Application Field
Between Formulation and Surface Stands Application Technology.
The best formulation delivers no effect if applied incorrectly. BPS advises equipment manufacturers and applicators on the technical parameters of liquid application of solid suspensions — from pump selection through operating pressure to system configuration for helicopter deployment. We develop and modify our own test equipment — always application-specific.
Consulting Levels
Who Comes to BPS with Which Question?
Application technology is not a secondary topic — it determines whether a formulation actually delivers its specified properties in the field. BPS advises at two levels: equipment development and operational configuration.
Equipment Design & System Optimisation
Manufacturers of hydroseeders, spray devices and special applicators develop equipment that must work with a wide variety of formulations and operators. BPS contributes knowledge of the behaviour of solid-containing biopolymer suspensions to the development process.
→Requirements profiles for pumps handling fibre-rich suspensions
→Pressure ranges and pressure loss calculation for different solids content
→System design for jet or agitator technology depending on target application
→Nozzle configuration and spray pattern optimisation — boom vs. single nozzle
→Weight and mobility requirements for different carrier systems
Equipment Selection, Configuration & Operation
Contractors and project owners face the question: which equipment is suitable for this formulation, this substrate and these operating conditions? How should it be configured? BPS advises based on formulation properties and site requirements.
→Equipment selection for specific formulations — viscosity, solids content, fibre length
→Operating pressure recommendation for uniform spray pattern without segregation
→Configuration for slopes, embankments, remote application
→System check and commissioning support on request
→Fault analysis for application problems during operation
Technical Parameters
Five Dimensions That Determine Success or Failure
The application of solid-containing biopolymer suspensions differs fundamentally from the discharge of pure liquids. The following five parameters determine the quality of the application result — and are frequently underestimated in practice.
Pump Selection
Solid suspensions with fibres, minerals or organic particles place high demands on the pump. Centrifugal pumps fail at high solids content. Progressive cavity pumps and peristaltic pumps are more suitable for fibre-filled suspensions — but have their own pressure loss characteristics.
Wrong pump selection leads to segregation, fibre damage and uneven application.
Operating Pressure
Operating pressure affects spray pattern, penetration depth and droplet size. Excessive pressure destroys fibres and creates mist that carries active material away from the substrate. Insufficient pressure leads to incomplete atomisation and uneven layer thickness. The optimal operating pressure is formulation-dependent.
For fibre-containing suspensions, different pressure ranges apply than for pure polymer solutions.
Foam Formation
Biopolymer formulations tend to foam under certain conditions — especially with turbulence in the pump, excessive pressure or certain combinations of binders and fibres. Foam in the suspension leads to dosing errors and uneven application quantities.
System configuration and formulation adjustment can control foam formation.
Spray Pattern — Boom vs. Nozzle
Boom systems produce a uniform surface application at low travel speed — suitable for embankments and large area coverage. Single nozzle application allows precise control of application quantity and impact point — suitable for structured surfaces, slopes and remote application. Both systems have specific requirements for pressure and suspension.
The choice of spray system depends on surface geometry and application distance.
Friction in Hose & Pipe
Solid-containing suspensions — especially fibre-rich formulations — generate significantly higher friction losses in hoses and pipelines than water. Line cross-section, hose length and bend angles significantly influence the effective operating pressure at the nozzle. Unaccounted friction losses lead to insufficient discharge pressure.
For remote application with long hose lines, friction calculation is mandatory.
System Configuration
Three Independent Decision Levels
Equipment configuration does not result from a single system choice, but from three sequential decisions: Which mixing principle? Which discharge principle? Which pump technology? Each level must be evaluated independently — and all three together determine whether a formulation is correctly applied.
Level 1 — Mixing Principle
Jet Principle — Hydraulic Recirculation
Mixing Through Return Flow
With the jet principle, the suspension is kept in motion through hydraulic recirculation — no mechanical agitator. The pump circulates the mass in a loop; the flow energy keeps the suspension homogeneous. For discharge, the return is closed and the mass is released through the nozzle.
Application Range
Suitable exclusively for very fluid mixtures. Fibre content must be low — in practice the jet principle works reliably only with cellulose. As soon as heavier solids, long fibres or mineral aggregates are in the suspension, the jet principle is no longer sufficient.
