Uses: Agricultural chemical mixing, fertilizer transfer, water treatment, de-icing liquids, and other industrial fluid transfer. 

Key Features: 

Corrosion-resistant 316 stainless wetted components
Suitable for a wide range of chemicals
Available in a variety of sizes

MP Chemflo Pump Options

The Chemflo pump family is made up of more than 30 unique models. These different models are designed to be used in many different applications. They vary in flowrate, drive type, port size (flanged & NPT), etc.

Sizes

Chemflo pumps come in very low to high flow options. Their CFX pumps have ½-1-inch ports with flow rates ranging from 10-40 GPM. The larger versions are available with 1-½ up to 3-inch ports and these pumps will provide maximum flow rates of 150-395 GPM. 

Materials

One of the primary features of this pump series is the cast 316 stainless steel components used to construct the pump. While stainless is not an answer for 100% of liquids, it does offer resistance to the effects of a much wider range of liquids when compared to cast iron.

While the housing, impeller, and other components are made from stainless steel, the mechanical seal is available with a variety of options including Viton, EPDM, and Teflon. You can always refer to our chemical compatibility charts to evaluate which materials and elastomers will be compatible with the liquid you need to pump. 

Drive Options

Like other MP pumps, the Chemflo series comes in a variety of setups included long-coupled pump and motor units, close-coupled pump and motor units, and hydraulic driven units.

For more details and explanation of close-coupled and long-coupled pump units, be sure to read this guide to the best fertilizer pump options. 

PetrolMaxx Series

Description: Pumping fuels in high-volume applications requires the right type of pump for efficiency, compatibility, and safety. MP’s PetrolMaxx series is a self-priming pump similar in design to the Flomax family but constructed with materials compatible with fuels. There are variations to ensure compatibility with diesel, biodiesel, gasoline, E85, and more.

Common Uses: High-volume fuel transfer. Loading and unloading bulk fuel trailers and trucks. Filling large equipment for construction and agriculture. 

Key Features: 

Self-priming
Available to Mate directly to engines/motors or with a bearing pedestal for long coupling
Flow rates of 150-700 GPM
Options for Ethanol, Biodiesel, Gasoline, Diesel, and More

MP PetrolMaxx Options

For safety and compatibility, it's crucial to use the right pump for each type of fuel. That's why MP has created a variety of pump models designed specifically for different fuels. Each model is built with materials that match the unique properties of the fuel it's meant to handle, ensuring safe and reliable operation.

One of the most popular versions is made to handle diesel. Dultmeier sells hundreds of two-inch PetrolMaxx pumps driven by gas-engines for high-volume diesel fuel transfer. These pump units help fill equipment much faster than the common 12-volt fuel pumps. You can get flow rates well over 100 GPM with the right size hose and fuel filters. 

MP Petroleum Pump Sizes

1-½ Inch 
2 x 2 Inch
3 x 3 Inch
4 x 3 Inch 
4 x 4 Inch

See More MP PetrolMaxx Pump Options Here

Materials

As mentioned earlier, the PetrolMaxx family of pumps consists of several pumps fitted for specific fuels. The materials used include: steel, aluminum, cast iron, ductile iron, nitrile, 316 SS, Viton, Ni-resist, and more. 

Drive Options

You can fit a PetrolMaxx pump to a gas-engine, electric motor, or hydraulic motor. It is important to note that some fuel types may require the use of an explosion-proof motor or gas-engine.

Dultmeier sales builds pump units on baseplates for easy installation. The units are available close coupled to electric motors or engines, and long coupled to electric motors. There is also a complete fuel unit with a hose reel, pump, fuel filters, fuel nozzle, and base plate. 

View All Pump & Engine Units

View Pump & Electric Motor Units

Final Thoughts 

MP Pumps has been a reliable supplier for years offering a wide range of pump solutions. Dultmeier sales has relied on MP as a competitively priced and durable pump for the rigors of the primary industries we have served. Including the fertilizer and ag chemical world as well as for de-icing, industrial, and fuel transfer. 

Tech Ag & Industrial Sales

Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.

Learn More About Author

Exploring Boomless Sprayers: Advantages, Applications, and Setup

Imagine being able to spray a large pasture and doing it without a large and cumbersome boom. With a boomless sprayer, you can do just that! 

With no boom to negotiate around obstacles, a boomless sprayer is a convenient way to cover large areas. However, it is not suited for every type of application. Today we’re going to break down the ins and outs of boomless sprayers. We will explain specifically what they are, how they operate, and when you should use them.

What is a Boomless Sprayer?

A "boomless" sprayer is designed to distribute liquids, such as herbicides, pesticides, and fertilizers, without the traditional long, horizontal boom. Instead, these sprayers use specialized nozzles to achieve wide coverage without the extensive boom. This offers several advantages.

A conventional sprayer boom has long arms extending from the sides of a sprayer that hold several nozzles at set intervals, providing a uniform application over a wide swath. In contrast, boomless sprayers use one or more “boomless” nozzles that are mounted at the rear of a sprayer. These nozzles can cover a similar span in one pass as a conventional boom.

Conventional Boom vs Boomless Setup:

Common Applications of a Boomless Sprayer

Boomless sprayers have gained popularity due to their unique advantages over conventional boom sprayers. They are particularly useful in areas with obstacles, uneven terrain, or narrow paths where maneuverability and flexibility are crucial. The absence of a boom reduces the risk of damage to equipment and surrounding fences, buildings, etc. This makes boomless sprayers a practical choice for farmers, ranchers, turf care pros, and property managers.

Boomless sprayers can be used for several applications:

Pasture spraying: Ranchers can spray areas of their pastures that are hard to access with a large spray boom. It allows you to spray steep hillsides, ravines, and fence lines.
Landscaping: Landscapers benefit from the flexibility of boomless sprayers when maintaining large lawns, parks, and golf courses. Without a boom, it is much easier to navigate around trees, bushes, and other landscape features making it an efficient tool for maintaining green spaces.
Forestry: In forestry management, boomless sprayers are employed to apply treatments over large, wooded areas. Their ability to cover wide swathes of land quickly and effectively helps in pest control and vegetation management.
Golf Course: Spraying Greens from the fringe.
Municipal and Public Works: Municipal workers use boomless sprayers for tasks such as roadside weed control and maintaining public parks. The ease of use and wide coverage make them suitable for maintaining large public spaces.
Food Plots: Many boomless sprayers can fit on ATVs and UTVs making them perfect for spraying remote food plots for wild game. 
Boom Extending: Used as the last nozzle on a conventional boom to extend reach, spray fence lines, waterways, etc.

This video demos what a boomless nozzle looks like in action on the end of sprayer boom: Golf course Boomless Rough Sprayer Nozzle Kit- KZ Valve

You can check out the details of the boomless nozzle control kit referenced in the video here: KZ Boomless Nozzle/Valve Control Kit

How Does a Boomless Nozzle Work?

A boomless nozzle has a unique design that projects fluid over a wide area. Inside the nozzle housing, a vane or diffuser breaks up the stream of fluid so that droplets are formed across the entire width of the spray pattern. 

With a typical spray nozzle that projects fluid over a great distance, the stream stays together as it travels through the air. Only dispersing into droplets in an isolated area. A boomless nozzle both projects fluid over a great distance but also provides coverage of the surface along the entire swath.

The design is rather ingenious and the only difference between a traditional boom sprayer and a boomless sprayer is the lack of a boom. In terms of the tank, pump, and controls, you can design and operate a boomless sprayer basically the same as other sprayer types.

Pros and Cons of a Boomless Sprayer

While a boomless sprayer is very effective in the right application, there are specific scenarios where it is not the best option. 

Due to the high-volume, wide-angle spray pattern, a boomless sprayer nozzle produces very coarse droplets. While these coarse droplets are less prone to drift, they do not offer the same consistent coverage as a conventional boom. 

Boom Sprayers

Pros:

Precise and uniform application
Suitable for large, open fields
Consistent spray pattern and coverage

Cons:

Difficult to maneuver in tight or obstructed areas
Risk of boom damage from obstacles
Requires more careful navigation and operation

Boomless Sprayers

Pros:

Flexible and versatile coverage
Easy to maneuver in irregular and obstacle-rich areas
Reduced risk of equipment damage

Cons:

Potential for less uniform coverage compared to boom sprayers
The spray pattern may need adjustment for different applications
May not be as effective in large, open fields where precision is critical

Boomless Nozzle Types

There are several different manufacturers of boomless sprayer nozzles. While they do vary in design and exact specifications, the basic premise is the same. They are available in stainless steel or poly material. Boomless nozzles range in both the volume of liquid they will deliver and the width of the spray pattern they produce. There are small nozzles that spray a 3-5 ft pattern up to larger nozzles that will cover nearly 40 ft in one direction.  

Generally, a boomless sprayer will consist of two boomless nozzles installed “back-to-back” on a sprayer about 6 inches apart depending on the exact nozzle. The standard boomlesss nozzles have a slight “kickback” so they overlap when mounted in this manner.

This is the nozzle you would use on the back of a sprayer in place of a conventional boom. With each nozzle acting as half of the sprayer swath. You can control these nozzles individually, giving you the ability to control whether you spray to the left, right, or full pattern. 

There are two varieties of this nozzle. They perform the same the only difference is in the direction of spray in relation to the inlet port. Most of these nozzles have an NPT inlet and the outlet is either opposite this inlet or perpendicular.

There are also boomless nozzles that will cover a full swath with one spray nozzle. These full-pattern nozzles are offered by Boominator and Teejet. 

Full pattern boomless nozzle.

TeeJet also offers a BoomJet boomless assembly that consists of multiple nozzles mounted on one body. Together they can cover a wide area with even coverage

BoomJet

Finally, we have the popular roadside or right-of-way boomless nozzle. This nozzle is similar to the standard types; however it has a significant distinction. Roadside nozzles do not have a “kickback” to their pattern. These nozzles are not intended to overlap with another nozzle. Instead, they are mounted on the side of a truck or other vehicle to spray road ditches, medians, or any area adjacent to the vehicle. With no “kickback”, there is no liquid sprayed on the vehicle. 

Roadside nozzle pattern does not feature kickback for overlap

Mounting Boomless Nozzles

No matter what type of boomless nozzles you use, it is crucial to mount them correctly. Incorrect mounting can limit your coverage and lead to poor results. Here are the basic guidelines to follow when you mount different types of boomless nozzles:

Boomless Nozzle Height

The vast majority of boomless nozzles are intended to be mounted and used at a height of 36 inches from the ground. Most will perform at a minimum height of 18 inches from the ground and a maximum of about 48 inches. Changing the height does result in slightly narrower or wider coverage. 

There are boomless nozzles that can be mounted lower than 18 inches off the ground. Boominator short pattern nozzles cover a narrower spray distance of about 3-10 ft. You can mount them 12 inches from the ground. 

Boomless Nozzle Spacing

A pair of boomless nozzles on a sprayer should be mounted about four inches apart. This ensures an overlap between them. Nozzles mounted higher than 36 inches may adequately overlap at 6 inches or more, but the nozzle angle may need to be adjusted up or down. 

Boomless Nozzle Plumbing 

Boomless nozzles deliver more fluid per minute than flat fan nozzles on a spray boom, so they require an adequately sized hose to feed them. If you are using a single nozzle, it is best to use a hose or pipe with an inside diameter larger than the nozzle inlet. If you are feeding two nozzles, then the hose should be double the inlet size of the nozzle inlet. This is especially important if you have a long length of hose between the pump and the nozzles. 

You can refer to the manufacturer's website for more specific boomless nozzle plumbing and installation instructions:

Boomless Sprayer FAQ

Question: What is the farthest a boomless nozzle can spray?

The widest swath you can cover with a boomless sprayer would require using two standard Boom Buster 504 nozzles. Each one can spray about 40 feet in one direction. With two of these mounted “back-to-back” you could potentially spray a width of 80 ft.

Question: Can I add a boomless nozzle to my sprayer?

Yes, a boomless nozzle can be added to basically any sprayer type. It is important to make sure your sprayer has a pump large enough to provide the flow needed for the nozzles you choose. 

Question: Do Boomless Sprayers Work Well?

A boomless sprayer works extremely well in the right scenario. They produce coarse droplets that are less prone to drift and are perfect for fertilizers, orchard spraying, de-ice, pasture spraying, and much more. They excel in areas with obstacles. 

They are less suited for applying herbicides that require thorough coverage of the target surface. If you need nozzles that produce finer droplets see our selection of flat fan sprayer nozzles. 

Question: How much volume can a boomless nozzle spray?

Boomless nozzles come in various sizes. The smaller nozzles can produce a flow of about 1-2 gallons per minute. At 2 GPM and a 30-foot spray width, this amounts to about 12-13 gallons per acre at 5 mph.

You can pinpoint the exact gallon per acre rate at different speeds in the boomless nozzle chart for each type. 

Boomless Nozzles Options 

There are quite a few options and the distinctions between them may seem arbitrary so here are the options we carry and some of the key benefits of each type.

TeeJet

BoomJet - Solid brass unit that is very durable and provides even coverage.
XP Boomjet - A cost-effective poly nozzle that is lightweight and easily added to Teejet Quickjet nozzle bodies with a Teejet ¼ cap.

Boominator

Boominator nozzles provide several different patterns that are made of durable stainless steel: 

Boom Buster

Unlike other types of boomless nozzles, Boom Buster nozzles do not have a “left” and “right” hand version. Any two nozzles can be used in tandem to create a full pattern. 

Hypro

Boom X Tender - These can be rebuilt with a repair kit.
Fast Cap Boom X Tender - Same as the standard X Tender nozzles but they fit on Teejet and Hypro quick jet nozzle bodies.

Boomless Nozzle Accessories

Boomless Nozzle Swivel Tee - Simple kit mount boomless nozzles
Golf Course Boomless Green Sprayer - Solenoid control and mounting kit for golf course sprayer booms, can be used on other sprayer types.

We have several of these in stock and we can ship them out the same day you order. Do not hesitate to get in touch with us if you need any help choosing the right boomless nozzle for your sprayer.

Tech Ag & Industrial Sales

Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.

Learn More About Author

Ultimate Guide to High-Pressure Cleaning Nozzles

In the world of cleaning, high-pressure nozzles play a crucial role in delivering the power and precision needed to tackle tough jobs. Whether pressure washing a driveway, detailing a car, or performing industrial cleaning, the right high-pressure nozzle can make all the difference. 

These nozzles are designed to enhance the effectiveness of your cleaning equipment by focusing water pressure into a powerful stream, capable of removing dirt, grime, and stains that would be impossible to eliminate with ordinary nozzles. They are typically constructed from stainless or hardened stainless steel to withstand high pressures. 

Here’s a comprehensive look at what you need to know about high-pressure nozzles.

High-Pressure Nozzles Applications

Most nozzles are rated to working pressures up to 4,000 psi, but higher-rated nozzles (up to 10,000 psi) are also available for more intense cleaning needs. Different pressure ranges are required to tackle the various cleaning tasks. It is important to identify the proper operating pressure for your scenario and size the nozzle accordingly. 

Here are some common applications and the general pressures required:

Pressure Washing

From driveways and sidewalks to commercial buildings and heavy equipment, pressure washing relies on high-pressure nozzles to deliver targeted cleaning power. These nozzles help remove stubborn dirt, mildew, and other contaminants. 

Pressure Range: 1000 - 4000 PSI, Nozzle Options: SS Quick Coupler Nozzles & Stainless NPT Nozzles

Car Wash

In the automotive industry, high-pressure nozzles are essential for achieving a spotless finish. They are used in both automatic car washes and self-serve bays to apply foam, rinse off detergents, and remove dirt without damaging the vehicle's surface.

Pressure Range: 1200 PSI - 2200 PSI, Nozzle Options: SS Quick Coupler Nozzles & Stainless NPT Nozzles

Industrial Cleaning

Factories, warehouses, and other industrial settings require heavy-duty cleaning solutions. High-pressure nozzles are often used in automated cleaning. They can be fixed to a machine or apparatus that is part of an industrial process to clean, strip, or prepare surfaces. Ideal for cleaning machinery, floors, walls, and other surfaces that accumulate grease, oil, grime, and other residues.

Machinery Cleaning: Typically, 2,000 to 5,000 PSI to remove grease and grime.

Paint Stripping: Around 5,000 to 10,000 PSI to effectively remove paint from surfaces.

Surface Preparation: Up to 10,000 PSI (or even more in some cases!) for tasks like removing coatings, rust, or other surface contaminants before applying new coatings or treatments.

Nozzle Options: Rotating Nozzles & Stainless NPT Nozzles

Selecting the Proper High-Pressure Nozzle

The benefits of using the right high-pressure nozzle for specific tasks cannot be overstated. Selecting the appropriate nozzle ensures:

Efficiency: The correct nozzle maximizes cleaning power and reduces the time needed to complete a task.

Safety: Using the right nozzle minimizes the risk of damage to surfaces.

Cost-Effectiveness: Proper nozzle selection can extend the life of your cleaning equipment and reduce the need for additional cleaning agents.

To identify the right nozzle for your needs there are several things to consider in addition to the pressure rating of the nozzle. These include the spray angle, pattern, material, flow rate, and other nozzle features such as stabilizing vanes and rotating turbines.

Understanding Spray Angles and Patterns of High-Pressure Nozzles

The spray angle of a nozzle determines the coverage pattern and effectiveness at various distances from the surface. Common spray angles include:

Zero Degree: Provides a concentrated, powerful spray for tough cleaning tasks. All fluid is directed in a narrow stream that impacts the surface in a very small area. Excellent for cutting through surfaces.

15 Degree: Offers a narrow, but slightly wider spray pattern; common for pressure washing and industrial cleaning.

25 Degree: Delivers a wider spray pattern, ideal for car wash and truck wash operations.

40 Degree: Provides the widest common spray pattern, excellent for general cleaning tasks.

A nozzle with a narrower spray angle will deliver more impact than a wider fan. So it is important to identify a good balance between the impact you need and the fan angle desired. Often the best way to determine this is by testing some different angles in your application, but knowing this can provide a good starting point. 

Sizing a High-Pressure Nozzle 

In addition to the spray angle, you need to determine the nozzle size for your application. The orifice size of a nozzle affects the flow rate (measured in gallons per minute, GPM) through the nozzle.

Nozzles are sized based on their flow capacity at 4000 PSI. In other words, how many gallons will flow through the tip/orifice of the nozzle at 4000 PSI? For example, a #4 nozzle will flow 4 GPM at 4,000 PSI. A #3 nozzle will flow 3 GPM at 4000 PSI. 

This chart shows the flow capacity of each orifice size at various pressures: 

Identifying your nozzle size requires that you know the parameters of your system and size a nozzle accordingly. Let's look at an example: a pressure washer that delivers 3 GPM at 2000 PSI. Using the chart, you can find 2000 PSI at the top and follow the column down until we get to 3 GPM. Then we can follow the row left to the nozzle size column on the far left of the chart. This shows us that a 4.5 nozzle or orifice size will flow 3 GPM at 2000 PSI. 

This nozzle will work for the system in our example, but it is a good rule of thumb to select a nozzle size slightly smaller than what you find in this chart. In this case a #4. This will provide some bypass and allow for nozzle wear over time without a decrease in pressure. 

If you are unsure of any aspect of nozzle sizing, you can always get in touch with our high-pressure cleaning team!

Nozzle Features

While spray pattern and nozzle size are the two main factors you must consider, there are other nozzle features and attributes to keep in mind.

Internal Stabilizer Vanes: Some nozzles come with internal stabilizer vanes which create a more defined spray pattern. These are particularly useful in industrial or process cleaning where precision is a necessity.

Rotating Nozzles: High-pressure rotating nozzles or “Turbo Nozzles” have an internal turbine that creates a rotating stream that vastly improves efficiency when compared to flat fan nozzles.

Pipe Thread Sizes: High-pressure nozzles are usually available in 1/8” or 1/4” male or female pipe thread sizes, making them compatible with existing wands, arches, or other cleaning equipment.

Quick Coupler Nozzles: Designed to fit 1/4” quick coupler fittings, allowing for easy change out or removal.

By choosing the right nozzle, you can maximize cleaning efficiency and ensure that your equipment operates at peak performance.

Conclusion

High-pressure nozzles are a key component in effective cleaning systems. Understanding their types, features, spray angles, and orifice sizes can greatly enhance your cleaning results. Always ensure you’re using the right nozzle for your specific application to achieve the best performance and longevity from your equipment.

Selecting the Best Fertilizer Pump For Your Application

We all know the key role fertilizer plays in crop production. Handling large volumes of these vital plant nutrients requires the right transfer equipment. At the heart of every fertilizer transportation system is the pump. Whether it is unloading rail cars or filling the tanks on your planter, the type of pump you use has an impact on your ability to run your operation smoothly.

In this guide, we'll dive into the various types of fertilizer pumps. We will also look at the specific characteristics and attributes that hold up to the rigorous nature of transferring fertilizer.

Understanding Fertilizer Transfer Pumps

The primary pump type used for high-volume transfer of fertilizers is a centrifugal pump. Known for their simplicity and effectiveness, They are ideal for any scenario where the goal is to transfer fluid as quickly as possible. In other words, high-volume transfer scenarios such as loading or unloading semi-tankers, emptying rail cars, loading sprayers, applying liquid on fields, etc.

Now, centrifugal pumps are not the only pump types used to handle fertilizer. There are many different positive displacement pumps used to apply fertilizers on planters or toolbars, and there are gear pumps used for some more viscous products, but centrifugal pumps are the primary choice for high-volume transfer.

Advantages of Centrifugal Pumps for Fertilizer:

Simple
High-flow
Easy to repair
Durable

Disadvantages of Centrifugal Pumps for Fertilizer:

Low pressure relative to other pump types
May not handle really heavy or viscous products
Cannot be run dry unless they have a lubricated seal

How Fertilizer Transfer Pumps Work

Before we get to the dirty details of fertilizer pump selection, it is worth your time to get familiar with the basics of centrifugal pumps. Especially, if you aren’t familiar with them or need a quick refresher. If you want to jump straight to pump selection, click here to jump ahead(Nyngh?).

In order to gain a thorough understanding of how a centrifugal pump works, we should first look at the main components. These are the housing, the impeller, the shaft, and the shaft seal. Depending on the specific type of pump and the design there may be other components like a pedestal, volute, bearings, etc., but these are the main pieces that make up all centrifugal pumps.

Basic Components of a Centrifugal Fertilizer Pump:

Housing
Volute
Impeller
Shaft
Seal
Gasket
Pedestal/Adapter

A centrifugal pump operates by using centrifugal force to move liquid. The impeller, mounted on the shaft, is driven by a motor or engine. As the shaft rotates, the impeller also rotates. The rotation of the impeller creates centrifugal force, which pushes the liquid inside the pump away from the center (the eye of the impeller) towards the outer edges

Pump Curves

Variations in pump construction result in different capabilities, such as flow rate, head, horsepower, and efficiency points. These differences arise from the various pump sizes, the shapes of the pump volute, as well as the sizes and designs of impellers. These factors alter the pump curve, which represents the pump's performance based on discharge plumbing parameters.

All these different variations mean that it is important to look at a pump curve when choosing a pump and not just physical attributes such as the port size or horsepower. Those alone don’t tell the whole story.

A pump curve is a graphical representation that shows the relationship between the flow rate and the head (pressure) of a pump. It illustrates how a pump performs under different conditions, helping users determine the best operating point for efficiency and effectiveness. By understanding the pump curve, you can select the right pump and the horsepower needed for your specific application, ensuring optimal performance and energy savings.

How to read pump curves

For more detailed information on centrifugal pump operation and pump curves, be sure to read this detailed guide on centrifugal pumps written by Tom Hansen, Head Engineer at Dultmeier Sales. 

Selecting a Fertilizer Pump

Now that we have a solid understanding of how a centrifugal pump operates, Let’s look at the different aspects you should consider when choosing the right one for your needs.

Straight Versus Self-Priming

While there are many variations and different designs, all centrifugal pumps fit into two main categories: straight and self-priming. Both of these types operate on the same basic principle, using centrifugal force to move liquid. They differ in their ability to maintain liquid inside the pump. This is an important factor to consider when you select a pump so let’s examine this a bit further.

Self-priming pump

A self-priming centrifugal pump can pull liquid from a level that is below the pump inlet (assuming it is properly primed initially). This is achieved via a combination of the design of the volute and suction created by the pump. A self-priming pump is designed to store fluid in the housing even after it stops running. Thus keeping the pump seal protected when it is started again and it begins to prime.

Priming is important because a standard centrifugal pump requires liquid in it at all times to lubricate the shaft seal. I say standard because there are centrifugal pumps that can be run dry but more on that later. 

This video thoroughly explains the principles of pump priming:

Self-priming pumps are often used as transfer pumps to load and unload sprayers or nurse tanks. They provide more flexibility in this scenario because they do not have to be installed lower than the tank outlet. This means they can be installed almost anywhere on a truck or trailer and pull liquid from the tank. 

Straight centrifugal pump

A straight centrifugal pump will also create suction the same way that a self-priming pump does, however, due to the design of the pump volute, they do not store liquid. The inlet of the pump must be gravity-fed so that the pump is not operated without liquid. If the pump inlet is not gravity-fed (flooded suction), You can use a check valve or foot valve in the suction line to trap fluid in the pump. This will protect the seal from cavitation when it starts again. 

These pumps are generally more efficient than self-priming pumps. They are simpler machines, with impellers and casings designed for hydraulic efficiency. Self-priming pumps, on the other hand, have additional features like a priming chamber that can create turbulence and energy loss, making them less efficient.

A straight centrifugal pump uses most of its energy for pumping, whereas self-priming pumps must expend some energy on the priming process, reducing their overall efficiency.

Straight centrifugal pumps are very common in scenarios where the pump is going to be permanently installed with a flooded suction port:

Bulk transfer from large storage tanks
rail unloading, etc. 
onboard sprayers
planters
fertilizer toolbars

Choosing between a straight centrifugal pump and a self-priming centrifugal pump depends largely on your specific application needs. Self-priming pumps are versatile and work for many applications, but if you want efficiency and the pump will have flooded suction, then a straight centrifugal pump is generally the best way to go. 

Types of Fertilizer Pump Drives

Another aspect to consider when selecting a centrifugal fertilizer pump is the means you will use to drive it. A pump can be driven any way you want as long as you have enough horsepower to handle the application. 

Common centrifugal pump drive types used for fertilizer transfer:

Electric Motor
Hydraulic Motor
PTO Driven
Gas-Engine

Electric Motor Units

Electric motor-driven units are the most common drive type in fertilizer facilities. There are two different pump and motor unit styles: close-coupled and long-coupled. As the name suggests, a close-coupled is where the pump is directly bolted to the electric motor. Long-coupled pump units are connected with a set of couplers. 

Close Coupled Pump & Motor Units

SCLFE471 

A close-coupled pump unit is a much simpler design that has many benefits. Both self-priming and straight centrifugal pumps can be coupled with a C-face motor. Pump manufacturers build pumps with motor adapters to mate with several different electric motor frame sizes. 

Pros:

Compact design 
less expensive
easy to connect
No alignment issues

Cons:

Leaking around the pump seal can damage the motor

Long Coupled Units

DUVF4x3-20-SGL

Although they are more complex and expensive, long-coupled units have many benefits. They typically consist of a baseplate, a 3-piece flexible coupling, and the pump and motor. Pumps used for long coupled units are called pedestal pumps. This indicates that they have a bearing pedestal with a solid shaft.

Pros: 

Design protects motor bearings from leaks
Flexibility for more pump and motor combinations

Cons:

Requires precise alignment
Can be more expensive due to baseplates and couplers required

Consider Chemical Compatibility 

Compatibility is a crucial factor to consider. As you know, fertilizer is a broad term encompassing several different liquids used to improve plant growth. Most of these products possess properties that lead to rust, corrosion, and friction wear on pump components. 

Centrifugal pumps can be constructed using various types of materials. Due to the wide variety of chemical properties of the different fertilizers, there isn’t one material that works best for all of them. It is important to look at individual products to determine the best material to use. 

Common Fertilizer Pump Materials

Although no material will handle all types of fertilizers, there are some that work with common fertilizers such as 10-34-0 or 32% nitrogen. For these products, we recommend polypropylene or cast iron pumps with Viton mechanical seals. Stainless steel is another material that will work with a broad range of fertilizers, but due to the cost, it is only used when necessary.

If you are not sure what materials are best suited for the type of fertilizer you use, you can refer to our chemical compatibility charts or call us for help. Our years of combined experience give us a good idea of what materials should be used with different products.

Regardless of pump type, it is recommended to drain corrosive liquid from the pump and fill it with a non-corrosive liquid such as crop oil or RV antifreeze. This will significantly prolong the life of cast iron pumps.

Choosing A Seal Type

No matter what type of centrifugal pump you are using, the shaft seal is the most important component to understand. The seal provides a barrier keeping liquid in the pump as the shaft rotates. 

There are different types of seals used in centrifugal pumps, but the most common we see used with fertilizer is a mechanical seal. This type consists of two seal faces, an elastomer, and a spring: 

Rotating Seal Face: Attached to the pump shaft and rotates with it.
Stationary Seal Face: Fixed to the pump housing and remains stationary.
Elastomer: keeps the rotating pieces tight on the shaft.
Spring: Pushes the two faces together to maintain a tight seal

Each seal face is smooth and consists of durable materials such as silicon carbide, carbon, or ceramic. The seal elastomers can be Buna, EPDM, Viton, or other material that is compatible with the fluid your are pumping. While the pump is operating a small amount of the fluid being pumped forms a barrier between these two seal faces. This lubricates the seal and provides a barrier that keeps the pump from leaking around the shaft.

Viton mechanical seal assembly

Without liquid in the pump housing, a standard mechanical seal can fail because it is not lubricated. This is called “running a pump dry”. The two faces rub together creating friction that will harm the seal face or crack it all together. Even slight damage to the seal face can result in a leak. 

Using a pump with a lubricated seal or double seal assembly can prolong seal life. These mechanisms keep the shaft seal of the pump lubricated with antifreeze or grease. This adds protection in situations where the pump might run dry, like unloading trucks or storage tanks. Any situation where a tank is emptied or prime could be lost. 

Pressurized wet seal assembly on fertilizer pump & motor unit.

If your pump will be installed in a scenario where it could be running dry or you don’t want to risk seal failure in the middle of your busiest season, a double seal or lubricated seal is your best option.

Pump Size

When we say pump size, we are talking about flow rate. The amount of liquid you need your pump to move in a given amount of time is important, but determining what pump will deliver your needed flow rate can be tricky. 

The flow rate in centrifugal pumps is closely tied to the discharge head. An increase in discharge head leads to a decrease in flow rate, and vice versa. Understanding this relationship is essential for selecting and operating these pumps, as it directly affects their performance in various scenarios. 

Of course, no two scenarios are the same so let’s explore how you can go about sizing a fertilizer pump for a specific application.

Sizing A Fertilizer Transfer Pump 

First, you need to consider the specific fertilizer you are going to be moving as well as the plumbing layout. This process involves gathering some information, here are the basic steps:

Determine Desired Flow Rate: Calculate the required flow rate in gallons per minute (GPM). Consider the application, are you filling tanks? Unloading trailers? How quickly do you want the load/unload process to be completed?
Identify Your Fertilizer Properties: Determine the viscosity and density of the fertilizer.
Calculate Total Head (TDH): Determining the total discharge head of a pump involves calculating the total head or pressure that the pump needs to overcome to move the fluid through the entire system. If you have plumbing in place already, consider any restrictions such as elbows, valves, strainers, meters, vertical pipes, etc. For more details, you can read this guide that further explains total dynamic head.
Identify Pump: Once you know your flow rate and TDH, you can identify a pump that can achieve your desired GPM given your plumbing setup. This requires examining the pump curves of different models to find a suitable option. The pump curve will offer insights into the most efficient option and the required horsepower for your application.

The total dynamic head, the pump design, and flow rate, combined with the viscosity and weight of the fertilizer will determine how much horsepower is required. Determining pump flow rates and horsepower requirements is a complex matter. If you have questions or just want us to walk through this process, you can give us a call any day and we can help you determine the pump and motor size you need.  

Final Takeaways

Choosing the right fertilizer pump is crucial for efficient and smooth operations. By understanding the advantages and disadvantages of different pumps and the specific needs of your application, you can make an informed decision. 

Remember to consider factors such as pump type, drive methods, material compatibility, seal types, and proper sizing to ensure optimal performance and longevity of your equipment. Investing time in selecting the appropriate pump will ultimately lead to better handling of fertilizers, increased productivity, and cost savings in the long run.

There are many, many different options for fertilizer pumps, so do not hesitate to reach out to us if you need some guidance selecting a pump!

Tech Ag & Industrial Sales

Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.

Learn More About Author

What Kind of Pump Do I Need for DEF?

Selective catalytic reduction is an advanced process that is intended to minimize pollution from diesel engines and contribute to better air quality. Diesel exhaust fluid, or DEF, is central to this process. 

If you use modern farm or construction equipment you are well aware of the regulations that require the use of DEF. Although DEF is a simple liquid, consisting of urea and water, it does have unique properties. So for those who need to fuel equipment, the question arises what kind of pump do I need for DEF?

In this guide, Will will be looking at the properties of DEF to understand what types of materials are compatible with it. We will also take a look at the different DEF pump options and accessories. 

Understanding What Pump Types Are Suitable for DEF

The most important thing to consider when selecting a pump for DEF is material compatibility. There are other factors to consider such as flow rate and drive type, but this is most important. Let’s look at the materials that work for pumping DEF and the types of pumps that will work. 

Material Compatibility 

Diesel Exhaust Fluid (DEF) is a solution made up of 32.5% urea and 67.5% deionized water. DEF is non-toxic, non-flammable, and non-hazardous under normal conditions. However, DEF is not compatible with most metals and some plastics. This limits the pumps that are suitable to be used with it.

How important is this really? What is the worst that can happen if you use just any old pump? Simply put, it may work for a very short period but it won’t be long before you have issues. DEF decomposes into ammonia, which corrodes incompatible metals like copper, zinc, and aluminum. It causes pitting, erosion, oxidation, and galvanic corrosion, weakening metal and leading to rapid component damage.

So what materials do work with DEF? Stainless steel (grades 304 and 316), polyethylene, and polypropylene are resistant to the effects of DEF. Therefore manufacturers use these materials to construct pumps suitable for DEF. The seals and gaskets used for DEF pumps are EPDM or Viton. 

Material suitable for handling DEF:

Polypropylene
Viton
EPDM
Stainless Steel

Pump Types for DEF

Although the materials suited for DEF are limited, there are several different types of pump that will work fine for DEF fluid. Centrifugal pumps, diaphragm pumps, gear pumps, and even submersible pumps. Again, the type is not as important as the materials and elastomers used to construct the pump. 

Centrifugal pumps are most common for large volumes, and diaphragm pumps are used for dispensing into vehicles and equipment. Diaphragm pumps for DEF will generally come as a kit that includes the hoses, nozzles, and couplings needed for DEF barrels or other pre-packaged containers (more about this in a moment).

Centrifugal Pumps
Diaphragm Pumps
Submersible Pump

Pump Drive Types for DEF

A variety of drive options can be used for DEF Pumps. Electric motors, gas engines, hydraulic motors, air-driven pumps, and more. No matter what kind of power supply, you can find a pump that will work for you. 

Electric
Gas-engine Driven
Air Operated

DEF Pump Couplings 

Many DEF tanks and containers utilize Micromatic RSV valves and couplings. These couplings are designed to prevent contamination of DEF. They have a dry-break mechanism that minimizes the exposure of DEF to the environment during connection and disconnection, maintaining the purity of the fluid

These couplings also help to eliminate drips or spills. Even a small amount of DEF fluid can corrode metals, so the dry-break feature is vital to protect any equipment around your DEF pump and tank. 

RSV Coupler

RSV Drum/Tank Valve

RSV couplings are the same type of couplings used on beer kegs and other chemical containers. There is a valve in the tank or drum, and there is the coupler on your pump or suction hose.

There are two different types of Micromatic couplers: 3-key and 4-key. The reason for this difference is to prevent cross-contamination of equipment. For example, it prevents you from coupling a DEF pump to a tank containing some other chemical.

