Spray Tunnel Nozzles Clog or Heat Bottles Unevenly

Map temperature and spray coverage by zone and lane, then inspect strainers, nozzles, pump flow, water quality, heater control, drains and conveyor residence. Reaming nozzles with hard tools can permanently distort the pattern.

Place affected product on hold and follow the validated food-safety plan. Isolate heat, pressure, chemicals and rotating equipment before inspection; only an authorized process authority may release product after a critical deviation.

Locate the fault

• One conveyor lane exits colder or hotter
• Nozzle jets are weak or off-pattern
• Pump pressure rises while flow falls
• Scale or debris repeatedly blocks strainers

Inspection sequence

1. Map package temperatures by lane and zone with an approved method
2. Inspect visible spray pattern from safe external points
3. Record header pressure, recirculation flow and zone temperature
4. Open strainers and nozzles only after isolation and retain deposits
5. Test water hardness and identify process contamination
6. Verify conveyor speed, drainage and zone-control response

Corrective work

• Clean nozzles with a non-damaging approved method and correct water treatment
• Service strainers, pumps and leaking product sources
• Calibrate sensors and repair zone heating or valves
• Restore drainage and conveyor residence

Operating records and follow-up

• Inspect nozzle pattern
• Control recirculation-water quality
• Trend pressure and flow
• Clean strainers by differential pressure
• Verify zone temperature and lane uniformity

Equipment details: Automatic Spraying Tunnel.