This is the second part of a series on snowmaking that started with a state-of-the-art overview in the May issue. Next issue: air/water and low-e guns.

Snowmaking is all about efficiency. Often, efficiency means hybrid systems that combine low-e and air/water guns with fans. These systems take advantage of the strengths of each—the production, throw and relative wind-resistance of fans with the lower cost and relative efficiency of low-e and air/water guns.

In many cases, efficiency, says SMI president Joe VanderKelen, “is a matter of infrastructure.” Upgrades or additions often involve figuring out how to best combine old and new, and combine fans, low-e and air/water. “We help to do that as value consciously as we can,” he adds.

Increases in labor and energy costs will continue to make efficiency a priority, and it’s possible to make big gains. According to Geir Vik, president of TechnoAlpin, Hidden Valley, Pa., was able to reduce snowmaking costs to $220 per acre-foot after upgrading to a system of mostly automatic fan guns. “That’s a target for other areas to strive for,” he says.

Many fan gun trends, such as automated operation, originate in Europe, where energy and labor costs have long been a concern. The latest trends have been for swiveling and telescoping towers, greater productivity, and ease of maintenance. Quieter guns may be the next thing; they are already big in Europe, and several are coming to North America in the near future.

Here’s a look at what manufacturers are offering currently in fan guns.


ARECO/SNOWNET
The workhorse Supersnow is getting some new features. It now offers electric tilt and 360-degree rotation as available options. The gun itself can be mounted on a mobile platform—either on legs or wheels—or on a tower, and can easily be moved from one platform to another. There’s a new lifting tower available, too.

A new E-Line delivers fan technology at a lower cost—it’s the new “standard” model. The E-Line operates on hill air, without an onboard air compressor, for use with existing infrastructure. It can also be ordered with an onboard compressor and swing automation as options. This stripped-down version of the Supersnow also has fresh graphics.

Speaking of efficiency: latent heat from the air compressor helps to keep the nucleation from freezing, along with some level of heat from the snowmaking water temperature (assuming that the water temperature is several degrees above freezing). All machines, both manual and automatic, use a thermal switch to cycle the heat elements on and off to maintain temperature for the water ring. However, on guns with onboard PLC automation, the PLC determines at what temperature to start the heat system. That saves energy in warmer temperatures. For temperatures below 24º F., heat operates automatically using the thermal switch.

For the future, Areco is currently performing tests with silent models, using sound-deadening technology and fan design to maintain a high level of production.


JOHNSON CONTROLS SNOW
Johnson Controls is continuing to develop its energy-efficient J10 fan gun. Engineer Travis van Ormer says some units are already deployed at areas. The goal is vastly reduced energy use in a normal-sized gun. The J10 is powered by a 10 hp fan and a 5 hp compressor, and it incorporates a lot of technology from Johnson Controls’ air/water and low-e guns.

“What is revolutionary about the J10 is that we’re using energy from the water,” says van Ormer. “We’re using a v-jet technology, like low-e guns. The way the nozzle works, unlike a swirljet, it retains more energy from the water pressure, thus propelling the water droplets further.” The J10 uses the same automatic valves as Johnson Controls’ Rubis gun.

“Energy efficiency is in line with the rest of our products. That’s really driven by the market in Europe, but it’s becoming more important here, too,” van Ormer notes.

The J10 is intended to seamlessly join with other Johnson guns in the company’s Liberty automation system. For ease of use, the guns are using a color touch screen for automatic setups.


LENKO
Lenko’s traditional multi-nozzle approach provides the economy to produce snow in marginal temperatures, though it is susceptible to clogging in areas that have limited supplies of clean water. Through the introduction of different nozzle orifice configurations, Lenko is working to find the happy medium of high production and low nozzle maintenance, says the company’s Bill Van Zee. During the 2010-2011 season, Lenko will test a new nosecone design that, through the use of larger orifice nozzles, will reduce clogging issues while maintaining production in the widest range of temperatures possible.

In recent years, Lenko has made a variety of modifications to its fan line. All new production machines since 2008 have come with Atlas-Copco oil-free compressors to reduce environmental impact and maintenance costs. Sound attenuation material has been added to more models following the introduction of the Whisper model in Europe.

Starting in 2007, Lenko has provided a totally redesigned waterbox on most models. To ease nozzle maintenance, the newest version features a machined aluminum manifold that, along with a two-inch ball valve, makes it possible to flush debris that has accumulated at the lower end of the manifold.


SMI
SMI’s workhorse remains the Super PoleCat, which the company calls a “big throw” snow gun. Each gun can be operated individually or can be outfitted to run on a central compressor feed. With 30 spray nozzles and a six-jet nucleator, the PoleCat works well in dirty water applications, Joe VanderKelen says.