How to Connect the Micro Matic RSV Dispense Coupler

DEF Pump Options

Due to the specific applications and the limited materials that are compatible with it, manufacturers have designed pumps and pump units specifically for DEF. There are 12-volt options available for mobile applications as well as stainless steel centrifugal pumps for bulk transfer. 

12-Volt DEF Pumps

Flowserve: CT6-DEF
Fill-rite: FRDF012-PO
Piusi: PJ33102
MP: MX35322
Dura: DP6518-AE12

115-Volt DEF Pumps

Piusi: PJ33101
Flowserve: CT6-DEFA
Fill-Rite: FRDF120-PO 
Dura: 6518-AE110

Air Operated DEF Pumps

Filrite: FRAP32V

DEF Pump Kits

Understanding that DEF is only compatible with certain materials, you must be careful when selecting a pump, but then you have to piece together a hose, nozzle, meter, and tank that is compatible. This is time-consuming and nerve-racking if you are not certain that an item will work with DEF.

DEF pump manufacturers understand this and offer comprehensive solutions. There are several DEF pump kits that include a pump, hose, RSV coupler, and all the other appropriate fittings needed. These kits are often designed to hang off an IBC tote or 275-gallon shuttle. Some of these kits will even include a tank. 

DEF Pump Kits for Cage Tanks/IBC Totes

12-Volt Kits:

Dura: DP6518-AE12
Fill-Rite: FRDF012
Piusi: PUF101A1A
Flowserve: SICT6-DEFD

110-Volt Kits:

Dura: DP6518-AE110
Piusi: PUF101AOH
Fill-Rite: FRDF120
Flowserve: SICT6-DEFE

DEF Pump Kits with Tank

58 Gallon Tank Kit: PUPPT58

116 Gallon Tank Kit: PUPPT116

135 Gallon Tank Kit: DP2512-AE-135

DEF Pumping Accessories

Your pump’s compatibility with DEF is vital, as are the accessories you use to handle it. Here are some essential accessories to consider and the types that work with DEF:

DEF Tanks

Polyethylene and stainless steel are the best materials for DEF storage. Poly is much more affordable. You can use just about any poly tank but you will want to ensure that the tank is properly sealed up and equipped with dry-break couplers to preserve the purity of your DEF.

As mentioned earlier RSV couplers are the common method to ensure closed system transfer. These can be added to a tank if you do not have them. The RSV tank valves are made to fit into different thread types. If you use a 275-gallon IBC tote/Cage tank, you can replace the lid with one that will fit an RSV coupler. 

DEF Tank Options:

DEF Hose

EPDM rubber is the preferred hose to use for DEF. Hose fittings should be either polypropylene or stainless steel. There are also poly and stainless hose reels designed to handle DEF.

Other DEF Accessories:

Let Us Know if You Need Help

DEF is a uniquid fluid with properties that dictate that you use the right type of pump and accessories to handle it safely. Fortunately, the pumps that work with DEF are clearly designed to do so. If you have questions about whether or not a specific product will work for DEF let us know. 

Tech Ag & Industrial Sales

Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.

Learn More About Author

Fertigation & Chemigation Injection Systems for Irrigation

Injecting a liquid into a center pivot is an effective way to deliver nutrients to crops later in the growing season. Getting a fertigation or chemigation system setup is pretty straightforward, but there are some key aspects that you must get right to avoid any issues.

So if you are not familiar with the type of pump you need, not to mention the other components that make it all work, this article will give you the information you need. Let’s get to it.

Components Needed for Injecting Fertilizer or Chemical into a Center Pivot Irrigation System

The main components needed to inject fertilizer are the pump, check valves, hose, strainer, and tank. Several types will work as long as they meet the necessary size, flow, and compatibility requirements.

Positive Displacement Pump
Check Valve
Tank
Hose/Plumbing
Strainer

It is important to note that in addition to the fertilizer components we discuss in this guide, you also need a chemigation backflow preventer or check valve on the well. The fertilizer is injected downstream from this valve. The specifics are dictated by local regulations. This chemigation check valve prevents chemicals or fertilizer from getting into the well and contaminating groundwater.

These chemigation check valves are not sold by Dultmeier sales. For more information, you can check out this article from North Dakota State University. You can also check with your pivot dealer.

Injection Pump for Fertigation or Chemigation

If you want to apply fertilizer or chemicals through a center pivot you need a pump. That may be obvious, but you cannot use just any type of pump. While centrifugal pumps are commonly used to transfer fertilizer they will not be effective when it comes to injecting fertilizer into a pivot or any other irrigation pipe.

You need a positive displacement pump to inject liquids into the center pivot or irrigation pipe. This is a type of pump that uses mechanical means to physically move it fixed amount of fluid with each stroke or rotation. These pumps create higher pressure and central pumps and they can overcome the existing pressure in the irrigation line.

There are different types of positive displacement pumps. Piston pumps are commonly used when injecting into an irrigation line but a diaphragm pump can also be used. These injection pumps are rated in gallons per hour. In addition to moving the liquid, the pump also serves as the metering device.

These pumps can deliver a precise amount of liquid into the irrigation pipe, consistently with each stroke. The rate can be adjusted according to the amount of liquid you need to apply.

Irrigation Injection Pump Options

EZ Meter Piston Pumps

Available in 5-30 GPH or 10-100 GPH
Up to 150 PSI
Wettable parts made of stainless steel and polypropylene, Teflon available
Motors available in 12-volt, single-phase 110-220 volt, and three-phase 220-440 volt
Easily repairable

View all the options EZ Meter pump options here.

Check Valve

We already talked about the chemigation check valve in the irrigation line to prevent backflow into the well. There is another check valve that is needed for the fertigation system. This is installed in the injection port. They ensure fertilizer is released in the center of the pipe, providing even dispersion.

These ensure only fertilizer gets in and nothing leaks when the pump is not running. They also provide back pressure to ensure the pump meters are accurate.

Storage Tank

The tank is pretty straightforward whether you are using a stationary tank or you have a nurse trailer, you must have a vessel to hold your fertilizer. Flat-bottom vertical storage tanks are very common and they are rated to handle heavy fertilizers.

Poly Vertical Tanks Tanks for Fertigation:

Hose/Plumbing

The hose that you use might seem like an afterthought, but the wrong hose could give you a lot of trouble. Just like with the pump, the hose needs to be constructed of material compatible with the fertilizer you are using. For nitrogen fertilizers, EPDM rubber hose works great.

You will need a reinforced suction hose on the inlet side of your pump. This means that from the supply tank to the pump. This hose should also have an inside diameter that is at least the size of the pump inlet. Using a smaller diameter hose can restrict the flow to the pump, damaging the pump and keeping you from hitting your application rate.

The discharge hose does not need to be rated for suction. It should be rated to handle some pressure, the EZ Meter pumps from John Blue can produce 150 PSI. The nature of how these pumps operate does create pulsing. This means that your discharge hose will jump around a bit. So be sure it won’t rub on anything that could wear a hole in it during operation.

This is a typical plumbing diagram for injecting metering pumps.

Rinsing the pump is important. You can make it easier to do this by installing a 3-way valve somewhere in the suction line. This would allow you to switch from the fertilizer tank to a freshwater source. You can also use a three-way valve in the outlet of the tank so you can both withdraw and fill the tank without disconnecting the pump.

Filters

It is also vital to use a strainer in the suction line. This strainer should also be at least the size of the inlet port on the pump. A piston pump does not handle solid particles well, so the screen should have a fine mesh. The manufacturer of our piston pumps, John Blue, recommends an 80 mesh screen size to protect the pump.

80 Mesh Line Strainer

Final Thought

With the right equipment and setup, you can deliver the nutrients your crops need through your irrigation system. Remember that the correct pump is vital to achieving the accurate results you want. Plumbing things correctly will help prolong the life of the pump and save you time.

Tech Ag & Industrial Sales

Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.

Learn More About Author

High-Flow Diesel Transfer: How Fast Can I Fill?

Whether it's farming, construction, or mining, the seamless supply of fuel to your equipment is vital to maintaining productivity. Using the right diesel transfer pump can keep refueling from becoming a bottleneck in your operation.

Several options are available for refilling equipment and bulk transfer of diesel fuel. I have been working with customers to identify efficient ways to refuel equipment for several years. Using that experience and customer feedback, I will break down the options and lay out the best diesel transfer units for several scenarios.

Getting Started: Diesel Transfer Pump Options

Diesel transfer pumps come in many forms to suit various needs. Two common types used for refueling and bulk transfer are rotary vane pumps and centrifugal Pumps. Because diesel is not as volatile as gasoline, there are typically different pumps or safety features required when pumping gasoline. In this article, we are solely talking about diesel fuel pumps and systems.

Mobile Fueling Options

When you are in the middle of a harvest or a construction project, you need to get fuel onsite. This calls for mobile fuel transfer options that run off the power available. Typically this means 12-volt batteries, hydraulic motors, or gas/diesel engines.

12-Volt Rotary Vane Pump Units

You are probably familiar with the 12-volt rotary vane pumps used for mobile fueling. These are the 12-volt pumps that are installed right on top of a fuel tank. Often the pump manufacturer such as GPI or Fill-Rite, will package their pumps as kits. These kits generally include a suction pipe that fits into the pump inlet, a 3/4" or 1" discharge hose, a fuel nozzle, and an optional meter. These pumps feature a 2-inch male NPT inlet that easily attaches to standard 2" tank bung threads.

12-Volt Fuel Pump Specs:

Flow rate: Up to 25 gallons per minute (GPM)
Manufacturers: GPI, Fill-rite, Piusi
Inlet: 2-inch male NPT
Discharge Hose: 3/4" or 1"
Features: Fuel nozzle, optional meter, suction pipe

High-Flow 12-Volt Fuel Pump Options:                                                   

GPI Model: GIV25-012AD

Filrite Model: FRNX25-12V

Piusi Model: PUEX100-PO

RELATED: Mechanical Vs Digital Meter: Which One is Best for My Application (not yet written)

These 12-volt pump units are relied on a lot for mobile refueling applications. These pumps are reliable and can last for years. One downside to this type of pump is the flow rate. The highest flow 12-volt fuel pumps are rated to about 25 gallons per minute. 

That is pretty good for most scenarios but it does not take into account the loss of flow from the hose, nozzle, fuel filters, and any elevation you are trying to overcome. (Think pumping fuel up into a combine or a large excavator.) When all of this is taken into account, your flow may be greatly reduced.

Pressure loss is a tricky thing to determine, but you can see charts on this page that will help know the pressure loss in your plumbing setup. We will get to ways to get the most flow out of your pump in a moment, but first, let's look at some other high-flow pump options.

Engine Driven Diesel Pump Units

So what if these 12-volt pumps won’t cut it? I mean, If you are filling a 300-gallon fuel tank at 15 gallons per minute, it is going to take some time. That is where engine-driven centrifugal pump units come into play. These units offer more flow potential than the smaller 12-volt pumps. That is why we have built diesel fuel pump units to offer a more efficient refueling option for large equipment. 

High Volume Diesel Fuel Transfer Systems

Dultmeier High-Flow Diesel Unit Specs:

Flow rate: Up to 60 GPM
Pump Type: Centrifugal pump units
Inlet Hose: 1-inch or 1-1/2 inch
Flow Rate (Assembled):
1-inch version: 30 GPM
1-1/2 inch version: 60 GPM
Additional Features: Shut-off nozzle, filter, hose, reel, meter (optional)

On its own, a two-inch diesel pump driven by a gas engine is capable of moving over 150 gallons per minute. The cost of these pump and engine units is often comparable to the 12-volt pumps that can move 25 gallons per minute. Now, that may sound too good to be true, so let me explain.

When you are filling equipment you will likely need all of these things in addition to your pump: a shut-off nozzle, a filter, plenty of hose, a reel, and possibly even a meter. The 150 gallons per minute flow from a gas-engine driven centrifugal pump is only achievable with the right size hose. For a flow rate of 150 gallons, you would not want to use anything less than a 2-inch hose (inside diameter). Smaller hoses will restrict flow and so will a fuel filter, auto nozzle, meter, and hose reel. 

Even though these items reduce the overall flow rate you are still getting a lot more flow from one of these units compared to the 12-volt rotary vane pumps. Especially when pumping vertically into a combine or other large piece of equipment.

We build a 1-inch version and a 1-½ version. Assembled with filters, nozzles, hose reels, etc.,  they will still deliver a flow rate of 30 and 60 gallons per minute respectively. This flow rate is at the nozzle and after pushing through 35 ft of hose. The primary limiting factor is the fuel filters used on each unit

30 Gpm Unit: DUFPU1P

60 Gpm Unit: DUFPU1.5P

These units are available in various configurations. Base units have recoil start engines and no meters, but you can upgrade to an electric start gas engine and add a meter. Contact one of our team members to learn more. 

Stationary/Bulk Storage Tank Pumps

If you have a tanker truck to unload or want to fill your fuel trailers from bulk storage tanks, then you probably need more than a 30 or even 60-gallon flow rate. Well, as we discussed earlier, centrifugal diesel transfer pumps can achieve much higher flow rates than this, you just need the right plumbing. Let’s examine the bulk diesel transfer pump options. 

Electric Motor Driven Centrifugal Pump Units for Diesel

As referenced above, a two-inch centrifugal pump is capable of well over 150 gallons per minute. But you don’t have to limit yourself, for bulk transfer you can use larger pumps. Three-inch pumps can potentially move 300-500 gallons per minute or more. There are also plenty of larger diesel transfer options if your scenario requires it. 

Options:

Flow rate: 50 gallons per minute and up
Explosion-proof motors available
Common 2-3 inch port sizes

Popular Electric Motor Diesel Pump Units:

Diesel Unit: DUMP3030C

Exp Proof Motors GR81-½-3P

How to Choose a Diesel Transfer Pump for Bulk/Storage Tank

When you are looking for a high-flow transfer pump to handle bulk diesel transfer or truck unloading, here are the main things to consider:

Flow Rate: Decide how quickly you need to move your fuel. For example, if you want to fill a 1000-gallon fuel trailer in 10 minutes, you'll need a pump with a flow rate of at least 100 gallons per minute (GPM).

Power Source: Determine what pump drive type will work best for you depending on available power sources and site conditions.

Self-priming vs Straight: Choose self-priming If the pump needs to lift fuel from a lower level, such as from an underground tank. Use a straight centrifugal pump when the pump inlet is permanently lower than the liquid level of the tank.

Material Compatibility: Select materials that are compatible with diesel to prevent corrosion and ensure longevity. Metals: stainless, cast iron, aluminum, ductile iron, Rubbers: nitrile, buna, VitonⓇ.

You might be asking, “But what about filters or fuel nozzles, won’t those limit the flow rate?”. They certainly can if they are not rated to accommodate higher flow rates. Fortunately, there are high-volume filters and nozzles available for these applications. 

Viking series filters are designed for high-volume fuel transfer. There are different models and they will handle 120-300 gallons per minute.

Viking Filters:

Viking 2

Viking 3F

There are also high-flow fuel nozzles for flow of 100 gpm or more. Of course, you can always use a brass or stainless steel ball valve as well.

2-inch Fuel Nozzles: Morrison 2-Inch 75 Degree Nozzle

How to Maximize Your Diesel Pump Flow Rate

To maximize the flow rate from a diesel pump, it's essential to consider several factors that can influence performance, including hose size, fitting size, filters, nozzle, and vents. Let’s break down each component and how they contribute to optimizing flow rate.

Hose Size

The flow rate of fuel through a hose depends on the size of the hose's inside diameter. If you double the diameter of the hose, the flow rate can increase significantly. Bigger hoses reduce friction inside the hose. Smaller hoses create more resistance, which slows down the flow of fuel. A larger hose allows the fuel to flow more freely and quickly.

Tips to Maximize Flow:

For discharge hose, use the largest hose diameter possible to minimize friction loss. Example: for a 2-inch pump, use a 2-inch or larger inside diameter hose.
Ensure the hose length is only as long as necessary; longer hoses can reduce the flow rate.
Ensure the suction hose or pipe (this is any pipe or hose prior to the pump inlet) is large enough for the pump. Again, for a 2-inch pump, you need at least a 2-inch (inside diameter) suction hose or pipe. Same for 3-inch, 4-inch, etc.

Fitting Size

Similar to hose size, the diameter of the fittings used in the diesel pump system must be adequate to handle the desired flow rate without creating bottlenecks. You might have a 2-inch discharge hose, but if you use a 1-½ elbow or swivel, that will result in a flow reduction. If you have multiple points where there is a smaller fluid path, this really adds up.

Tips to Maximize Flow:

Select fittings that match or exceed the inner diameter of your hoses.
Avoid unnecessary bends, elbows, and reducers that can increase friction and reduce flow.

Filters

Filters are crucial for maintaining fuel quality but can introduce resistance and reduce flow rate if not appropriately sized or maintained. There are two size dimensions to consider with a fuel filter: port size and filter size.

Filter port size refers to the inlet and outlet on the filter. As a rule of thumb use a filter head with ports that match your hose size and pump outlet. Not all filters flow the same even if they have the same port size. One filter may allow a max flow of 18 GPM while another may be designed for 25 GPM. We can provide the flow rate of various filter types to find the best fit for your operation.

The reason for the different flow capabilities is due to the type of filter element inside the filter housing. These are available in various levels of filtration. Often this is measured in micron size. The smaller the number, the smaller the particles it will filter. 2, 10, and 30 microns are common filter sizes for fuel. While finer filtration is good, it can significantly affect your flow rate. 

Tips to Maximize Flow:

Choose filters with a flow rating that matches or exceeds your pump’s flow rate.
Regularly maintain and clean filters to prevent clogging and flow restriction.
Use 10 microns for most applications, and 30 microns for heavier fuels like diesel fuel.

Shop Fuel Filters

Nozzle

Discharge nozzles are necessary to stop flow when filing is complete, but these nozzles, especially automatic nozzles, can restrict flow. It is important to know that not all nozzles will flow the same even if they appear the same size. 

You can see high-flow fuel nozzles here. There are typical nozzles that will handle 15-20 GPM, but also larger auto nozzles that can handle flows of 75 and even 100 GPM.  

Tips to Maximize Flow:

Only use automatic or “service station” style nozzles when needed. For bulk transfer use ball valves instead as your shut-off. These have higher flow rates.

Vents

Proper tank venting is essential to maximize your flow. You must be able to remove air from your tank to add fuel, and you must allow air into your tank to withdraw fuel.

Venting is not just about flow rates, it is also a safety issue (see what can happen here). Diesel fumes can be flammable. Ventilation allows these fumes to escape safely, reducing the flammable vapors inside the tank. This minimizes the risk of fire or explosion.

Tips to Maximize Flow: Ask tank manufacturers/retailers to help size vents
Check the vent regularly for clogs or damage

Time & Money Saving Diesel Pump Accessories

Hose swivels are a great tool that makes handling your fuel nozzle easier, but they also keep your hose from wearing out at the ends from the natural twisting and bending that occurs over time when the hose is handled. 

View fuel swivel options and other petroleum accessories here.

Similar to a swivel, but these fittings are not “live” swivels. Pipe unions allow for the quick disconnection of pipes without the need to rotate them. This is particularly useful in tight spaces where turning a long pipe might be impractical. You can see the different size unions for fuel here. 

Hose Reels

How a hose is handled and stored has a profound effect on its lifespan. For example, a hose rolled up and hung on a hook can wear at the pressure point over time. A hose drug on gravel or rough concrete will suffer from abrasion and be prone to potential leaks. 

A hose reel helps to avoid these issues. It also removes the hard labor of rolling up and unraveling a hose. You will also avoid the potential safety hazards from a hose lying on the ground. 

Electronic rewind and spring rewind hose reels are available to work with fuel and they come in sizes that can handle up to three-inch hoses:

1 Inch Spring Rewind Fuel Hose Reels:

HNN818-25-26BTR 1 inch x 35 ft of hose

RFFD84050OLP 1 inch x 50 ft of hose

1-½ Inch Spring Rewind Fuel Hose Reel:

HN922-30-3115.5 1-½ x 50 ft of hose

Conclusion

In the world of demanding industries like farming and construction, the efficiency of refueling operations is crucial. The right diesel transfer pump can transform refueling from a logistical headache into a smooth, efficient process that keeps your equipment running without delays. 

There are many options, understanding the specific needs of your operation and the technical aspects of these pumps will help you make an informed choice. Always consider flow rates, power sources, and additional features like filters and nozzles to optimize your setup for maximum productivity.

You can reach out to one of our sales team directly via email or phone if you have any more questions!

Tech Ag & Industrial Sales

Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.

Learn More About Author

Understanding the Numbers on a Sprayer Nozzle: A Comprehensive Guide

It is no secret that there are quite a few options when it comes to sprayer tips. In fact, our catalog has over 30 pages dedicated to different spray nozzles! Fortunately, there is an international standard in place to ensure the consistency and performance of sprayer nozzles used in agriculture. This is crucial because nozzles need to perform reliably to apply pesticides, herbicides, and fertilizers effectively.

This standard, specifically known as ISO 10625, defines these specific nozzle characteristics: spray pattern, flow rate, and droplet size. The standard achieves this by implementing a numbering system that helps identify and categorize nozzles based on their performance characteristics and specifications.

Numbering System for Spray Nozzles

Now that we have the reasoning behind the numbers out of the way, we can examine what these numbers tell us. 

Each spray nozzle is assigned an identification code. This code may consist of letters and numbers. It provides the nozzle type, orifice size, spray pattern/spray angle, and material of construction. 

Nozzle Type: Manufacturer nozzle type/name. Denotes specific designs or features specific to this nozzle series such as extended range (psi), twin fans, droplet size, etc.

Spray Angle: The numbering system specifies the angle of the fan produced by the nozzle. Nozzle spray patterns have a vital role in effective coverage. For more details, take a look at this chart that shows the theoretical coverage of nozzles at different angles and spray heights.

Nozzle Size: The numbering system classifies nozzles based on their flow rate at a standard pressure (40 psi). This helps in selecting nozzles that deliver the correct amount of chemical per unit area.

Material/Features: The final part of the code will include information about the nozzle material (e.g., brass, stainless steel, plastic). It can also note other nozzle features such as a specific shape or characteristic of the spray pattern.

Let's look at an example of nozzle numbering using an “XR 110-04 VK” spray tip:

Here is the breakdown of what each section of this sprayer nozzle number/code means for this specific nozzle:

XR: This indicates the type or series of nozzle, in this case, the XR TeeJet, which stands for “extended range”. Extended range refers to the wide range of PSI the nozzle will operate at.

110: Represents the spray angle in degrees. This particular spray tip, therefore, will spray at a 110-degree angle.

04: Indicates the flow rate. In this case, it signifies a flow rate of 0.4 GPM at 40 PSI.

VK: Describes the material of the nozzle. "VK" stands for VisiFlo ceramic. This indicates that the nozzle tip is made of ceramic and follows the VisiFlo* color code.

*Just a quick note, VisiFlo was the color coding system started by Teejet to categorize different-size nozzles. This system was adopted by the ISO standard that is used today. The code assigns a color to each nozzle side:

Not all spray tips make it this easy. In some cases, spray tip numbers are not displayed as clearly on the nozzle face but instead may be labeled on the side or base of the nozzle. This variance in numbering location is because manufacturers often offer numerous nozzle types that vary in design, which of course further differs for each manufacturer.

Further complicating matters, some spray nozzle brands do not adhere to the ISO color coding system. To illustrate these differences, let's take a look at a few examples. 

Example Sprayer Nozzle Numbers & Comparisons

First, lets look at two nozzles from the same manufacturer and family/type. The only difference between the two is the sizes or flow rate:

The red nozzle is an 04 size and the yellow nozzle is an 02 nozzle. 

Now, sometimes the numbers are not this clearly displayed. Both of these are Teejet nozzles, but they are different types. You can clearly see the numbers on the XR spray tip but this other nozzle does not have the numbers listed in this form.

You can see that the nozzle does have an 04 on the tip, this along with the color indicates the size, as all red nozzles are going to be an 04 size. It does say Turbo and Teejet on the side but it is hard to see.

You will notice that there is no indication of the spray angle or the material. But, if we look up a TT nozzle in our catalog you can see that a Turbo TeeJet is going to have a 110-degree tapered flat fan and is made of polymer. This is an example where the manufacturer, because of the unique design of their spray tip, has only labeled the nozzle with the nozzle series (Turbo Teejet/TT) and the size (04).

Since all sizes within this family of nozzles share the same spray angle and material, the nozzle type is understood to stand in for this information without it having to be shown directly on the tip as with the XR nozzle. If you are uncertain or have a nozzle that lacks numbers clearly displayed on it, call us, we can help you!

In our next photo, we have two nearly identical nozzles. Same brand, same type, same size, and color; however, there is a significant difference in the spray pattern produced by each one. Once more, the numbers tell the story. 

First Number: We know the first set of numbers is the spray angle. So here, the nozzle on the left produces an 80-degree fan, while the nozzle on the right will produce a 110-degree fan.

Second Number: We know this portion of the number signifies the size of the nozzle, which in this instance is 04 for both. We know this from the number as well as the color.

Letters: This is where things start to get interesting. The nozzle on the left does not have any prefix numbers (More on this in a bit). Conversely, the nozzle on the right is an XR tip. As we explained earlier, this means it is an extended-range flat fan tip. The final set of letters indicates the material of the tip, which for the nozzle on the left is VS (stainless) and on the right is VK (ceramic).

But what about that “E” before the VS on our first nozzle? This notes that the nozzle has a special spray fan. It is not the standard tapered flat fan found on most ag sprayer nozzles. Instead the “E” tells us that the nozzle produces an even spray pattern.

This one little letter makes these two nozzles very different. The XR nozzle will give you a tapered flan fan pattern. It applies the most spray in the center of the pattern, with less towards the edges. This is designed to overlap with other nozzles on a boom. An even fan spray nozzle, on the other hand, produces a uniform spray pattern across its entire width. This type is ideal for band spraying, where a consistent amount of spray is needed over a specific strip or band. Unlike the tapered flat fan nozzle, it does not taper off at the edges.

Image from Teejet.com

For our last comparison, let’s look at Greenleaf TurboDrop nozzles. These nozzles all consist of two pieces that each have different numbers on them. This can lead to some confusion. The reason for the two sets of numbers is that they are made up of two sections: a venturi pre-orifice and a tip/cap.

Below we have a TDXL11004 TurboDrop series nozzle. The venturi, which is the red portion, has a size number on the side. For the TDXL11004, that number is TD 04. This follows the same color code and size code as other flat fan nozzles. 

The tip/cap, which is white for this particular nozzle, will also have a number. You will notice that our number is 110-08 and the color is white. If you remember, a nozzle with 04 in the number will have a flow of 0.4 GPM. So what is this 08 tip doing on a nozzle that says it is rated for 0.4 GPM?

Greenleaf TurboDrop nozzles are designed to reduce drift and still offer excellent coverage. Their two-piece design pulls air into the droplets to create a consistent droplet size. The venturi or pre-orifice controls the rate while the tip/cap produces the fan. Consider the TDXL11004, On its own the white 08 tip/cap could be used as a standard 11008 spray tip that will produce finer droplets.

When combined with the venturi, though, it becomes an effective air-induction nozzle. The tip is double the size of the pre-orifice and this difference is what helps pull air into the nozzle resulting in larger air-filled droplets.

Using These Numbers: Spray Nozzle Charts

Once you understand spray nozzle numbering, you’ll be able to better choose the right nozzle for your specific application. Identifying the number on the nozzle is just half the battle. You will also need to know how to read a spray nozzle chart to compare nozzles and examine the different characteristics of each type. 

A spray nozzle chart provides all the necessary information you need to determine how a nozzle will perform under various operating pressures. These charts are provided by the nozzle manufacturers, TeeJet, Wilger, Hypro, Greenleaf, etc. Nearly all spray charts will display the following information:

Flow Rate: The amount of liquid delivered per minute at a specified pressure, usually measured in gallons per minute (GPM) at 40 psi.
Spray Angle: The width of the spray pattern produced by the nozzle, measured in degrees.
Droplet Size: Classification of the droplet size produced, which can range from very fine to extremely coarse.
Operating Pressure: The range of pressure that the nozzle will perform as intended, usually measured in pounds per square inch (PSI).
Application Rate: The amount of liquid applied per unit area, expressed in gallons per acre (GPA).

Spray nozzle charts warrant a more detailed discussion to thoroughly understand them. While we won’t get into those details in this guide, for more information check out this article on how to use sprayer nozzle charts.

Spray Nozzle Selection Tools

Many spray nozzle manufacturers now also offer electronic spray tip selection tools that offer nozzle recommendations based on your specific application inputs. These tools make nozzle selection easy, but a basic understanding of the numbers behind the nozzle is still important when using these tools:

Conclusion

Understanding the numbering system for spray nozzles is crucial for selecting the right one for your application. The ISO 10625 standard provides a clear and consistent method to identify and categorize nozzles based on their performance characteristics. 

Dultmeier handles a large quantity of TeeJet, Wilger, Greenleaf, and Hypro sprayer nozzles in stock and ready to ship. If you need assistance sizing and selecting a nozzle, don’t hesitate to reach out for expert help. 

Tech Ag & Industrial Sales

Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.

Learn More About Author

Gallons Per Minute (GPM) Calculator: Determine Spray Nozzle and Orifice Size

Sprayer nozzle or fertilizer orifice selection requires that you know the flow rate or size of tip that you need. This tool will help you quickly and accurately calculate the flow rate required per sprayer nozzle to apply your desired application rate.

GPM Calculator

Gallons Per Acre (GPA):
Miles Per Hour (mph):
Nozzle spacing (in inches):

Using This Information

With this information, you can use a sprayer nozzle chart to find a nozzle that will apply this flow rate. For more information, refer to this complete guide to finding a nozzle size, that breaks down using a spray nozzle nozzle chart. If you need help sizing nozzles for a PWM system then refer to this guide.

Understanding The Formula In This Calculator

We use the GPM formula to determine the spray nozzle or orifice size needed for your specific sprayer and application requirements. The formula looks like this:

And here is what each value in the equation represents:

GPM (Gallons Per Minute): This is the flow rate of each nozzle on the sprayer. It tells you how many gallons of liquid are being sprayed out of each nozzle every minute.
GPA (Gallons Per Acre): This is the amount of liquid you want to apply per acre. Your target application rate.
mph (Miles Per Hour): This is the speed at which you're driving the sprayer, tractor, UTV, etc.
W (Width in Inches): This is the nozzle spacing from center to center of each nozzle.
5,940: This is a constant number used to convert the units back into a number that is easy to work with. It is a derivative of the different units involved in this formula. The important part is that you know you need to use 5940 in this formula.

Example Calculation:

You want to apply a rate of 20 gallons per acre. The average speed you will spray at is 5 mph. The distance between each spray nozzle is 20 inches (center to center).

In this case, you would Input these values into the calculator:

GPA: 20
Speed: 5
Nozzle Spacing: 20

Click "Calculate GPM" and you get:

GPM: Approximately 0.34

This means each nozzle should deliver 0.34 gallons per minute to apply 20 gallons per acre at a speed of 5 mph with nozzles spaced 20 inches apart.

This formula works for broadband spraying applications with overlapping flat fan nozzles as well as solid stream nozzles used on fertilizer bars and applicators.

Finding a Spray Nozzle

Nozzle size is a major factor when selecting a spray nozzle but it is not the only thing to consider. You also should consult the label on the product you apply for guidance on the specific spray nozzle requirements for your application.

Dultmeier Sales carries a wide range of sprayer nozzles for nearly any application:

Broadcast
PWM
Drift-control
Pre or Post-emergent
Contact or systemic
Soil applied
Insecticides
Fungicides
Herbicides
Fertilizer

If you are looking for guidance, get in touch with us and we can help you with sizing and finding a sprayer nozzle.

Tech Ag & Industrial Sales

Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.

Learn More About Author

A Comprehensive Guide to Pre-Season Preparation for Farmers: Maximizing Yield and Efficiency

This guide focuses on the unique needs and challenges of row crop farming, emphasizing efficient use of resources, technology integration, and sustainable practices to enhance productivity and profitability.

1. Soil Testing and Field Preparation

Conduct Detailed Soil Tests: Test each field for pH, nutrient levels, and soil composition to guide precise fertilizer and lime applications. Soil sample analysis can be done by your local soil laboratory or extension service.

Field Preparation: Implement tillage practices suited to your soil type and crop needs. Minimum tillage can preserve soil structure and moisture, while conventional tillage may be necessary in certain conditions to prepare a seedbed, control weeds, or incorporate amendments.

2. Crop Selection and Rotation

Select Adapted Varieties: Choose crop varieties with high yield potential, disease resistance, and adaptability to your climate. Consider traits such as drought tolerance or herbicide resistance as applicable.

Implement Crop Rotation: Rotate crops to break pest and disease cycles, improve soil health, and optimize nutrient use. Plan rotations to include legumes to fix nitrogen, reducing the need for synthetic fertilizers.

3. Seed Treatment and Planting

Use Treated Seeds: Opt for seeds treated with fungicides and insecticides to protect against early-season pests and diseases. Consider seed treatments that enhance germination under cold or wet periods or seed varieties which tolerate drought or high-wind conditions.

Precision Planting: Use precision planting equipment to ensure uniform seed depth and spacing. Calibrate planters for specific seed sizes and adjust planting rates based on germination tests and field conditions.

4. Water Management

Irrigation Efficiency: For irrigated fields, optimize irrigation schedules and methods (pivot, drip, or furrow) based on soil moisture monitoring and crop water needs. Consider technology like soil moisture sensors and weather-based irrigation scheduling.

Drainage: Ensure proper field drainage to prevent waterlogging and enhance root development. Install or maintain drainage systems where necessary.

5. Integrated Pest Management (IPM)

Scouting and Monitoring: Regularly scout fields for pest and weed pressure. Use thresholds to make informed decisions about the need for interventions.

Chemical and Biological Controls: Use targeted chemical controls when necessary and consider biological controls like beneficial insects for sustainable pest management.

6. Machinery Maintenance and Calibration

Equipment Readiness: Ensure all planting, tillage, and spraying equipment is in good working order before the season starts. Perform necessary maintenance and repairs during the off-season.

Planter Calibration: Precisely calibrate planting equipment to match seed size, type, and desired planting rate. Check and adjust downforce, seed tubes, and closing wheels to ensure optimal seed placement. Perform a short test swath of planted seeds to ensure all settings are correct before planting entire fields.

7. Technology in Farming

Adopt Precision Agriculture: Utilize GPS-guided equipment for precise planting, fertilizing, and spraying. Consider variable rate technology (VRT) for applying inputs based on soil and yield data.

Data Management: Use farm management software to track field operations, input applications, and crop performance. Analyze data to make informed decisions for future seasons.

8. Weather and Climate Adaptation

Weather Tracking: Use weather forecasts and climate data to plan field operations and mitigate risks from extreme weather events.

Resilience Practices: Implement practices to increase crop resilience against climate variability, such as cover cropping, diversified cropping systems, and conservation tillage.

9. Economic Planning and Risk Management

Cost Analysis: Conduct detailed cost analyses for each crop, considering input costs, projected yields, and market trends.

Risk Management: Utilize crop insurance and marketing strategies (futures, options, contracts) to manage price and yield risks.

10. Professional Development and Networking

Continuous Learning: Stay updated on agronomic research, crop protection products, and new technologies through extension services, agricultural publications, and professional associations.

Collaboration: Engage with local farming groups, cooperatives, and research institutions for shared learning, market opportunities, and collaborative projects.

Choosing the Best Type of Flow Meter for Your Application

Flow meters are some of the most versatile and integral components in any fluid handling system. From agriculture chemical production to water treatment facilities, meters offer a reliable means to monitor how efficient your operation is and provide a tangible reading to identify potential issues within the plumbing system. This makes choosing the right flow meter for your application even more important. Selecting the wrong meter causes inaccuracies within your flow monitoring processes and creates inefficiencies throughout the rest of the system, not to mention significant unintended costs.

Dultmeier Sales is here to ensure that doesn’t happen.

