A leading sausage producer wanted to improve their anti-microbial spraying process. Up until recently they were using a spraying system with basic nozzles to spray their sausages at the lowest possible cost. Unfortunately this approach started causing a lot of issues that were actually costing them more money than they were saving with a cheap solution.
Basically, the old system was turned on as soon as the sausages started passing the anti-microbial spray and switched off when production was finished. This approach leads to a lot of wasted, expensive, spray product. Additionally, the excessive spraying was polluting the surrounding environment and causing slippery working conditions. These regularly needed to be cleaned up to avoid safety risks for employees.
Worst of all the basic solution wasn’t reliably delivering the anti-microbial solution to the sausages. This lead to quality issues and product recalls.
Clearly the producer needed a more reliable system to spray the sausages. Spray coverage and optimal efficiency were the key requirements to improve product quality, prevent safety risks and decrease costs.
AutoJet® Anti-microbial Spraying System
Our local spray expert was consulted to offer a more performant anti-microbial spraying system. Unfortunately we often encounter similar situations were a non-performant spray solution is creating excessive waste and costs. Luckily, we have the necessary expertise and systems to efficiently spray pretty much anything.
Thanks to our Precision Spray Control (PSC) technology we can turn nozzles on and off very quickly to control the flow rate. This means that the anti-microbial will only be sprayed when there is a sausage passing the nozzle. This cycling is so fast that the flow often appears to be constant. With PSC the pressure remains constant enabling flow rate changes without changes in spray performance. As a result the spray is only applied on the sausages and not on the surroundings.
After the anti-microbial supplier verified the spray efficiency of our solution in their lab the customer insisted on stress testing everything on their production line. The results were immediately noticeable and the sausage producer decided to order the same AutoJet® Anti-Microbial system for their other production lines as well. Each system contains:
- • AutoJet® F1850+ Spray Controller
- • PulsaJet® AAP10000-114860-X-VIFC food contact nozzle
Result
It’s difficult to precisely calculate the impact of installing the AutoJet® Anti-Microbial system on multiple lines. The biggest relief for our customer was that the product quality issues have been fixed. Additionally, they’re also seeing huge cost savings (over 50%) by only spraying the anti-microbial when sausages are passing under the nozzle. This more efficient spraying has also minimized overspray and its related safety issues. Altogether the savings were so impressive that the sausage producer is now also looking into installing our system in other facilities as well.