The PoleCat comes in several models, with compressor choices that cover a range of economy and production considerations. The options include 5 hp piston compressor, 5 hp rotary vane, 7.5 hp piston , and 10 hp rotary vane compressor, along with 5 hp and 10 hp oilfree compressors. Why so many choices? “Different folks prefer different equipment,” says VanderKelen. “Areas have different energy loads; their best option depends on their situation. With our range of compressors, we can cover just about any request or situation.”

Automatic valves control water flow to 30 spray nozzles in each unit, providing up to 142 gpm, with a central 6-jet nucleator. Flow rates step up or down in 3- to 6-gallon increments, to follow the weather window. Available options include a spray manifold heater, tower or carriage mounting, and oscillation.

“The trend continues toward more automation,” VanderKelen says, “but it’s still a bit of a slow trend. And even with automation, you need a couple of guys paying attention. Automated does not mean unattended.”

SMI’s Wizzard, with 300 nozzles that create smaller droplets, remains a good option for resorts that have clean water and marginal temperatures, he notes. “A lot of people are still buying Wizzards,” especially in places such as Southern California and North Carolina, he says.


TECHNOALPIN
TechnoAlpin will introduce a new fan gun at the NSAA winter show at Snowbird in January, dubbed the T40A. It’s “an M18A on steroids,” according to European resorts that have tested it, says Geir Vik. The gun has the same power consumption as the M18A, but with increased throw and flow. A new fan shape with more blades—developed from the quiet-operating Piano gun—improves fan efficiency.

Also new this year: the M18A has 24 steps of water regulation, double the old number. “We’re trying to emulate the wet bulb curve throughout,” says Vik, to maximize the flow at all temperatures.

TechnoAlpin is also incorporating Bluetooth technology, so personnel can remotely control the gun. “You can cross-train the groomer to control the gun from the cab,” Vik says. “You don’t always have a crew out there running the guns.” Another software function activates a filter cleaning sequence that makes it easy to backflush the filter and get the gun back into production quickly.

TechnoAlpin also offers a hydraulic lift tower, so snowmakers can change tower height. This facilitates maintenance and dealing with wind issues.

Arm towers are becoming more popular in the U.S., too, Vik says. The gun sits on a cantilever that goes up 30 feet; it can swivel 360 degrees, and can raise or lower the gun as best suits the situation. Alta replaced three stationary guns in a terrain park with one on such a tower. “Even if you replace just two guns, you’re way ahead [on cost],” Vik says, adding that one auto gun on an arm tower can replace two manual conventional towers—and do a better job.

To help resorts adopt new technology, TechnoAlpin offers its own version of “cash for clunkers.” “The less efficient your gun is, the more you get from us,” Vik says.


TOPGUN
The Topgun fan gun, a small, light, simple design, has been in development for a few years, and was tested at a couple of areas last winter. Designer Troy Jervas intends for it to have the lowest energy consumption on the market, and not just because it’s a smaller gun than most.

The unique head allows for significant throw with only a 3 hp fan. The external mix nucleator requires only 15 cfm and will run on hill air or with an on-board 5 hp compressor. The gun uses Topgun’s 9-stage valve, with no need for external heat for the valves or the nucleator, resulting in additional energy savings—in the Topgun design, water is the heating element that keeps components from freezing. The fan has a near-stepless flow curve, allowing for fine adjustments to small temperature changes by the turn of a handle. Typical output range is 5 to 75 gpm, but it can be set up to produce up to 125 gpm. Its small, light construction makes it easy to move.


TURBOCRISTAL
There have been several recent modifications to the SuperCrystal gun based on feedback from operators: new jack, new position for the weather station, more accurate reading, especially for auto guns, and a more user-friendly ATM-style display panel.

Perhaps the biggest change, though, has been to the central module. This single nozzle design, unique to Turbocristal, has been reworked to achieve production similar to multi-nozzle guns at warmer temperatures. The SuperCrystal remains a high-output unit in colder temperatures, as it was designed to be—peak production approaches 250 gpm.

Another advantage of the single-nozzle design: “You basically open the nozzle fully to flush it, then go back to business,” says sales manager Ismael Fréchette. It’s also an easy item to replace on the hill, should that be necessary. The parts are easy to install, and light enough to be transported via snowmobile. “When the module is worn, it’s just a single item to replace. It’s a one-minute change that can be done on the hill. It makes the whole operation simpler,” Fréchette says.

Resorts with older models of the Turbocristal fan gun can retrofit these with the new module. That’s been tested successfully on a gun put into service in 1991. This, too, is a simple operation. “It’s just a matter of a quick cam lock to get off and on,” Fréchette says.

As with other gun suppliers, Turbocristal is focused on efficiency and versatility. To that end it’s developing a smaller version of the SuperCrystal, with a smaller fan motor—20 hp rather than 30 hp. The standard 30 hp motor is 60 amps, but some areas, especially in the Midwest, have only 30 amps. The new gun will accommodate that limitation, albeit with less throw and hang time.