In this guide to flow meter selection, we’ll take a look at several common meter types and the various applications in which they are used. We will also highlight some key considerations to keep in mind so that you always choose the best flow meter for your application needs. So, without further ado, let’s get started.

How to Choose the Right Flow Meter

Simply put, a flow meter is a device that measures the flow of material—typically either liquids or gases—through a pipe. The flow meter then calculates the volume and flow rate of the product, referred to as the “fluid,” being measured. Flow meters are, however, more complicated in practice.

Fill-Rite mechanical flow meters & digital flow meters

For one, no two meters are exactly alike. Depending on application and metering needs, you may have several meter options or a single very specific one from which to choose. Complicating things further are the many external considerations your meter must satisfy in order to accomplish its intended purpose. As they say, the “devil is in the details,” and the same goes for choosing the best flow meter for your application.

Below are some key characteristics to keep in mind when selecting the proper flow meter:

Accuracy & Repeatability
Type of Fluid (liquid, gas, slurry, steam)
Density
Viscosity
Conductivity
Temperature
Pressure
Flammable/Oxidizer
Corrosiveness/Toxicity
Flow Range/Turndown
Materials of Construction
Environment/Location & System Configuration
Hygiene Requirements (pharmaceutical, food processing, etc.)
Costs
- Initial Investment
- Installation
- Long-term Maintenance

While the meter you ultimately select should ideally meet every factor above, ensuring it meets the most important ones for your operation will help guarantee you receive the best results. Let’s dive into a few of the main ones on which you should focus.

Accuracy & Repeatability

Near the top of the list when evaluating flow meter specs is flow meter accuracy. Accuracy is how close a measurement is to the actual true value passing through a system. Expressed as a percentage (i.e. +/- 1%) accuracy represents how close the meter’s output is to its calibrated parameters. Generally, the lower the percentage, the more accurate a meter is.

However, accuracy is not the only side of the coin. Repeatability, or the production of like outcomes under the same conditions, is perhaps even more important when evaluating which flow meter to choose. This is because accuracy is only reliable so far in as its consistency. As you can see below, repeatability is possible without high accuracy, but high accuracy is not achievable without repeatability.

Flow meter accuracy & repeatability

If your flow readouts are unreliable—meaning you receive inconsistent results despite the same conditions—then you aren’t gaining any value. Likewise, if your flow volume falls short of or exceeds your meter’s rated flow range (also known as turndown), you won’t receive accurate readings either.

Precision readings go hand in hand with any well-tuned operation. Choosing the best flow meter accuracy and repeatability percentages that meet your application requirements ensures your system maintains the precision readings you desire.

Liquid, Gas, or Semi-Liquid?

The type of fluid you work with is another big factor when choosing which flow meter best fits your application. Fluid type breaks into four categories: gas, liquid, slurry, and vapor—each with it's own unique characteristics.

Properties such as fluid density, temperature, viscosity, and corrosiveness/acidity all must be determined before a final selection. This ensures you avoid choosing a flow meter incompatible with the fluid type you are attempting to measure. Electromagnetic flow meters, for example, won’t work with non-conductive fluids like hydrocarbons. Likewise, few meter types are capable of measuring slurries because of their unique semi-liquid characteristics.

Illustration of how slurry particles behave between homogenous & heterogeneous mixtures

Here is a shortlist of flow meter types commonly used for the four fluid categories:

Gas: Coriolis, Thermal Mass, Positive Displacement, Turbine, Variable Differential Pressure, Ultrasonic
Liquid: Coriolis. Thermal Mass, Positive Displacement, Variable Flow, Paddlewheel, Turbine, Variable Differential Pressure, Ultrasonic, Electromagnetic
Slurry: Coriolis, Electromagnetic, some subsets of Differential Pressure
Vapor: Vortex, Ultrasonic, Floating Element

While not comprehensive, this list should offer a good starting point. That said, not every meter listed may work for your specific setup or needs. For instance, if your operation handles multiple fluids, you’ll want to ensure that the meter you go with is compatible with all fluids—not just one. Otherwise, you likely spend valuable time calibrating your flow meter each time you handle a different product or troubleshooting why your inventories are off from your readouts.

Location & System Configuration

Meter location, as in real estate, is another major consideration. Will the flow meter be installed inside a controlled environment or outdoors in the elements? Is space a non-factor, or must size be considered? Certain flow meters even require stretches of straight pipe before and after the meter to generate accurate flow readings.

As a rule of thumb, pipe lengths of 10X (where X = pipe diameter) are needed before and after a meter for straight runs of pipe. So, if your plumbing’s diameter is 2” you would need 20” or approximately 2 feet of pipe before and after the flow meter. This goes for just about any meter type, but it is always best to check the manufacturer’s specs.

Also, keep in mind horizontal or vertical mounting. Some meters can be mounted in either orientation while others must be one orientation or the other. Variable flow meters, for example, rely primarily on gravity in order to measure flow rate. Thus, they must be installed vertically to work. Determining how and where a meter will be installed while choosing a meter saves installation time and avoids costs related to unintended system reconfiguring.

Differentiating Between Volumetric vs. Mass Flow

Before we breakdown various flow meters, it is important to say a word on flow measurement. While there are many types of flow meters, most used today fall under two primary categories according to how they calculate flow: volumetric and mass.

As their name suggests, volumetric flow meters measure flow by calculating the volume of a fluid. Flow is often directed through an intrusion metering device such as a turbine or orifice plate, which then measures fluid velocity proportionally to the volume of matter passing by. Volumetric flowmeters make up the majority of meter types today and include turbine, magnetic, positive displacement, ultrasonic, and vortex meters to name a few.

Volume flow vs. mass flow within a cylinder

Mass flow meters, meanwhile, calculate flow rate by measuring the mass of a fluid. Mass meters have become increasingly popular due to their precision performance and truer reading of product flow compared to older metering technologies. In the diagram above, for instance, the product volume significantly changes depending on the position of the piston—even as mass remains the same. Today, mass meters have more or less become synonymous with Coriolis mass meters, but other types do exist. We’ll discuss how mass meters work later in the article.

Whether you choose volumetric meters and mass meters depends on your application and metering needs, as well as your operational preferences and cost differences. In the end, you can still calculate volume to mass or mass to volume so long as the fluid density, surrounding temperature effects, and other conversion factors are all understood.

Comparing Flow Meter Types

There is, unfortunately, no such thing as a universal flow meter. Each flow meter type has fluids and applications for which it is well suited, and similarly, ones for which they are not. The following is a breakdown of some of the most common types of flow meters and the pros and cons of using each one.

Positive Displacement Flow Meters

Pros

Accurate across wide flow ranges
*Can handle very viscous fluids
Versatile applications—simple, reliable design
Require no power supply
Cost effective

*Thicker viscosity fluids create larger pressure losses & reductions in flow rates

Cons

Requires medium to high flow applications
Experience greater pressure drops
Larger/heavier than other meters
Not recommended for dirty fluids or gases
Some subsets require constant lubrication
Many moving components need regular maintenance and replacement

Positive displacement (PD) meters consist of chambers featuring mechanical components that rotate in relation to volume flow. As fluid passes through, the reciprocating components—generally a type of gear, vane, or diaphragm—divides the fluid into fixed, metered volumetric units. The number of units rotated through within a specified time frame directly correlates to flow rate. Subtypes include screw meters, rotary vane meters, diaphragm meters, reciprocating or oscillating piston meters, and helical or oval gear meters.

TCS 700 Series Rotary Fuel Meter with Register

Since PD meters only measure flow while fluid passes through, they’re ideal for applications where metering is crucial to calculate fluid usage. The TCS 700 series rotary vane meters, for example, are widely used in oil and gas custody transfer industries, while diaphragm meters are commonly installed on residential or municipal water and gas lines. Their fluid driven design additionally makes positive displacement flow meters one of the more cost effective options since they require no outside power supply to operate. However, these meters are ill-suited for impure fluids such as wastewater or slurries, as the suspended soils can clog or slow the reciprocating elements and create inaccurate readings.

Electromagnetic Flow Meters

Pros

Obstruction-less/No moving components
Highly accurate—unaffected by density, viscosity, turbulence, or pipe configuration
Can handle wide flow ranges & multiple fluid types
Zero pressure drop
Bi-directional
Cost effective

Cons

Cannot measure gases, vapors, or non-conductive liquids
Limited fluid temperature range
Interference possible with certain suspended fluids
Specialized subsets can be expensive

Electromagnetic flow meters, also known as magnetic flow meters or magmeters, are rather unique in the technology they use to measure flow. Magmeters feature two parts, a transmitter and an inline sensor, the latter of which features coils that generate a magnetic field. When a conductive fluid passes through the field, a voltage is produced proportional to flow. This flow principle is known as Faraday’s Law.

Unlike other meters, magnetic flow meters can measure fluids regardless of fluid density, viscosity, or flow turbulence. This makes mag meters highly accurate and reliable across a wide range of solutions. Additionally, their design features no obstructions in the pipe, making these meters ideal for a wide spectrum of applications, from highly sanitary liquids to slurries and highly corrosive fluids. Electromagnetic meters can be found in industries such as pulp and paper, metals and mining, food and beverage, water and wastewater, chemical transfer, and many more.

Magnetic meters, however, only work with conductive fluids. This means hydrocarbons such as oils or gasolines or deionized liquids are not recommended with mag meters. Suspended solids, such as those found in various ag chemicals and fertilizers, can also sometimes pose a problem. The suspended soils, which may not be conductive, can interrupt the magnetic field and throw off the reading’s accuracy. Newer, specialized magmeters such as slurry magmeters are engineered to counteract this magnetic interference. However, these units generally feature heftier price tags compared to standard models.

Turbine Flow Meters

Pros

Highly accurate
Cost effective
Capable of measuring low flow rates
Versatile applications—simple, reliable design

Cons

Not recommended for dirty or suspended liquids
Require straight pipe runs for best results
Limited to certain pipe sizes
High flows rates can cause damage or inaccuracies
Moving components need regular maintenance and replacement

Like paddlewheel or propeller flow meters, turbine meters feature a multi-bladed rotor mounted inline to fluid flow. Sensors attached to one or more of the turbine blades transmit the number of revolutions the turbine makes. The speed at which these revolutions happen is proportional to volumetric flow rate. Similar to positive displacement meters, turbine and paddlewheel meters only measure flow when fluid mechanically acts upon their metering components.

Because turbine meters provide accurate readouts in relation to linear flow—even at low flow rates—they are widely used in the oil and natural gas, custody transfer, and petrochemical industries. In fact, turbine meters are often used to help verify accuracy on other meter types.

Turbine meters aren’t without their limitations, though. For starters, turbine meters are not well suited to handle dirty or highly viscous fluids, as the turbines can be easily fouled by the soils. These meters also require straight runs of pipe before and after the meter to stabilize flow for the most accurate results. Additionally, larger pipe diameters are incompatible from an engineering standpoint. This limits where and for what applications turbine meters can be installed. Finally, as with any technology with moving components, regular maintenance is necessary to keep these meters in peak performing condition.

Coriolis Flow Meters

Pros

Extremely accurate
Low maintenance
Can handle a wide spectrum of flow ranges
Compatible with many dirty, corrosive & difficult to handle fluid types
Versatile installation—no straight pipe runs required
Serviceable without removing from pipeline
Easy in-field calibration
Capable of measuring gases

Cons

Expensive initial investment
Not suited for low pressure gases
Limited to certain pipe sizes

Coriolis meters, more commonly known as mass meters, differ from other meter types in that they measure mass flow instead of volume flow. These meters also feature a unique means of calculating flow rate based upon the Coriolis Principle. Check out the video below for a quick look at Coriolis meter technology.

Advantages of Mass Meters

Mass meters generally hold an NTEP certification and are widely used in legal-for-trade (resale) applications. In the Dultmeier Sales world, this generally means fertilizers or chemicals with respect to the agricultural industry. Back in the 1990s, Dultmeier Sales partnered with Kahler Automation to offer some of the first automated solutions for fertilizer/chemical plant automation.

The mass meter was at the heart of the system because it was new technology that allowed end-users to sell using the real-time density of the product – a truer way to meter liquids. For example, water is known to be 8.34 lbs. per gallon at 70⁰F. However, as temperature drops, the weight of water increases. Thus, the solution of water becomes denser as the ambient temperature drops. This would mean static volumetric calculations would be off if one pumped 1000 gallons of water and converted to 834 lbs. (using 8.34lbs/gal as the constant conversion factor) if the water were only 50⁰F.

This same principle happens with fertilizer and chemicals – as they are generally water-based solutions. Volumetric meters of the time; however, were unable to account for this change in density in relation to volume flow. Take this scenario for example, which was quite common in the 1990s and early 2000s:

Let’s say that it’s 40⁰ F. and we’re loading a 10,000 gallon tender trailer, running 32% Nitrogen into the vessel. We’re using a paddlewheel meter as our measuring device and pumping the product into the vessel. Once we reach our hit point of 10,000 gallons – the automated equipment shuts down and we send our trucker to the scale. The scale breaks in 20 lb. increments.

Our potential for error:

Paddlewheel meter runs at approx. +/- 2% accuracy (mass meter is +/- .3% accuracy)
Paddlewheel cannot determine density reading, so we have a static calibration factor that was calibrated at 70⁰ F. (or another temperature) and we are using that static factor to now calibrate pounds to gallons at 40⁰ F.
Scale breaks in 20 lb. increments vs. mass meter measuring in increments of 1/10th of a pound
Scale cannot account for “slosh” or movement of liquid as truck stops abruptly on the scale

Considering these many variables and the potential for error, it’s no wonder why inventories could, and often would, be way off come year-end. We know that a solution’s density changes constantly if in an ambient environment. For this reason alone, mass meter technology is the preferred method of measurement in many instances. By using a mass meter that can continually read this fluctuation in density on-the-fly, we offer our customers a better method to dispense and record inventory.

Automated Mass Meter Systems—Praxidyn

MixMate Flow Stack System

Choosing the right flow meter for your application can often come down to dollars and cents. Coriolis meters with automated equipment controls like what Praxidyn offers can provide a more accurate way to measure and sell fertilizer and/or chemicals. Praxidyn has a complete line of automated meter systems that fit almost any application, from grower specific operations to global industrial applications. Analysis has proven that an automated system can pay for itself in just one season – based solely on shrinkage/cost savings alone. Figure in the savings from enhanced efficiency and mass meters more than pay for their high initial investment costs.

Flow Meter Price, Performance & Popularity

Unfortunately, there is no universal flow meter that works for every application. Depending on how diversified your operation is, that could mean multiple types of flow meters are needed. While it is fair to research the most popular meters for your industry, don’t buy the first meter you think will work.

Price, quality, and other key factors do play a significant role in a flow meter’s overall performance. Simply because everyone else uses a certain meter does not mean you should be. Low purchase cost, for instance, shouldn’t be the deciding factor in choosing the best flow meter for your application. When choosing a flow meter, you have to consider not only the initial purchase price, but the overall lifetime costs and long term returns on investment, too.

For instance, while a Coriolis meter boasts a hefty price tag at initial investment, it provides a great ROI because less maintenance and greater product savings are realized over the long run. Mass meters’ exceptional accuracy, versatile flow ranges and fluid compatibilities, minimal wearable parts, and the ability to recalibrate without removing the meter from the pipeline all translate to fewer dollars spent overall. When it comes to the bottom line, spending more money upfront can outweigh years of hemorrhaging dollars spent repairing or replacing inefficient meters.

That said, not every operation needs an expensive, high-end flow meter. It’s a good idea to run a cost assessment evaluating application needs against initial investment costs and long term cost savings. This way you have the best picture of whether a certain meter is practical or worth the price tag over the long haul. If you need help assessing meter options and determining what is best for your application(s), we are always just a phone call away at 1-888-677-5054.

Final Words

We hope this article has provided some insight into the world of flow meter solutions. Although we covered some of the most common types, these are by no means the only flow meters out there. Choosing the best type of flow meter for your application all starts with knowing what you need and researching your best options. Compare all associated costs—both short and long term—and avoid making a decision based on price tags alone. Ultimately; however, the manner in which you choose to meter is entirely up to you.

If you have any questions regarding flowmeter selection, give us a call at 888-667-5054 or dultmeier.com. Dultmeier Sales carries a diverse inventory of chemical and water flow meters, flow meter repair parts, and flow meter accessories. No matter what meter your operation requires, our experience and technical expertise will help make sure you select the right one.

Disinfectant Basics - 3 Methods for More Effective Disinfecting

We speak a lot about sanitation and disinfection these days. From the office and classroom to our own personal spaces, we are focused on cleaner, safer areas more than ever. And while many businesses are just now taking a closer look at how they clean their facilities, disinfecting in food processing has long been serious business. That doesn’t mean all disinfectants for food processing cleaning are made equal.

Disinfectants come in a variety of forms, each with its distinct advantages and disadvantages. In fact, which disinfectant you choose for your application is just as important as the why and how you disinfect. As we’ll cover in this article, understanding the basics of each disinfectant type and the general rules behind applying them ensures a more comprehensive and cost-effective cleaning regimen. Read on for our breakdown of disinfection basics for more effective disinfecting.

Contents

Why Disinfecting in Food Processing is So Important

Choosing the Right Disinfectant for the Environment & Application

Cleaning vs. Disinfecting

Disinfectant Type Comparison: Foam, Spray & Steam

Foam Disinfectants

Spray Disinfectants

Steam Disinfectants

Disinfecting Scope—Know Before You Go

Safety First: Personal Protective Equipment (PPE) for Disinfecting

Why Disinfecting in Food Processing is So Important

While commercial processing facilities spend the majority of their time up and running, their most important activity occurs when the production floor is empty and silent. Maintaining clean, sanitary workstations and equipment, particularly in food processing, is integral to public health and safety. In the United States, such standards are overseen by government agencies such as the EPA, CDC, and USDA.

But why disinfect at all?

E. coli, a common bacterial target of disinfecting food processing facilities

Well, for starters, food processing plants are not the cleanest places once production gets going. Soils, in the form of fats, oils, blood, and other animal protein and production byproducts, quickly collect on equipment and surrounding surfaces. Such deposits, if left unaddressed, make these surface areas ideal breeding grounds for countless hosts of bacteria, viruses, and other potentially harmful microorganisms.

Proper cleaning removes these unwanted soils and contaminants, providing significant benefits downstream. Maximized production efficiency, increased product shelf life, safer work conditions, and fewer mechanical failures and delays are but a few positive outcomes to attentive housekeeping. Scheduled cleaning and disinfection also significantly decrease the chances of costly product recalls due to food hazard risks such as food poisoning or foreign body contamination.

A processing plant’s commitment to a culture of health and food safety can easily be seen by how devoutly they approach the cleaning and disinfecting processes. And yes, there is a difference between the two.

Cleaning vs. Disinfecting

For most of us, cleaning, sanitizing, and disinfecting are all one and the same concept. They are, however, three distinct steps within the larger cleaning process. Cleaning is the process of physically removing unwanted substances and contaminants from a given surface. The cleaning stage, sometimes referred to as the detergent stage, is often characterized by the removal of common soils such as dirt, grease, or oils via manual scrubbing with brushes or wipes or washing with a high-pressure spray wand. Cleaning a surface in this manner alone; however, will not kill germs present.

Heavy Duty Cleaning Wipes for removing difficult soils

Disinfecting on the other hand, does kill bacteria and other microorganisms left behind following the cleaning stage. While similar to sanitizing agents, which merely reduce the number of bacteria and other germs to acceptable levels of health safety, surface disinfectants make a surface truly contaminant-free. Their high bactericide concentrations of chlorine or bleach eliminates the ideal growing conditions bacteria and other microorganisms thrive on.

Every cleaning application will follow a distinct set of variables, generally known as TACT. The four aspects of this cleaning/disinfection concept are time, temperature, action, and concentration. How prominently each phase is in the disinfecting cycle depends specifically upon your unique needs, including the soils you’re wanting to destroy, and the chemicals being used. Followed properly, the combination of them all will achieve the desired result of a clean, disinfected space.

It’s important to understand that cleaning must take place before the disinfecting stage. Since disinfectants do not break through heavy soils on surfaces, removing such deposits ahead of time ensures the disinfectants are able to work with the greatest efficacy.

Choosing the Right Disinfectant for the Environment & Application

Today, disinfectants cover a wide spectrum of chemical concentrations and applications. Choosing the right disinfectant for a specific environment, therefore, can be a task in and of itself. A few things to consider.

First, the choice of disinfectants depends foremost on a user’s requirements. In other words, where are they disinfecting and what type of contaminants are they trying to eliminate. After that, the type of processing and cleaning equipment used, the application method, and, to some degree, the personal preference of the user all play a role in selecting a disinfectant.

Also, review a disinfectant’s toxicity, leftover residues, and any possible chemical reactions related to water hardness and various surface types. This is particularly important within the food processing industry. Any residual chemical compounds left behind after disinfecting can adversely affect product taste, curing, and shelf life. In the brewing industry, for example, certain disinfectant cleaners are avoided because they linger on glass surfaces. (Soapy beer anyone?) Understanding a disinfectant’s proper application process and any residue properties it has helps prevent product quality from suffering.

Once a disinfectant is chosen, the most important thing to remember is to always read your disinfectant product labels! Always. With effective cleaning practices, disinfectants will kill 100% of germs listed by the label—when used properly.

Ignoring what’s detailed on the label—or choosing not to read it altogether—is a great way to undermine a disinfectant’s effectiveness and cause mechanical failure of your disinfecting systems. It’s also quite dangerous. Later in this article, we’ll cover some of the safety considerations and equipment needed when dealing with disinfectants. For now, just remember that the label is the law. By following the label, you keep you, your cleaning staff, and anyone who comes in contact with the disinfected area, directly or indirectly, safe.

Disinfectant Type Comparison: Foam, Spray & Steam

Most of the food processing industry today relies on three common disinfectant application types: foam, spray (aerosol), and steam. Since no two environments are exactly alike, no two disinfectants will perform equally across the board either. Below we’ve provided some comparisons for these three disinfectant types and some general considerations to have before choosing the right disinfectant for your situation.

Foam Disinfectants

Pros:

Better coverage of surfaces
Greater visibility of coverage
Lower pressure application
Less product needed to work
More cost-effective than other disinfectants

Cons:

More challenging mix ratios
Added costs if needing separate surfactant agent
Greater attention to spray nozzle orifice size
Greater flow needed to apply

Foam disinfectants are quite common in most food processing and industrial operations. Why? For starters, foam disinfectants can offer up to 50% more coverage than sprays. This is because foam expands as it comes in contact with a surface, greatly increasing coverage and disinfecting performance. In large production spaces, such as production floors or livestock barns, this helps keep cleaning costs down. Users can realize up to 50% cost savings on chemical alone, with additional savings possible in application time as well. Foaming is also a great option for disinfecting ceilings and vertical surfaces since the foam adheres better than sprays and therefore extends disinfection dwell time.

One challenge with foam disinfectants, however, is the need to include a surfactant. A surfactant is a foaming agent that chemically reacts with your disinfectant chemicals. Surfactants also lower the surface tension between two materials, such as water and dirt, making the soil easier to remove. Without a surfactant, your disinfecting solution will not foam properly, making it less effective. While some disinfectants include a surfactant already, most do not. Be sure to read your labels prior to starting your cleaning process to ensure proper solution effectiveness.

Additionally, check that your application equipment is compatible with foam solutions. Using a high-pressure pump without the appropriate chemically compatible elastomers is a great way to ruin an expensive pump. It is imperative, therefore, to check the chemical compatibility of ALL components throughout your entire cleaning systems. That includes examining the largest pump to the tiniest o-ring. In doing so, you not only avoid costly equipment damages or failures, but also prevent ineffective treatment from taking place.

Opt for chemical spray foamers and accessories that feature downstream injectors that bypass incompatible seals and components. Better still, invest in a complete foaming system like the Hydro FoamMaster. Available in multiple mounting styles, the FoamMaster is ideal for larger industrial cleaning applications, from washdown facilities and meatpacking plants to animal production buildings, such as the dairy barns shown in the video above. These compressed air units allow a user to set the desired dilution rate for their specific application. From there, the system mixes the chemical and surfactant with the carrier agent (generally water) to create rich, clinging foam.

Dultmeier has even helped develop custom disinfecting systems. Check out our work on the JBI Poultry Disinfectant Foaming Trailer here.

Spray Disinfectants

User disinfecting with spray in an industrial kitchen

Pros:

Fewer chemical compatibility issues
Quick-and-easy to apply
Wide variety of disinfectant types
Usable for almost any application/environment

Cons:

More chemical usage to achieve adequate coverage
Generally higher pressures applications
Greater health concerns due to aerosol emissions

Dultmeier’s DC1 Air-Driven Disinfectant Applicator

Aerosols are the most widely used disinfectants used for industrial cleaning tanks to their incredible versatility and ease-of-application. You can find disinfectant sprays for nearly every circumstance and apply them using a commercial pressure washer, handheld or backpack sprayer, or similar system without any chemical compatibility issues. Dultmeier’s DC1 disinfectant applicator system, for instance, features an air-powered diaphragm pump, a 25 gallon storage tank with an automatic mixing valve, and a trigger spray wand that can easily store and apply most disinfectant products without a problem.

Complete Plant Washdown/Industrial Clean System

The thing about spray disinfectants is that they can be costly. For one, most disinfectant sprays require a high-pressure system to be applied well. These systems; while effective, can be expensive to fund. Furthermore, since so much energy goes into turning a disinfecting solution into spray, an operator may have to use more product to disinfect an area compared to if he used foam.

Steam Disinfectants

Dry steam disinfecting for food processing sanitation

Pros:

Effective against a wide range of microorganisms
Not affected by soils or hard water
Non-corrosive or chemically reactive
Leaves behind zero residue

Cons:

Cannot be used on heat-sensitive equipment or surfaces
Does not remove large soil deposits
Dangerous high temperatures to human contact
Difficult to maintain consistent temperature and exposure

As their name suggests, steam disinfectants work using steam to kill bacteria, spores, and other contaminants. The prolonged exposure to the moist high heat destroys microorganisms, leaving surfaces truly decontaminated.

Although a viable disinfectant method, we recommend using either foam or spray detergents for most applications. The main drawback to steam is that high temperatures, generally either 250° F or 270° F (or greater), must be maintained throughout the disinfection process to ensure microbial death. Such high temperatures can also damage certain components and surfaces. Foams and sprays have much wider applications, which simply makes them better and more-cost effective options for most operations.

Disinfecting Scope - Know Before You Go

No two areas are created equal when it comes to cleaning and disinfecting. Case in point, you don’t clean and disinfect an office space in the same way you do a meat packing processing floor. That makes understanding your scope of disinfection all the more important before ever beginning the cleaning process.

Product Needs

Purehard surface disinfectant; ideal for food processing & food preparation

For instance, the size of the area you’re disinfecting will greatly influence the amount of product needed. Do you need a 5-gallon bucket of disinfectant or a 55-gallon drum? Maybe you need more. This is where foam disinfectants really have the advantage. Their enhanced coverage and prolonged contact time with the applied surface allow less product usage.

Make note of the GPM flow of your system. If you have a pump that produces 3 GPM of flow attached to a 50 gallon tank, you effectively have 16.5 minutes of continuous application time. Time is money, so how much time will be spent mixing solution is an extremely important thing to remember when disinfecting large areas.

Disinfectant Systems

Your style of disinfectant system is something else to keep in mind. Most operations have some level of clean-in-place (CIP) process. However; for a vast majority of the disinfecting process, mobile cleaning units are necessary to leave an area truly decontaminated. Portable disinfectant systems equipped with powerful pumps and spray wands allow an operator to spray disinfectant at a variety of angles, speeds, and tailored quantities. This versatility ensures every hard-to-clean space can be adequately decontaminated.

Portable Sani-Mister disinfectant unit

Ventilation

Finally, take a minute to evaluate your space’s ventilation. Taking the office vs. processing floor scenario, ventilation is likely very different between the two spaces. On the processing floor, the larger area means aerosols and vapors have more room to dissipate or be dispersed by exhaust fans. In the smaller office space, however, chemical fumes become more of a hazard. Respirator masks may be required based upon the chemicals used and/or size and ventilation capabilities of the application area.

Always be cognizant of how to enter a space for disinfection and understand how your solutions react when in use. Evaluating how to approach an enclosed space for disinfecting and how long someone should be exposed to that environment once they start keeps everyone healthy and safe.

Safety First: Personal Protective Equipment (PPE) for Disinfecting

Regardless of the style of disinfecting you ultimately use, you need to wear personal protective equipment, also known as PPE. This protective equipment ranges from nitrile chemical gloves and safety goggles to full body TYVEK coveralls. These products protect you from spills, splashes, and unexpected contact with the disinfectants which can cause serious chemical burns.

Certain aerosol disinfectants may even require a respirator mask to protect you from harmful chemical vapors. Even if the disinfectant label doesn’t list a respirator as required PPE, you may still choose to wear one if working in a small, poorly ventilated space. Each chemical application is different.

Read your product labels for the proper PPE required to handle specific disinfectants safely. Regularly inspect PPE for wear or damages and replace if needed. Also, ensure your facility has clearly marked eyewash stations and safety showers in case of an emergency. Whether you need gloves, eye protection, or water-resistant clothing, we can help you find the gear you need to be best equipped for the tasks at hand.

Conclusion

Proper cleaning and disinfecting procedures will always be a serious focus in the industrial and food processing industries. In fact, one of the most important activities that occurs in any industrial processing facility is their disinfectant regimen. Even so, disinfection practices and policies will continue to change with new health research, product development, and societal perceptions. With that in mind, having a reliable, knowledgeable company you can trust to support you is imperative to your business’s success.

Dultmeier is that company you can trust. We carry an extensive catalog of disinfectants, personal protective gear, and cleaning equipment and supplies from trusted brands like Mosmatic, DEMA, Suttner, General Pump, Hydro Systems, Boss, and others. While we cannot ultimately tell you how to disinfect, we can share with you the many different methods and assist your operation regardless of your choice of application. We’ll happily help answer all your questions about various disinfecting types and work to get you the equipment and products you need to ensure your workspaces are cleaner than ever.

Reach us at dultmeier.com or give us a call at 888-667-5054. Your Experts in Delivering Fluid Handling Solutions – WE KNOW FLOW!

A New Age of Spraying – How To Size PWM Spray Nozzles

The commercial spraying industry continues to improve technology. At this point, incremental gains can make a tremendous impact and that incremental gain can be as smaller than a 60 micron droplet. If you have a new spray rig, you’re probably not alone. Favorable grain prices paired with government payouts related to COVID-19 have allowed many operations to afford asset upgrades this past year. Maybe that asset upgrade came with Pulse Width Modulation technology? If so, this post is a must read for you prior to sizing your spray nozzles this season.

Speak at length with anyone involved in the ag sprayer industry about the new advances in sprayer technology, and there is a solid chance you’ll hear the phrase “pulse-width modulation” mentioned. Although the technology isn’t exactly new, advancements in spray nozzle design and overall efficiency of pulse-width modulation (PWM) spray systems arrive on the market every year, along with a slew of new PWM spray nozzles.

Following up on our article on sprayer nozzle sizing, we’ll focus on explaining how PWM systems work and provide you example-based guidance for how to size a PWM spray nozzle on your own. We’ll also explore the benefits of PWM spraying and why it may be time to consider making the switch from a conventional sprayer system to one outfitted with PWM spray nozzles and accessory components. Read on for all the details and be sure to use the table of contents to help you get around.

Contents

Pulse-width Modulation Explained

Pulse-width modulation was first developed for the agriculture industry in the 1990s by Dr. Ken Giles, a professor of Biological and Agricultural Engineering at the University of California, Davis, and Capstan Ag Systems. For many farmers and agronomists today, however, pulse-width modulation still presents considerable degrees of uncertainty and understanding. So, let’s clear up the confusion.

Pulse-width modulation, in ag-related terms, refers to how liquid flow rates are controlled via an electronic signal and shut off valve. Unlike conventional sprayer booms, a PWM system features nozzle bodies each equipped with an electric solenoid. As this solenoid turns on and off—typically an average of 10 times a second—an intermittent, pulsed spray is created through the nozzle. The proportion of time that the solenoid is open is known as the pulse width or duty cycle. It’s this percentage of time the nozzle is open vs. closed that ultimately dictates your rate of application.

Cross-section illustration of a PWM solenoid-actuated nozzle body.

Because duty cycle plays such a significant role in determining proper sprayer calibration for PWM operation and PWM nozzle sizing, it’s best we dive a little deeper into how this concept works. That way, you will know exactly how to choose the proper size spray nozzle for your specific agricultural operation.

Duty Cycle — The Driving Force Behind PWM

One of the limitations of conventional sprayer systems is that nozzle flow varies indirectly with sprayer pressure. As the sprayer speeds up, the system must adjust pressure to also adjust flow rate to deliver the same application rate per acre. Generally, a device called a rate controller automatically recalculates the necessary adjustments for you. So, when the sprayer increases speed, the rate controller causes spray pressure to increase as well until the flow rate sensor shows that the nozzle flow is enough to maintain the target application rate desired.

There are two related problems with these conventional spray systems. First, pressure must be increased significantly in order to increase flow rate as speed is increased. For instance, nozzle pressure must be doubled for nozzle flow to increase by just 41%. Moreover, pressure must be tripled to increase flow by 73%. Most sprayer pumps cannot achieve this doubling or tripling of their output while increasing flowrate.

Secondly, sprayer tips are very sensitive to changes in spray pressure. Go too slow and the lower pressure can cause the spray pattern to collapse. The result is poor, inconsistent coverage. Drive too fast, though, and your droplet size becomes finer, creating drift problems. This delicate balance means traditional sprayers must remain within a very specific, narrow speed range, which is not always possible given field conditions or with variable rate applications.

A key aspect in PWM systems is that spray nozzle output is no longer tied solely to sprayer pressure. Instead, PWM systems focus on duty cycle. Again, duty cycle is the proportion of time that the solenoid is open/on, meaning the percentage of time that your spray nozzles are actually spraying.

Typical duty cycle ranges are between 20-100%. Although lower duty cycles are possible, they are not recommended since droplet size and spray pattern can become inconsistent.

During operation, every nozzle can spray at its maximum flow (100% duty cycle) or a fraction of its flow capability. That means a nozzle operating at a 20% duty cycle will deliver about one-fifth of the flow of a spray nozzle spraying 100% of the time. Even so, the pulses occur so quickly that spray pattern and droplet size won’t be adversely affected.

What does this mean in practice? For one, while duty cycle is still linked to changes in sprayer speed, the spray pressure remains constant. This enables a sprayer operator to make pressure adjustments to maximize coverage or drift control independent of speed and the rate of application. The end result is a spray application that is not only more accurate but also more consistent across diverse field conditions.

Calculating Duty Cycle

Duty cycle directly correlates to ground speed. When calculating duty cycle to correctly size your PWM spray nozzles, you want to aim for an average speed around 75% duty cycle. For example, if you figure you’ll travel between 10 and 20 MPH while spraying, you’ll want to choose your spray nozzle for an average speed of 15 MPH—or 75% of your maximum speed. This gives you plenty of flexibility to adjust the duty cycle up or down if you experience unexpected changes in speed without compromising your droplet size or spray pattern integrity.

Selecting the Appropriate Spray Nozzle for PWM Systems

Since the means of controlling nozzle flow rate is different between traditional sprayer setups and those with pulse-modulation, sizing PWM nozzles likewise differs a bit from conventional spray tips. This means that you won’t necessarily be able to use traditional flow rate tabulation charts to size your nozzles. No need to fear, though. The PWM spray nozzle sizing process is still easy to understand.

There are three things to remember when selecting PWM nozzles. For starters, you want to always choose wider angle spray nozzles for pulse-width systems. One of the biggest concerns regarding PWM spraying is the risk of application “skips” as you move through the field. Wider angle nozzles such as 110° flat fans ensure you’ll produce enough overlap in your spray coverage to eliminate skipping.

Additionally, you’ll want to avoid using air-inducted spray nozzles for PWM spraying. The introduction of air can compromise the spray pattern and droplet size as the nozzle pulses off and on. As shown in the video below (at 3:18), this deterioration of droplet size is especially obvious upon the valve pulsing off, where residual air causes the application to dribble out from the air inlets—thus rendering the spray nozzle ineffective.

