MeeFog vs. the Competition: A Fogging System Comparison for Data Center Cooling

Comparing Fog Systems for Data Centers

In environments where precise cooling and humidity control are essential—such as data centers—fogging systems play a critical role. A detailed comparison was conducted between MeeFog systems and a competitor’s fogging solution for a data center project in the U.S. The results highlight significant differences in design, performance, and long-term reliability. This comparison outlines why MeeFog remains the industry leader in fogging technology.

Inside Mee Industries’ U.S. manufacturing facility, where fogging systems are built to the highest standards for mission-critical cooling applications

Fog Nozzle Design: Precision Where it Matters

Three elements of fog system design are critical to achieving more efficient evaporation, fog nozzle flow rate, nozzle coverage, and droplet size: flow rate, coverage and droplet size.

1. Nozzle Flow Rate – Mee vs. Competition:

• MeeFog system nozzles flow 0.032 gpm.
• Competitor’s nozzles flow 0.10 gpm.

One of the most critical elements in any fogging system is the nozzle. MeeFog nozzles are engineered for high-efficiency evaporation. Fog nozzles used for heat exchanger cooling have a flow rate of 0.032 gallons per minute (gpm) when operated at 1000 psi, producing extremely fine droplets that are optimized for rapid evaporation.

In contrast, the competitor’s nozzles have a flow rate of 0.10 gpm which is approximately three times the flow rate of the MeeFog nozzles. This higher flow rate produces larger droplets, which tend to fall out of the airstream before fully evaporating. This not only reduces cooling efficiency but can also lead to over-wetting of coils downstream, causing water to drip to the ground, removing it from the evaporative cooling process and making the system less efficient.

2. Nozzle Coverage – Mee vs. Competition:

• MeeFog = 74,418 fog nozzles
• Competitor = 23,700 fog nozzles

MeeFog system designs use a far greater number of nozzles than the competitor—over 74,400 compared to only 23,700 used by the competitor. This higher nozzle density allows MeeFog to provide more uniform fog coverage across the entire cross-section of the heat exchanger, preventing over-wetting of the coils and eliminating gaps where untreated air could pass through. The air is evenly and efficiently cooled before entering the building.

A system with too few nozzles causes gaps between the nozzles which allow air to pass the nozzle array without being cooled. A higher nozzle flow rate causes over-wetting of the coils and wasted water rains back onto the ground.

3. Nozzle Droplet Size –  Mee vs. Competition:

• MeeFog – 27-micron droplet
• Competitor – 46-micron droplet

Droplet size directly affects how efficiently a fogging system can operate. MeeFog nozzles produce droplets with a Dv90 value significantly smaller than those of the competitor. Dv90 means 90% of the water flow is in droplets of the specified size or smaller.

The chart shows Dv90 droplet size for nozzles with different flow rates. MeeFog’s smaller droplets not only stay suspended longer in the airstream, but they also present a much higher surface-to-volume ratio, which is key to rapid evaporation.

To put this into perspective, a 27-micron droplet offers 1.74 times more surface area per gallon sprayed compared to a 47-micron droplet. Since evaporation occurs at the surface of the droplet, MeeFog’s finer droplets evaporate much faster, making the system more efficient and effective at cooling.

Fog Manifold Design

MeeFog’s attention to detail extends to nozzle lines and adapters. The MeeFog design provides robust construction and leak-free performance. Proudly Made in the USA to the highest manufacturing standards, every MeeFog system is built for reliability from the ground up. Nozzle adapters are made from stainless steel and are TIG welded directly to the tubing, ensuring structural integrity and leak-free operation. Each line is factory-tested before delivery, which eliminates the risk of field leaks that can be difficult and costly to fix after installation. The inclusion of manual isolation valves for each bay makes system maintenance and troubleshooting more straightforward.

The competitor threads the wall of the stainless steel tube and directly mounts the nozzle to the tubing, but the wall is thin, so only about 1.5 threads are holding the nozzle in the tube wall. Others use plastic fittings, which are subject to failure. Nylon tubes with slip-lok fittings, are also prone to premature failure. MeeFog’s welded design ensures long-term reliability—and like all MeeFog systems, it is proudly Made in the USA to the highest manufacturing standards.

Advanced Pump Skid Design

MeeFog has decades of experience in building industrial quality pump skids, which shows in every component. MeeFog pump skids are UL 508A certified and are equipped with advanced PLCs to interface seamlessly with the customer’s control systems.

In this comparison, MeeFog’s design included eight skids, each with two high-efficiency, water-lubricated, multi-stage centrifugal pumps. These pumps operate for up to 20,000 hours between servicing, require no oil changes, and are direct drive, meaning there are no belts to tension or replace. These features make the MeeFog system much more reliable and easier to maintain.

The competitor proposed a system with 100 small pump units. These were essentially patio misting pumps, which are not suitable for industrial applications. The proposed pumps were reciprocating, piston pumps which require frequent servicing to replace pump oil and high and low-pressure seals.

Furthermore, the competitor’s pumps are plunger-style and operate at 1725 RPM, a speed that significantly accelerates wear on seals and internal components. Maintenance is more frequent, with seals needing replacement every 1,000–2,000 hours and oil changes required every 500 hours.

MeeFog systems use large stainless-steel 10-micron filters, with only eight filter vessels needed for the entire setup. In contrast, the competitor’s system relies on over 100 pump units each with their own filters—greatly increasing maintenance time and cost. The 100 separate pump units also require individual water and power connections, adding to installation costs and introducing multiple potential points of failure.

MeeFog pump skid system designed for mission-critical cooling, featuring stainless-steel construction and PLC integration.

Proven Experience and Engineering Excellence

MeeFog brings more than 50 years of experience in designing and manufacturing industrial grade fogging systems. MeeFog’s expertise spans a variety of sectors, including electrical power generation, data centers, agriculture, and manufacturing.

Inside Mee Industries’ U.S. manufacturing facility, where fogging systems are built to the highest standards for mission-critical cooling applications

Over the years, MeeFog has contributed to the advancement of fogging technology by publishing several ASME peer-reviewed technical papers on topics such as fogging efficiency and water atomization.

What sets MeeFog apart is the in-house, Made in the USA manufacturing capability. The company maintains a TIG welding shop, CNC machining center and a full assembly line at their Southern California headquarters. In-house engineering capabilities include electrical and mechanical engineering, along with PLC programming for system integration. This gives the company full control over product quality and allows it to deliver custom-engineered solutions to meet the most demanding specifications.

Conclusion: MeeFog Stands Apart

The comparison makes it clear. MeeFog outperforms the competition in virtually every category—from nozzle-line design and droplet size to system reliability and maintenance requirements. MeeFog systems offer better fogging coverage, more efficient evaporation, lower operating costs, and fewer maintenance concerns.

In mission-critical environments where downtime is not an option, MeeFog provides a dependable, high-performance solution built on decades of engineering excellence.

Interested in learning more about how MeeFog can improve your facility’s cooling efficiency? Contact our engineering team today for a custom consultation or request a quote below.