Nozzle Troubleshooting

One of the lowest cost items on your sprayer has the potential to waste the most money. Spray nozzle difficulties can result in a number of more serious issues such as spray drift, over application and distorted spray patterns. Ultimately nozzle troubles take away from your bottom line. 

Before taking your sprayer out in the fields, it is important to check for spray uniformity among all of the nozzles. This can easily be done by spraying water on a concrete surface and observing the drying patterns. If the nozzle produces excessive accumulation in the spray pattern, a variety of minor problems could be occurring such as nozzle wear, low boom height, low operating pressure or too much nozzle spacing. 

Check manufacturer recommendations on boom height, nozzle spacing and operating pressure to assure you are operating at the optimal conditions. 

Irregular spray patterns can result from other sources as well including clogged nozzle tips, mismatched nozzles, uneven booms and uneven pressure consistency along the boom. Restrictions in the spray hose or a spray hose that is too small, in terms of diameter, may cause noticeable pressure differences. To check for pressure differences, it is recommended to use an accurate, quality pressure gauge. 

Never use different nozzles across the boom as this can result in uneven spray patterns and a lack of coverage or over application. If a nozzle becomes clogged, it is best to blow out the dirt with a soft-bristled brush or compressed air; you should never try to blow it out with your mouth or clean with wire because the orifice can easily be damaged. Once you have determined that the pressure is even, the booms are level and all of your matching nozzles are unclogged, if you are still seeing irregular spray patterns, it may be time to replace the nozzle tips. 

Inaccurate applications due to nozzle wear can waste chemicals and money, making it important to evaluate the nozzle tips. Worn nozzles produce increased flow rates resulting from an increased nozzle orifice area. It is recommended to replace nozzles if the flow rates are 10 percent or more in error. 

The nozzle material is a major contributing factor to the rate of nozzle wear. Nozzle tips come in an assortment of materials including nylon, brass, stainless steel, thermoplastic, tungsten carbide and ceramic. Generally, nozzle tips manufactured from nylon or brass will wear out much quicker than ceramic, tungsten carbide and thermoplastic. Thermoplastic nozzles are noted for their resistance to harsh materials, but they are also known to swell with some chemicals. Stainless steel nozzles will typically produce a more uniform pattern over a more extended period of time. 

Source: http://www.hpro-eu.com/NR/rdonlyres/5C8BFEA9-2D63-4E6C-BDB0-96AEF92B450D/2564/Nozzleweartestschartsqu.jpg

 

Nozzle wear is also affected by the abrasiveness of the chemicals used for application. More abrasive substances will wear down nozzle tips much quicker than less corrosive chemicals. 

Ultimately, achieving spray uniformity will cut down on non-target contamination and minimize overuse of chemicals allowing you to achieve the most effective spray application. Regular maintenance and checks on spray nozzles will result in more accurate, precise applications in the field. 

Sprayer calibration is essential to checking spray nozzles and their spray patterns. To assist with sprayer calibration, a variety of calibration products are available including the Spot On sprayer calibrator, SpotOn mini-patternator and Hypro calibration jugs. The sprayer calibrator can assist you with choosing a nozzle and finding worn nozzles. The mini-patternator will help you visualize your spray pattern and spray coverage.

Existing Farm Bill here to stay, at least for another nine months

The Farm Bill was extended in a last minute effort to avoid reverting back to the 1949 Farm Bill. This extension did not include farm policy reform but rather gave Congress a deadline of September 30, 2013 to decide on new policy.

In the meantime, a majority of the 2008 Farm Bill legislation was extended minus a number of conservation and disaster relief programs that lack funding. This means that even though the programs are on the books, there is no additional funding to carry out the programs.

Conservation, disaster and emergency assistance programs have drawn the short straw in terms of funding. Many of these programs lost their mandatory funding and now receive only discretionary funding which is allocated by Congress. 