Now, new advancements have been made regarding air-induced nozzles regarding pulse-width modulation. TeeJet, for example, has several air-induced nozzles that have been approved for PWM use. However, your best bet is still to use non-air-inducted nozzles such as the Turbo TeeJet and Turbo TwinJet. The Greenleaf Soft Drop or Blended Pulse Dual Fan (BPDF) series or Wilger ComboJet series are good options, too.

Finally, an important point to remember when using PWM systems is that nozzle pressure is different than boom pressure. This is because nozzle pressure/flow is now controlled by the solenoids which are independent of your overall system’s pressure reading. As the solenoids turn off and on, a pressure drop needs to be accounted for with higher boom pressure.

Difference between gauge pressure and nozzle pressure for an 0.8 nozzle.

For example, for a 110-04 spray tip, the average drop is only about 3 PSI. A larger 110-08 tip, however, will push the limits of the solenoid even further, creating a greater decrease in pressure. This can be anywhere from 6 PSI at 30 PSI gauge pressure to 13 PSI at 60 PSI gauge pressure! If the pressure drops too low, the nozzle won’t be able to form a uniform spray pattern and droplet size. Therefore, the larger the nozzle orifice, the greater the boom pressure required to compensate.

PWM charts calculate against this pressure drop and offer speed ranges for operating specific nozzles at a given gauge pressure.

Sizing PWM Sprayer Nozzles

Alright, let’s size some spray nozzles. A few things you’ll need to know ahead of time:

Target application rate
Typical average speed
Desired droplet size

Using these three components, you’ll be able to quickly find the correct spray nozzle size for your PWM application.

Once you start looking at the charts, just like with conventional spray tips, you want to select a PWM nozzle which falls near the center of the pressure range for your desired droplet size. In most cases, this will be between 40 and 70 PSI for the best pattern and droplet size retention. However, it’s difficult to suggest the proper droplet size and nozzle type for every application. As always, check your chemical labels for proper application droplet size before beginning.

Sizing Greenleaf PWM Nozzles

For this first example, we’re going to find a nozzle within the Greenleaf line of spray nozzles using their PWM tabulation chart. To start, we take our target application rate, let’s say 12.5 GPA on 20” spacing, and set our average speed at 15 MPH. Keep in mind we want to maintain a 75% duty cycle through the field. This means we can go as fast as 20 MPH (100%) or as slow as 5 MPH (25%) without exceeding our chosen nozzle’s pressure rating or compromising our droplet size or application rate. Our droplet size for this example is Coarse to Very Coarse.

Next, moving down the 75% duty cycle column, we find where our average speed of 15 MPH falls within the 40 to 60 PSI gauge pressure range. Looking left, we see that the best fit is a 0.8 nozzle. We can also readily see that only one nozzle, the BPDF, will provide our desired droplet size.

We could’ve chosen an 0.7 nozzle, but we’re already pushing the pressure limits of that nozzle at our speed. If our average speed was to increase by even one mile to 16 MPH, our droplet size would decrease to Medium. Choosing an 0.8 nozzle still retains our Course-Very Course droplet size even if we were to decrease pressure or speed.

Sizing TeeJet PWM Nozzles

TeeJet has a similar approach to sizing PWM nozzles, though their tabulation chart works a bit differently. Instead of providing you with the duty cycle columns, they simply display your minimum/maximum speed range. This means you have to calculate what the 75% duty cycle speed would be on your own. Once you have that however, you can quickly find your ideal spray nozzle.

In the example below, we chose to apply a 15 GPA at 10 MPH with a desired Ultra Coarse or Extremely Course droplet size. We actually have two nozzle options to choose from in this case—the Turbo TeeJet Induction (TTI) and TTI TwinJet (TTI60). Both are again in the 0.8 size.

We also have the Air-Inducted Turbo TwinJet (green box) with an XC droplet size if we wanted. However, the larger UC droplet size of the other two nozzles and the fact that they aren’t air induction nozzles makes them better options.

Sizing Wilger PWM Nozzles Using the Wilger Tip Wizard

Wilger has made selecting their Combo-Jet nozzles for PWM systems even easier via their online Tip Wizard. Here, simply enter your GPA, speed, and target droplet size into the specific fields. You’ll also enter nozzle spacing, spray tip angle, and which PWM system you’re operating on. Many PWM systems, from Capstan PinPoint to Case AimCommand, Raven Hawkeye to John Deere ExactApply have different actuation speeds. The Tip Wizard will then provide you a list of the best nozzle options given your specifications.

For a complete guide to using Wilger’s Tip Wizard and understanding results when sizing nozzles for PWM, click here. They even have a video walkthrough if you prefer that option.

Advantages of Using Pulse Width Modulation Nozzles

Although there is no indication that conventional spray nozzles will become obsolete in the near future, the rise of PWM nozzles will undoubtedly continue to assume an increasing share of the industry. And for good reason.

First, PWM spray nozzles allow you to maintain constant pressure across a wide range of speeds. Having a wider range of travel speeds means that even when speeding up or slowing down through the field, you retain the necessary pressure—and therefore droplet size—to correctly apply your desired chemical rate without sacrificing coverage.

Drift control is another benefit of using PWM nozzles. While PWM systems do not significantly improve drift control alone, they do make it easier. This is because they offer a wider speed range to work with, meaning you can use larger sprayer nozzles designed for coarser spray patterns. Even if you tweaked your pressure higher or lower, your duty cycle would internally adjust to apply the same application regardless of speed. The larger droplet sizes then allow you optimal drift control.

Illustration of turn application rates for conventional spray system with rate controller only (left) vs. a PWM system with nozzle-by-nozzle turn compensation capability (right)

Finally, greater precision. The consistency across numerous speeds means PWM spray nozzles provide incredible application accuracy. Reduction in chemical costs, fewer over- or underapplications, and less drift potential gives PWM operators much more control over their spray operation. Many systems today even have the capability of controlling individual nozzle flows. This nozzle-by-nozzle sectional control enables greater turn compensation and more accurate, site-specific application through the field.

This feature is especially important when turning around at the end of the row. When turning in a conventional sprayer system, the inner boom nozzles become effectively stationary and substantially over apply chemical. Meanwhile, the outside boom nozzles move faster than the application rate can be accurately applied. PWM systems featuring turn compensation such as Capstan’s PinPoint overcome this by individually controlling each nozzle, maximizing efficiency and accuracy.

Final Thoughts

As industry leaders continue developing new, better PWM spray equipment systems, understanding PWM technology and how to apply it to your own operation becomes increasingly important. Not unlike sizing conventional sprayer tips, choosing the correct PWM spray nozzle plays an integral role in ensuring the accuracy and efficiency of your sprayer system. After all, your application is only as good as your spray tip.

For any questions regarding sprayer tip sizing and PWM spray systems, be sure to check us out at dultmeier.com or give us a call at 888-667-5054. We’re happy to assist you with whatever questions you may have and provide you the technical expertise and diverse products necessary to get you back in the field. Let us help you find what you’re after today so that you get the best sprayer performance possible.

Your Experts in Delivering Fluid Handling Solutions – WE KNOW FLOW!

Sprayer Nozzle Sizing — How To Properly Size Spray Nozzles

Whether it’s 1980 or 2021 – Dultmeier Sales fields thousands of calls each spring on this topic alone. How do I size my spray nozzles? We don’t help you select the type of spray tip for your application(s) – we advise you to consult your agronomist in this instance so they can get eyes on the crop situation to help develop a custom plan for your operation. That being said, once you’ve identified which type of nozzle(s) you need, we can absolutely assist in the sizing of said nozzles. This post is a great resource to use that helps to outline what we do just about every day during spring.

It’s spring, and with the frenzy of field preparation, fertilizing, and putting seed in the ground on everyone’s mind, the height of the planting season is nearly upon us. This time of the year also signals, if you haven’t started already, that the time for you to begin readying your sprayer for your early season spraying is fast approaching.

Between calibrating your sprayer pump and checking all your hoses, you already have a lot to get done in order for your sprayer to be ready for the field. One of the most important parts of your sprayer prep; however, is ensuring that you have the correct sprayer nozzles appropriately sized for the chemical and fertilizer solutions you’re looking to apply.

Without serious attention to detail, improper nozzle sizing can lead to a multitude of mistakes and delays when you can least afford them, not to mention the increased costs. In this article we’ll examine the proper approaches for how to size nozzles for various spray application types and how to attain ideal nozzle coverage and drift control. We’ll also share why correct sprayer nozzle sizing is so important to your sprayer and crop performance. Read on at your leisure or use our table of contents to help you navigate through the article to find the answers you’re looking for.

Contents

Nozzle Sizing Information to Know Before You Begin

Sprayer nozzle sizing can often be a confusing bit of business, especially with new tips and nozzles being designed every season. Pulse width modulation anyone? Luckily, the way you decide which nozzles you need has remained essentially the same for years. The first step is ensuring you have three pieces of critical information:

Rate of application – in gallons per acre (GPA)
Average sprayer speed – in miles per hour (MPH)
Nozzle spacing – in inches (W)

Once you have those pieces of information nailed down, you can then plug them into a standardized formula and calculate how many gallons per minute (GPM) that you need to apply. Here’s the formula:

GPA x MPH x W / 5,940 = GPM (per nozzle)

Knowing the number of gallons per minute you need to spray then allows you to reference a sprayer nozzle sizing chart that you can use to locate the ideal nozzle size for your specific sprayer setup. There are also plenty of tip sizing tools available online that calculate the best tip size for you. You can try our GPM calculator or use these from Wilger, Pentair, and TeeJet.

In the next section we’ll put this formula into practice and walk you through a few examples of how to size your sprayer nozzles for different chemical and fertilizer applications so you have a better idea of how to approach it on your own.

Sprayer Nozzle Sizing for Different Applications

Although sizing spray nozzles is largely uniform across the board, there are a few slight differences in how to size a sprayer tip depending on the type of liquid solution you’re applying. Here, we’ve included the two most common application types when sizing broadcast nozzles: chemical/water solutions and liquids heavier than water.

Sizing for Ag Chemicals and Water Solutions

A vast majority of your sprayer applications will fall under this category since it includes most of your herbicides, insecticides, fungicides, and other common ag chemicals. Sizing nozzles for this type of application is also the most straightforward since you’re using water as the base agent and aren’t having to adjust for a higher relative density.

Relative density, also commonly referred to as specific gravity (SG), is the ratio of density—or mass of a unit volume—of a substance to the density of a standard reference material. For liquids, specific gravity is almost always measured against water since water has a specific gravity of 1.0. When calculating the application rate of liquids heavier than water, you must use a conversion factor to compensate for the higher solution density. We’ll cover more on these conversion factors when we discuss sizing sprayer nozzles for liquids heavier than water a bit later. For now, though, assume that our examples are calculated with the SG of water.

Now, many sprayer nozzle sizing charts will display a wide selection of common spraying speeds. If your speed is already in the table, simply cross-reference your nozzle spacing and speed and locate the GPA you want to apply. But what if the speed you want to spray at isn’t shown on the table? This is where the formula plays such an important role.

Shows how to find nozzle size for 8 GPA at 6 MPH for 20” nozzle spacing when all information is listed in the chart.

So, example time.

Let’s say we want to spray 20 gallons per acre of 2,4-D. Our average sprayer speed in the field is 12 miles per hour (not shown in the table), and we are operating on 20-inch nozzle spacing. Our formula would look something like this:

20 x 12 x 20 / 5940 = 0.808 GPM (per nozzle)

Let’s also say that we want a course droplet size and are looking to use a Turbo Teejet wide-anglespray tip. Taking our 0.808 gallons per nozzle rate and using the Teejet sizing chart for this model of spray tip, we scroll down the Capacity in One Nozzle column to the nozzle size most closely matching our desired specifications. In this example, that would be the white tip nozzle.

It’s best practice to find a nozzle that meets the GPM rate as close to the middle of the PSI range as possible. This is important in relation to your speed. Most spraying systems rely on largely consistent speeds across the entire field for the optimal performance. As a result, slow down too much, such as at the end rows, and you compromise your spray pattern and improperly apply your chemicals. Go too fast, and your sprayer pump may not be able to match your new pressure rate for the nozzles you have, setting off system alarms.

Even if your sprayer pump can match the higher speed, your droplet size then becomes much smaller, increasing your risk of drift. Neither case is what you want. Having a spray nozzle in the middle of the range ensures that you’re able to maintain spray pattern, solution density, and droplet size—even with slight rises and drops in speed.

Sizing for Ag Liquids Heavier Than Water

When sizing your spray nozzles for liquid solutions heavier than water, such as liquid fertilizer, you’ll follow a very similar process as sizing nozzles for your water-based ag chemicals. The difference in sizing for this type of application; however, is that you need to adjust for the higher density of your solution. You accomplish this by using a density conversion factor seen in the chart below.

So, let’s say we wanted to apply some liquid nitrogen fertilizer. Using the conversion chart above with our previous example, our formula would look like this:

20 GPA x 12 MPH x 20 W / 5940 = (0.808 x 1.13 Con. ) = 0.91 GPM

In this case, you’d still use the white nozzle tip from our previous example since the 0.91 GPM still falls near the middle of the pressure range for the course droplet size desired. If your speed is shown in the chart, simply take your intended GPA multiplied by your conversion factor to locate your nozzle size.

The key in either case is to factor in the conversion factor before you reference the sizing chart. Otherwise, you’ll select the wrong spray nozzle and wind up with improper droplet size and inaccurate application. In the next sections we’ll examine why these two ideas, spray coverage and droplet size, are tied so closely to the idea of proper nozzle sizing.

Nozzle Spacing and Spray Heights for Proper Coverage and Overlap

It should come as no surprise that sizing your spray tips correctly is just as important as where you put them on your sprayer. In fact, nozzle spacing and sprayer boom height are two aspects you mustn’t ignore when choosing the size of the spray tip that you need.

For starters, nozzle placement—both width between nozzles on the boom and the height of the nozzles above the ground—determines how well your spray coverage theoretically performs based upon the fan angle a nozzle has. Most setups will use some type of nozzle which creates a fan-shaped spray pattern. This means that the heaviest concentration of spray is at its center and tapers off to nothing at the edges. Common sprayer systems operate on 20, 30, or 40-inch nozzle spacing, and the arrangement of nozzles at these spacings determines how uniformly your application is ultimately applied.

To achieve uniform application; however, you’ll need to create a pattern overlap in your spray coverage. Overlap—or the combining of spray patterns—is necessary, particularly in broadcast spraying, because the outer edges of spray patterns don’t have uniform volume distribution. Without overlapping coverage, you risk leaving portions of your field under-treated or even skipped. That means you’ll likely spend more time and money correcting the mistake.

Illustration of spray pattern overlap.

Factors that affect spray nozzle overlap

Three factors affect overlap in relation to sprayer nozzle sizing. First of all, your nozzle fan angle determines the total width of the spray pattern. The wider the fan angle, the wider the spray pattern. Today, 80-degree and 110-degree fan angles are the most used nozzle angles in agriculture applications, though others are available. Second, spray tip spacing. The closer the nozzles are to one another, the more the patterns will overlap. Farther apart, and the amount of overlap is lessened.

Finally, adjusting your spray tip height will further affect how much overlap you have. The higher the boom, the more overlapping because each pattern has more room to spread out. Another good thing to remember regarding the height of your spray tips is that the higher above the row your boom/tips are, the more susceptible to wind and drift your solutions are. We’ll touch on this a bit more in relation to droplet sizing in the next section, but for now keep it in mind.

Now, unsurprisingly, not all spray nozzles are the same. Finding the proper height in relation to your nozzle spacing then is imperative. In the table below for example, you can see the height recommendations of various TeeJet nozzle series based upon nozzle fan angle and boom spacing.

In most cases, your ideal overlap for broadcast spray nozzles is approximately 30%. Adjusting your nozzle spacing and boom height accordingly will give you the best chance to maintain adequate, uniform coverage across the entirety of your system, even when other variables such as wind speed and pressure decreases occur.

Maintaining Droplet Size for Optimal Drift Control

Finally, we want to share a few words on droplet size. Namely, follow your labels.

After all, the label is the law! Not following how a specific chemical or pesticide is meant to be applied can create serious damage to not only your crops, but your fellow farmers' as well. This has become especially important when dealing with volatile chemicals like Dicamba.

Burn damage caused by Dicamba drift.

Make sure that you’ve chosen and sized a sprayer nozzle capable of producing the appropriate droplet size recommended for the chemical you’re applying. If the label lists a specific nozzle or droplet size to use, follow those listings to a T. Furthermore, install your spray tips at the proper boom height and operate at the required pressure range to achieve the stated recommended droplet size of a given chemical. This will significantly reduce the likelihood you experience issues with ‘hanging’ droplets and drifting.

Consulting the spray label is just smart practice. It can determine whether or not you need to make any additional adjustments to your spray equipment or need to purchase additional nozzle accessories to attain the right nozzle spacing and droplet size specifications.

Importance of Proper Sprayer Nozzle Sizing

We don’t have to tell you that your time is money. When it’s time for you to be spraying in the field, you can’t afford troubleshooting on the fly or stopping to recalibrate your sprayer a second or third time.

Which is the exact reason why you should take the time well in advance of spraying season to research the agricultural chemicals and fertilizers you intend to apply. Running long or short of chemical means your solutions were not applied efficiently and may not work as effectively as intended.

In fact, overapplication due to poorly sized or worn out sprayer nozzles is a serious problem if left unaddressed. Ag chemicals are very expensive, and if you’re over applying it, you’re wasting money. All the major manufacturers that we represent recommend replacing any spray tip if it’s overapplying by 10% of the rate of a new nozzle. That includes TeeJet and Hypro to Wilger, Greenleaf, and Delavan. If you find that at least two of your nozzles are overapplying by this rate anywhere across your boom, replace every nozzle in the system. Using a sprayer nozzle calibration tool, like the one shown below, will give you the fastest and most accurate reading of how your nozzles are performing and if you need to swap them out for new ones.

SpotOn Electronic Sprayer Calibrator, 0-1.0 GPM

Incorrect spray tip sizing has ramifications on your other sprayer components as well. Your sprayer pump especially may struggle to operate at its ideal performance. This can substantially increase the wear and tear on your pump components and lead to an inability of your pump to create or hold the spray patterns and proper application density.

Conversely, your pump outperforming your spray nozzles at higher speeds can change the droplet size. Higher pressures create smaller droplet particles and lead to increased risk of drifting that can cause serious damage to you or your neighbor’s crops when dealing with many of the volatile chemicals used today. Be sure to routinely examine your sprayer tips for wear of the nozzle orifice for the reason that you ensure they aren’t in need of replacement in order to maintain the correct droplet size you’re after.

In the end, understanding how your agriculture chemicals and fertilizers are meant to be used and their proper droplet size ensures both appropriate solution application and adequate drift prevention. Once you have that information, the rest is relatively easy.

Conclusion

Although the science behind sizing sprayer nozzles has become more dynamic in recent years, the process doesn’t have to be complicated for you. Following the guidelines in this article will give you a great start to your spraying season and ensure you aren’t left reworking your sprayer when you should be in the field.

Be sure to check us out at dultmeier.com or give us a call if you have additional questions regarding sprayer nozzle sizing. We offer a huge selection of TeeJet, Hypro, Greenleaf, Wilger and Delavan spray nozzles to suit your unique sprayer setups. Our team of experts will be glad to assist you with any concerns or questions you may have and discuss how to ensure you’re getting the best performance from your spray nozzles.

After all, we’re your Experts in Delivering Fluid Handling Solutions – WE KNOW FLOW! ®

Sizing a Pressure Tank - Your Step-by-Step Guide

Pressure tanks are used in a variety of applications, but a common usage is system efficiency. For example, one reason someone might install a pressure tank in a plumbing system would be to keep the pump from constantly running. In doing so, the pressure-regulating tank increases the longevity of the pump/motor and reduces maintenance and down time – ultimately resulting in lower operating costs. Let’s dive into a step-by-step how to of sizing a pressure tank.

Contents

0.1 Info You NEED to KNOW Before Starting

0.2 General Rule of Thumb for Sizing a Pressure Tank

0.3 Pressure Tank Sizing Explained

0.4 Relationship Between Pressure & Tank Size

Info You NEED to KNOW Before Starting

Before beginning the process of sizing a tank, there are a few important important input data points to know in order to properly size a pressure tank:

Flow Rate
Cut-in/Cut-out Pressure
Target Run Time

A general rule of thumb, that most manufacturers suggest, is a run time of less than one minute if the horsepower is less than 1HP. If the motor is over 1HP, then a good guideline to follow, is a run-time of 2 minutes or more. Always confirm this, with your tank manufacturer of choice, as guidelines can vary.

General Rule of Thumb for Sizing a Pressure Tank

Generally, as a rule of thumb, one can follow these guidelines when sizing a pressure tank:

0-10 GPM: 1 gallon of drawdown per 1 GPM of flow
10-20 GPM: 1.5 gallons of drawdown per 1 GPM of flow
20 GPM+: 2 gallons of drawdown per 1 GPM of flow

Drawdown can be defined as the amount of volume loss in the tank as the plumbing system “draws” off this pent up pressure. After all, the purpose of a pressure tank is to maintain pressure in a given system and give the pump a break. This way, the pump doesn’t need to run constantly to remain at system pressure. While a pressure tank can appear costly up front, it will save in the long run. Less run time for the pump means less maintenance and less money in energy costs.

There are various orientations of pressure tanks and the most common are horizontal, inline, and vertical. Be sure to determine which orientation works best for your plumbing setup.

Once we have identified our flow rate in gallons per minute (GPM), have identified our cut-in/cut-out pressure, and confirmed our target run time – we must determine what cut-in/cut-out pressure we want to set the system at.

Pressure Tank Sizing Explained

An important equation to remember when sizing a pressure tank is below:

Flow Rate X Run Time = Tank Draw Down Capacity

Example:

Let’s say we have a pump that produces 5 GPM and is ran by a ¾ HP motor. Since I’m operating a motor that is less than 1 HP, we are going to assume that “ABC Manufacturer” recommends a 1-minute runtime. We want to design this system to cut-in (turn on) at 40psi and cut-out (turn off) at 60psi.

5 (Flowrate) X 1 (Runtime) = 5 gallons of Draw Down (at 40/60PSI)

So, I will need to select a tank that allows for 5 gallons of draw down at a pressure setting of 40PSI cut-in and 60PSI cut-out. If I need a vertical tank, I could select a WOMAX-220. If my plumbing layout would accommodate a horizontal tank better, I could select a WOMAXH-220. This would give me approximately 3.5 minutes of run time before the pump would cycle back on. Horizontal pressure tanks have a plastic pump stand so you can maximize space when designing a plumbing system. This is certainly a nice feature when working in confined spaces where space is at a premium.

Relationship Between Pressure & Tank Size

An important thing to remember, the higher the operating pressure – the larger the tank must be. Pressure and tank size have a direct correlation – as one increases, so does the other. The higher the pressure setting, the less the drawdown is and thus, the need for larger tank capacity.

After we have these three points determined, we can then proceed with sizing a pressure tank. Pressure settings are another important factor with any plumbing system. The most common pressure settings are 30/50; 40/60; 50/70. Most manufacturers will have a pressure tank sizing chart that will allow viewers to quickly size a tank’s drawdown based upon their system’s pressure settings.

We can supply you with this information on the Wilo MaxAir® product line if you want to get into the details. Just give us a ring or visit www.dultmeier.com 24/7. Here is a drawing of a Wilo MaxAir® horizontal tank that outlines some features which set this product line apart from the rest of the pack and really make it one of the top line products in the marketplace.

Cutaway of Wilo MaxAir Horizontal Pressure Tank

You can view the full offering of Wilo MaxAir® Pressure Tanks Right Here on dultmeier.com. As always, should you have further questions about pressure tank sizing or other applications – don’t hesitate to contact us. That’s what we are here for. Your Experts in Delivering Fluid Handling Solutions – We Know Flow!

TeeJet - Spraying Systems - A Pioneer & Goliath of the Spray Industry

A Look Back in Time – The History

In order to completely understand the powerhouse that TeeJet has come to be, we first must look back in the annals of time and address some of the major milestones that helped elevate the Spraying Systems brand to the worldwide leader of spray equipment. So, let’s dive right in and look at the inception of the company.

Spraying Systems Co. was co-founded in 1937 by two European immigrants to form the basis of the dynasty that exists today. The company enjoyed a rather humble start in a small 600 square foot garage in Chicago, IL. I bet those two men never imagined, in their wildest dreams, how the company would evolve and grow – and what their company would achieve over the next eight decades.

TeeJet is Born

In 1947, the origins of the TeeJet spray tip were conceived. The side profile of the first spray tip embodied a “tee” shape. This combined along with the “jet” family of names is how the TeeJet name came to be. For many years, the industry only required two sizes of spray tips. One must remember that the agricultural industry was still using manure and egg shells as the primary means of fertilizer up until the late-1950s.

One of Dultmeier Sales’ long time employees, Bob Hansen, joined the industry in the early 1960s and recalls that the TeeJet family had just two spray tip sizes at the time – a 5 gallon and 10 gallon capacity. Both spray tips were offered only in brass. We will circle back to the expansion of fertilizer distribution later on in this write up and how that quickly elevated TeeJet to Goliath status in the spray industry. For the time being, let’s get back to the chronological progression of the company.

GunJet & TeeValve Become Staples

In 1952, TeeJet introduced their first spray gun product line. Models such as the AA43 and AA2 were the first introductions. Today, farmers have a much wider range of trigger and twist-handle guns for spot-spraying applications. Many of those products can be viewed here.

Next up was the introduction of the TeeValve in 1956. This was revolutionary in the agricultural spray industry as it allowed an operator to remotely control three boom sections on a sprayer. The compact design quickly gained popularity and became a staple in the agricultural industry. This product was so well-built and engineered that it is still used today. You can view this product here.

An offshoot of the TeeValve is the DirectoValve. This product has been slightly modified over the years. The neat feature of this product is that is extremely versatile – it can be banked together to create a manifold, or it can be used alone as a singular valve. However, this is another testament to the superb engineering and functional design from Spray Systems Co. – many of their products from the mid-1900s are still widely popular within the industry. It’s neat to see the old archive below and compare it to today’s version. The electric version of the DirectoValve can be viewed here.

Agricultural Spray Technology is Rapidly Expanded

In 1968, Spray Systems Co. designed the first electronic spray pattern analyzer in-house. This innovative piece of equipment allowed the company to drastically improve qualities of the expanding TeeJet family. This technology allowed the company to more accurately measure droplet size which is a critical component of nozzle design and functional application.

By now, the agricultural spray industry had been experimenting with a new fertilizer called anhydrous ammonia, or NH3, for about seven years. This wonderful fertilizer helped increase growth rates and yields of crops. Not only did it improve crop growth rates – but also weed growth rates. The TeeJet family had positioned itself superbly.

2,4-D and DDT were the primary chemicals used in the agricultural industry up until the introduction of anhydrous ammonia as a prominent fertilizer. Once weeds began to expand rapidly, as a result of this wonderful fertilizer – new formulations were necessary to keep them at bay. With new chemical formulations came the demand for new spray nozzles.

Chemical applications rapidly expanded over the next decade to combat the exploding growths of weeds – along with crops. The industry needed to quickly kill weeds to ensure that crops received as much of the fertilizer nutrients as possible. Let the weeds live and they starve crops of precious, and expensive, input resources. Rather abruptly, the industry changed its practice to combat weeds from cultivation equipment to liquid applications in the form of various chemicals. The TeeJet family was a natural fit to help fuel a major industry boom.

1970s & 1980s

This period embodied an era of rapid growth and expansion for Spraying Systems Co. 1970 marked the beginning of construction on the state-of-the-art office and manufacturing facility in Wheaton, IL. In 1976, LH AGRO was founded in Denmark by two gentlemen named Larsen and Henning. The company’s first product was a grain loss monitor.

TeeJet entered the 1980s with a bang. The introduction of the Quick TeeJet system again revolutionized the agricultural spraying industry – and the rapidly growing carwash industry, as well. The 1/4-turn quick attach cap and body system substantially reduced the effort required to install or change spray tips. This system also provided an automatic spray pattern alignment across the boom for optimum distribution.

As Dultmeier Sales evolved into the carwash industry, Mike Hansen the Wash Division Manager, greatly relied on the partnership of TeeJet to help offer a solid product line for soap and wax application in self-serve carwash industry. And the Quick TeeJet product line helped Dultmeier Sales do just that. As the agricultural market struggled throughout the 1980s, the carwash industry helped to diversify both Dultmeier Sales and Spraying Systems. Even today, as you move through more sophisticated carwashes – you will see the Quick TeeJet products on many of the stationary boom structures.

The Quick TeeJet is introduced in 1981

In 1983, Midwest Technologies (Mid-Tech) was founded in Springfield, IL. Mid-Tech quickly became recognized as a pioneer of direct chemical injection systems and quickly advanced the Spraying Systems brand into the electronic sprayer & spreader control markets – and eventually into GPS guidance systems. Mid-Tech joined the TeeJet family in 2000.

In 1984, the LH1200 was launched in Europe and marked the entrance of the LH AGRO product offering into the sprayer control market. LH AGRO would eventually become a member of the TeeJet family in 2000 with a focus on electronic controls and precision farming equipment. Then, in 1985, the next major introductions into the TeeJet family came with the VisiFlo and XR TeeJet flat fan tip series.

The VisiFlo system incorporated color-coded plastic tip bodies with a stainless steel orifice. End users were able to quickly identify the tip capacity based upon the color of the spray tip – another revolution within the spray industry. The VisiFlo color-scheme quickly became the industry standard and was adopted by ISO as the worldwide standard in agricultural tip capacity identification.

The XR Flat Fan spray tip series was created based upon new manufacturing techniques that enabled the production of an orifice that offers excellent pattern formation and spray distribution across a wide range of operating pressures. The XR tip series has become the standard agricultural spray tip and continues to be one of the highest selling spray tips manufactured today.

Retro XR TeeJet and VisiFlo Bulletin

The 90s – Advanced Controls & Air Induction Spray Tips Introduced

The 1990s brought about further product diversification and advancement for Spraying Systems Co. The company acquired the ECOSpray product lines in 1993 which further expanded its offering in sprayer controls. Then, in 1995, the QJ360 nozzle turret was introduced. This multiple outlet nozzle body quickly found favor with OEMs and farmers, alike. TeeJet knocked another one out of the park with the simple design and easy use/installation of the QJ360 series.

Then, in 1998, TeeJet entered the air induction spray tip into the marketplace with the launch of the AI tip series. The combination of a pre-orifice and venturi produces large, drift-resistant droplets. TeeJet felt it was necessary to develop this product due to the continued growth in the use of non-selective herbicides like Roundup. These types of chemicals drastically increased the demand for products that reduce spray drift.

The Next Century – GPS Guidance & Precision Technology

The turn of the century lead to further product enhancements and new technologies that allow end users to become more accurate and more efficient. In 2000, the Mid-Tech Swath XL lightbar launched and marked the entrance of TeeJet into the growing GPS guidance market.

Then, in 2006 the CenterLine 220 revolutionized the GPS market – it brought GPS guidance functionality to every farmer due to the simplicity, reliability, and affordability. Easy operation paired with quick installation make this product appealing and quickly grew its popularity. You can view the CenterLine 220 here. Another important introduction in 2006 was the Turbo TwinJetspray tip. This was the next generation as it offered a twin spray pattern with superior drift control. Market demand for twin spray patterns experienced a rebirth during the early 2000s and TeeJet sought to capitalize on this trend.

2009 came along with another large advancement in the GPS market with the introduction of the Matrix guidance console. This product features a 3-D touchscreen interface and brings GPS guidance with live video to form the patented RealView guidance over video feature. The Matrix quickly became the preferred platform for GPS guidance. Additionally, this product allowed end users to leverage new technology called FieldPilot. Which further enhanced efficiencies and helped to reduce waste through features such as auto-steering and automatic boom section control. The Matrix 430 can be viewed here and the Matrix 570 can be viewed here.

The Aeros 9040 field computer was introduced in 2012 and emerged as the most powerful controller offered in TeeJet history. This field computer is targeted towards the self-propelled OEM market. Functionalities include GPS guidance, automatic rate control, automatic boom section control and droplet size monitoring.

In 2017, TeeJet introduced a couple more key products. The TTI60 TwinJet and the DynaJet Flex 7140. The TTI60 TwinJet tip/cap combined flat spray patterns and ultimate drift control capabilities of the proven TTI spray tip. The DynaJet Flex 7140 brought Pulse Width Modulation (PWM) nozzle control to the TeeJet family of electronics. The unit boasts ISOBUS compatibility for seamless integration into a wide range of control systems and machines.

The Dultmeier Sales-Spraying Systems Co. marriage goes back many years. Back to the days of just two brass spray tips and the introduction of anhydrous ammonia as a fertilizer into the agricultural industry. It’s nostalgic to look back and see how far we’ve come. But we are eager to see what the future holds.

We hope you enjoyed this manufacturer highlight of Spraying Systems Co. – TeeJet. Stop by in the future or check out more posts here. As always, if you enjoyed this post – please give us a share.

Sprayer Productivity – How to Increase & Achieve a Greater ROI

What do we look for in a sprayer?

Is it to merely kill weeds? How well does a certain sprayer kill weeds? The size – is bigger necessarily better? Or, do we also need to assess the value of that sprayer against how long it spends in each field? All these questions should be carefully considered when making a large investment into a piece of equipment that drastically affects the yield of your crop(s).

After all, a sprayer is one of your most important asset management tools when maintaining and ensuring your crop health – thus effectively ensuring that you get the most out of your yields – regardless of the crop you’re raising. Therefore, I think the answer to the questions above is that we must absolutely consider each question when determining a true Return on Investment (ROI) for a sprayer – regardless of the operation size or scope.

In this write-up we will assess the four questions above. To start, let’s dissect each question at a high, strategic level.

How Well Does a Certain Sprayer Kill Weeds?

This is a somewhat loaded question as chemical types, brands, and mix rates are involved. But if your accessory products/equipment, which are used to move the solutions onto the plants are lacking, then your sprayer effectiveness will undoubtedly be lacking, as well. Therefore, we must consider year-end maintenance programs. Boom-end flow rates, line obstructions in accessory products such as strainers and valves. Leaking pump seals, poor shaft alignment, and worn spray tips all factor into the efficiency and productivity of your sprayer. Neglect these important features of your sprayer and your operation, and your crop yields will undoubtedly suffer. So, to answer the question outlined in the opening paragraph – your accessory products, that are used to help move solutions, – are just as important to your operation as the sprayer itself.

Year-End Maintenance

It is necessary that a season-end maintenance program is followed to ensure your operation sees success in the ensuing season. Follow our recommended winterization process. Hoses, pumps, motors/engines, valves, strainers, and spray tips should all be inspected to help create a post-season inventory/repair list, in preparation of the upcoming season.

Spray Tip Selection

Have the proper spray tips been selected for the job(s)? Consult your local agronomist for specific details on the product(s) you will be spraying for the upcoming season. When spraying Dicamba products, only specific spray tips are approved for each product – and at specific pressure ranges. You can read another post related to Dicamba. Undoubtedly, always check the label of the product you are spraying to ensure you are spraying “on label”. You can have all bases covered in preparation for an upcoming season. However, if you choose incorrectly on spray tips – or size your spray tip orifices incorrectly based upon the rates you intend to apply – the consequences could be catastrophic to your operation – or your neighbors’ operations. Here is a tip sizing tool from TeeJet.

Sprayer Size

Does bigger necessarily mean better? It depends. If you’re out in western Nebraska and have straight runs for a mile plus, then you may want to consider 120-foot booms with auto steer functionality. However, if you’re in Western Iowa and you have many fields that are 75 acres or less, you probably want to opt into a smaller, more agile spray package. Regardless of your choice, one question should drive your purchasing decision – what is the potential ROI?

Speed and Efficiency

How long does it take to spray each field and how many acres do you anticipate covering daily? This should be one of the largest focal points when assessing your operation. Don’t focus on non-productive time in an operational day (i.e. travel from field to field, rinse-out, rain/wind delays). These are variables that we have little to no control over.