Agitator / Paddle Shaft — Mechanical Stirring
Mixing Through Paddle Shaft
A mechanical agitator — the paddle shaft — keeps the suspension homogeneous through physical movement. Independent of solids content, fibre length or component density. Discharge is via a separate pump.
Application Range
Mandatory for fibre-rich formulations, mineral aggregates and heavy masses. Principle: the more fibre in the formulation, the more essential the mechanical agitator. No jet principle as an alternative — this is a technical limit, not a preference.
Level 2 — Discharge Principle
Close Return → Discharge via Nozzle
With jet equipment, the return is closed for discharge. The entire volume flow of the pump is redirected to the nozzle. Pressure and flow rate depend directly on the pump characteristics — no separate feed pump.
Jet equipment onlySeparate Feed Pump → Discharge via Nozzle
With mechanical equipment, a dedicated pump conveys the suspension from tank to nozzle. Mixing and conveying are decoupled — the agitator runs independently. Operating pressure and flow rate are controlled via the pump.
Mechanical equipmentLevel 3 — Pump Technology (Mechanical Equipment)
Centrifugal Pump
Conveys by rotation of an impeller. High flow rate, low wear with clear liquids. With increasing solids content, conveying capacity decreases — sensitive to blockage by long fibres.
Suitable for low to medium solids content · not for fibre-rich masses
Cavitation Pump
Uses cavitation effects for conveying — generates fine pressure differences in the fluid stream. Suitable for suspensions with medium solids content. Shear-sensitive components can be stressed by cavitation — relevant for biopolymer formulations with long-chain molecules.
Medium solids content · consider shear effects on formulation
Gear Pump
Conveys through intermeshing gears — volumetric operating principle, virtually independent of viscosity and solids content. Suitable for very heavy, viscous masses with high solids and fibre content. Pressure-stable and low-wear with highly viscous suspensions.
First choice for heavy masses and high fibre content
Decision Logic: With increasing fibre content in the formulation, pump selection shifts necessarily towards gear pumps. Centrifugal pump → Cavitation pump → Gear pump is not a quality hierarchy, but a deployment classification based on suspension properties. The wrong pump not only leads to poor conveying performance — it damages the formulation or blocks the system.
Mobility & Weight
Weight Is Not a Minor Point — It Is a System Requirement
Application equipment is frequently reloaded in practice, operated on different carrier vehicles or configured for helicopter deployment. Equipment weight is therefore a primary system requirement — not a secondary detail. BPS considers weight and mobility requirements from the start of the design process.
Carrier Vehicle Switching
Equipment operated on different carrier vehicles requires standardised interfaces, defined centre-of-gravity positions and clear weight limits. Design from system inception.
Helicopter Deployment
Helicopter application places maximum demands on weight, centre-of-gravity stability and operability. BPS develops and modifies equipment specifically for these requirements — including remote control and underslung mounting.
Backpack & Handheld Devices
For difficult-to-access terrain, small areas and remedial work, BPS develops compact handheld devices and backpack sprayers that work with the same formulations as the larger stationary systems.
In-House Development
BPS Test Equipment
We develop our own test equipment — from scratch or by modifying existing systems.
Every BPS simulation project and every field test requires application equipment precisely tailored to the respective purpose. Off-the-shelf equipment rarely meets these requirements fully — too generic in design, too inflexible in configuration. BPS builds its own test equipment or modifies existing systems to precisely meet the requirements of the respective project.
This competence is also available to external partners. Equipment manufacturers can engage BPS as a development partner for prototypes and special equipment. Applicators with specific requirements can commission a custom-built device.
→New development of test equipment for specific formulations
→Modification of existing hydroseeders and spray systems
→Prototype development for equipment manufacturers
→Special equipment for helicopter and backpack deployment
→Documentation and handover as a reproducible system
Development Parameters
Application Technology as a Research Component
The development of application technology systems for nature-based formulations is part of several EU funding programmes in the areas of precision agriculture, climate adaptation and nature-based solutions. BPS contributes in-house development competence and operational field experience to relevant project consortia.
Application Problem or Equipment Question?
Describe the formulation, substrate and operating conditions. BPS will assess which system is suitable — and whether equipment development or modification is advisable.