While neither the Republican side nor the Democrat side seem particularly pleased with the Farm Bill extension and a majority expressed interest in abandoning the direct payment program, the extension seemed to be the only last minute option to solve the so-called “dairy cliff” problem.

On the other hand, a significant change that came from the last minute legislation involves the estate tax that was set to revert back to 55% tax on estates valued over $1 million. Instead, with the extension, the rates rise from 35% to 40% for estates valued over $5 million. This is important to farmland estates since a few hundred acres can quickly max out the exemption.

Section 179 and Bonus Depreciation are back for one more year!

With higher deduction limits of $500,000, Section 179 has boosted its previously set limits in 2012 for the 2013 tax year. Additionally, the higher deduction limit of $500,000 will work retroactively for the 2012 tax year which was previously set at $125,000.  

Equipment purchases made in 2012, including sprayer purchases, can use the new deduction limit instead of the original $125,000.

As a reminder, the Section 179 deduction is available for use on most new and used capital equipment; however, the additional bonus depreciation is only available for us on new equipment. The bonus depreciation allows for an additional 50% tax deduction beyond the Section 179 deduction. Typically, to calculate the total deduction, start with Section 179 and then add in the bonus depreciation. The exception to this rule is when the business has no taxable profit in the given tax year. 

Apache Maintenance: Daily Checklist

Proper maintenance on your Apache is essential to its longevity and overall performance. Routine maintenance will cut down on downtime in the field and costly repairs. Some maintenance checks only need performed once a year or once a month, while others need to performed every week or daily before and after every use. Let’s review the daily maintenance checklist on the Apache 20 series.

Oil and Fluid Levels

Before taking your Apache sprayer out in the field, it is imperative to check oil and fluid levels. Starting off, check your engine oil, and always use a 15w40 when adding more. Beyond this, check the engine coolant level, transmission oil level and the hydraulic fluid levels. A sensor is located in the top of the radiator that will alert the operator when the coolant is low. To check hydraulic fluid levels, look at the indicator gauge on the right hand side of the hydraulic tank. The level should be between half and three-quarters full when the machine is shut off. Top off any fluids that are low before using the sprayer. 

After completing fluid checks, inspect the A/C belt and the serpentine belt tension to ensure nothing has loosened or is out of place. While inspecting the belt tension, also look for cracks in the grooves of the belt. Cracks are a sign of wear on the belt and potentially the belt could break if not replaced when cracks are visible.

Engine Air Intake System

A daily maintenance check would not be complete without inspecting the engine air intake system. This involves not only the air filter housing, but also inspecting the connections from the air filter box to the air intake for holes and leaks. Also, make sure the charge air tube clamps are tight and that the boots are in good shape. Regular checks will let you know when it is time to replace parts before they break. 

Booms

Serving as one of the most important features on the sprayer, the boom needs regular maintenance as well. Grease the boom daily before using your Apache by greasing the rack lift parallel bars, boom fold pivots, sway pivots and cylinder flag pins after every eight hours of run time.

Tire Pressure

Don’t forget to check the tire pressure and add air if needed. Depending on the model of tires your pressure will vary. We recommend 35 PSI on the front tires and 49 PSI on the rear tires for standard tires. The narrow tires should be set at 41 PSI on the front tires and 78 PSI on the rear tires. Tire pressure is important because it can affect the size of the footprint your sprayer leaves in the field which contributes to the amount of compaction. 

Once your tires are set, ensure that all of your lighting and flashers work properly and that your Slow Moving Vehicle sign is set. It is important to maintain visibility on the road.

Calibration Check

Finally, before using your Apache, review the field computer calibrations and check each boom calibration, valve calibration, meter calibration and speed calibration.

After using your Apache, it is important to rinse out the wet system to prevent chemicals mixing with the next application. Here is a video guide on flushing your Apache’s wet system.

In addition to flushing the wet system, clean the boom strainers and main product strainer to ensure chemicals are not left lingering. Finish your daily checklist by walking around the machine to inspect for product leaks or hydraulic leaks.

