A multi-duct orchard sprayer is designed in this paper to address the problem of low droplet coverage during plant protection in walnut orchards in South Xinjiang, China. This spray comprises a base frame, a pesticide tank, an air delivery system, a copying base frame and a drive system. Effects of the sprayer structure on the flow field were simulated using computational fluid dynamics. Operation parameters were optimised using the response surface analysis and validated using a field test. The results demonstrated that five jet tubes in the simulation design could fulfil the design requirements of GB/T 32250.3-2022. The upper, middle and lower droplet coverages were 74.92%, 90.01% and 69.9%, respectively, when the sprayer’s advancing speed, the angle of jet tubes and the nozzle diameter were 0.53 m/s, 70.27° and 0.81 mm, respectively. The machine can effectively enhance the spraying efficiency and droplet coverage of each canopy during plant protection operations in the new walnut orchards of South Xinjiang, China, and provide references for designing and optimising fruit tree spraying machinery.