Optimization of spray control parameters for improving performance of the tunnel sprayer

• All spray control parameters were found significant against spray deposits and recycling rate, except operating pressure in recycling rate response. • Spray deposits varied from 2.02 × 10 -4 to 3.14 × 10 -4 µg/mm 2 , assuring effective spray coverage for better insect pest management. • Tunnel sprayers save 38.56% of applied pesticide, contribute to sustainable agriculture, and reduce chemical use. • Targeted adjustments of optimized spray control parameters improve the system’s consistency and efficiency in the optimal use of chemicals. • Optimized parameters under distinct leaf area index promote practical use of the spraying system. The tunnel sprayer is well known for both recycling system, and achieving better spray characteristics like spray deposits spray coverage uniformity and deep canopy penetration. These performance parameters influenced by the spray control parameters, namely LAI, forward speed, air velocity and operating pressure because these input parameters effect the canopy physiology, and droplets dynamics. Thus, it becomes very crucial to study the impact of these parameters on the spray characteristics like spray deposits and recycling rate for enhancing the performance of the tunnel sprayer. Therefore, a novel tunnel sprayer was developed and tested for the spray deposits and recycling rate. Initially, spatial spray distribution and droplet density analysis were carried out to identify the worst spray deposit zones of the both hybrid trees. Average spray deposits of these worst zones used to study the effect of these selected parameters on response, numerical optimization and validation. All the input parameters were found significant, except operating pressure for the recycling rate, which implies that these parameters are very crucial for a better version of the existing system. The optimized spray control parameters, such as forward speed (0.69 m/s), air velocity (15 m/s), and operating pressure (0.75 × 10 6 Pa), yield sufficient spray deposits (3.14 × 10 -4 µg/mm 2 ) and save 38.56 % of the applied pesticide. The laboratory based validation results confirmed the reliability and accuracy of the developed system for the spray deposits and recycling rate. From the comparison of the previous studies findings, it can be concluded that tunnel sprayer ensure crop protection by facilitating sufficient spray characteristics and offered additional recycling advantage to the farmers.