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PROBLEM: An Ohio-based food processing plant freezes 4,000 lbs. (1814.4 kgs.) of hamburger patties per hour at a temperature of -60°F (-51°C). However, there was a problem with the new unit they purchased – "snow" was forming on the condenser coils in the freezer tunnels. This caused multiple problems. First, it required the company to send a maintenance worker into the freezer for five minutes every hour on the hour with an air hose to blow off the snow. In addition to exposing a worker to extreme temperatures, safety codes demanded that if this manual process continued, a second door would need to be installed in the freezer. Secondly, since the snow build-up caused the freezers to operate less efficiently, the line was slowed down to ensure that the patties were freezing properly.

The food processor went back to the original equipment manufacturer and asked them to solve the problem. The OEM tested blow-off type nozzles. However, the spray nozzles did not offer enough velocity and therefore did not solve the problem.

SOLUTION: The maintenance manager at the plant consulted with Spraying Systems Co., since he had worked with them in the past. Together they tested a manifold with Model 727 WindJet® air control nozzles. The manifold was controlled by a timer which activated the nozzles for four seconds every five minutes. The system worked! Based on the results of this test, 30 WindJet air control nozzles have been installed on each of the 12 headers in the 12 different freezer zones of three separate freezer tunnels. One zone is purged every five minutes with a blast of air at about 100 psi (7 bar).

In addition to improving the efficiency of the freezing application, the concerns over worker safety and the possible expense of adding a new door have been eliminated.

Model 727 WindJet air control nozzles convert a low-pressure volume of compressed air into a targeted, high-velocity flat fan pattern. The nozzle's air stream is discharged through 16 precision orifices that ensure uniform distribution and spray pattern integrity.

In this application, the WindJet air control nozzles were specified in aluminum to withstand the frigid temperatures.

WindJet® air control nozzles improve performance, reduce noise and save on air costs. The design features of WindJet air control nozzles create a better quality air pattern than open pipes, drilled holes and other air control nozzles. This is more effective, whatever the application and will save on compressed air costs. And when reducing noise is important in the workplace, WindJet air control nozzles can help. They can reduce the noise from compressed air by over 50 percent.

The Model 727 WindJet air control nozzle creates a flat fan air pattern. Another model, the Model 707 WindJet air control nozzle, produces a tightly directed round pattern with minimum noise levels and features extended ribs to protect the recessed orifices against external damage. The ribs provide an air escape should the nozzle be placed against a flat surface and they also accommodate a deep well socket.

Both the Model 707 and 727 WindJet air control nozzles are available in aluminum. The Model 707 WindJet air control nozzle is also available in stainless steel.