Routine maintenance on your Apache will keep you in the fields instead of spending valuable time fixing costly repairs.

This checklist is designed for the 20 series Apache, and older models may need additional maintenance. For more information, check out an Apache sprayer clinic.

Application Trend Update: Application types, droplet size and nozzles

Technology continually changes the way chemicals are applied to crops. Decreasing spray drift and increasing application effectiveness are two important goals when making spray application decisions. The type of application and the chemical being used will determine which type of nozzle to use and which droplet size will be needed.

According to Tom Reed, regional manager from TeeJet, the trend in spraying is moving towards using larger droplets to decrease the amount of drift. In reality, it is much easier to control droplets in the medium to extremely coarse ranges.

Soil Incorporated Applications

Looking at soil-incorporated applications, larger droplets are more desirable. In this type of application, larger droplets are used since they will reduce drift potential. Beyond this, coverage is less of a concern because soil moisture or tillage will distribute the output. Since the full cone nozzle generally produces larger droplets, it is a good nozzle tip to use for soil-incorporated applications.

Pre-Emergence Applications

Much like soil-incorporated applications, larger droplets will provide sufficient coverage with pre-emergence applications. Flood nozzles create large droplets and work well for pre-emergence applications.

Post-Emergence Contact Applications

Moving along, post-emergence contact applications require complete coverage of the plants to ensure application effectiveness. In this application type, the chemical is only active at the site of contact. The twin orifice nozzle tip is often associated with this application because the two directions of the output combined with the smaller droplets improves coverage and penetration of the canopy. The hollow cone nozzle is also equipped to handle post-emergence contact applications. It is designed to produce smaller droplets ensuring better coverage.

Post-Emergence Systemic Applications

On the other hand, in post-emergence systemic applications complete coverage is not essential for application effectiveness since the chemical will translocate throughout the plant. In this instance, it is not necessary to use smaller droplets. In many systemic applications, due to the chemicals used, drift can cause a great deal of damage, so air induction nozzle tips or extended range flat-fans are recommended due to their larger droplet outputs. 

After sorting through the types of applications and determining the type to be used, it is also essential to factor in the spraying process that will be used. Broadcast spraying varies a great deal from banded or direct spraying and requires different types of nozzles.

Band Spraying

In band spraying, only a certain portion of the land will receive the chemical application leaving untouched areas. This type of application requires the spray nozzles to produce a uniform amount of spray over the entire sprayed area, or band. In this case, even-flow fans are more desirable for their ability to produce the uniform spray pattern. Hollow cones and twin even-flat fans are also appropriate choices for band or direct spraying applications depending on the type of application that will be applied. The nozzle tips do not require overlap to produce a uniform spray output making them useful for applying pesticides to specific areas.

Because of the different spray patterns produced by even flat-fans, it is essential not to confuse the even flat-fan tips with other flat-fan nozzles which are primarily used for broadcast applications.

Broadcast Spraying

To achieve uniform distribution in broadcast applications, overlap the outer edges of individual spray patterns. The recommended amount of overlap will depend on the nozzle tip design. For many broadcast applications, using a full cone nozzle or a flood nozzle will produce the desired results. Additionally, consider the special feature nozzle tips such as the extended range or the drift reducing nozzles for their ability to produce complete coverage during broadcast spraying.

It is important to evaluate the application goals and make changes accordingly. Customizing your application with the best nozzle to use and the recommended droplet size will cut down on spray drift and increase your application efficiency. 

Apache takes home No-Till honor for third time

Equipment Technologies has taken home the “Spraying Equipment Product of the Year” at the 21^st Annual National No-Tillage Conference. The Apache received its national recognition for the 20 Series sprayers in Indianapolis, Ind. on January 11, 2013. 

Pictured (Left to Right): Jeff Goodman, Chad Ringer, Adam Kivett, Matt Hays

Spraying equipment was one of 13 product categories recognized at the awards luncheon. The Product of the Year awards are chosen by popular vote among No-Till Farmer readers. Equipment Technologies was recognized in front of the 1150-plus attendees at the No-Till Conference. Additionally, the Apache was recognized in the No-Till Farmer Winter 2013 issue of No-Till Farmer’s Conservation Tillage Guide.