However, a large area in which we do have control over is nursing, or fill, times. If you can cut your fill times, regarding both fuel and chemical, how much more productive can you make your operation? Let’s look at some products that can help you achieve this task. First, let’s look at a study done by Praxidyn’s Doug Applegate, regarding average sprayer price in comparison with cost per acre/hour. The numbers displayed reflect average prices/costs from various suppliers/operators in a regional area in Western Iowa.

Conclusions:

Slower loading times increase the cost per acre/hour of productivity. Increased cost ranges from 26 to 42 percent.
Spending 10% more for larger capacity/coverage in a sprayer will increase productivity roughly 8%.
Spending 7% more for an automated mixing system can increase productivity by 20% to 30%.
Smaller sprayers are actually more cost effective for their capacity.

The main takeaway here is that, in general, an operation can lower operating costs by, roughly, 20%. Let me repeat….20%. And by simply shaving off 10 minutes from fill times. It’s important to note, as the sprayer size increases, the cost savings are reduced. For instance, a sprayer with a 600-gallon tank and 90-foot boom can effectively realize over 29% savings by reducing fill times down to 5 minutes. Consequently, when looking at a sprayer with a 1200-gallon tank and 120-foot boom, we see about 20% cost savings.

Praxidyn MixMate

The Praxidyn system allows users to automate loads. You can prepare loads the night before from your living room while watching TV or from an office chair. Send the loads to the operator in the field. No math needs to be done by the operator. The biggest change the operator would make to the load is regarding weed height. Upon arrival to the field, if the operator notices weed height on the order calls for six inches, and the weed height is actually 10 inches – the operator can make that adjustment to the order and the software will recalculate input quantities on the fly – no math is needed.

Another value-added feature to the MixMate system is the ability to track and record data. Through the cloud-based software, a user can record exactly how much product was applied to each field – and the exact time of the load or batch. This will continue to be ever-more important as regulations continue to tighten.

MixMate Fusion – New for 2019

We hope that you enjoyed this write-up on increasing sprayer efficiencies. Should you have any questions or feedback don’t hesitate to get in touch with us at www.dultmeier.com!

Inventory Levels Matter at Dultmeier Sales - Proof In the Pudding

JIT vs. Quarterly Inventory Strategies

Inventory management and the best strategy to successfully achieve maximum efficiency. It’s the long-standing question of any distribution or supply channel. What is the best methodology to follow when managing inventory? Just-in-Time (JIT) relies heavily on the concept of inventory turns. The more inventory turns, the less carrying cost a supplier must maintain. Lower carrying costs result in a lower market resale price.

JIT is one method by which suppliers can help control their costs. Why order a year’s worth of inventory when you can rely on the supply chain to help “offload” some of those costs on your partners? Furthermore, a JIT strategy allows the business to ebb and flow with demand fluctuations within their respective market(s).

In certain instances, a JIT strategy does hold merit. However, at Dultmeier Sales we have a contrarian approach to this type of strategy. While we have certain products lines where a JIT strategy does work, there are other lines where we cannot afford to not have the products on the shelf – and ready to ship promptly.

Our business is an extremely cyclical one. Roughly 50% of our revenue comes in about a three-month period. Due to the nature of our business, we must have inventory on-hand. Therefore, we load up heavy in the fall and winter in preparation for the spring season. In doing so, we allow our customers to use a JIT approach to run their businesses. This helps our customers lower their carrying costs & provide them with fast deliveries. Furthermore, when critical equipment failure occurs – we have the products on the shelf to get them back to operational status – as soon as possible.

What We Do For You

We pride ourselves on being a business partner of this nature. Inventory levels are something we constantly focus upon and look for ways in which we can continually provide better service levels with higher order fill rates and faster, more accurate shipping.

What We Can Do For You

Because let’s face it, when you’re down and out – you need the part or piece of equipment fast. By maintaining considerably larger inventory levels than the competition, we can effectively promise a 95%+ fill rate on stock orders.

That means if you order 20 items – we have 19 in stock ready to ship promptly. And most of the time it’s consolidated from one origination point – meaning we help lower and control freight costs for our customers – by reducing multiple shipment orders. Consequently, one shipment means one freight bill.

Who We Are

In addition to healthy inventory levels, we pride ourselves on warehouse accuracy. In all honesty, if we have the item on the shelf, but cannot get it to the customer for whatever reason – we didn’t live up to our promise of impeccable service. Therefore, it has been and will continue to be our long-standing goal to exceed and maintain 99.8% shipping accuracy. This means we accurately ship the item(s), and quantities, written on the sales order over 99/100 times.

You need it – We have it. That was fast. Pretty simple concept. But, to produce extreme simplicity, one must solve the extremely complex. Therefore, we continue to invest in ourselves and our operating systems. We continually invest in our people and technology to ensure that we constantly improve and strive for the ever elusive 100% success rate for our customers.

Additional Value Added Services

We back our inventory strategy up with some of the best technical expertise in the industries we serve. With over 250 years of combined technical experience, we have most likely run across your application question. Furthermore, if we don’t know, we will help to provide a solution that improves the efficiency of your operation – all the while, doing our best to help lower your operating costs. We invest in our people, technology, and inventory to make your business more profitable and efficient.

We also want to highlight the fact that we have a Free Freight Program that runs throughout the year. This can further help reduce costs for our customers to help them maintain a higher level of profitability. You can check out our Free Freight Program right here.

Careers

Banjo Liquid Handling Products

The Inception of Banjo

The story of Banjo starts in a small garage in Crawfordsville, Indiana. We need to go back to 1959 to see where the spark ignited for Banjo. Jack Canine set out to solve problems by offering high quality products - and nothing short of that attribute. Soon after he set out to accomplish this feat, he was able to move out of the garage and established Terra-Knife. Which was a small fertilizer knife supplier that focused on delivering quality products to farmers throughout the United States.

As the agricultural industry grew, so did the small supply company known as Terra-Knife. Jack Canine and his team recognized the need to expand their product offerings. The company quickly began offering ball valves and cam lever couplings. Shortly after this product line expansion the company was renamed to Terra-Products, in an effort to better represent its added product offerings.

The name Banjo Corporation came as a result of Jack Canine’s personal hobby and love for the stringed instrument. An additional factor was that the shape of one of the company’s newly heralded key products, the ball valve, somewhat resembled a banjo. Thus, Terra-Products transformed into present day Banjo Corporation and rapidly expanded their production capacities of polypropylene products.

4-Bolt Ball Valves

Current Day Banjo

Let's time warp forward a few decades to 2006. Banjo Corporation joined IDEX Fluid & Metering Technologies Division. This further strengthened the IDEX global position and allowed them to deliver complete fluid handling solutions for Agricultural and Industrial applications. In today’s marketplace, Banjo is recognized as a world-class producer of a broad and diverse range of mechanical/electrical valves, self-priming centrifugal pumps, and fittings for agriculture and various industrial applications. The Banjo name is prevalent wherever quality fluid handling solutions are required throughout the world.

Banjo boasts a large fleet of molding presses and numerous machining and assembly cells. OEM customers worldwide trust Banjo due to the long track record of delivery quality products. This sets Banjo apart from the rest of the pack:

Part specification tolerances at one-ten thousandth of an inch
36 plastic injection-molding presses
Capacity of up to 17,000 valves produced each day
3-day lead-times
98%+ first-pass yield

Commitment to Quality Control

In order to maintain their quality, Banjo has implemented various checks throughout their manufacturing process:

Multiple finished goods inspections
Daily process checks to isolate potential issues
Monthly Rapid Improvement Events to identify opportunities where operations can be improved
Inbound material inspection

Jack Canine ingrained a commitment to product innovation at the inception of this organization. That commitment to product innovation has continued since 1959, when Jack set out to design a better knife to apply anhydrous ammonia. Not only is Banjo committed to product innovation but to customer-driven innovation. Some examples of that include:

Quick-change manifold systems to improve ease-of-use and versatility
Electric valve product line tailored to specific OEM needs
Patented Dry-Mate dry disconnects which tremendously reduce the possibility of spillage

The Banjo name is synonymous with high quality products delivered on time. From oilfield applications all the way to cornfield applications you can see the Banjo name prominently displayed on various valves, fittings, and couplers. Here is a link to our Banjo manufacturer page on dultmeier.com. We hope you enjoyed this manufacturer highlight. Stop back any time!

Wheat Prices Set to Soar - Or Are They?

Wheat Market - From Then to Now

If you have had your finger anywhere close to the agricultural market in the past few years you know it is somewhat depressed. Especially, since we hit highs for corn around $7/bu back in 2013. This was such a rapid incline in grain prices that it somewhat threw the markets out of balance. Anyone that has remotely studied markets is familiar with the pendulum effect. If a market swings drastically in one direction, it is bound to swing back just as hard - if not harder - in the opposite direction.

This market effect could be potentially unfolding before our eyes this summer. Heat waves around the world are driving the price of wheat higher. Europe and Asia are seeing abnormal heat, which is burning up the wheat crop on these geographical regions. While the United States has seen heat as well - it hasn't necessarily been in wheat country. We live in a tremendously global market environment. The prices we see daily, are affected by what happens across the pond and all over the world.

European & Asian Wheat Farmers

Therefore, the distress that European and Asian farmers are currently experiencing is positively impacting the US wheat farmer. Simple supply and demand is causing this increase in the wheat market. Because there is less supply going into the market place from our European and Asian competitors, their 2018 wheat crop is expected to be less than the forecast. Whenever there is a shortage in a market, the commodity begins to increase in price. The less you have of something the more valuable it becomes.

Russia, Ukraine, France, and Great Britain are all European countries which have wheat farmers that are being negatively impacted by the 2018 heat waves. On August 2nd, Chicago wheat futures hit three-year highs to around $5.50/bu (The Wall Street Journal).

A Look Back into History

Looking at an aggregate chart of wheat prices since 1960, we can see fairly large market clips occurring about every seven to ten years. On average, these pullbacks are about 50% down from the high. The most recent high was back in December of 2007 at just under $12/bu. We seem to have found a level of support at roughly $4/bu. Currently, we are sitting at a $5/bu.

Wheat Prices Since 1960, Source: www.macrotrends.net

Looking at historical trends it appears as though wheat prices are on the up-and-up. It seems that the market has found a much more agreeable level of support. I say 'agreeable' since one can clearly see the higher lows met with higher highs in 2016-2018. We did not see this back in 2010-2012 failed rally. The market wasn't ready to correct and thus we were sent into a further recession.

Now, it seems the market is posed to regain the losses from 2012. Where we have seen about a 57% clip in the price of wheat - to the low in August of 2016.

Sometimes markets require a little extra push or catalyst to take off. A shortage in supply can absolutely be that catalyst. The US is positioned well in the current global wheat market and pose to reap the rewards of healthy crops.

Is an Increase in Wheat Futures a Certainty?

Now, we must acknowledge the tariff war and how that could potentially affect US wheat farmers. China has imposed tariffs on American grain and oil-seed imports. If we could look at wheat prices in a vacuum, one would say the US wheat farmer is posed to prosper over the next few years. The global supply and demand issues we addressed above, along with the technical analysis of the chart presented above both suggest this is the case. However, trade wars generally don't impact the farm market in a beneficial manner. It's difficult to say what is going to happen but all things aside - wheat looks posed to make a run.

As always we hope you find this post to be informative and educational. You may ask yourself how Dultmeier Salescomes into play in the wheat market. We offer a wide product selection to help enable producers plant, fertilize, and protect their crops through herbicide/fungicide applications. Check out our Agricultural Division page here. Stop back soon!

Fill-Rite: The Red Pump - A Tuthill Brand

Intro to Tuthill

In this month's Manufacturer of the Month highlight we showcase Fill-Rite. The long-standing, reliable 'Red Pump' has been an industry staple for years. When someone sees a red fuel pump in the field they quickly recognize the Fill-Rite brand. Our primary connection with Fill-Rite is in the petroleum and fuel delivery industries that we serve. Let's dive a little deeper into the history of this wonderful brand.

The Inception of the Tuthill Gear Pump

The inception of this company dates all the way back to 1892 in Chicago, IL. An industry dilemma of construction material supply sparked the creation of Tuthill Pump Company. James B. Tuthill needed to come up with a way to efficiently transfer clay from deep in the quarries to supply the rapidly expanding Chicago urban development industry. His invention to solve this supply issue was a steam-powered truck engine.

However, a critical component that truly paved the future for Tuthill was the small gear pump that injected fuel oil directly into the truck boiler. As Tuthill refined the pump design he began to market it to companies that produced oil-fired boilers for use in residential and industrial heating. Then, in 1927 the Tuthill Pump Company was formed by James B. Tuthill and Gary B. Tuthill. The sole purpose of this venture was to manufacture and sell lube/oil burner pumps. The Tuthill internal gear pump was widely accepted by the marketplace and opened the doors to what is the present-day Tuthill Corporation.

Fill-Rite - A Brand is Born

In 1961 Tuthill acquired Ossian Engineering Company. This acquisition resulted in the introduction of the Fill-Rite brand of fuel and metering products. Since the early 1960s the Fill-Rite brand has been a leader in the fuel/oil transfer industry. Innovation, ruggedness, quality, and reliability are all synonymous with the Fill-Rite name. Tuthill Transfer Systems broke ground on their state-of-the art production facility in Fort Wayne, IN in 1995. This facility continues to serve as a world-class production facility, to this day.

Then, in 1998 the Fill-Rite brand was grown even further with the addition of Fluid Power Products, Inc. While offering an extremely reliable and efficient way to move and transfer petroleum based products - more was deemed necessary. It only made sense to offer an ancillary product line where the solutions could be accurately measured, in addition to being efficiently transferred. Today, this product line is now known as Fill-Rite Precision Meters. The expansion of the Fill-Rite brand extends the capabilities of fuel pumps by offering highly accurate weights and measurement metering systems. You can view our manufacturer's page on Fill-Rite meters here.

Innovation Continued in Fuel Delivery

This past year, Fill-Rite has continued to offer new products that ensure its name stays at the top of the pack in petroleum-based product transfer applications. We want to point out the NX3200 Series pump with Nextec Intelligence. This pump can be operated in either 12V or 24V DC with a continuous duty motor - the first of its kind. This highly efficient pump produces 25 GPM with an extremely low amp draw. Furthermore, Intelligent Tones inform operators when attention is needed.

Innovation Continued in DEF Delivery

Furthermore, Fill-Rite has offered a new Diesel Exhaust Fuel (DEF) delivery package in the past year. The AdBlue Pump System allows for efficient transfer of DEF. The bracket allows the pump to be mounted directly over a IBC shuttle valve on a cage tank. This pump package can produce 8 GPM. It is available in either 12 Volt or 120 Volt options. You can view a 120 Volt package here and a 12 Volt package here.

A long and fruitful relationship has allowed us to reach this point in our partnership and we are looking forward to many more years together. You can view our Fill-Rite Pump page here to shop the various Fill-Rite pump products that we offer. Fill-Rite meters can be viewed here. We sincerely hope that you enjoyed this Manufacturer of the Month highlight and look forward to visiting in the future.

We are your Experts in Delivering Fluid Handling Services. Remember, at Dultmeier Sales - We Know Flow.

GREAT PLAINS INDUSTRIES (GPI) – A CUT ABOVE THE REST

Markets Served by GPI Brands

GPI products are heavily used in the petroleum and oil transfer industries. Furthermore, they serve in agricultural, industrial, chemical handling, construction, mining, and many other markets. Great Plains Industries is home to the GPI, FLOMEC, and GRPO brands.

Where the Products are Made

Great Plains Industries’ products are produced in the heart of the Midwest – Kansas. At their Witchita headquarters, more than 200 employees help manufacture GPI products. In 2013, the company acquired Trimec Industries of Sydney, Australia. Trimec, now called GPI Australia, is one of the top Australian manufacturers of positive displacement oval gear, insertion and impeller flow meters. Both Great Plains Industries and Great Plains Industries Australia are recognized and known for rugged engineering and durability.

Dultmeier Sales inventories and offers a wide array of GPI product lines, From rotary pumps to either 12V or 115V options to a multitude of meters. Additionally, we inventory some GPI oil and lube pumps.

GPI’s strong work ethic is evident throughout a long-standing heritage – one of commitment to serving their customers and exceeding expectations. The business is family owned, and this fact continues to play heavily into their customer focus mentality.

Flexible Manufacturing System

Recently, Great Plains Industries has embarked on a number of manufacturing technology improvements. For example, the Flexible Manufacturing System project has allowed the company to achieve greater efficiency, production capacity, and higher quality control. CEO Vic Lukic stated, “Innovation is key for GPI and these capital investments create tremendous value for us as a supplier, but more importantly for our distributors and their customers.”

“We continually improve processes and examine new and better ways of producing our products,” said Jeff Methe, Operations Manager. By continually improving their processes, Great Plains Industries can ensure a commitment to improving efficiencies, reducing waste, and lowering costs – all to better serve their customers around the world.

You can shop GPI products on dultmeier.com or give us a ring Monday through Friday (7:30 am to 5 pm Central Time). Check out our GPI Manufacturer page right here. Enjoy!

Giant Pumps - Performance Under Pressure

Thanks for stopping by again. This month we want to dive into Giant Industries and highlight them as a partnering manufacturer. Giant Industries works to provide superior solutions in all markets they serve and here's how they do it. Let's start out by looking back into the history books address how Giant has evolved over the years.

The History of Giant Industries

Ray Simon founded the Giant Towel Company in 1972. Towels were sold all over North America to car wash OEM's and through wholesale distribution channels. Then, in the mid-1970's Giant became the North American distributor for Speck Kolbenpumpen Fabrik, a German pump manufacturer. Speck offered a unique pump line, along with accessories, that quickly gained market acceptance. Widespread use by OEM's and distributors, alike, helped the Giant name become known as a staple product in the car/truck washing, pressure washing, and sewer/jetting markets. Furthermore, the quality of this German pump and accessory line gained widespread demand throughout various industrial applications, as well.

Giant Pumps Begin Manufacturing

When the 1980's rolled around, Giant Industries began to offer their own manufactured items to compliment the German-made pumps and accessories. This was done to address some unique requirements for pumps and accessories in the North American market, specifically. Giant Pumps began building its own line of accessories such as shut-off guns, accumulators, and unloader valves. As the Giant-manufactured products began to gain market acceptance, their manufacturing requirements increased, thus forcing the organization to acquire new facilities in order to meet market demand.

In the mid-1980's Giant began to offer pump and motor units to the pressure washing market. Additionally, Giant started to make axial pumps in Toledo which sparked the requirement for further expansion and yet, another facility. The addition of this facility has allowed Giant Pumps to meet various market demand - from car/truck washing all the way to sewer cleaning. At the current facility, Giant is able to manufacture both axial and plunger pumps, pump systems and a line of towel products.

Giant Triplex Plunger Pump

Vertical Market Exposure

As Giant has expanded in its manufacturing capabilities it has decided to take on more market exposure in existing markets - by offering those markets even more cross-related products under the Giant umbrella. The main focal point being an offering of complete pump systems. Offering custom-units helps Giant Industries' customers concentrate on they key tasks that allow their businesses to remain profitable. Giant offers pumps and pump systems that require more than 1,000 HP to drive pumps. That is a massive pump system. To put that in perspective, the largest pump unit that Dultmeier Sales has manufactured, to date, is a 150 HP centrifugal pump unit. That unit weighed 3,100 lbs. And we thought we dealt with some large pumping systems!

Giant Turbo Nozzle

Giant Industries Product Mix

Dultmeier Sales has been a long-time partner with Giant Industries and we truly do value the relationship that we have built, together, over the years. While Dultmeier Sales does represent many other manufacturers that are viewed as competitors of Giant Pumps, we know that when we are selling Giant products to a customer we can assure them nothing, but the best of quality - followed up by impeccable service. Whether you are in the market for Giant pumps, spray guns, towels, pump oil, wash prep systems, nozzles, unloader valves or relief valves - we can be your one-stop-shop for all things Giant pump related.

Giant Pop-Off Relief Valve

As always, thanks for stopping by and we look forward to visiting soon. Take care!

John Blue - An American Icon in Agricultural Pumps

How it All Began...

John Blue's story originates in Richmond County, North Carolina during the late 1800s. Cotton was the main cash crop that fueled the local agricultural industry during that time period. Manual labor was the primary labor input with additional power supplied by mules. A young man, by the name of John Blue began to see an opportunity develop. His innovative mind began to realize how the cotton farming process could be improved and how greater efficiencies could be brought into the industry.

John and his father, Angus, established a business to repair cotton gin parts in 1886. As the industry evolved, the need for more efficient methods of distributing fertilizer and cottonseed birthed the invention of the John Blue Cotton Planter. This invention helped to revolutionize farming. As the business grew, its ability to manufacture implements and cast metal parts evolved, as well. It wasn't until the early 1900s that John Blue obtained patents for all of his inventions.

John Blue's Vision for Agriculture

The primary goal of John Blue was to make farming dependent upon machinery - not man-power. He set out to make implements available to all farmers - and to do this, he understood that he must continually lower his cost of production.

In 1945 disaster struck as the John Blue Foundry was destroyed by fire. John Jr. then moved the company to Huntsville, Alabama where it still exists today. The Huntsville location was chosen not only for the fact that it lies in the bosom of southern agriculture but also because it is in close proximity to iron ore. Lastly, there was a coal foundry available. These three, key, ingredients allowed the company to flourish into new product offerings. In the early Huntsville years, the John Blue Company manufactured liquid applicator pumps, self-propelled sprayers, cotton module makers, small tractors, nurse units, cotton wagons, and dry/liquid anhydrous ammonia applicators.

In 1967 the John Blue Company was sold to new ownership. Then in the 1980s, the challenges of the agricultural economy gave the company good reason to consolidate its product offerings and focus on pumps, flow dividers, manifolds and accessories for applying liquid chemicals and fertilizers. During this time frame, CDS Ag Industries, Inc. was operating on the west coast - out of Chino, California. Their primary business was a manufacturer of squeeze tube pumps and irrigation pumps. These two companies merged in 2000 to form what is present-day John Blue Company, which is a division of Advanced Systems Technology.

Next Generation Ground Drive Piston Pump (NGP8055)

130 Years Later...

John Blue products are synonymous with the ruggedness, quality, and reliability that the agricultural industry demands. Recent innovations include the variable rate hydraulic driven piston pump and direct hydraulic drive for piston pumps. Other product offerings such as the patented electronic liquid blockage monitor system and visagage orifice selector continue to bring John Blue Sr.'s dream to reality - revolutionize farming and ensure dependency upon quality machinery - not man-power.

Check out our manufacturer's page which highlights all the John Blue products that we offer.

Pulley & Sheave Sizing - All Types of Pump Motors

We commonly receive the call to help assist in properly sizing pulleys and sheaves for pump applications. Generally, this is in high pressure wash applications but we also run into a fair amount of agricultural applications where this knowledge can be leveraged. Pulleys or "sheaves" are commonly used for connecting pumps to motors or engines via drive belts. Most pulleys are cast iron or aluminum construction and are offered in either fixed-bore or tapered bushing styles.

Why is it Necessary to Size Pulleys for Each Application?

For proper operation of any brand or pump type, it is critical to size pulleys and sheaves, correctly, in order to maintain correct RPM, (revolutions per minute). RPM speed is what determines the pump output flow rate - in gallons per minute, liters per minute, etc.

Incorrect pump RPM will adversely affect the pump performance. If the pump is turning too slow - it will not give full performance. Conversely, if the pump is turning too fast, it could cause premature mechanical failures (i.e. valve wear or elastomer failure).

Therefore, it is absolutely critical to ensure correct pulley sizing and analysis of the drive unit, (motor, engine, etc.) relative to the pump. For the sake of this discussion, we will assume standard electric motors at 1750 RPM and standard gas engines at 3400 RPM. Do note, one must determine the rpm of their drive unit to be able to accurately calculate the pulley/sheave size.

If you start with an incorrect figure for RPM - you will size your equipment incorrectly. This could lead to shorter equipment lifespans and/or reduced output flow rates. Thus, ultimately a less efficient system which equates to more down time and added cost of operation. The scope of this post will be focused towards plunger pump applications. We assemble many units using this method in Omaha, Nebraska. Dultmeier Sales is proud to display the Built in the USA logo on our products. Here are just a handful of the pulley-driven pump products that we offer.

The Math of Pulley Sizing

There are complicated formulas for determining pulley ratios but in generic, layman terms, simply divide the driven component (pump) by RPM, the driver component (motor or engine) rated by RPM to get the required ratio. In the example below, the pump RPM is 1070, for full output, while the motor is 1750 RPM.

Therefore, the ratio of the required pulleys would be:

1070 (pump RPM) divided by 1750 (motor RPM) = .611

This means the pulley ratio must be .611 to drive the pump correctly. Hypothetically speaking, if we had a 4 inch pulley on the motor, we would require a 6.55” pulley on the pump. That mathematical equation is as follows: 4” divided by .611 = 6.55”

For the same pump, driven by a gas engine

1070 (pump RPM) divided by 3400 (engine RPM) = .315

If the drive pulley on the engine is 4 inches in diameter, we need to calculate 4/.315 = 12.70. This means that the pump pulley must be 12.70 inches, in diameter, to run the pump at 1070 rpm. You can view a technical page from our catalog here - it will help to further explain the calculation process.

Tapered Bushing vs. Fixed Shaft Bores

Most pulleys, or sheaves, are designed with either fixed shaft bores or tapered bushing hubs. Replaceable hubs fit the required motor or pump shaft size in either inch or mm sizes - depending on the application requirement. These hubs come with bolts to attach them to the pulley, or sheave.

Tapered style hubs simply fit into the pulley opening and then are tightened with two or three set screws, which draw the bushing and pulley together to make one assembly. The pulleys are then attached to the driver (electric motor or gas engine) and driven components (pump). The type of hub, H, SD, SH, etc. must match to a pulley with the same designation for proper fit.

Therefore, make sure to identify what type of hub you have PRIOR to ordering.

Pulleys can be measured in a number of ways. Two of the most common methods are belt pitch and outside diameter (O.D.). When using the, most common A/B, belt pitch method, one must identify both A belt pitch and B belt pitch. This is the pitch diameter of the V-belt you are using, (A/B) is the measurement of how the belt fits into the groove of the pulley.

A belts are not as wide as B belts and, therefore, sit lower in the pulley groove. While this may seem as a minor detail - it absolutely affects the ratio measurement when properly sizing a pulley.

Pulleys are available with different numbers of grooves. The number of grooves matches the number of belts that the pulley will accept. A two groove pulley will accept two V-belts. A single groove pulley will only accept one belt.

Again as a general rule, (but not intended to use in every application) single groove pulleys with single belts can be used up to about 5 horsepower. Two groove belts can be used from 5-15 horsepower and three groove belts up to 25 horsepower. Use this as a general guideline but always make sure you consult us if you are unsure of your application needs.

Two Groove Pulleys

For correct belt sizing, there are charts available that show the sum of the pulley diameters and the center distance they are apart, from each other. We will be happy to supply you with one of those charts if you wish to have a copy.

For instance, the sum of the two pulleys, in the above electric motor example is 4 inches + 6.5 inches = 10.5 inches. The mathematical equation to figure this out is as follows:

A - Pump Pulley O.D. B - Motor Pulley O.D.

Belt Size = [A*1.57] + [B*1.57] + [2*center distance between pulleys]

76.5 = [4*1.57] + [6.5*1.57] + [2*30]

If the pulleys are 30 inches apart, center to center, then the required belt length would be 77 inches.

As the information above shows, there are many things involved in order to determine the correct pulleys required to drive your pumps correctly. It is important to remember the larger the difference in pulley sizes, the larger the center distance required to maintain minimum contact with the smaller pulley. We would be glad to help with any sizing for your specific applications. Your Experts in Delivering Fluid Handling Solutions - We Know Flow!

Dura Products - Technology with Lasting Value

The Chemical Transfer Equipment Industry Challenges

A long-standing challenge within the chemical transfer equipment industry has been rugged electronics that can stand up to harsh environments. In the past five years, one company stepped up, in a big way, to address this issue. The issue I am hinting at is the necessary ruggedness required by the agricultural industry for chemical pumps and meters. End users in the chemical transfer industry have, in the past, wrestled with the challenge of finding a meter/pump combination that is able to take the necessary beating the agricultural industry throws at it - while maintaining accuracy and performance attributes.

The use of products that lack ruggedness and robust design results in decreased efficiency, inaccurate readings, poor use of time, and higher maintenance/repair costs. Every single point I just hit on directly increases the end users' cost. Dura Products has and will continue to help the end user lower those costs by offering the market place something it was so desperately seeking - Rugged Quality Products.

Dura Products & Lasting Value

Dura Products has decided to step up and address this concern that has challenged the industry for years now. From simple in-line meters to diaphragm pumps to complete pumping systems - Dura has ensured quality control on their products and they genuinely care about how that quality is perceived by end users.

At the time of this writing, Dultmeier Sales has been a distributor for Dura Products for roughly one year. Dura Products runs the extra mile, in regards to, ensuring quality in their products has helped them stand out in the market place. We are starting to see more and more customers gravitate towards Dura Products. Are they offering sweet incentives to purchase their products? No, they are not. What they have done is supply the market place with rugged and quality products and tremendous service to back up those products.

Less downtime, more accurate readings, improved ruggedness, and increased quality are staples the end user can expect when running a Dura Products item. This company shows an insatiable desire to deliver quality to the market place. That is what I have witnessed in our short and blossoming relationship with Dura Products.

Dura Products Offering Package

Ag Dura-Pump Features

Shop Dura Product Pumps Here

Dura-Meter: True Ruggedness

The meter is the user interface to 76% of Dura Products' Ag Systems packages. Dura Products has addressed a major issue in the design of this meter. That issue being the majority of meter failures result from moisture and abuse. Now, let's be real - the agricultural industry isn't going to play any nicer with a $50 widget than it is with a $500 widget.

By acknowledging that simple and known fact, Dura Products justified the need for a rugged meter that was able to withstand the beating thrown at it by the agricultural industry - and still maintain the ability to accurately measure chemical in the field. Thus the Dura Meter was born.

Key Benefits of the Dura-Meter

100% Moisture Sealed Circuitry
Faceplate Made of Impact Resistant
Easy-to-Calibrate
Menu Driven, Backlit Display
Plumbed for Both In-Line and 90 Degree Applications - no additional adapters needed
Extended Battery Life: 4 "AAA" Batteries
Power Life Constantly Displayed
Features 2 Year Warranty
You Can Use the Face Plate to Fit a Flowserve/Scienco Meter - the bolt hole patterns match between the two meters

Dura-Pump Easy Caddy

The Easy Caddy system is an efficient and clean way to keep your chemical distribution system tidy, as well as, protected. The Easy Caddy keeps the pump directly above the IBC shuttle valve - this is beneficial as forklift operators need to only be concerned with one side of the shuttle. All the equipment that could potentially be damaged is contained on one side of the shuttle and kept neatly organized.

Conversely, if the end user fancies a top mount or, the more portable, ground version - those options are also available. We have seen many retailers and growers, alike, gravitate towards the side mount style, recently.

Shop Dura-Pump Easy Caddy Now

Dura Auto Batch System - Limitless Opportunities

The Auto Batch system allows the operator to remotely program and distribute chemical. Again, the Dura Meter is the main interface for this system. The Auto Batch system does have a manual mode if you wish to top off a shuttle or container. The system can be reverted back to automated mode at the flip of a switch.

Shop Dura Auto Batch System Now

Chemical Compatibility

Dura Products not only ensures greater quality in their products, but they want to make sure that customers are educated on proper chemical compatibility. You can have the greatest pump/meter combination in the world but if you are running a product that is incompatible with the elastomers - you are going to ruin the equipment.

For this reason, Dura Products relies on distributors and end users, alike, to confirm chemical compatibility. Dura Products offers their pump and meter systems in three stock elastomer options: EPDM, Viton, and Silicone. Check out a previous post that we wrote up on the product trade-named Resicore and the importance of chemical compatibility.

Here is a link to a wonderful Chemical Compatibility Chart that Dura Products has published.

It's extremely reassuring to know that a manufacturer, not only puts this much emphasis on quality assurance but an equal emphasis on chemical compatibility. Marketplace education is a huge focal point for the Dura Products team, as it is with the Dultmeier Sales team.

2 Year Maintenance & Warranty Program

So, now that we have discussed all the wonderful benefits of Dura Products physical attributes in their products - let's touch on their two-year warranty program for pumps and meters. All Dura Products items have a two-year service warranty program. If it breaks or malfunctions - Dura Products wants it back. They will make the repairs and then send out the refurbished unit(s). This further helps maintain their process of quality control.

It's extremely reassuring to work with a manufacturer that exemplifies this commitment to producing and ensuring quality products. Equipment that falls under warranty period and parameters will be repaired, or replaced, and returned at no cost to the customer.

Secondly, the two-year maintenance program allows customers to coordinate a return to Dura for refurbishment of pumps and meters - at no charge. Within this program, Dura Products will triple rinse pumps and/or meters to ensure no cross contamination is possible. All equipment will be taken apart and evaluated to ensure seals, gaskets, and internal components are operationally acceptable.

During this process, any parts that are still under warranty will be replaced at no charge. If any parts need to be replaced, that are not under warranty (i.e. broken housing, damaged parts, chemical compatibility issues, cut cords, etc.), they will be replaced and charged to the customer with NO additional labor charges. Lastly, the customer will be notified of all findings associated with cost and ETA of when the equipment can be expected back to the end user. This is another facet that truly sets Dura Products apart from the rest of the pack.

This concludes our Manufacturer of the Month highlight. We hope that you enjoyed this write up on Dura Products and sincerely hope that you stop back soon. Take care and be safe out there.

Hydra-Flex - Fluid Innovation

Hydra-Flex History

Hydra-Flex was started in 2002 in a small machine shop. The company originated as a 2-man outfit and quickly grew in ranks from there. The core motivation for HydraFlex was driven by the simple belief to "find a better way" to produce innovative and reliable fluid handling products.

The core values that drive Hydra-Flex are Innovation, Reliability, and Accuracy. These values are clearly visible in the products they develop. Hydra-Flex is proud to boast its reputation as The Most Trusted Name in Chemical Dispensing.

This Eagan, MN company holds a committed focus to reduction of waste, salvage of resources, reduction in operating costs and the promise to provide exceptional - and measurable results for end users. Located within the innovative Twin Cities community, Hydra-Flex continues to strive for nothing short of exceptional product delivery.

Hydra-Flex is listed on Inc. 5000 Fastest Growing Private Companies and winner of Best in Class at the 2016 MN Manufacturing Awards.

Chem-Flex Injectors

Hydra-Flex holds patents on chemical dispensing and nozzle technologies. Also named one of Minnesota's Top Inventors by Twin Cities Business Magazine, Hydra-Flex continues to be recognized locally, as well as, nationally. The underlying premise of finding a "better way" to apply fluid handling technologies guides their strategy and solutions offerings.

Taking a common design called a venturi, Hydra-Flex has revolutionized the vehicle washing industry. A venturi is not a new idea - the venturi was actually discovered by an Italian physicist, Giovanni Battista Venturi in 1797. A venturi induces a small portion of another fluid into a carrier fluid. This is created by creating a pressure differential between the inlet and outlet. Constricting the flow of the carrier fluid actually creates a vacuum, thus allowing the secondary fluid to be induced into the carrier agent. Furthermore, mixing the two fluids together through a venturi, ensures proper and equal mixture throughout the solution.

Hydra-Flex created the Chem-Flex injector to take venturi technology to the next level. Chem-Flex injectors use the most chemical-resistant and longest lasting components available on the market. This includes Kynar venturi inserts, stainless steel connections, a hastelloy spring, teflon check ball and Hydra-Flex's exclusive XFC O-ring. Chem-Flex injectors are built with the goal of finding a "better way" to induce and mix chemicals.

Benefits of Chem-Flex Injectors:

Small Footprint - Forget the need for large mixing tanks. Do it inline and mount these systems on the wall - maximize the space in your equipment room.

Better Vehicle Coverage - Using the same dilution rate but increasing delivery pressure allows for less solution usage and better coverage. Chem-Flex injectors have an application pressure capacity of 65-80 PSI versus traditional chemical dispensing systems that generally run from 25-40 PSI.

