#spray pump

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Spray Away!  Selecting the perfect spray pump

The pump is the heart of power-spray systems used for pest and weed control, landscaping, golf courses and tree fertilizers. The right pump can make the job a breeze; the wrong pump will quickly ruin your day. And a high-quality pump in the wrong application is a waste of money.

Selecting the right sprayer pump requires answering some important questions:

What is the application?

What is the material being sprayed?

How hard will the pump be used?

What is the skill level of the applicator?

What is the ability of the maintenance staff?

What is the availability of repair/replacement parts?

What is the budget?

What is the total ownership cost of this pump?

If you are unsure of any of the answers, get input from staff, colleagues and vendors. NOTE: For this article, I will focus on gas-powered pumps.

1. What is the application?

What volume and pressure are required to do the work? For example, applying a weed pre-emergent doesn’t require much pressure, but significant volume may be required to treat large areas. Spraying 60-foot trees requires high volume and high pressure. Cleaning picnic tables requires pressure, but not much volume.

Higher-pressure pumps are required to reach extreme heights, push material through long hoses, and/or throw material over some distance. Higher-volume pumps may be required to drive booms or boomless nozzles.

Piston/plunger pumps provide high pressure, but not much volume. Roller pumps are great for volume at moderate pressure. Diaphragm pumps can supply both volume and pressure. Centrifugal pumps can provide volume, but not much pressure.

Design your sprayer for its most common use. Many organizations waste money designing a sprayer that handles all situations, but in the field doesn’t handle any application well.

All pump manufacturers provide volume- and pressure-output specifications. Remember that these spec charts are usually maximums at the pump, and actual results at the end of the hose will be lower. Plumbing fittings, valves, constrictions, hoses, distance, pump wear, and extreme temperatures will reduce output. Charts are available to calculate pressure loss through a given size and length of hose. Spec charts also provide horsepower requirements. Be sure to select an engine that can power the pump to provide the results you need.

If using jet agitation in the tank, be sure to consider this when determining the required pump output.  Click here for more on jet agitation at Sprayequipmentblog.com.

2. What is the material being sprayed?

If you are just spraying water, this is not really a concern. Generally speaking, granular fertilizers and herbicides are tougher on pumps than other products, such as pesticides. These materials can be corrosive or abrasive, and will significantly reduce pump life if an appropriate pump is not used. If the material is not corrosive or abrasive, there is a lot of flexibility. Diaphragm, piston, plunger, gear, roller or centrifugal pumps may all be appropriate.

If spraying herbicides, the best choice may be a diaphragm pump or a high-end roller pump. If applying granular fertilizers, a diaphragm pump or poly-centrifugal pump may be the best bet. If a pump is not appropriate for the material being applied, you will know it quickly, and the boss will ask why you need another pump so soon.

3. How hard will the pump be used?

If the pump will be subjected to rigorous use, either through long operating hours or by technicians who are tough on equipment, you may want to upsize the pump.

If the pump is barely large enough to provide the required output, it may be running at the high end of its operating range. Most pumps are designed to run “in the red” for short periods only. Running the pump full-out for extended periods will significantly reduce pump life.

My experience is that spray technicians tend to run pumps fast to get the jobs done quickly. If you have a slightly larger pump than needed, you may be able to get longer life and better results. For example, a six-roller pump may provide the output required, but for slightly more money, an eight-roller pump will provide the required output at a much slower speed.

4. What is the skill level of the applicator?

Some pumps are more sensitive than others, so technician skill is critical. For example, a diaphragm pump may be run dry for a short time without causing much damage, but a roller pump run dry will be destroyed in no time. Similarly, gear pumps can be great general-purpose pumps for many applications, but require periodic field adjustment. If you don’t have confidence in spray techs to perform this operation, then a gear pump is not the right choice. Be sure you understand operating requirements before buying a pump.

5. What is the ability of maintenance staff? What is the availability of repair/replacement parts?

A pump requires maintenance, and if not well maintained, it will require repairs. Be sure to understand the maintenance requirements of a pump.  What tools are needed?  What skills are required?  Where does one buy spare parts?  Ask these questions in advance, and you will save time, money, downtime and lots of aggravation.

Read the pump owner’s manual to understand and plan for the recommended maintenance. Make sure the required parts are in stock or readily available.  I recommend a rebuild on a pump once a year. If a pump is used constantly and you can’t afford downtime, perhaps more frequent rebuilds are in order.

Rebuild a pump at the end of the season or before the start of the next season. Too many organizations wait for the pump to break before doing the repair, which costs time and money and can turn an inexpensive maintenance job into a complete pump replacement. Ouch!