“This is such an accomplishment for these companies to be honored by our readers as No-Till Products of the Year. It says something when no-tillers recognize a product but it says a great deal when products are honored in consecutive years. Equipment Technologies should feel proud to receive such national recognition three years in a row,” says Darrell Bruggink, executive editor and publisher of No-Till Farmer.

In 2010 and 2011, the Apache was recognized as the Application Equipment Product of the Year winner based on the 20 Series Apache sprayers in 2011 and the AS715 model in 2010.

According to CEO of Equipment Technologies, Matt Hays, “Sprayers are a critical part of any no-tillers’ operation. To have the readers of No-Till Farmer validate for a third year in a row the Apache self-propelled sprayer as Application Equipment Product of the Year is a tremendous honor. This award comes from the diligent efforts of our employees and dealers, as well as listening to our customers to ensure we produce the very best application product possible.”

During the summer of 2012, product nominations for each category were sent out to No-Till Farmer readers and agriculture companies, and the voting for category winners started in September and ended on November 9, 2012.

2013 represents the eighth year for the annual No-Till Product of the Year awards program offered at the National No-Tillage Conference. 

High oil prices fuel no-till trend

It's not by happenstance that the spike in fuel costs has coincided with the increasing trend of no-till farming methods across the country.

For the past five years, Justin Noggler, an Apache owner from Texas, has practiced no-till farming methods on the 11,000 acres he farms. During this time he has noticed major differences in his operation.

"We save several thousand gallons a year on fuel," Noggler said. "We also need fewer guys in the field had have noticed better crops."

Since oil prices continue to increase, farmers opt to adapt new methods to cut down on fuel costs, and many look to no-till as a viable option. No-till farming significantly cuts down on the number of trips a grower makes through the fields. More specifically, the United Soybean Board estimates in a soy checkoff-funded report, U.S. Soybean Production: A Comparison of Sustainable Production Systems for Conventional, Biotech, and Organic Soybeans, that farmers make an average of 1.8 fewer trips across the field when using no-till methods. Ultimately, a decrease in the number of trips across the field relates to a decrease in fuel usage. 

Another added benefit of decreasing fuel usage is a reduction in CO₂ emissions. In the United Soybean Board report, it was also approximated that the decrease in CO₂ emissions brought about by no-till farming in 2008 is equivalent to removing 125,750 cars each year. 

According to a Wall Street Journal article Plowing Through the Confusing Data on No-Till Farming, no-till farming was first introduced in the 1960s but did not become popular until the 1980s when fuel prices spiked.  

The United States Department of Agriculture estimates that soybeans, corn and other crops have increased the usage of no-till acreage by about 1.5 percent each year since 2000. Additionally, USDA statistics also reported in 2009 that almost half of all soybean acres were planted using no-till methods, and 35.5 percent of all of the country's cropland was farmed in no-till operations.  

When comparing costs associated with no-till farming versus conventional tilling, the three biggest factors are labor, fuel and herbicide. Generally, higher labor and fuel costs are associated with conventional tilling, and herbicide costs are higher with no-till methods. 

Beyond this, no-till farming is noted for protecting land against erosion, reducing nutrient depletion and decreasing runoff. According to the United Soybean Board report, conservation tillage is used on over 65 percent of U.S. soybean acres and results in the following achievements:
                -A 93 percent decrease in soil erosion
                -A 31 percent decrease in wind erosion
                -A 70 percent decrease in pesticide run-off
                -An 80 percent reduction in phosphorus contamination of surface waters
                -An annual soil moisture evaporation loss of reduction of 5.9 inches
                -Greater than 50 percent reductions in fuel use 

The rise in fuel prices combined with the increased environmental benefits make it easy to understand why no-till farming is a growing trend.