Consistency - Fluctuations in local water pressure do not affect the dilution rate of the injectors. Because the injectors use the pump's regulated pressure you need not worry about this variable. Thus, instilling a greater degree of consistency into your wash system(s).

Reliability - The simplistic design minimizes moving parts and, therefore, reduces the potential for failure due to mechanical wear. We have already mentioned the added chemical resistance brought on by the internal components used in Chem-Flex injectors - this is an added reliability factor. Rest assured - Chem-Flex injectors will stand up to some of the toughest chemicals on the planet.

Precision - Color-coded injectors (by flow rate) and metering tips (by dilution ratio) offer precise optimization and easy maintenance of the chemical delivery system.

Environmentally Friendly - Due to the fact that the solution is applied to the vehicle at higher pressure, less solution is needed to clean the same size surface. This often results in substantial reductions in water and chemical usage. Furthermore, the use of highly concentrated chemicals can help reduce packaging waste and freight costs. If you can order in smaller packages you can help reduce a variable cost in freight expenses.

The Nozzles

Hydra-Flex offers five models of nozzles - each one provides a solution to various industry applications. While there are five different models the nozzles can be split into two larger categories - Rotating Turbo Nozzles and Static, Zero-Degree Nozzles.

Rotating Turbo Nozzles

Blast-Tec Pro (1000PSI) - designed specifically for high-pressure, high-impact wash applications such as wheel blasters, undercarriage cleaning, rinsing and high pressure cleaning.

Ripsaw (3200PSI) - specifically designed for hydro-excavation industry. An extremely heavy-duty and high impact nozzle that is ideal for pothole applications. The cone-shaped flow patter provides 18 degrees of coverage.

Aqua-Rocket (4000PSI) - designed and engineered for the industrial cleaning industry. This nozzle blasts a concentrated 0 degree water jet while rotating at an optimal speed to form a 22 degree cone-shaped spray pattern. Here is a video below

Static, Zero-Degree Nozzles

Blast-Force (1000PSI) - This nozzle produces a solid-stream and was specifically designed for spinning, high-pressure vehicle wash applicators. Constructed with corrosion-resistance tungsten carbide nozzle orifices, this critter will get the job done - and then some.

Switchblade (3200PSI) - Dig Faster. Save Water. Another hydro-excavation nozzle but in a stationary in design. Cut deeper, cut faster. A neat feature of this nozzle is the flexibility it offers. There are individual, replaceable, color-coded nozzle pills that allow the end user to change water flow rates and pattern based upon various soil conditions. Here it is in action:

Whether you're in the market for nozzles or chemical injectors, you need to consider Hydra-Flex as a viable option in your decision making process. For further questions on other products we offer you can stop by our website any time you wish. Thanks for stopping by and we hope you enjoyed this post.

Valve Applications & Valve Purchasing Guide

Dultmeier Sales stocks valves of all different makes, models, and applications. Here you will find all you need to know about the different types of valves we stock and the various applications they are used for. More importantly, we will help you determine what you need to know prior to making a valve purchase. Let's dig in...

Valve Definition & Common Trade Names

What is a valve? What are some common trade names, associated with, the valves that Dultmeier Sales stocks and distributes? In a nutshell, a valve is a product which is used to constrict, cut off, redirect, or regulate the flow of a liquid or gas. While we do sell pneumatic valves we will be primarily focusing liquid, or solution, valves for this educational segment. Some common trade names associated with the valves we stock are as follows: butterfly, ball, gate, globe, angle, needle, solenoid, check, regulating, diverter, foot, relief, unloader, backflow prevention, and float valves.

As with any product, it's crucial to identify the type of valve, the manufacturer, inlet/outlet size, operating and maximum pressures, solution temperature, and the solution passing through the valve. It's critical to know what solution is passing through the valve to ensure proper chemical compatibility. Knowing the solution's PH level can also be another important factor when determining suitable components and materials.

How to Size a Valve

We size valves similar to how we size pipe. Always measure the inside diameter of the inlet/outlet port. This will identify the size of the valve in question. A common mistake is that people measure the outside diameter of the inlet/outlet ports of a valve. There is one exception to this rule - if working with tubing - measure the outside diameter of the tubing. For hose and pipe, only pay attention to the inside diameter measurement.

If flow rate is important, the coefficient of volume (Cv) of various valves can be compared. Now, I understand that sounds rather technical. However, in layman's terms all that means is the higher the Cv for a valve, the more flow rate will pass thru it with the same pressure loss. In the majority of applications, this will be a non-factor but it is still important terminology to be aware of in the vast world of valves.

Manufacturer Identification & Valve Type Explained

Most manufacturers will have a metal tag on their valve bodies to identify their brand. That manufacturer tag will identify the brand of the valve, the model, and serial number. This is an important first step in identifying what product you currently have. That being said, let's begin with a look at butterfly valves.

Butterfly Valves

Here at Dultmeier Sales, we stock a variety of butterfly valves. In the butterfly valve world, it's important to first determine which style of butterfly valve you possess. The two most common styles are Wafer or Lug bodies. A wafer-style butterfly valve has "thru" bolt holes that run along through the outside rim of both pipe flanges. In contrast, a lug-style butterfly valve has threaded bolt holes on both sides of the valve body to allow for "end of line" applications. Lug-style butterfly valves are, generally, less common than wafer-style butterfly valves. Below, you will see a wafer-style valve on the left and a lug style valve on the right:

Butterfly Valve Actuators

Next, we get into the topic of valve actuation. We primarily stock butterfly valves that are manually (seen above with handle) or pneumatically actuated with either double acting or spring return actuators. A double acting butterfly valve actuator requires air pressure to open the valve and then air pressure to close the valve.

A spring return butterfly actuator is used in fail-safe applications. If there is a loss of air pressure the valve will automatically close (or open) - due to the spring tension of the actuator. Spring return actuators are used in many production plants that require system flow to cease once power is cut or lost - as mentioned above, this is a fail-safe application example.

Electric Actuators are also used in many industries. While we don't stock electric actuators for butterfly valves - we have access to them. Actuators can also be provided with “positioners”, limit switches and other controls.

We stock Butterfly Valves and Air Actuators from Keystone and Pratt.

Ball Valves

A ball valve is probably the most common type of valve that exists - across all industries. It gets its name due to the fact that it actually has an internal ball that sits in a "seat". When the handle or knob is turned 90 degrees from the inlet/outlet ports, the valve is closed and one can see the convex shape of the internal ball. When the handle is turned parallel with the inlet/outlet ports, the valve is open and one can view through it - unhindered.

On the left, below, is an example of an air actuated, stainless steel, female pipe thread, ball valve. While on the right, you will see a Banjo, polypropylene, manual, flanged, ball valve.

Standard Port vs. Full Port

By design, ball valves that are listed as Standard Port actually have less fluid path than the inlet/outlet ports size limitations - this is somewhat misleading to those that are unfamiliar with the concept of Standard vs. Full Port valves.

For example, if you have a 2 inch Standard Port valve your flow characteristics will be closer to that of a 1.5-inch fluid path. The technical reasoning behind this is the fact that a smaller opening creates more friction loss (i.e. pressure drop) thus resulting in a decreased flow rate. Standard port ball valves are cheaper than full port valves but restrict the system flow rates; somewhat. So, if flow rates don't matter or affect your system then you can save money up front by selecting standard port valve(s) for your plumbing system.

Full port valves allow the plumbing system to realize the full flow characteristics of the valving. If all valves in a system are two inch full port, valves then we can reasonably assume increased flow rates in comparison to a system that contains all standard port valving. A full port valve has a slight design change that allows for this increase in flow characteristics. While the valves may look the same externally, there are internal design changes that are not visible to the naked eye.

High Pressure vs. Low Pressure

This is another crucial step in determining the correct valve for a specific application. If necessary, place a pressure gauge at various points in the plumbing system to determine the system operating pressure. Never guess the operating pressure of a system. If a low pressure valve is installed into a high pressure system, serious or fatal injury could occur. As a general rule of thumb, anything below 150 psi is considered Low Pressure - that being said, there are valves rate for pressure less than 150 psi.

This gets back to one of our core fundamentals when selecting a proper valve - determine operating pressure and maximum pressure for the intended plumbing system.

Ball valves are a perfect example of how the same style valve can be used in multiple applications - both high pressure and low pressure. We have some ball valve product lines that have use applications which are limited to certain industries - due to their operating/working pressure limitations. However, we have many ball valve lines that carry over into multiple industry applications.

While we do carry many products that can be cross-utilized in various industries we always want the customer to confirm an operating pressure. This ensures safety in application and use. Furthermore, it minimizes the possibility of injury and lessens the chance of damage to the valve and other plumbing system components

Air Actuated & Electric Motor Driven

We carry ball valves that can be remotely operated via automation, as well. The most common types are pneumatic (air-operated) and electric motor-operated ball valves. Air operated are most widely used in chemical facilities, fertilizer plants, or industrial plants. Electric ball valves are most commonly used in agricultural applications for spraying applications. The trade name electric ball valve or pneumatic ball valve simply refers to how the valve is actuated.

When you drive down the road and see a large self-propelled sprayer, spraying in a field, you can be certain the booms are being remotely controlled. The boom valves are remotely controlled from the sprayer cab, with the help of electric ball valves. The sprayer operator sends a signal from his, in-cab, boom controller to turn certain sections of the sprayer boom on/off - based upon the field's specific application requirements.

We also see electric ball valves in the turf industry. Golf courses or residential sprayers will commonly use this type of ball valve on their sprayer setups. It is more prevalent in the turf industry due to the fact that the booms are much smaller than the agricultural industry.

Lastly, we do a fair amount of business in the liquid deicing industry. If you have ever seen a department of roads/transportation vehicle that is applying liquid before a winter storm - you have witnessed this industry in action. These vehicles are applying a solution called liquid salt brine (sodium chloride, magnesium or calcium chloride solution). Electric driven ball valves are common in this industry because pneumatic valve airlines would freeze in the frigid winter temperatures.

For those interested, here is a link that further explains the process of creating the salt brine solution. Below is a picture of a pneumatic-operated ball valve, on the left. On the right you will see an electric-operated ball valve.

Gate Valves

A flanged gate valve is used in larger flow applications. In the Dultmeier world, we most commonly see this style of valve used on large bulk fertilizer, fuel tank storage applications, and float storage tanks in the vehicle and fleet washing industry. Gate Valves are generally designed with a circular handle that is turned clockwise to close the valve and counter-clockwise to open the valve.

Just as any other valve, we need to confirm the solution that will be passing through the valve to ensure chemical compatibility and then confirm the working or operating pressures that are required by the plumbing system. Most commonly, we are supplying flanged gate valves for lower pressure ranges. Below is a picture of a common flanged gate valve used in the bulk fertilizer industry.

Globe & Angle Valves

A globe valve is very similar, from an external view, to that of a gate valve. However, when we look at the valves internally, they are quite different. As can be seen from the previous section, the gate valve operates almost like a wedge or slate that constricts or completely closes off flow. A globe valve has a different seat structure and more of a plunger that constricts or completely closes off flow. See below:

Below is a photo of a couple different sized globe valves on an Anhydrous Ammonia application. These valves are for a receiving bulkhead system where a plant facility will offload large bulk transports into their bulk storage tanks. The larger valve is on the liquid line transfer and the smaller valve is on the vapor transfer line.

In the Dultmeier Sales world, we most commonly use globe valves in the Anhydrous Ammonia industry. That is the same for angle valves. The most common application we see angle valves used in would be on toolbars or supply risers for Anhydrous Ammonia fertilizer applications. Continental Nh3 Products and Squibb Taylor are our two largest suppliers for these types of valves. An angle globe valve can be viewed below:

Needle Valves

Next up we will take a look into needle valves and the various applications they can be used for. Most commonly, we see these valves used in higher pressure applications such as car/truck wash and high-pressure cleaning. Here is a grouping of various needle valves on our website, to further illustrate the variety of options. That being said, we do sell a fair amount of needle valves in the Anhydrous Ammonia industry for a bleed off application.

As always, in any application we want to confirm the solution passing through the valve, working or operating pressure range, and temperature of the solution. Below you can view a picture of a needle valve.

Solenoid Valves

We carry a wide supply of solenoid valves from a number of suppliers. The most notable brands we offer are GC Valves, DEMA, KIP, Kingston and more. A solenoid valve is another example of an electric valve. However, they are drastically different than electric ball valves. That being said, solenoid valves can be controlled remotely and are used in a number of industries.

We most commonly use them in high-pressure vehicle or fleet washing applications, industrial applications, and agriculture or turf spraying applications. Some users in the agriculture industry are starting to migrate away from solenoid valves to ball valves - the primary reason being the necessity for the ruggedness of a ball valve versus over a solenoid valve. Mother Nature in combination with aggressive chemicals is an extremely harsh environment for a valve.

Normally Closed vs. Normally Open

This is an important topic to address - especially in the realm of solenoid valves. If a valve is "normally closed" it means that the valve is closed in its uncharged state. More simply put, if there is no electrical current passing through the valve coil then then it will remain closed. If a valve is "normally open", that means the valve is open in its uncharged state.

Various applications will call for either style. Coils in these valves can be 12 volt, 24 volt, 110 volt and even 240 volt, which allows for a wide and versatile range of applications.

For example, in the vehicle washing industry, we may want to have a weep application on a spray gun. We would do this to ensure the gun doesn't freeze shut in lower temperatures. Therefore, we want ambient water to continuously run through the system or spray gun - if a loss of power occurs. So, in this instance we would want to ensure a normally open valve be installed in this type of a plumbing system.

Solenoid valves are still highly used in the car/truck wash industries due to the fact that they are generally stored in temperature-controlled environments while limiting exposure to the harshness of the natural elements.

Check Valves

Next up, we will look into the world of check valves. This product is used to prevent backflow of a solution in a plumbing system. For instance, a check valve would be utilized when pumping a solution up a vertical pipe and you do not want the solution to backflow, due to gravity, when the pump is turned off. A check valve is a form of backflow prevention.

Furthermore, check valves keep a plumbing system charged. By keeping the system charged we can ensure more efficient delivery of product and reduce the number of air pockets that are present in the plumbing system, which reduces pump priming time and other potential pump problems. The more efficient a plumbing system is - the less it costs to keep it running.

Types of Check Valves

There are multiple types of check valves and each has its own benefits. We will briefly touch on the different types, here. First, is the most efficient type - in terms of maximizing flow characteristics. The swing check valve allows for maximum flow characteristics due to its design that reduces restrictions (i.e. a high coefficient of volume).

Regardless of the check valve style, we need to remember the cracking pressure. The cracking pressure determines the PSI at which the valve opens. Therefore, if a check valve has a cracking pressure of 2 psi it will not open until the plumbing system generates an operating fluid pressure greater than 2 psi. Below is a cross-cut section of a swing check valve:

Secondly, we have a ball check valve. This type of check valve has a preset mechanical spring that allows the valve to open based upon a pre-determined working pressure. These types of check valves are commonly used in high-pressure applications such as car and truck wash, but also within industrial and agricultural applications.

Lastly, there is a plunger style check valve. This style is pictured below:

Things to note when ordering a check valve:

Operating and maximum pressure requirements
Solution or product passing through the valve - check for chemical compatibility
Cracking pressure
Inlet/Outlet size
Body type (wafer, NPT, flanged, etc)

Shop Check Valves Now

Regulating Valves

A regulating valve can technically be any valve. In this sense, if you can constrict or control the flow by manipulating the opening threshold of the valve - you have just regulated the system flow.

To that note, we are going to look at this section with this one caveat in mind - a regulating valve needs to be remotely controlled. To do this, let's first look into electric motor driven valves.

There are certain types actuators of ball valves or butterfly valves that manipulate the flow rate of the solution by opening or closing the valve stem a to a certain degree. Without getting too technical this is done in conjunction with some type of flow monitor that is able to communicate with the valve actuator through a control mechanism.

This control mechanism can be a simple rate controller in a sprayer cab or as complex as a computer dashboard in a chemical production facility. The regulating valve communicates to the flow monitor through the system controller to reach and/or maintain the desired flow rate. This controller can be a simple rate controller or a complex computer system.

Regardless of the application - in order to remotely control a regulating valve we must have a controller that sends a signal to the valve based upon the desired flow rate of the operator.

As always, any application we want to confirm the solution passing through the valve, operating pressure range, and temperature of the solution.

Diverter Valves

A diverter valve functions very similarly to a remotely controlled regulating valve. The main difference between a regulating valve and a diverter valve lies within the functionality. A diverter valve is designed only to guide product flow through a system. Therefore, the most common example of this would be a three-way ball valve.

We look at this section with the same caveat in mind - a regulating valve needs to be remotely controlled. To do this, let's first look into electric motor driven valves.

The diverter valve would be remotely controlled through a similar mechanism as a regulating valve. The main difference is that the diverter valve "diverts" flow down fluid path A versus fluid path B - based upon the desired location sent by the controller or computer.

Foot Valves

Foot Valves are commonly used in transfer systems that require the pump to maintain it's prime. A foot valve is essentially a type of check valve. Foot valves are placed at the beginning of a suction line and are generally designed with some type of a strainer or screen to protect the plumbing system from sucking in foreign objects.

If you recall the design of the check valve, you will remember that a check valve closes when there is backflow pressure applied on the spring check. This forces the valve to close and keeps the system suction line primed, with liquid - thus increasing the overall efficiency of the plumbing system. The less time it takes to prime the pump the more efficient the plumbing system becomes. Below you can view a diagram of a plumbing system that includes a foot valve, with strainer.

Relief & Unloader Valves

Relief and unloader valves are commonly used in higher pressure situations with positive displacement pumps. These valves are used to protect system components from dead-head scenarios. A positive displacement pump will continue forcing product downstream in a plumbing system until there is a system failure such as a burst pipe, fitting, hose, etc. Thus, the term: dead head scenario. To help combat this scenario, relief and unloader valves were designed. Here is a diagram that explains a relief valve scenario

Wash Diagrams

This video will explain the difference between the two styles of valves. As always, Cat Pumps does an amazing job explaining content.

Back Flow Preventers

In any wash down application where an operation has a water supply line connected to a public water source then it's absolutely necessary, by regulation, to have a back flow prevention valve in place. We distribute for Watts and commonly sell these units in vehicle/fleet wash applications, industrial applications and fertilizer/chemical facility applications. A backflow prevention system products the main water supply in the scenario where a local business would have a system failure and back up chemical, fertilizer, hazardous material, etc. into the main water supply - backflow prevention systems inhibit this scenario from taking place.

Below is an example of a Watts back flow preventer

Float Valves

Float valves are used in a wide array of applications. Virtually anywhere you need to maintain the level of a supply tank - you can leverage the assistance of a float valve. Some common float valve product lines that we distribute and carry include BOB Valves, Jobe Valves, Hydro Systems, Kerrick Valve, Dema, Walters Control, and Suttner.

Below is a Dema liquid level proportioning control unit with a siphon breaker.

Another application that is extremely common with float valves is in the cattle industry. We sell a unit that allows the user to tie into a warm water source to keep stock tanks from freezing closed in frigid temperatures. The Ice Bull Automatic Ice Prevention System is engineered to automatically open when the stock tank water temperature falls below 42 degrees Fahrenheit.

When the Ice Bull sensor valve opens, .20 gallons per minute of warmer water bypasses the float valve and flows into the tank through the discharge hose. Then, when the water temperature rises above 42 degrees Fahrenheit, the thermo valve shuts off. The Ice Bull Sensor is pictured below:

In Conclusion

We hope that this has been a helpful guide to valves. While not all valve types are listed in this post, you have certainly enhanced your general knowledge and should be better prepared to choose the correct valve for your desired application needs.

Don't forget to confirm in any application - the solution passing through the valve, operating pressure range, maximum pressure, and temperature of the solution and always confirm chemical compatibility.

As always, thanks for stopping by and come back soon.

Ace Roto-Mold Tanks - A Division of Den Hartog Industries

The History of Ace Roto-mold & Den Hartog Industries

Ace Roto-Mold is a Division of Den Hartog Industries. With the goal of involving everyone in the organization to continually improve products and processes to ensure total customer satisfaction, this manufacturer stands up with the best. Den Hartog Industries, Inc. was founded on February 9, 1976, by John and Ann Den Hartog. Hospers, IA was the original homestead for the company and it remains so to this day.

Today & Business Scope

Den Hartog Industries, Inc. is a family-owned business that is now in the second generation of lineage. Den Hartog Industries has grown from a small metal manufacturer to a leading figure in the plastics manufacturing industry. The current facilities boast over 381,000 square feet that includes corporate offices, manufacturing & mold fabrication facilities, shipping, warehouse space, and fleet maintenance.

Divisions and Services Offered

The company currently operates four divisions. Those divisions include Ace Roto-Mold Rotational Molding, Injection Molding, Blow Molding, and Sowjoy Metal Fabrication. Customer rotational molding, injection molding, metal fabrication, blow molding, custom assembly, and secondary operations, custom packaging services, flotation, and structural foam filling are all services offered under the Den Hartog Industries umbrella.

Engineering services are also offered by the Den Hartog Industries team. These engineering services include full product design assistance with 2D, 3D and solid modeling. Furthermore, tooling, dedicated customer service, quality assurance, and delivery services are also provided.

You can view and shop Ace Roto-Mold tanks on Dultmeier.com right here.

The Advantageous Upside to Pure Water

What is Pure H2O?

Crystal clean, pure, and without blemish. If all water entered our appliances, equipment, and food in it's purest form we would have a lot less headaches. Face it - hard water is tough - not just on equipment but on our bodies. If we can introduce pure water into a plumbing system it will accomplish things from reducing friction all the way to keeping maintenance costs lower. Fortunately, we can accomplish this through a process called reverse osmosis.

Think about it this way - let's say you setup two equal plumbing systems but the only factor your change is the water hardness. If you are pumping water that has 450 Parts Per Million (PPM) in System A, versus water that has 10 PPM in System B - which system will outlast the other?

I hope you guessed System B. Common sense tells us the less wear and tear we can put on mechanical pieces of machinery the longer it will last. Therefore, if you have hard water (water that contains more abrasive or suspended particulates) you are going to undoubtedly add to variable expenses in the form of increased operating costs - the upkeep of your equipment will require more routine maintenance and repairs - no way around it. Below you will see a cut-out view of a membrane used in reverse osmosis systems.

But what if I told you a simple investment, up front, could lower those variable costs and effectively keep more money in your pocket? You keep more money in your pocket by allowing your system to run more efficiently and lessen the likelihood of additional maintenance and repairs costs.

Bottom line - if you can keep your system operating longer and minimize down time, whether that's scheduled maintenance or emergency maintenance, more money stays in your pocket.

Determining Water Hardness

Let's get into the heart of this discussion and throw some numbers out there. Water hardness is determined on parts per million. The EPA allows for 500 PPM in drinking water. Vehicle washing requires, a maximum, 50PPM.

More and more greenhouses are beginning to monitor their water hardness, as well. Greenhouses and farmers across the country need to monitor their pH levels constantly. They do this to ensure that their plants are given the correct ratio of nutrients required to improve yields. By rigorously monitoring the purification of the water supply, an operator can ensure that a clear, and controlled, chemical reaction takes place with their soil matter.

The process of reverse osmosis allows operators and farm/greenhouse managers to effectively oversee this chemical reaction - in a much more efficient manner.

Reverse Osmosis & How it Works

Reverse Osmosis is a process in which microscopic particulates are captured by an extremely fine membrane that allows the solute, in this case, water to pass through. This process is so effective that it can take water with 500PPM and reduce that number to less than 10PPM - and, in many instances we can do much better than that.

This process is achieved through pressurization and, as noted above, extremely fine membranes or filters. The solute is retained on the pressurized side of the membrane and the solvent is allowed to pass through the membrane. The reason this process must occur under pressure is that the solution needs to be forced through the fine holes of the membrane. In many systems there will be multiple stages of filtration.

The first filtration step will occur through an extremely crude manner. In many instances, the process will include a sand bed filtration that is gravity fed. This step is no more complicated than allowing the solution to percolate through a large sand bed - thus extracting many of the large particles that would clog finer filters and membranes - which are downstream in the plumbing system.

The next stage typically involves another filter, or series of filters, that catch particulates and suspended particles that were small enough to pass through the sand bed -which is stage 1 of the filtration process. By implementing this second stage filter the process, in most instances, the solution is ready to actually pass through the finer filters/membranes - thus completing the reverse osmosis process.

Prior to running the solution through the final filtration stages, it must be ran through a "booster pump" that creates the pressurized portion of the system.

Once under pressure, the solution is ran through another membrane or series of membranes. Depending on the water hardness, it might be necessary to use a series of reverse osmosis membranes to reach the desired PPM the operation requires. Basic system components for a reverse osmosis system, used in the vehicle washing industry, can be viewed here.

Upstart University Video Explanation

Here is a video from Upstart University on how reverse osmosis can benefit farmers and greenhouse managers.

For further product questions or inquiries about reverse osmosis systems and or replacement components and parts - don't hesitate to contact us or check out our website at Dultmeier.com - Thanks for stopping by and take care!

Mosmatic - Clear Sighted & Ground Breaking

Mosmatic At a Glance

The journey to an assured future. Look no further than Mosmatic Corporation. The Switzerland-based company specializes in the manufacturing of high-pressure cleaning equipment. With over 40 years of experience, Mosmatic has the common sense knowledge to back up their revolutionary solutions which serve a wide range of industry issues.

The construction of a new facility in Bristol, WI has allowed Mosmatic to better penetrate the US market place. From high-pressure swivels to rotary nozzles and carwash booms - all the way to roof cleaners and gum removers - this company offers just about everything you need to keep your business clean and looking pristine. You can view our Mosmatic Manufacturer page here. This is one of Mosmatic's top videos - which clearly illustrates many of their product high-pressure cleaning offerings.

Hurricane Pro

The Hurricane Pro is highly popular. Not only is one able to clean underneath vehicles but it also allows the user to pivot the spray deck. This allows for multiple cleaning angles to get into tight crevices and blast debris free. This adjustable angle feature allows for an "all-around" cleaning of construction equipment, agricultural machinery, fleet vehicles, boats, and the list could go on - you get the picture. The Hurricane Pro is an extremely versatile undercarriage cleaner that is packaged into one sleek and high-quality model. Shop Mosmatic Now. This product can be used with either hot or cold water.

Technical Data

Maximum Pressure - 4000 Psi
Maximum Temperature - 250 Degrees Fahrenheit
Inlet - 3/8"NPTF
Adjustable Spray Angles - 0 Degree to 90 Degree Spray Deck Adjustment

Here is a product-focused video on the Hurricane Pro.

High-Pressure Vehicle Washing

Mosmatic is also a staple name in the high-pressure vehicle cleaning industry. From booms to swivels, spray guns, foaming products, and rotary wheel cleaners - Mosmatic offers just about everything one would need. The Mosmatic Wheelblaster Pro is a highly effective and versatile solution for just about any style or type of vehicle. Due to the nature of its design, there is no need to be extremely close to ensure a polished clean.

The water pressure actually turns the rotor arm - so as long as there is water pressure the rotor arm is spinning - no added motors are necessary. Generally, the Mosmatic Wheelblaster Pro is found in automatic car wash facilities, but this product can be used for buses and fleet vehicles, as well.

We hoped that you enjoyed this Manufacturer of the Month highlight. Mosmatic is a wonderful company that is seriously concerned with the quality of their products. No one says it better than their managing director, Patrick Rieben. "For us Quality is not just a slogan, but the bench mark for our efforts, priorities and goals."

Take care and don't forget to stop by Dultmeier or give us a call at 1-888-677-5054. Thanks for dropping in.

Cim-Tek Filtration: World-Wide Leader in Filter Technology

Cim-tek is at the head of the pack when it comes to filter technology. The Cim-tek brand can be recognized in petroleum, industrial, agricultural, heavy-duty machinery/equipment, and biofuel markets. Over the past 70 years, Cim-tek has continued to perfect their design and expertise in fluid filtration applications. From water detection/removal products to top-of-the-line filtration efficiencies you will find it all when in need of a solution filter.

History

A. Richard Ayers developed a product named "Pre-Vent" in 1956. The "Pre-Vent" is, essentially, a fill cap with a pressure/vacuum release that reduces the amount of evaporation in gasoline storage tanks. Furthermore, the Pre-Vent helps maintain a higher quality of the stored fuel. Think of it this way - you fill up a gas can at the station, put the cap back on, and put it in the back of your truck. On the drive home, you hit a few bumps, take some sharp corners, and tap the brakes a little too hard at a stop sign and come to a jolting halt. Then, when you arrive home you pick up the can and place it on your garage floor only to realize that the can is slightly bulging. To alleviate this pressure you open the cap and an abrupt "pssssst" is exhausted from the can.

Even at rest, gasoline (or other solutions) will continue to build pressure inside of an air-tight vessel, tank, or storage container - unless you alleviate the pressure. This is exactly what the Pre-Vent cap does - it alleviates pressure - without the need to remember and manually perform the task on a schedule. Now back to the history lesson...

Richard needed a manufacturer to construct his new design so he founded Central Illinois Manufacturing Company (CIMCO) in Bement, Illinois. Over 70 years later the Pre-Vent cap is still being manufactured by CIMCO. Richard continued his research on fuel filtration - as requested by a large petroleum distributor. In 1958, the "Clean-Flow" filter was introduced. The Clean-Flow was followed by the "Gas-O-Line" series which is now known as the 200 Line Filter. Later, down the road, CIMCO established the trademark name Cim-Tek Filtration. The company continues to be operated as a family-owned business.

Innovation

Throughout the years, Cim-Tek continues to innovate their current product lines and research/develop new products. However, to note that some of their original products are still industry leaders is remarkable. It is a testament to the quality and the foresight of the engineering, design, and manufacturing of the original staples such as the Pre-Vent cap and the 200 Line Filter. Filtration is a necessity in all markets across the world. And you can bet that Cim-Tek intends to continue to be a worldwide leader in offering that necessity.

From Nebraska to Maui - HDPE Can Be Found

Maui - A Tropical Paradise

We recently traveled to Maui, HI. The tropical paradise, virtually, has it all. From breathtaking beaches to arid, Sahara-like, geography, all the way to volcanic rock. In our travels, it's hard to find an industry in which the products we work with don't have a footprint or an impact. In this instance, our example is High-Density Polyethylene Pipe (HDPE). However, let's hold there and get to the island stuff first...

Let's face it - when in Maui you could simply hang by the beach for the entirety of your stay and be able to soak in tons of the island life. However, for those more adventurous, I challenge you to explore all that this wonderful oasis has to offer. The Hana Highway is a unique adventure for those interested.

If you plan to take the Road to Hana - make sure you get a Jeep. The mini-van made it but may or may not have required an alignment check after the trek. From hairpin turns along the tropical mountainside to sheer cliffs among the arid ocean walls of the Southeast side of Maui, Mother Nature will treat you and leave you stunned at the beautiful sights.

The trip starts on the North shore of Maui and takes you past Jaws aka Pe'ahi - a popular surf destination on the island. From there one starts to climb - and climb fast. As you begin to make your way up Mt. Pu'unianiau you will wind your way through a seemingly endless amount of bridges, turns, and stunning views.

Don't forget to stop and get your banana bread - it's a little island secret but we don't want to give that away here. Just make sure where to ask to stop along the Road to Hana and you will won't be sorry that you did. It is absolutely, hands down, the best banana bread in the world.

Once you get through Hana you will begin making your way around the South side of the island - this is where the topography, as well as, geography begins to drastically change. What was once luscious jungle gives way to a Sahara-like climate.

Along the South side of Maui, you will come across the southern end of the Halekala National Park. Within this national park, you will be able to walk to the Oheo Pools or the Waimoku falls along the Pipiwai Trail. While embarking on the trek of this trail (3-mile loop) you will make your way through a bamboo forest that is truly remarkable. The gentle breeze creates a "clicking" and "clanking" that reverberates throughout the forest.

It was here, along the Pipiwai trail that we ran into our instructional scenario of the excursion. The park uses High-Density Polyethylene Pipe, or HDPE pipe for short, to transfer crystal clear water from the upper pools down to the recreational center hundreds of feet below, along the ocean shoreline.

HDPE Uses - An Extremely Versatile Product

We see HDPE pipe used from agricultural fertilizer applications to the petroleum industry in the oil fields and all the way to municipalities. The applications and uses for HDPE are endless. As the product is chemically compatible with a large number of solutions, it is a natural and obvious choice for many scenarios. Furthermore, it is an extremely economical option in comparison to steel or stainless steel pipe.

The ease of installation makes HDPE another enticing choice - a fusion machine allows installers to, essentially, weld the pipe together in what's called a butt fusion - which is an extremely robust and sure connection. Below is a simple video that illustrates HDPE pipe and a butt fusion weld to a 45-degree elbow.

While the majority of the applications, with which we are most familiar, are within the agricultural industry we do get into projects ranging from wash facilities to oil pipelines - and everything in between. If you have further questions about how HDPE pipe and/or fittings could be applied in your specific scenario don't hesitate to contact us. Here's to a wonderful 2018

~ Aloha Friends ~

Resicore & Learning Which Elastomers Work

Did you or your customers apply the product labeled as Resicore last season? Any issues with elastomers in pumps, seals, fittings, etc. failing? We had quite the troubleshooting experience with this product over the past 2017 season. Our partner, Dura Products, has invested a significant amount of resources to ensure this problem has been resolved. We feel confident in their findings and want to make sure that you are well informed when working with this product.

In the 2017 season we sold a significant amount of Dura Auto Batch Systems and ran into some seal failures at the two to four week operation period. Failure from a Dura Product after such a short amount of time is extremely rare and once Dura Products was notified they immediately went to work finding the culprit behind these seal failures.

Testing and Findings

After weeks of research and testing, Dura Products concluded that the product, Resicore, could be causing the findings. Resicore is a Dow AgroSciences product which is used as a corn herbicide and was widely used in 2017 - there are thoughts that more will be applied in 2018. Once we were able to identify a common theme across these product failures Dura Products began testing multiple elastomers to determine their longevity when completely immersed in the solution. Here are the compatibility recommendations from Dow AgroSciences Bulk Storage and Handling Guide:

The only materials that are acceptable for constant contact and greater longevity with the product Resicore include stainless steel, Teflon, ultra-high molecular weight polyethylene (UMHW), High & Low-Density Polypropylene and silicone rubber. Of all these options silicone is the only elastomer that was found to be acceptable for constant contact- over an extended period of time.

Furthermore, it was found that polypropylene, a common plastic used in pump housings and pipe fittings, is actually only moderately acceptable. Dura Products' research found that polypropylene only lasts about 175 days before deterioration is evident.

The Solution For Resicore Transfer

We want to ensure that your products operate when you need them to operate and that they operate in the manner they are designed to operate. Research that Dow AgroSciences has provided and silicone elastomers that Dura Products has developed helps us to ensure that your operation continues to run smoothly.

If you are handling Resicore in the future you must be aware of the recommended compatibility of the wetted materials of construction for Resicore are Stainless steel, Teflon, Ultra High Molecular Weight Polypropylene, High and low-density polypropylene. The ONLY elastomer that you should be using is silicone.

Below is a photo of a soak test conducted by Dura Products: Viton seal on the left and Silicone seals on the right.

Throughout Dura Products testing and experiments, it was concluded that silicone was the best-suited elastomer for constant contact with the product labeled Resicore.

As you can see, Resicore has compromised the integrity of the Viton elastomer. It has also slightly discolored the O-ring. These are both clear identifying qualities of a chemical compatibility issue. Given the same testing parameters, the silicone elastomer held up just fine - as it is compatible with Resicore. Here is another blog post that further explains the importance of doing your research and homework to ensure chemical compatibility.

Whenever questions arise due to chemical compatibility, it's absolutely necessary to consult the material handling guide of the product you are applying or handling. In this instance, when reading the handling guide - Dow AgroSciences specifically states that stainless steel is preferred when transferring the Resicore product. The Resicore handling guide specifies these materials below:

Stainless Steel, Glass Lined Steel or Epoxy coated carbon steel - OK Rating - Comment: Stainless Steel is preferred.