6. What is the budget? What is the total ownership cost of this pump?

Obviously, the above criteria are meaningless without a budget to support them. Generally speaking, diaphragm pumps are the most versatile and the most expensive. If there is not enough money in the budget for everything you want, try to find somewhere else to save money, including talking to an equipment provider. Don’t skimp on the pump--it will cost you. Also, some pumps require larger engines, which can quickly raise the total package price.

Remember, the cost of the pump is not just the price. Consider productivity, maintenance/repair cost, downtime, etc. If you buy the wrong pump and it takes a spray tech twice as long to do a job, have you saved money? Conversely, you may be able to use increased productivity to justify the purchase of a larger pump. If you buy too small a pump or the wrong pump and it always breaks down, you will pay in the long run.

There are a number of steps you and your staff can take to get better results from your spray pump.  These simple steps, if followed, can:

Improve pump performance

Reduce pump down time

Extend pump life

1. Pump Selection. Select and use the correct spray pump for your application. Not every pump can be used for every job. Pump selection should be based upon:

Material to be applied – Generally speaking, herbicides and granular fertilizers are very tough on pumps. The best pumps for these applications are usually Diaphragm or Centrifugal Pumps, which can handle the abrasive materials. Pesticides are usually not as tough on pumps and therefore can be applied with a wider variety of pumps (roller, gear, piston, centrifugal, diaphragm, etc.).

Desired Pressure & Volume – Higher pressure pumps may be required for applications such tree spraying. Higher volumes may be required to spray large areas quickly. Generally speaking, higher volume and pressure requires a pump that costs more. Diaphragm pumps and roller pumps can supply volume and pressure. Centrifugal pump can provide volume but not much pressure. Get specs & parts breakdowns for your pumps and parts.

Budget – Obviously your budget is a limiting factor. Generally speaking, diaphragm pumps cost more to purchase than other types of pumps. Be sure to calculate productivity impacts when selecting a pump. For example, a diaphragm pump that provides the volume and pressure to do a job quickly may cost more initially, but pay for itself through improved applicator productivity.

2. Good Filtration Ensure that only water and chemical gets to your pump. Foreign material should be filtered out to reduce the chance of pump damage. A filter that is too coarse may allow debris to pass to the pump. A filter that is too fine may clog too easily and starve the pump. Most pumps will sustain serious damage if not fed properly. If your water is not debris-free, consider additional filtration. Installation of a filter basket on the input side, or two filters (first a course then a fine strainer) may be appropriate.

3. Good Agitation Use of granular or non-soluble products requires good agitation both to ensure the proper ratios of product are applied and to keep the material from clogging lines and starving the pump. The selection of jet versus mechanical agitation will be covered in future articles. Please feel free to contact the author (email: [email protected]) for more information.

4. Proper Plumbing Ensure your equipment is plumbed properly according to manufacturer specifications. Examples include: - Proper input line size to feed pump, - Clear feed to pump (too many constrictions or turns on the input can place undue stress on pump) - Proper return to tank (many pump manufacturers will not warranty a pump if agitation is on the return line) - Centrifugal pumps require a vent line return to prevent pump damage.

5. Keep Equipment Clean. Clean your tank periodically to remove buildup and debris. Debris will clog lines and starve your pump. You may be surprised at what finds its way into your tank. In our customer’s tanks we have found: rocks, rope, trash and men’s underwear. Flush your system periodically with fresh water.

6. Run Your Equipment Slowly. You can extend life by running your pump at the slowest speed necessary to complete the job. In our experience, applicators tend to run pumps at full pressure to finish the job as quickly as possible. Most pumps are not designed to run at maximum for extended periods. Refer to your pump owner’s manual or contact your equipment supplier for effective operating ranges.

7. Maintain Your Equipment Don’t wait for the pump to fail. Perform preventative maintenance to prevent problems and keep your pump running properly. Consult your owner’s manual. For rigorous users, we recommend rebuilding pumps annually. For example, replace diaphragms annually to prevent more costly repairs.

8. Train Your Staff Ensure your staff knows the proper operating ranges for the pump. Have them check filters and hoses. Ensure they know how to identify problems. For example, a diaphragm pump may still function with burst diaphragms. However, if your staff is trained to check the oil reservoir for contamination, you can keep a diaphragm replacement from becoming a total rebuild or a new pump purchase. Likewise, many pumps, if run dry, quickly become a total loss. Tracking equipment problems by crew, individual or by shift may help identify training opportunities. These simple ideas can help keep your equipment running, your staff productive and your boss happy.