Silicone Rubber - OK Rating - Comment: Preferred Elastomer.

Polypropylene (High and Low Density), Teflon, Ultra High Molecular Weight Polypropylene - OK Rating - Comment: Good Resistance, High-Density Polypropylene preferred.

Viton, SBR - Caution Rating - Comment: May swell and soften moderately, may have a useful life for short time periods.

Mild Carbon Steel, Brass, Copper, Aluminum - NO Rating - Comment: Moderate to Severe corrosion due to the products low pH level.

PVC, ABS, Acetal, and Nylon - NO Rating - Comment: Disintegrates, embrittles or stress cracks.

Buna N, Neoprene, EPDM, and Hyplon - NO Rating - Comment: Severe swelling, softening or absorption.

In Conclusion

Always make sure that you consult the label of the product which you are applying and/or handling. Furthermore, we are happy to continually be a source knowledge such as this blog post. If this post was useful and relevant please, don't hesitate to share it with your friends and colleagues. Take care.

Husky - A Breed Apart

As we continue to grow in the petroleum/fuels industry we want to highlight a long-standing and well-respected partner in Husky. We use many Husky nozzles in our own manufactured products such as our diesel transfer units. Quality, assurance, and dedication are all fantastic descriptors of this wonderful company.

Husky has been serving the petroleum industry for over 70 years. Husky has hung its hat on developing ground-breaking products such as American-made fuel nozzles, hoses, safe-t-breaks and accessories, and oil/lube products. Extremely dependable customer service not only supports, but compliments the Husky brand. The company headquarters is in Pacific, Missouri which is in the surrounding St. Louis area.

Safety, Quality, Customer Loyalty, Team Building, and Productivity are the five pillars which Husky focuses on daily to ensure that the Husky brand exceeds expectations. A constant recognition of the past helps keep this proven industry leader at the top.

- Shop Husky Now -

Shortly after World War II, Eugene Sutcliffe designed the first gas guard in his home. The design originated to protect car exteriors from scratches when fueling. Soon after this new product began to gain momentum Sutcliffe was designing fuel nozzles that would revolutionize the petroleum industry.

Sutcliffe traveled from gas station to gas station, across the country, selling his products out of the back of his car. He was always accompanied by his dog - a husky. He made it a point to bring his companion along on sales calls to portray the message of dependability, intelligence, and steadfast trustworthiness. This is the unique story of how the brand logo, and company name, came to be.

- Shop Husky Now -

Roughly 70 years later Eugene's son, Grenville, heads the company and continues the tradition that was long ago started by his father. A tradition that embodies the admirable characteristics of a canine companion - dependability, loyalty, endurance, and trust. Here is Grenville explaining one of Husky's American-made nozzles.

Raven Industries - Applied Technology

Raven was founded in Sioux Falls, SD in 1956. The company originated as a designer and manufacturer of high-altitude research balloons to solve challenges related to space exploration. From that single product line, they have evolved into an extremely diversified technology company.

Raven Applied Technology

Raven Applied Technology was created in 1978 and has helped to create, define, and redefine precision agriculture practices and technology. In today's agriculture industry when the topic of precision agronomy comes up - there is no doubt that Raven Industries will be discussed, as well. The two go hand-in-hand. From field computers, application controls, guidance/steering/wireless connectivity, and cloud-based data management, Raven is at the cutting edge of some fascinating technology.

This innovator offers tremendous resources to the industry, as well. For instance, take their technical support website Ravenprecision and recognize the amount of information that is available at your fingertips. From locating dealers, product support, to groundbreaking news you will find it all here.

Drones

Raven Applied Technology announced a partnership with AgEagle Aerial Systems early this year. AgEagle Aerial Systems is a leading provider of unmanned aerial systems technology that is used in precision agronomy. Drones are becoming more of the farming community and faster than one would think. Raven has aligned themselves as the exclusive distributor for AgEagle and their RX60 fixed-wing UAV.

During flight, the RX60 captures aerial images of the field and can identify crop health in each and every field it passes over. This is accomplished through special camera lenses and software that can correlate crop pigmentation into plant health. For instance, one measure of plant health is the amount of green pigmentation that is present in the plant.

- Shop Raven Now -

If the plant has more of a yellowish hue this identifies with nitrogen leach or nitrogen deficiency. A farmer can easily see this when crops are smaller. However, when crops get above shoulder height it is extremely difficult to monitor this - that's where UAVs come into the picture.

Many people in the agriculture industry recognize the actionable data that drones can provide. For this reason, many people understand that drones will continue to impact the agriculture industry and Raven feels that they are aligning themselves in a great position to re-solidify their position as a cutting edge technology provider.

How to Start a Car Wash

Everything You Need to Know About Starting a Car Wash

Have you been pondering the idea of starting a car wash? Does the idea of passive income sound appealing? That's because it is. Do know that there is an extensive amount of upfront work and then there is the issue of on-going maintenance. That being said, once you have an operational car wash up and running - you can consider it passive income.

The information below is a compilation of countless periodicals, customer surveys, and testimonials. At any point in the process of your new adventure, should you feel the need to ask about something in more detail don't ever hesitate to contact us. Let's dig into what you will need to do in order to properly align yourself to start a car wash.

Lot Selection

A general rule to follow when sizing lot is that you will need a lot approximately 100 - 120 feet deep by a minimum of 75 feet wide - depending on the number of bays. Keep in mind a typical four bay self-serve car wash would need a lot 120 feet long by 100 feet wide - minimum. Another key attribute when selecting the ideal lot for your car wash is that it is accessible from both directions of traffic flow.

For instance, if you select a lot that is on a one-way street it will negatively affect the volume your wash is capable of producing. The ideal traffic speed in the area of your lot selection should be around 40 miles per hour. This ensures that drivers have ample time to select your wash as their destination. The lot size and shape will determine if you design a "drive-in-back-out" or "drive-through" building.

Data shows that income streams do favor the "drive-through" design. Lastly, when selecting your ideal location it is a good idea to target areas near residential neighborhoods, apartment complexes, or busy traffic routes. When determining if your ideal lot selection is a good fit for your business plan, you should consider the finances, as well.

A safe rule to adhere to is that the cost of the property (monthly lease payment) should not exceed 15 - 20% of the gross monthly income of the wash. This ensures that you will not over-extend yourself, financially.

Bay & Building Sizing

An ideal bay is 16 feet wide by 28 feet long - these are the interior wall measurements. If you are planning a semi-truck bay make sure to account for internal wall measurements of 18 feet wide by 28 feet long. You can make a smaller bay work for trucks but why not just do it right from the start? The typical pump (equipment) room is 10 - 15 feet wide by 28 feet long (internal measurements).

Furthermore, the typical bay height is 10 feet high for cars and 12 - 14 feet high for semi-trucks. Your lot size above will vary depending on what your overall wash purpose is (car vs. semi-truck) and the number of bays you intend to have. That's why we recommend determining the bay purpose and number of bays at the same time you are selecting your ideal lot location.

Building Placement

It's always best practice to consult local regulatory agencies to ensure your building is within code. That being said, your building should be situated on the lot to allow for one to two cars, minimum, to be parked behind each bay, waiting to wash. Vacuums should be placed in this area, as well, but should not be an impediment to the normal traffic flow into the bays. Another important concept to consider is that you ensure there are adequate drying and vacuuming areas.

These areas should be out of the main traffic flow to avoid congestion. It is a good idea to allow for a southern exposure of your bays. This helps to reduce ice build-up in colder weather climates. Finally, make sure you plan for the "set-back" requirements on your building placement - this will vary with local ordinances.

Inside vs. Outside Bays

This aspect really does depend upon your market. Therefore, drive around and study the target market for the area which you have selected. That will give you a good idea of whether or not you need to have an outside bay or an inside bay. Washed located in a rural setting can be built with an open outside bay to accommodate trucks, trailers, and tractors. While this isn't required it can, and will, only allow for more traffic at your wash.

Do keep in mind that an outside bay will bring in 50-60% of the revenue that an inside bay will. It is always better, from strictly a revenue standpoint, to enclose all bays and build one larger bay for semi-trucks - if you feel that your market will demand that. This larger bay can always be used for car traffic when an overflow bay is needed.

Revenue Projections

Our experience tells us that it takes a population of about 1000-1500 people to support a single self-serve bay car wash. Therefore, one can conclude that a town of 5000 people will support a total of 5 self-serve bays - between ALL competitors. Given the current population level of the United States, the national average one can project roughly $2000/bay per month during peak traffic season(s). This is an estimated average - revenue can and will vary.

The ideal number of vacuums to have is 1.5 vacuums per bay of service. Therefore, a three bay wash should have four to five vacuums in an area of the lot that will not affect traffic flow. The national average per vacuum is approximately $200/vacuum per month. Again, revenue can and will vary.

National averages of vending revenue are generally around the $400 per month range. This figure is based on offering at least four to five different vending products. Do keep in mind that revenue can be increased with multiple product, clear front vending machines.

Operating Cost Projections

One can expect that average operating costs are approximately 50% of gross revenue. This figure includes 13% for attendant labor, which may or may not be needed. Do note that lease payments, income tax, debt reduction or depreciation are not factored into this number. Furthermore, we must be clear that one should recognize these figures can and do vary from region to region.

Options & Features

A standard self-serve wash will offer hot wash/hot rinse in the winter and cold rinse in the summer. Additionally, hot or cold wax, foamy brush and spot-free rinse should be considered. Spot-Free rinse is an important feature. It increases revenue due to the fact that customers need to "buy" another cycle of time to get this feature. What does this mean? Double the income from each customer that decides to use this feature. Tire cleaner and pre-soak systems are also options that increase customer satisfaction and increase revenue.

We highly recommend that instantaneous tankless water heaters be used in place of conventional water heaters. An instantaneous heater can reduce gas consumption by up to 40% in comparison to a conventional heater. For example, if it rains for an entire week, only the pilot light is using gas in the instantaneous tankless system. If only the pilot light is running that takes considerably less fuel, and therefore, less money - directly affecting your bottom line - in a positive way.

Conversely, the conventional water heater will continue to heat the water regardless of demand. Think of it this way - the instantaneous heater only fires when water is needed, thus making the system much more efficient. Another important feature to consider is floor heat.

Every cold climate wash should have a floor heat system. Floor heat systems reduce liability and increase customer satisfaction. An in-floor circulating system is the most popular design. That being said, above-head radiant tube heaters also give the benefit of heating the floor as well as the customer. Keeping your customers warm while they are in your bays will keep them happy and ensure they continue to come back as a repeat customer.

It is wise to account for heating a three to four-foot area on the entrance and exit aprons of each wash bay. This will reduce customer liability in the walk areas as they use bill changers and vending machines. Ice will build up in colder climates and you want to ensure you do all within your power to mitigate injuries on your property.

Another important topic to address is the use of proper signage. It is frustrating to use a wash that is poorly explained due to the lack of proper signage. Yes, many people will be able to figure it out. But, why let this be part of your customers' experience? Don't you want them to get exactly what they want out of your wash? Get in, get out, and have a clean and sleek finish. Here are some examples of car wash signs we offer.

Additional Revenue Streams

Do not overlook vending products such as towels, Armorall, window cleaner and fragrance trees. These are additional revenue streams. Piggybacking off vending machines, every wash should have bill changers. This is an absolute necessity. Studies have shown a minimum 10% increase in gross revenues for washes that have bill changers.

Another trending area that has taken off in the past few years is the addition of pet washes at car wash facilities. The demand is there and many people will wash their cars and pets in the same visit. This has been a profitable investment for our customers that have installed pet wash facilities at their locations. You can view some options here. As always, should you have more questions than can be answered by our website don't hesitate to contact us.

Dicamba and Proper Application Techniques

With the big shift in application products and techniques taking place in 2017, many of the foundational principles still remain in 2021. The biggest principle is to ensure that you "stay on label" when applying Dicamba products. Strict adherence to label instructions will help reduce liability greatly. We know that wind and humidity are major factors when selecting application day(s) and time(s). Now that the country has a few solid seasons of good spraying data, we can look back and use the data to help us continue to progress forward and improve applications.

One major change to the market place since this blog was posted back in October of 2017 is the Bayer-Monsanto merger. This merger has brought together two titans in the ag-chemical world and has further consolidated the marketplace. In the write up below there is some good information regarding application and snapshot in time of where we started out when not much was yet known with these products.

One thing is for certain - Dicamba is here to stay and we, as an industry, need to continue to stress the importance of training and proper application techniques. Firsthand experience tells us that these products, when applied correctly, smoke RoundUp Ready resistant weeds. Our farm on the Nebraska/Kansas border has much cleaner fields after having made the switch two seasons ago. But, Mother Nature always finds a way to survive....That begs the question - how long before we start to see Dicamba-resistant weeds?

Dicamba Leading up to 2017 and In-Season 2017

Herbicide-resistant weeds have been expanding across the country for the better part of the past decade. Crop protection product companies such as Monsanto and Dow Chemical along with seed companies such as Syngenta have come up with multiple options to help combat these pestering weeds. The most promising solution appears to be within the Dicamba-resistant strains that were first made available for the 2017 season. Even before these seeds began appearing in fields in early 2017 there was a significant amount of skepticism.

Many people shared the sentiment that Dr. Kevin Bradley expressed at the Wisconsin Crop Production Association annual meeting in January 2017. Dr. Bradley stated, "There is no question the Dicamba option is coming, there's no question about it. But it's another question altogether whether we can steward this technology, and time will tell if that's true or not." He also pointed out the volatility of Dicamba and how finite amounts of this product could damage crops.

By the middle of 2017 states such as Missouri, Arkansas, and Tennessee had already received multiple complaints from growers of suspected Dicamba damage. It is estimated that more than 3.1 million U.S. acres have suffered from Dicamba-related crop damage (Crop Life: Special Report Managing Weed Resistance). Arkansas is actually on the verge of banning the application of Dicamba products - completely.

Even if it doesn't get banned it has been voiced that application restrictions will make it virtually impossible to actually apply the product. For example, if you can only spray the product with winds between 3-10 mph you don't have much of a window in the Midwest. We don't have too many days during spray season with winds between 3-10 mph. By the time you're able to actually spray (within regulations), it's too late because the weed plant is too far along to actually kill. This scenario is speculation, but is certainly a real possibility.

The Wall Street Journal reported that Monsanto actually sued the Arkansas State Plant Board in October. This came after the board's decision to ban Monsanto's new herbicide. Monsanto claims its herbicide is being held to an unfair standard. Arkansas has been the focal point of complaints with almost 900,000 acres of crop damage reported. It is noted that farmers in 25 states have submitted more than 2,700 claims to state agricultural agencies. The complaints share the common theme of neighbors' Dicamba spray drift and account for 3.6 million acres of total reported crop damage.

Dultmeier Insight from In-Field Observations

Our traveling sales representatives found evidence of Dicamba-related damage in a widespread area of our travels. The conventional beans that were affected appeared to be "cupped". The plants didn't canopy until later in the season - much later than normal. We will start to know how much of an impact this chemical had on yields as the combines get in the fields and begin to report yields. Some actually thought it could have a positive impact on yields since 2,4-D is a growth killer.

Some of the Dicamba products are derived from the chemical 2,4-D which basically grows a plant to death by oversupplying it with hormones. The thought process behind this theory is that if the plant pulls through the "cupping" stage and comes out of it, the farmer could actually see a yield bump. Again, that theory is yet to be proven...Below is an image of soybeans cupping due to Dicamba damage.

Even though many conventional fields were harmed there were much cleaner soybean fields this summer versus 2016 - at least in the areas we traveled. The conclusion being, it worked - for those fields that were Dicamba-resistant seeds. But we did see a number of conventional fields that looked awful. They looked awful from the perspective that the soybean plants were small and sickly looking. That being said - weeds were not present - so you can make the argument that the Dicamba did kill the weeds.

Drift is a major topic when the phrase "Dicamba" is brought up. We even had one customer in the Polk, NE area that mentioned they witnessed product from an applied field actually lift up and move to an adjacent field a week after it had been applied - an entire week later! You can ask the chemical companies and they will say that's not possible. The proof is in the pudding, folks - there are many instances similar to this over the past year. If we have learned any lesson, it's that these Dicamba products are extremely volatile and we must continue to educate, educate, educate.

Training and How Crucial It Is

There is a simple and basic rule to follow: The Label is the Law. If you are applying a product with a spray tip that is not on the label and you damage a neighbor's crops - you're liable. If you are running a spray tip that is on-label, but operating out of the required pressure range or spraying in too heavy of wind and damages a neighbor's crop - you're liable. The days of using one tip for every chemical applied are long gone. An applicator must be 100% certain they are operating within parameters specified on the product label.

Always consult your label if you have questions about what application products or techniques you should be using. For instance, a common theme is wind speed. Labels limit wind speeds between 3-10 mph on many of the Dicamba products.

It has been mentioned that during periods of high temperatures and high humidity vapor drift can readily be witnessed up to three days after application. Recall our example from Polk, NE and know that vapor drift from inversion has been documented outside that three-day window. What is inversion? Inversion takes place generally from 3 pm to 8 am the following day.

Generally, air near the ground is warmer while the air higher up away from the earth's surface is cooler. When an inversion takes place the opposite happens. Colder air is closer to the earth's surface and the warmer air is higher up - away from the earth's surface. This phenomenon can commonly be seen in the fall around harvest time - when soybeans are cut and the dust hangs in the air it can be reasonably assumed that an inversion is taking place. Tiny spray droplets will "hang" in the colder air and can float around on slight breezes.

Driftable fines of these Dicamba-based products have been found to drift miles from the application site. Due to this fact, the spray tips that are approved are those that create a larger and coarser droplet through air induction. Such as Teejet's Turbo Teejet Induction Nozzle.

There is a wide selection of approved tips from various manufacturers such as Wilger, Hypro, Teejet, and Greenleaf. Remember, always consult your specific product label to ensure the tips you are choosing from are actually approved - you need to be on-label to safely and responsibly apply these products. Furthermore, you can visit these chemical websites as additional resources: BASF - Engenia & Monsanto - XtendiMax.

As of mid-October 2017, Monsanto has voluntarily proposed to offer further educational programs to ensure farmers have success with the Roundup Ready Xtend Crop System for the 2018 season. These updates include mandatory training, new recordkeeping requirements, and a Restricted Use Pesticide (RUP) designation. This will limit the sale and use to certified applicators or those acting under their supervision. All of these steps are supported by the Environmental Protection Agency (EPA). The new recordkeeping requirements will better track label compliance and help protect farmers using the Xtendimax system - as long as they follow the product accordingly - adhering to all label instructions.

Equipment Rinsing & Maintenance

Thorough clean-out is a must for any equipment used in Dicamba application. Applicators must keep the sprayer completely clean after Dicamba applications. Due to the volatility of the product if there is any residual left in the plumbing system of a sprayer it will be applied at the next application site and drift from there. Triple rinse with fresh water has become the industry standard. Check out this other blog post for rinse-out techniques and tips.

This triple rinse process includes the entire plumbing system - strainers, screens, dead spots in the booms, nozzles, valves, pumps, etc. Hypro has designed their Express Boom End Cap to aid in flushing booms. Similarly, Wilger has come up with their own design to fit CASE IH Patriot sprayers. Both of these products help eliminate dead space in the boom where residual chemical builds up and can cause headaches - major headaches when dealing with Dicamba products.

Furthermore, we have had a small handful of customers actually install chemical weighing systems solely for the dispensing and selling of Dicamba-products. This keeps the product completely and totally isolated from any others in their inventory to avoid contamination. Here is an example of Junge Control's Chemical Weighing System.

Moving Forward and What that Means for Dicamba

So what does all of this mean for the future of Dicamba-products and how widely used they will or will not become in the near future? One side can make the case that due to the number of claims and issues that were found this past season, more farmers will plant the Dicamba-resistant seeds in 2018 as nothing more than an insurance policy. After all, we did hear, in a number of instances, that growers actually planted the Dicamba-resistant seeds in 2017 solely as an insurance policy. They knew their neighbors would be spraying Dicamba and chose to use this method as an insurance policy.

The other side could argue that due to the widespread damage created by the conventional seed vs. Dicamba-resistant seed issues this past year we might not have any Dicamba-resistant seeds available for 2018 planting. Arkansas is leading the regulation wave here. They are about one step away from banning Dicamba-based products altogether, at the time of this writing. There are a handful of other states that are leaning in this same direction. However, there are times when the market will actually overtake regulation. Demand is a powerful force and we could see that process take effect very soon.

In my travels as a territory sales representative over the past four years, I have seen glyphosate-resistant weeds migrating north from central Kansas to central Nebraska - over 300 miles. Each year the soybean fields get dirtier and dirtier - and the number of dirty fields has been increasing - at an alarming pace. 2017 was the first year I actually noticed a number of fields that were "clean".

Weeds raise hell not only on crops, but on equipment as well. Some fields have gotten so bad that one cannot run a combine through them. They were just cut for silage. We heard of many instances where growers spent twice their normal budgeted amount on combating/controlling weeds in 2017.

When it gets to the point where you spray a field five times (I heard this nightmare more than once) and still cannot get a kill on the weeds - you need to do something different. A wise old man by the name of Albert Einstein once said, "Doing something over and over while expecting different results is the definition of insanity."

"The vast majority of farmers using our low-volatility Dicamba product have had tremendous success in 2017, both with on-target applications and good weed control," says Ty Vaughn, Monsanto's Global Regulatory Lead. "The product was extensively tested for volatility and other forms of off-target movement before it was made available to farmers this season. We are confident XtendiMax can continue to be used successfully in the System next season."

Mother Nature is forcing our hand and we need to adopt alternative methods to combat weeds. Say that Dicamba-based products are outlawed. It doesn't mean it will keep growers and producers in this country from finding a way to improve their yields and solve this weed issue. The market creates the demand and demand is a powerful force.

Xtendimax Label (pdf)

Changes in Dicamba Application for 2018

The long-standing USDA/EPA requirements for Restricted Use Pesticide (RUP) application is as follows:

Product Name
EPA Registration Number
Total Amount Applied to the Field
Date of Application (M/D/Y)
Location of Application (legal descriptions, longitude/latitude, etc.)
Crop Name (Xtend soybeans, NOT just 'soybeans')
Size of Area Treated (in acres)
Name of Certified Applicator
Applicator Certification License Number

The additional requirements for 2018 are as follows:

Proof of Dicamba - Specific Training (NDA website is OK)
Receipt(s) of Purchase of RUP Dicamba used
Product Label (Not Required to be On Person at Time of Application)
Buffer Distanced Maintained - Consult Product Label
Evidence of Susceptible Crops Nearby (Date that this Review was Conducted)
Start and Finish Time of Application (include AM or PM)
Pre or Post Emergence Application - if Post Emergence Notate How Many Days After Planting
Air Temperature at Boom Height at Start and Stop Times
Wind Speed and Direction at Boom Height at Start and Stop Time
Tank Mix Partners - Including all Non-Pesticide Products. If Other Pesticides are Included, Records Must Show EPA Regulation Numbers for Each Product
Spray System Cleanout Procedure. At a Minimum, Records Must Indicate Spray System Was Clean Before Application was Made and What Cleanout Procedure was Used. Date of Cleanout is Required

Furthermore, each state may go above and beyond the requirements listed here so be sure to check your local state regulations BEFORE applying RUP products.

If you enjoyed this read, please, feel free to share with family, friends, and/or associates. Be safe out there.

How to Rinse & Winterize Your Sprayer

Step-by-Step of How to Properly Winterize a Spray Unit

In order to begin you need to ensure that your entire system has been evacuated of the solution(s) you were spraying with the unit. That means you need to evacuate the pump housing, hoses, strainers, tank(s), spray wands, etc. Start at the tank and run through the entire plumbing system - no component of the system that comes in contact with liquid should be left out of this process. If something is neglected, odds are good that you will have issues when you go to start up next season. Let's avoid that at all costs. Here's how....

Any system should be thoroughly flushed with clean water. Industry standards recommend a triple rinse. Add one-half tank of fresh water and flush all tanks, lines, booms, nozzles, wands, etc. for no less than fifteen minutes. Do this using a combination of agitation and spraying. Remember that rinsates (solution you create while flushing your system) does contain residual from your system. Therefore, any pesticides, herbicides, fungicides, etc. that you were spraying will be flushed from the system out of your orifice(s). Do not allow rinsates to flow into streams, rivers, ponds, lakes, floor drains, sewers, or sinks.

It's best practice to use containment pads such as these to collect rinsates and then apply them to labeled sites at or below labeled rates. If possible, consider rinsing the system at the application site. Furthermore, the product label should specify best rinse practices - always consult the product label. Lastly, proper protective clothing should be worn to avoid chemical contact with any exposed skin.

Remember, many of the chemicals out there are designed to kill living organisms - that means it's not good to get it into your blood stream. If you do get any product on exposed skin make sure to wash the contaminated area with soap and water immediately, for no less than 15 minutes.

This is also a good time to clean strainers of any debris that was picked up during the past season. By performing this task you will help ensure that you don't starve your pump and blow out seals when you start up next season. Here is another post on pump cavitation to further explain how detrimental this can be. Sloppy clean up practices are a main cause of equipment failure or malfunctions. You're here to prevent that and avoid expensive down time.

You can create a cleaning solution by doing the following:

Fill the tank with fresh water and the recommended cleaning solutions or tank cleaner.
Agitate this solution for no less than 15 minutes.
Add one of the following to 50 gallons of fresh water.
1. Two quarts of household ammonia (let sit in sprayer overnight for herbicides such as 2,4-D or Dicamba. It's recommended to consult your label for recommended cleaning agents*)
2. Or add four pounds of trisodium phosphate cleaner detergent. (It's recommended to consult your label for recommended cleaning agents*)
Operate spray booms or wands long enough to ensure all lines and orifices are filled with the cleaning solution.
Let the solution stand in the system for no less than three hours.
Agitate and spray the solution onto suitable areas for rinsate solution.
Add more fresh water and rinse the system again by using a combination of agitation and spraying.
Remove strainers, screens, regulators, etc. and clean in a separate bucket of your cleaning solution.
Rinse and flush the system again with fresh water.

Don't neglect the fact that, any product left in the plumbing system, that is allowed to dry, is much more difficult to remove and will eventually build up enough to plug lines and orifices. Plugged lines and orifices not only decrease the overall efficiency of your plumbing system, but will bring about a slough of other headaches. Always wash down the external portion of the spray unit at the wash site, as well. This helps to remove any external residue that the unit collected via spills or drift.

Repairs

Next, let's move on to the pump itself. Remove the pump from the drive unit - generally on most skid sprayers this will be a gas engine. It's always best practice to take the pump completely apart BEFORE you order repair parts. For instance, you may order a complete overhaul kit and find that you really only needed to replace some gaskets. We strongly recommend to get the pump opened up and thoroughly inspect it.

Once you have completed this and have drawn up your parts list - only then should you order repair components. We have an extensive parts breakdown file, to help you identify the correct parts you need. In order to use this resource you need to know the manufacturer, pump type, and model number. Click here for access to our Parts Resources. For additional resource videos see below. The first video is for a Hypro 7560 roller pump. The second video is for a Hypro D403 diaphragm pump.

If you absolutely need to store your unit outdoors over the winter make sure to remove all hose and any polymer (plastic fittings, connections, etc.) Some companies recommend adding lightweight oil such as diesel fuel or kerosene to a system for off-season storage. We don't recommend this as oil-based products don't like EPDM elastomers. For this reason, we suggest using a 50/50 mix of RV antifreeze and water. We recommend this treatment for your entire plumbing system - whether you store your unit indoors or outdoors. The reason we recommend this treatment is based upon experience. We have had customers store units in temperature controlled environments, during the off-season, only to have their heat source fail. This resulted in the pump housing cracking due to their own negligence. If they would have charged the system with a solution that would not freeze they could have avoided an expensive surprise come spring.

Here is another post on chemical compatibility and how it's worthwhile to perform due diligence. Run this solution throughout the entire plumbing system for a minute or two in order to ensure that your total system is winterized and safe from freezing.

It's also recommended to remove all gauges and store indoors if possible. Change out your oil if you are running a diaphragm pump unit - this ensures you are ready to rock-n-roll come go-time next spring. Remember, the main reason for failure or malfunction in any spray system is neglect and improper maintenance. Lastly, make sure to replace air/oil filters on your gas engine. Don't forget to add a fuel stabilizer treatment to your engine and run it for a few minutes to ensure the treatment reaches all internals of the engine.

If you can ensure following these steps in your post season shut down process we know you will be in much better shape come next season. All of your equipment should be good to go and ready when you - and more importantly - your customers need it to be. Thanks for stopping by and have a great off-season.

Sources:

Some of the information in this post was found through The University of Nebraska-Lincoln the Cleaning Pesticide Application Equipment publication from August 2013.
Hypro - Pentair

Chemical Handling & Resistance

Ensure that You and Your Team Remain Safe, Productive, and Efficient by Properly Confirming Chemical Compatibility

Have you ever encountered a nightmare situation where a hose miraculously turns to an icky, nasty, pasty goop? Or how about a pump that starts leaking from virtually every connection point and fitting? What about a fitting that has a pinhole wear through it after only a few days in service? These are all scenarios we have witnessed and can help prevent. Here's how we are going to get you set up with correctly identify chemical compatible products and solutions from the get-go.

It is extremely important when working with any variety of chemicals or solutions that pumps, hoses, fittings and safety items are correctly matched for chemical compatibility. Most manufacturers offer chemical resistance charts for their specific product lines and are readily accessible when required. Check out a thorough chemical compatibility chart from Dura Products in our Resources Library. And if that chart isn't enough here is another resource for you. For the safety of you and your employees, it is critical that a proper analysis is made between the solutions you will be handling and the products used to transfer those solutions.

Warranty Issues

Also, most manufacturers will not warranty products for compatibility issues if an analysis was not properly completed - prior to product use. If it is concluded that a specific chemical compatibly issue caused a product to fail or perform there will be, in most scenarios, no warranty granted by the manufacturer. Failure to perform a proper chemical compatibility check prior to solution handling could result in catastrophic failure of your equipment and extensive unnecessary costs due to downtime and repair/replacement of equipment and components.

Experiences & Materials

We have seen EPDM hoses turn to mush when used to transfer oil based products. Similarly, we have witnessed pump elastomers (seals, O-rings, gaskets) completely deteriorate and create an environment where metal is creating friction against metal inside of pumps. Without elastomers inside a pump, it cannot function properly. Furthermore, we have seen PVC fittings completely deteriorate after only one to two weeks in service.

All of these scenarios could have been avoided had the operators approached us beforehand and identified the solutions to be transferred with their initial choices of products. Should you ever have questions about chemical compatibility - don't hesitate to contact us - that's what we are here for.

Common construction materials for pump bodies and housings are Polypropylene, Stainless Steel, Cast Iron, Kynar (PDFV), Brass, Bronze and Aluminum. Materials generally used in constructing pump seals are Viton, EPDM, Buna, Hytrel, Teflon and Santoprene. Common construction materials for fittings and accessories, such as strainers and valves, include Polypropylene, Nylon, Brass, Stainless, Cast Iron and Acetal.

Hoses and tubing are generally constructed of Buna, EPDM, Viton, Teflon, PVC, EVA, Polyethylene or Neoprene. That being said, your specific application could call for a unique material to be used - given the parameters of the solution you are transferring.

Next Steps

Once we have identified the solution we are transferring we can then determine what products are suitable for the transfer of that solution. Here at Dultmeier Sales we don't guess - we want to do as much as possible to ensure chemical compatibility from the start. If there are ever questions as to what a solution consists of - you should acquire an SDS or Safety Data Sheet. This document was formally known as an MSDS (Material Safety Data Sheet).

By acquiring an SDS we are able to see the highest concentration of a substance in a percentage breakdown. It is always best practice to find a product that can safely handle all substances that make up a solution. That being said, that is not possible in every scenario. In those instances, one should identify the top substance(s) and locate a product that is chemically compatible. Safety items such as gloves, aprons, boot covers, and arm covers are commonly offered in Neoprene, Nitrile, Latex, PVC.

The first step for proper handling and transfer is to check both the body and the seals of your pumps for compatibility against any number of chemicals. Remember to consult the SDS of the product(s) you are handling. The pump body may be rated to handle a specific chemical but the seals may not. Also, valves and diaphragms need to be reviewed as does any material that will come in contact with a specific chemical or solution.

If we don't perform this step our operation will most assuredly come to an inevitable halt - due to failure to properly identify chemical compatibility. Another note to be aware of is that if you choose to mix multiple chemicals and transfer with one pump - we cannot definitively say what chemical reactions will take place with your elastomers, hoses, fittings, etc.

When you mix multiple chemicals together you have just altered the chemical makeup of the solution. We recommend avoiding this scenario unless you are certain the products you are mixing are like products.

If the pump construction is compatible, next check against fittings and hose that will be used in the application. We cannot stress this enough - always check compatibility with any and all items that will come in contact with the chemical or solution. As a general rule Kynar and Teflon are used for very aggressive solutions but are at the high end of the cost spectrum.

There are some more economical options in EPDM, Viton, and Buna. EPDM and Viton may work fine for soaps, waxes, and some herbicides and/or pesticides. Do note that Buna is not suitable for many agricultural chemicals, but is compatible with petroleum-based solutions. While EPDM is compatible with many chemicals, it is not suitable for oil-based products - stick with Viton or Buna in those scenarios.

Temperature & Pressure

Furthermore, it is important to confirm temperature and pressure as these two variables can also affect compatibility. Temperature and pressure should always be taken into consideration as it can vary with every application or between applications. For instance, a chemical may respond differently with changes or fluctuations in either temperature and/or pressure.

The fluctuations may actually cause the chemical to completely alter it's structure and no longer be compatible with elastomers or products that were previously identified as chemically compatible. Long story short, you may be fine transferring and handling a product at ambient temperatures, but may find an issue at higher temperatures or pressures.

Remember to check for compatibility with all of the item groups above. Any chemicals or solutions that you may be handling or transferring should always be confirmed with an SDS - if chemical compatibility is in question. Think chemical compatibility first for safety and protection of yourself and others. Furthermore, we want to ensure greater longevity and performance of your pumps, valves, fittings, and hoses. Request a Free Catalog here.

If you enjoyed this post check out our technical library for more resources. Can't find what you're looking for? Give us a buzz or drop by our website. Be safe out there.

Hypro-Shurflo

Hypro-Shurflo is actually a subsidiary of Pentair. Pentair is a parent company that delivers industry-leading products and solutions all over the world, specifically in the liquid handling, thermal management, and equipment protection industries. The Hypro name has been known and trusted for the last 65 years.

That being said Hypro has a product mix that is focused on higher end capacity flow applications. Hypro was also the first company to come out with piston pumps originally used in the carwash industry. The old dinosaur pumps of the early 1970s have evolved into the plunger and piston pumps of today’s market. Hypro is also largely relevant within the Agricultural industry. Sprayer pumps, transfer pumps, spray nozzles, strainers, fittings, and much more can all be found with the Hypro name stamped on them.

Recently, Hypro has come out with their ForceField pumps to help combat seal failure in centrifugal sprayer pumps. It is designed with the mindset of a maintenance-free wet seal chamber. The wet seal chamber is self-regulating and does not require the operator to monitor the pressure to ensure the pump seal is constantly engulfed in the lubricating fluid. Hypro boasts the self-regulating and monitor-free design over competitors such as Ace Pumps and their Oasis wet seal design.

This is What Happens When a Tank Isn't Vented Properly

One must always keep in mind that it is extremely crucial to have proper ventilation - IN ANY tank that holds liquid. A tank vent may seem like a small component of the system, but it is absolutely necessary. If there is a pump attached to the tank and that pump is drawing suction from said tank, it is imperative to properly vent the tank.

Without proper ventilation one can turn a rail car - as seen in the video above - into a pop can. Do note, that tank above is a standard liquid transport rail car and weighs approximately 68,000lbs (34 tons) with a minimum wall thickness of 7/16IN plated steel. Bottom line - make sure you have a tank vent installed in any tank you use.

Even in the smallest of tank applications, it is absolutely prudent to install a vent in every tank. We have seen many applications over the years where a turf applicator, using a small 50-100 gallon tank, did not properly vent their tank and collapsed the sidewalls by using a small transfer pump. A vacuum can be created rather quickly in many plumbing situations.

Another example is commonly found in the retail fertilizer industry. Many companies will pull from 275 gallon cage totes with concentrated chemical and dispense into smaller containers or mix with other products. If these polyethylene tanks do not have a tank vent and are, therefore, not vented properly, they too will collapse.

This does not only happen in transfer tank scenarios. There are many applications in which actual bulk storage tanks have collapsed due to the creation of a vacuum in the plumbing system. When a pump is starved of liquid, it will begin to cavitate. We will have a future post on what pump cavitation is and how to avoid it. In larger bulk tank storage scenarios we have seen tank vents become clogged up with dirt, debris, bugs, etc. This happens from simply being exposed to the environment. The inspection of ALL tank vents should be written into any annual or bi-annual safety inspection protocol.

With ever-increasing OSHA regulations, this task could be difficult to accomplish without repercussions. OSHA does not want employees on top of storage or transfer tanks for obvious safety reasons. Should they find a company employee on top of tanks, potential fines could be imposed. That being said, if no one is inspecting tank vents how do we prevent tank collapses from happening more often?

Below are a couple of images of bulk tanks that were sucked in or "collapsed" due to pump cavitation. The cavitation was so great that it essentially created a full vacuum and collapsed the tank walls. A tank collapses because a complete vacuum has been created in the plumbing system and, due to the tank having the largest surface area, it is generally one of the weaker points in the plumbing system; relatively speaking.

A vacuum is the absence of pressure. If there is no pressure internally, there is no force to combat atmospheric pressure. There is and always will be a constant force (atmospheric pressure) acting on the exterior of the tank walls. Atmospheric pressure is 14.7 pounds per square inch. When a full vacuum is created there is no internal pressure in the tank to combat atmospheric pressure (external force) and the result is evident in the video above.

In smaller applications, such as a spot sprayer or small acreage spray unit, a basic vented lid cap can be used to avoid tank collapse. Do note, that the user will see some slosh or spillage come out of the vent. This is normal as the vent is doing what it is intended to do - allowing the tank to exhaust internal pressure and "breathe". Even in small tank applications like this spot sprayer, it's critical to have a vent. Many solutions will tend to vaporize as they warm up. This causes an expansion due to added volume that the vapor creates. Without a vent, an end user will notice a swelling in even the smallest of tanks.

Many smaller vent caps are simplistic and just have an internal spring. The spring acts as a relief valve and exhausts the pressure in the tank. Furthermore, the vent allows air to enter the tank, as well - it's a bidirectional valve.

Therefore, when pressure builds in the tank - due to product heating up, expanding, or vaporizing - the tank valve allows that pressure to be released or exhausted. Thus, a vent can work in two different ways.

First, it helps a tank from collapsing in on itself if a vacuum is created in the plumbing system. As seen in large tank pictures above, we can do the same thing to smaller tanks if we create a vacuum in the plumbing system. Secondly, the vent allows a tank to breath outward if the liquid inside the tank begins to vaporize - when a liquid vaporizes and turns into a gas it actually takes up more space. This can be seen with a small plastic gas tank if left out in the sun. While a tank can collapse inward it can also rupture outward.

The bottom line, key takeaway from this discussion topic - always use a tank vent valve to ensure that your tank remains in service and you don't have a major mess on your hands. If you have further questions don't hesitate to give us a shout. Your Experts in Delivering Fluid Handling Solutions - We Know Flow!

All You Need to Know for Goodall Anhydrous Ammonia Hose

The fall/spring application of the fertilizer Anhydrous Ammonia, also known as NH3, is always a hectic time for those in the agricultural industry. The race to get the precious fertilizer in the ground is fast-paced and everyone is running like gang busters. Every season fall/spring we field phone calls that stem from concern due to the reliability and service of ammonia hoses. This post should clear up many questions and will provide some valuable education to you and your team. Below you will find a listing of common questions we run across throughout a season. As always, we are happy to help share our wealth of technical knowledge and experience.

Residue on Hose Exteriors

Question: At times a residue forms rings or cones all over the cover of my anhydrous ammonia hose. This residue resembles or looks like white spots.

What causes this residue to appear and what is it?

Answer: Goodall anhydrous ammonia hoses have a minimum of eight rows of evenly spaced pinpricks. The pin pricking is a safety requirement. These pinpricks allow trace amounts of NH3, to permeate through the tube. The pinpricks allow minute amounts of anhydrous ammonia to easily escape into the atmosphere through the hose cover. There is such a trace amount of anhydrous ammonia being released that it is not harmful.

A hose that has been improperly pricked will cause the cover to blister and eventually blow out - this is the same for a hose that has not been pricked at all. A hose blows out when NH3 becomes trapped between the layers in the hose, heats up, and vaporizes - thus causing rapid expansion and bursting through the hose cover.

The single drawback to pin pricking is the residue that is left on the hose and the resulting appearance that the hose is somehow defective, after use. Remember, as the anhydrous ammonia escapes through the pinpricks it comes in contact with the atmosphere and forms the white residue that many operators commonly see throughout the season. The color and consistency of the residue are affected by the amount of dust and relative humidity present in the atmosphere. This residue does not indicate a defective hose and is no way identifying a problem or unsafe situation for operators. Furthermore, it is a reminder of this built-in safety feature to the anhydrous ammonia hose and that it is, in fact, working as intended.

Basketing

Question: My stainless steel braided anhydrous ammonia hose has ballooned out behind the coupling.

Why is this happening?

Answer: The symptom described above is referred to as "basketing". Basketing is the result of the thermal expansion of trapped anhydrous ammonia in the hose. By design, the hose is intended to expand in a controlled fashion when this over-pressurization occurs. Most commonly, a user will see basketing form behind the coupling - this intended consequence is meant to keep the NH3 hose from a catastrophic blowout.

Thermal expansion generally occurs when anhydrous ammonia remains or leaks out of a shut-in hose assembly and is allowed to heat up or "cook" in the sun. Extremely high pressures occur, internally, as the black hose is exposed to sunlight for extended periods.

It is highly recommended that all hose assemblies be emptied before storage and downstream valves checked for compliance and acceptable operation regularly. Furthermore, hydrostatic relief valves should also be check for correct operation and compliance pressures depending on state and local fire marshal requirements.

Goodall New Hose Expected Service Life - When Coupled by Authorized Goodall Locations

N1446 - Super Long Life - 10 Year

N2595 - Rifleman - 8 Year

N2000 - Century 2000 - 6 Year

Maintenance and Care

Maintenance and Care of Your Goodall Anhydrous Ammonia Hose:

New Hose

Ensure you have the correct hose. All Anhydrous Ammonia (NH3) hose will be strip branded, stating that the hose is for Anhydrous Ammonia, the working pressure, the name of the manufacturer, and the month and year the hose was made.
Make sure the couplings are properly put on. After the hose is charged with anhydrous ammonia, check that the couplings are secure and that they have not moved.
Ensure that the new hose is free from cuts, gouges, and imperfections. Perform a visual check of each hose in service. Run your hand down the length of the anhydrous ammonia hose, checking for soft spots.
Never secure the coupling in a vise when attaching valves.
Goodall highly recommends that all relief valves are replaced at the same time a new hose is installed.
If any of the above imperfections are found to be existent, remove the hose from service immediately.

Used Hose

An anhydrous ammonia hose that is currently in service or has been carried over from the previous year:

Applicators should remove anhydrous ammonia hoses from the nurse tank(s) before winter and stored in a cool, dry place. Keep away from direct heat and any motors that are operating. The best place to store an anhydrous ammonia hose is to hang the hose in a vertical position from the shoulder of the coupling. By doing this one relieves stress on the hose. The hose will be out of the way so as not to be damaged by individuals walking on it, trucks driving over it, or anything being piled on top of it. Furthermore, the storage of anhydrous ammonia hoses indoors prevents damaging UV rays from the sun ruining the hose.
NH3 hoses should be checked in the spring in the same manner as a new hose is inspected - this way the user ensures that Anhydrous Ammonia hose is, in fact, Anhydrous Ammonia hose.
Each hose should be checked at least daily, if not each time the hose is used, to ensure proper function. Make sure to check for: movement of couplings, cuts, gouges or cracks in the cover. Check for any soft spots - this is done by running your hand down the entire length of the hose.
Should any of the above imperfections in an anhydrous ammonia hose be found, immediately remove the hose from service.

Always remember - visual and manual inspection SHOULD BE DONE DAILY

Don't hesitate to contact us should you have any questions. Be safe out there...

Farm Fuel Transfer - How to Decrease Filling Times

A common misconception with any pump, for that matter, is that the flow rating of the pump is the output that a user will see - regardless of the plumbing system that the pump is installed into. For further explanation check out one of our previous blog posts about centrifugal pump sizing, applications and how a plumbing system affects pumps differently.

While most 12 Volt fuel pumps are not centrifugal pumps the flow rates of these pumps is still drastically affected by the plumbing systems in which they are introduced into. Think of it this way - while your car speedometer maxes out at 160 mph you certainly can't drive the vehicle that fast - at least for an extended period of time without catastrophic failure. A pump is very much the same - while it may be rated to 25 gallons per minute (GPM) that doesn't mean that you will see flow rates equivalent to that output.

One solution to decrease filling times is to evaluate your plumbing system. Do you have 3/4IN lines? Can you bump up to 1IN? Remember, the greatest thing we can do in order to increase the efficiency of our plumbing system is to increase the size of the plumbing system. How about a high flow fuel nozzle?

If we simply have a standard flow nozzle that will certainly affect your flow rates in a negative manner. Keep in mind that many 12 Volt transfer fuel pumps from manufacturers such as Fill-Rite or GPI are rated 20-25 gpm. Now if you have nozzle at the end of your plumbing system that is rated only to 20 gpm don't think that your 25 gpm pump is going to achieve that flow rate. You have just capped your flow rate at 20 gpm with the limiting factor being the nozzle.

Should you have a 3/4IN line you will see an even greater reduction in flow rates - again the greatest thing one can do to increase the efficiency of a plumbing system is increase the size of the plumbing. Another major plumbing constraint to be aware of is the filter. Ensure your plumbing system has a high flow capacity filter such as Cimtek's CI1000.

What can one do to drastically reduce filling time in the field or at the farmstead? Invest in a high flow transfer unit such as our DUFPU1.5P. This unit has been tested to 60 gpm. Check out another blog post dedicated to this unit here. This can cut your fill times by 1/3 of the time it takes to fill using a standard 12 Volt pump or gravity feed elevated tank.

Simple fact - that means less downtime for you and more time in the field - ultimately equating to greater profitability. For those wanting a simplistic engine driven diesel fuel transfer pump check out these 5.5HP - 11HP options. Remember we can go slightly lighter on the horsepower requirements when pumping a material such as diesel fuel.

This is due to the fact that diesel fuel actually has a lighter specific gravity than water (8.34 lbs/gal) and, therefore, we can use less horsepower to achieve the desired flow rates. We will have a blog post on specific gravity and how that correlates to product flow rates at a later date. Stay tuned...

Water Hardness and Total Dissolved Solids

Low water hardness and low TDS (Total Dissolved Solids) are critical for proper cleaning and reduction of water spotting in car and truck wash applications. Water hardness is measured in grains of hardness. Typical drinking water can range from 100-250 grains of hardness. However, water hardness under 5 grains is usually best for the most efficient use of detergents or soaps in vehicle cleaning.

A water softener is usually required to get hardness down to zero grains which is necessary to, in turn, get TDS down to zero. The size of the softener required is a function of the quality of the incoming water, as well as, the gallons required in a typical day for a specific facility. Left untreated, high mineral content in a plumbing system can tremendously affect the efficiency of the plumbing system, as well as, reduce the life of pumps, valves, and other equipment.

TDS (Total Dissolved Solids) is the makeup of minerals, salts, metals, etc. that are present in a volume of water. This can include any inorganic element that is present in water other than pure (H20) water molecules. Typically TDS is measured in PPM, (Parts per million). The EPA allows up to 500 PPM for human consumption in water but vehicle washes need to be in the range of 0-50 PPM to rinse and dry without spotting.

Therefore; typical reverse osmosis, spot free rinse vehicle system will produce zero parts per million (PPM) of TDS when the filter/membranes in the system are new. Thin-film Composite or Cellulose Acetate membranes are designed to reduce zero grain water to zero TDS water. As membranes provide the filtering process over time, they will begin to plug or foul. The amount of time for this to occur depends on water usage and flow.

Typical testing will show TDS increasing, with spotting occurring about 40PPM. At this point, membranes should be replaced which will bring the TDS back to zero and the process begins again. Membrane material differs and is specifically designed for tap water, brackish water and seawater. Tap water membranes are used with typical city supplied water.

There are many simple devices available to test for water hardness and TDS to ensure your softeners, spot-free rinse system and filters are operating properly and efficiently. If you have further questions about reducing the amount of total dissolved solids in your business plumbing system give us a call at 1-888-677-5054 or visit us here. Take care!

Liquid Withdrawal Nurse Tank Valve Flow Rates

What is Anhydrous Ammonia?

Anhydrous Ammonia or more commonly known as Nh3 is a common fertilizer that provides a wonderful supply of Nitrogen to crops. First and foremost, let's get some basics down on this fertilizer. In its natural state, Nh3 is a gas. When pressurized, the anhydrous ammonia converts to liquid form. By pressurizing a vessel such as a nurse tank we can transport the nitrogen rich fertilizer from a bulk storage facility to the field. Because anhydrous ammonia is a gas, in its natural state, it wants to return to that state. Therefore, any pressure drop in a plumbing system allows the liquid to vaporize.

Once Nh3 vaporizes the plumbing system becomes exponentially less efficient and, therefore, you as an applicator become less efficient. Bottom line - if you have a poor or inefficient plumbing system you will spend more time in the field. Because you have to run your tractor at slower speeds in order to apply the same amount of Nh3. The longer we are able to keep the anhydrous ammonia in liquid form, the less product we lose to the atmosphere as it exits a knife orifice.

Nurse Tank Valves

Now that we have covered a little background information on Nh3 let's discuss liquid withdrawal nurse tank valves. Nurse tank valves may be rated the same, but they are NOT built the same. Take it from Judd Stretcher with Continental Nh3 Products. Judd insists on nothing but top notch quality for the products that Continental turns out. If you could achieve 20% greater tractor speeds by simply changing out your nurse tank valves, would you? Let's look at a scenario from a recent field test that Continental Nh3 Products performed.

Continental lined up their B-1206E, B1206-F, A1406-F, A1406-FBV and A1507-F against some of the top names in industry. What Continental found was staggering. Through standard plumbing equipment, 1-1/4" hose, break away and 1-3/4" acme fittings and a single Continental 30GPM Heat Exchanger Judd was able to prove that quality and efficiency really do pay off.

Flow Ratings Explained

Before we continue, let's clarify ratings on valves. If a liquid withdrawal valve is rated to 42 gallons per minute (GPM), like the B-1206-E or F you MUST understand that this is not the product flow rate of the valve. A valve "rating" in the Nh3 world actually identifies the flow rate at which the excess flow check will engage. This is another safety feature mandated in the anhydrous ammonia world. A valve rated to 42 GPM will close and not allow product to flow from the nurse vessel if the flow rate EXCEEDS 42 GPM.

This is designed to protect the operator if there is a catastrophic release - such as a hose failure. The nurse vessel will remain sealed due to the excess flow check. By having this excess flow check in place we don't allow the tank to completely evacuate - thus protecting the operator. So, a valve that is rated to 42 GPM, by industry standards, will actually flow around 24 GPM of product through standard plumbing equipment listed above. In regards to this specific field test, we are concerned with product flow rates.

Continental was able to find that their valves actually outperformed the competition by 10-20 percent. Their valves are able to achieve this due to design and quality. Even a one to two PSI drop at the nurse tank valve can allow for a drastic expansion of product which then allows the Nh3 to vaporize.

The more vapor you put into a heat exchanger the less efficient the heat exchanger, or cooler, is and that ultimately leads to less product going in the ground. Which finally boils down to you spending more time in the field. I will ask the question again, if you can increase your tractor speed by 10-20%, because you have improved the efficiency of your plumbing system, would you?

Money in Your Pocket

Let's look at a basic calculation for Nh3 application: If you are applying 200lbs/acre of Nh3 running 5 mph across a tool bar 55 feet wide you will need a system that can flow 27 GPM as you will be applying 1620 gallons per hour. So if the price of anhydrous ammonia is projected to retail for $350/ton in eastern Nebraska this fall. An application rate of 27 GPM. Means that you are spending $1560/hr (math calculations below). You could theoretically save $312/hr from increasing your plumbing efficiency by 20%. And that, you can take to the bank - calculate that over a 10 hour day and you're looking at savings of roughly $3,118/day. Put that number across an entire season and think what you could do with those savings! If you have further questions check us out at here or give us a shout at 1-800-228-9666.

Math Calculations:

8910lbs/2000lbs = 4.455 tons*$350 = $1559.25/hr - total expenditure on Nh3/hr

(Nh3 weighs 5.5lbs/gal so 1620 gallons = 8910lbs; then 8910lbs * .20 = 1782lbs/hr saved which = $312/hr.

*Nh3 projections for fall in eastern Nebraska are around $350 retail. Nationwide average is approximately $300/ton

If you found this post useful feel free to share with friends, family, and colleagues. We are here to help and share our knowledge. If you have further questions don't hesitate to contact us. Thanks for stopping by and take care!

Properly Sizing a Centrifugal Pump

Properly sizing a centrifugal pump is a crucial step in any plumbing system. There are some important variables and qualifiers you need to first identify in order to ensure that your plumbing system(s) reaches the desired output flow rates. Centrifugal pumps fall into a category of their own and need to be sized for various applications in a different manner than other pump families. In this post you will learn some basic steps to help you properly size a centrifugal pump for your application.

The Basics

Many pump users mistakenly think that a centrifugal pump will provide its maximum published flow rate in all applications.

However, unlike positive displacement pumps (gear, roller, diaphragm and others), the flow rate from a centrifugal pump will vary significantly depending upon the details of the suction and discharge piping and other “head losses” in the user’s system (restrictions to flow such as elbows, tees, reducers, strainers, meters, valves, etc) and the vertical rise (or drop) from the supply source to the discharge point.

Total Static Head

The total vertical rise in the system is commonly referred to as Total Static Head. Total Static Head consists of both Static Suction Head and Static Discharge Head, and each of these can be positive or negative, depending if the supply source and discharge point are located above or below the pump elevation. Also note that some systems have a pressurized supply and/or discharge point (pressure vessel or pressurized pipe); these will also add to the Total Static Head.

Once calculated, static head doesn't change for a system - unless a plumbing change is made.

If that sounded a little technical it's because it is! Long story short - your centrifugal pump doesn't dictate your flow rate - your plumbing system does.

Think of it this way - the speedometer on your car may say 160mph, but is your car capable of that speed? What if you put on larger mud tires or constrict the exhaust? The car certainly will not reach 160mph - and a centrifugal pump operates under this same premise. Now, back to today's lesson:

Total Dynamic Head

In addition, each system has a Total Dynamic Head (TDH) which is the sum of head losses due to friction through each foot of pipe, all fittings, valves, meters, strainers, etc. The reason these frictional head losses are called “dynamic” is that they vary with the flow rate moving through the system. As the desired flow rate goes up, the Total Dynamic Head goes up, and usually quite quickly.

The Total Head in a pumping/piping system is the sum of Total Static Head and Total Dynamic Head. A “System Curve” can be computed, for a variety of desired flow rates, and plotted against the particular “Pump Curve”. The Centrifugal Pump Curve is published by the pump manufacturer.

The “Operating Point” (Gallons Per Minute Flow rate) of the pump, in a particular system, is at the intersection of the Centrifugal Pump Curve and the Plumbing System Curve.

If this sounds complicated, do not be concerned. Dultmeier Sales has experienced engineers on staff, along with pump flow computer programs, to properly compute and size centrifugal pumps for your applications.

Simply give our engineering department a call with your flow rate requirements and some basic details on your piping system, and we will properly size your centrifugal pump to meet your requirements. You may wish to check out our Technical Library, as well. Let us know if there is any other way we can be of service.

Horsepower Sizing for Various Pumping Applications

Have you ever wondered how to quickly and accurately solve the problem of correctly sizing the horsepower for a pumping application? In this post we offer a short lesson in yet another technical application that our Sales Team deals with on a daily basis. We practice the principle of horsepower sizing almost every day at Dultmeier Sales.

In order to correctly size the horsepower for an application one must perform the following equation(s) in order to calculate. For positive displacement pumps we use the output pressure & flow rate required to determine the required horsepower. Centrifugal pump horsepower sizing is calculated using different methodology. We will elaborate on centrifugal pumps later in this post.

For positive displacement pumps, such as plunger, piston, diaphragm, or roller pumps we want to take the pressure (psi) x flow rate (gpm) divided by the constant for the particular type of pump, (which is based on the general efficiency of the pump type).

Determine the Type of Pump & Drive Option

For Piston and Plunger pumps, the constant factor is 1460. Roller pumps we use 1030. Lastly, Diaphragm pumps we use a factor of 1370. These constant factors are used for pumping water solutions - if we get heavier or more viscous solutions than water - our factors will need to be altered.

Centrifugal and Gear pumps can vary greatly and must be engineered to the specific application. That being said, we can look at some examples further down the line in this post.

We also need to consider the type of drive option that will be used. For instance, when using an electric motor versus a gas or diesel engine, there are varying drive constant factors, as well. More on this below in the post.

Horsepower Sizing Examples Explained

Example 1: Plunger pump rated flow is 4 gpm at 2000 psi. “EBH” or Electric Brake Horsepower required would be 4 x 2000 = 8000 divided by 1460 = 5.48. This equation shows us that we would require an electric motor with at least 5.48 horse power output to allow the pump to operate at peak performance. In this instance you would most likely need to use a 7-1/2 HP electric motor as most motor brands are generally 1HP, 1.5HP, 2HP, 3HP, 5HP, 7.5HP, 10HP, 15HP, 20HP, 25HP, etc.

It is important to note that electric motors have a rated horsepower and your specific application will have a required horsepower. Required specifies the horsepower needed to produce the desired output flow and pressure. While, rated horsepower defines the horsepower at which the motor is rated. For instance, if the application requires a 13 HP motor, one would need to select a motor that is rated for 15 HP (there is not an electric motor rated for 13 HP or 14 HP). Best practice is to select a motor that has a rated horsepower which exceeds your required application horsepower.

Example 2: Diaphragm pump rated flow is 12 gpm at 500 psi. The EBH would be calculated as such: 12 x 500 = 6000 divided by 1370 = 4.38 This would require an electric motor with at least 4.38 horsepower output to allow this pump to operate at peak performance.

Specialty Applications - Diesel Transfer Horse Power Sizing

For calculating gas or diesel engine horsepower requirements, a general rule is to take EBH required x 2.0. Example 1 above would require 5.48 EBH x 2. 0 = 10.96 engine horsepower requirement. Therefore you would need a gas or diesel engine that will develop at least 10.96 horsepower to allow the pump to operate at peak performance.

You can look at some diesel transfer units (centrifugal pump) that we have sized specifically for flow rates at the nozzle. We have multiple offerings that are designed to produce flow rates through a plumbing system. When calculating, we figure in the Total Dynamic Head of the plumbing system. In the case of our Diesel Transfer Skids, that means the pressure loss through the hose reel, 32ft of hose (inside diameter varies based upon specific unit) and a discharge nozzle. We use a self-priming centrifugal pump in these skid systems. When dealing with self-primer centrifugal pumps a safe efficiency factor to use is 50% efficiency.

When using gas or diesel engines to power pumps, depending on specific brands, “engine” horsepower requirements could be reduced slightly in some instances. For instance, some engines may have a higher compression or provide more torque as a result of enhance production practices. This is generally a smaller factor but something to consider when powering a pump with an engine.

Centrifugal Pump Horsepower Sizing

A major difference in sizing centrifugal pumps lies in the size, or trim, of the impeller. Based upon the solution, desired flow rates, and TDH in the plumbing system - we will size a pump to have a certain impeller trim and this directly correlates to the required horse power.

Generally speaking, we use pump curves to assist in sizing a centrifugal pump for a specific application. A pump will ALWAYS operate on it's curve. That's why it is vital to accurately determine our desired output flow rate, TDH, and solution being transferred. All of these factors, and actually many more like temperature and viscosity can, and will, affect the required horse power and impeller size of a centrifugal pump.

We have multiple tools at our disposal to assist with this process. One of them comes from a supplier of ours, Wilo. Dultmeier Sales' expertise paired with the expertise of Wilo helps us to provide a value-added service for our customers in pump/motor sizing for many applications.

Standard Efficient vs. Premium Efficient Electric Motors

Another important note to make is the difference between a standard efficient motor and a premium efficient motor. With the passing of Department of Energy regulations in January 2020 - many pumps (specifically straight centrifugal pumps) are now held to a certain degree of efficiency standards. The main goal being power consumption. Premium efficient motors are designed to be just that...much more efficient than a standard efficient motor.

Many pump manufacturers have since, or are in the process of switching, to premium efficient motors to assist in ensuring their pump products meet the mandated efficiency standards. Some manufacturers were able to re-engineer their pumps to meet the regulations - while others needed to redesign the pumps and upgrade to premium efficient motors.

Be aware, in some larger NEMA frame motors, the premium efficient option can boast a larger footprint. If your motor footprints do not match, this could cause an issue when you go to install the replacement motor. This is an important thing to consider when replacing standard efficient motors.

Service Factor in Electric Motors

Lastly, we want to consider the service factor in an electric motor of choice. A common service factor that many motor manufacturers use is 1.15. This means if your horsepower is rated to 20 HP then you actually have some leeway to go slightly beyond the rating - if necessary. 20 HP x 1.15 Service Factor = 23 HP. If our application had a required horsepower of 22.25 HP we could select this example motor with a service factor of 1.15.

While it's certainly not advised to select the example 20 HP motor in this instance - it could work. We would always caution on the side of error and advise the end user to select a rated 25 HP motor.

We certainly hope that this post provided useful content. As always, should you have any questions about pump sizing - don't hesitate to call us at 888-677-5054. Be good out there.

Dultmeier Sales Renews Contract with Kansas DOT

Dultmeier Sales has recently acquired a contract renewal for the patented Brine Production System. The Kansas Department of Transportation recently finalized the contract for 20 new brine makers. While boasting the Easiest Cleanout on the Market, Dultmeier's Brine Production System also features:

Full Clean-out in less than 10 minutes
Use any standard loader bucket (8ft wide)
High Capacity - 4000 to 6000 GPH Production Rate
6 Cubic Yard Hopper
Heavy Duty Construction
10 Gauge Stainless Steel Hopper & Brine Tank
3" x 3/16" Stainless Square Tube Frame

The days of crawling inside a brine hopper and shoveling out the "waste" are over. Dultmeier Sales has engineered a design that allows a skid loader to pull under the hopper and unload the hopper completely in less than 10 minutes. The Brine Production System also allows for a user to automatically produce salt brine and quickly adjust the salinity of the brine, on the fly, with a manual valve. Salinity can quickly be monitored by the mounted salimeter.

One of the other beneficial features of this Brine Production System is that there are no computer components or circuit boards that will indefinitely fail - leaving the user dead in the water. The simplicity of this system is what also makes it extremely reliable - especially in crunch time.

Dultmeier has over 100 of these units throughout the Midwest including Nebraska Department of Roads (NDOR), Kansas Department of Transportation (KDOT), and Oklahoma Department of Transportation (OKDOT). Furthermore, this Brine Production System was highlighted with a product demonstration at the APWA Snow Conference in Des Moines, IA on April 23-25, 2017 and caught the attention of Iowa Department of Transportation.

Dultmeier Sales' Brine Production system will be on display at the Kansas Winter Expo in Topeka, KS September 6-7th 2017. Any additional questions don't hesitate to contact Dultmeier Sales DeIce division at 1-800-228-9666.

Fuel Transfer Pump Unit

Looking for that perfect fuel transfer pump unit? Look no further. We assemble these units in Omaha, Nebraska in our production facility. These fuel transfer pump units are available in either 1" transfer or 1.5" transfer capacity - flow characteristics vary drastically between the two versions.

The Dilemma & Our Solution for You

The 1" fuel transfer pump unit (DUFPU1P) will produce a flow rate of 32 GPM - at the nozzle. This is a true representation of the flow rate that the end user can expect - at the end of the plumbing system. While competitive systems will notate "max flow rate", many of them are portraying the flow rate the fuel transfer pump outputs at an open discharge. Open discharge means unrestricted flow and isn't an accurate representation of what an end user will experience, in terms of flow rate at the nozzle, once the fuel transfer pump is installed into a plumbing system. Here is a quick example of how friction loss is calculated through a plumbing system to determine flow rate - at the nozzle.

Our 1.5" fuel transfer pump unit will produce a flow rate of 60 GPM - at the nozzle. Most 12V diesel fuel transfer pumps will produce a flow rate of approximately 18-20 GPM at the nozzle. This is making the assumption the plumbing system consists of approximately 30 feet of 1" fuel transfer hose.

By making the transition from lower volume 12 Volt or 115 Volt fuel transfer pumps to the 1" DUFPU1P, end users can effectively decrease their fill times by 78%. If you choose to bump up to the, larger, DUFPU1.5P you can decrease fill times by 233%.

That is a serious cost savings when looking at the operational expenses of paying operators to wait around while large equipment fuel tanks are being filled. If you are able to save 15 minutes of fill time, per fill, how much money does that save you in a week? How about a month or a year?

Reduce waste, reduce cost, and increase efficiencies of your operation. Bigger, faster, stronger is the name of the game and these Dultmeier fuel transfer pump units will help you achieve that status.

Either fuel pump transfer unit option, that we manufacture, is fitted with the MP Pumps PetrolMaxx 2" self priming diesel fuel transfer pump. These fuel pump transfer units are designed to safely handle diesel or bio-diesel fuels and significantly reduce operating expenses and improve the efficiency of your operation.

Product Demonstration

Our, larger volume, DUFPU1.5P boasts the following features:

PowerPro 6.5 HP manual start engine with C.A.R.B. rating.
MP PetrolMaxx 2" self-priming cast iron pump with Type 21 Viton® mechanical seal designed for diesel fuel
Hannay spring rewind hose reel
Husky high flow automatic nozzle with swivel.
Cimtek 1-1/2" 60 GPM fuel filter with 2-30 micron Hydrosorb elements,
38' of 1-1/2" fuel transfer hose and Husky 1690 1-1/2" high flow automatic nozzle.
Mounted on steel base plate (powder-coat finish)

Here is a video to help further display the unit. Enjoy!

Matching Pump Rotation

How do I match my pump rotation? This is a commonality that we address on almost a daily basis but many people do not understand how to accomplish this task. At Dultmeier Sales we are glad to help out and explain over the phone or you can get your answer right here:

First off, let's address how we look at a pump - the direction of rotation is always determined when FACING THE SHAFT. Centrifugal pumps are available in two options, either Counter Clockwise (CCW) or Clockwise (CW). To match the pump shaft with a drive shaft we always MATCH THE OPPOSITE ROTATION.

A gasoline engine will match up to a CW drive centrifugal pump. A front tractor crankshaft PTO rotates in CCW direction and therefore must be mated to a CW centrifugal pump. While a rear PTO shaft drive (CW rotation) application must be mated to a CCW pump. This is somewhat counter intuitive to those new to the concept but a "standard drive" centrifugal pump will actually be CCW rotation. Therefore, a "reverse" drive pump is actually CW.

Confused yet? Check out Ace Pumps description for further clarification along with pictures. A common symptom of not properly matching shaft rotation is no pressure generation by the pump. We receive calls from people describing that their brand new pump won't create any pressure and immediately point at the pump as the culprit. More often than not, it's not the pump's fault - generally there is an application error or human error causing the issue. In the scenario described above the first thing to confirm is that we have the correct pump shaft rotation matched with drive shaft choice. More often than not, this is the root of the headache. If you are still struggling give us a buzz and we will be happy to lend a hand.

Let us know if this was useful content. We certainly hope so. If there are other topics you would like addressed in future posts, by all means, let us know!

Be good out there.

Disinfecting Foamer Excites Poultry Industry

Leading Poultry Producers have recently approved the patent pending design of the JBI Poultry Disinfectant Foaming Trailer. JBI Services partnered with Dultmeier Sales in early 2017 to transform this idea and design into reality.

Inception of the JBI Poultry Disinfectant Foaming Trailer

Several of the nation’s leading poultry producers have been rigorously testing a disinfecting sprayer designed by JBI Services and Dultmeier Sales. JBI teamed up with Mike Hansen (Dultmeier Sales) to make their vision become reality. The idea for a portable trailer unit, designed to disinfect poultry barns, originated in early 2017 and became reality with the aid of Dultmeier in the component supply.

Poultry Barn Environment

Poultry barns can be a breeding ground for nasty viruses and a whole host of insects if not managed and disinfected on a regular basis. In order to ensure that the entire barn population doesn’t die an operator must efficiently and properly control bacteria and insects.

Recommended by Veterinarians, the applying of disinfectants that are foamed, produce a better contact time for bacteria kill on all surfaces in a poultry barn. Such was the creation of the JBI Foaming Poultry Trailer. Some of the common poultry diseases include salmonella, blackhead disease, avian malaria, avian influenza, and clostridium dermatitis.

The Poultry Federation is an extensive resource for best practices for poultry house cleaning and disinfection

Product Insight

We were able to hook up with Mike Hansen (Dultmeier Sales) and Butch Belt (Belt Auto & Trailer Sales) to get a testimonial from both of them and gain a little more insight as to how the idea/concept came to be an actual physical system that is solving a serious issue for the poultry industry. A solution that could potentially revolutionize the bio-security industry.

Butch Belt: “Dultmeier Sales was a key to our success in building our Poultry Barn Foaming trailer used for clean out and disinfectant for bio-security and animal welfare in poultry barns. There are many existing poultry trailers in the marketplace, but none that are focused on providing a foaming action. Foaming allows for disinfectants to provide thorough contact time on all surfaces within a poultry barn operation. Mike Hansen with Dultmeier Sales provided the expertise and experience that we needed for our team. Parts, pricing, engineering and just plan ideas, got us to our goal of a revolutionary Poultry Barn Foaming Trailer.”

“Dultmeier Sales and Butch Belt of Belt Auto & Trailer Sales worked together to design a portable trailer unit for disinfecting poultry barns. Dultmeier supplied all of the components that create the foam for the hand wand as well as the floor and wall booms along with a transfer pump that meters correct product concentration to the supply tank. Butch and his staff helped with this design as well as testing and training for customer approval. Currently, one system is on test at Tyson Foods and we are eagerly awaiting their test results and approval to move forward with supplying more of these units.” - Mike Hansen, Dultmeier Sales

KZ Valve

KZ Valve is based out of Ashland, NE and was started by two brothers Keith and Kevin Ziegenbein. They two brothers created their first product, the Hydra-Halt, to be used on their family farm. The Hydra-Halt was an instant success as it replaced manual valves on fertilizer applicators with a new hydraulic remote control. Customers still preferred to have an electric valve. At the time, existing electric valves were solenoid type - not as dependable of a valve type the market demanded. Thus the electric ball valve was born - and KZCO was the first to introduce this new piece of equipment into the industry.

In 1982 the Electra-Halt was introduced. It took four years of research to get to the product release and it was well worth the investment of time and resources. The Electra-Halt revolutionized the industry and 10 years later in 1992 the Electra-Halt 2, or EH2 for short, was introduced. Since the inception of the EH2, it has evolved into thousands of new valve types, sizes, motors and wiring options.

Then in 1997, the EH3 and QC3 were added. This allowed KZCO to essential offer valve option configurations that touched the million mark. Over the years, KZCO has continued to expand its product line and offerings. Their engineering philosophy of "Form follows function, and price follows quality" continues to direct their overall goal to bring quality products to an ever-changing industry. KZCO recently celebrated their 40th Year Anniversary in 2016 and plan to continue their commitment of excellence and quality for many years to come. Don't hesitate to contact us should you have any questions about this amazing manufacturer.