Spraying Systems Deutschland GmbH

Problem:
A bakery producing hamburger buns for a major fast-food restaurant was using air atomizing nozzles
to apply egg wash to the top of buns before baking. The system clogged frequently and required
shutdowns every three hours for maintenance. In addition, misting from the nozzles resulted in worker
safety issues and additional cleaning time to remove the egg wash from equipment.

Solution:
An AccuCoat® Chilled Egg Wash System is now being used. As pans with buns pass through
the spray station, PulsaJet® electrically-actuated hydraulic spray nozzles apply the chilled
egg wash. PulsaJet nozzles achieve very low flow rates using larger orifices and provide
comparable performance to the air atomizing nozzles used previously, but eliminated the
clogging and misting issues. The AutoJet® Model 1550+ spray control panel works in tandem
with PulsaJet nozzles to provide Precision Spray Control (PSC). PSC ensures the proper
volume of egg wash is supplied even when operating conditions like line speed changes. The
egg wash is kept at the proper temperature and consistency through the use of a chiller and
agitator in the pressure pot.

Problem:
Geary’s Bakeries, one of Britain’s best known craft bakeries, needed to ensure that seed
toppings would consistently adhere to baked goods. A key market segment for Geary’s is
sandwich production, which requires that rolls are sliced, buttered, filled and then repacked
before sale. Ensuring that seeds adhere to the rolls throughout this process is an important
measure of product quality.
Precise application of water is critical for proper seed adhesion. Too much water can cause the
seed to sprout and too little water results in the seed falling off. Previously used automated
systems hadn’t worked consistently, often spraying too much or too little water. Because of
quality concerns, Geary’s had returned to the time-consuming, manual process of dipping each
dough ball in water and then pressing it into seeds before proofing. With weekly demand for
seeded rolls in excess of 200,000 and increasing, the bakery needed to increase production
speed while maintaining high quality standards.


Solution:
An automated spray system utilizing Precision Spray Control (PSC) now applies the water,
eliminating over- and under-application. The system applies a precise volume of water to the
rolls and automatically adjusts the flow rate for variations in line speed.
Spraying Systems Co.’s solution uses a wall-mounted AutoJet® Model 1550 Modular Spray
System with PulsaJet® automatic spray nozzles. The system’s spray controller allows operators
to conveniently set the delay time between detection of the
leading edge of the baking tray and when the nozzles spray. The
duration of the spray time for various baked goods is also easily
set. Accurate control of these operating parameters ensures
precise coverage of the rolls every time.

Problem:
A manufacturer was using an enrober to apply chocolate compound to 100,000 cannoli shells daily.
The enrobing process wasted a significant amount of chocolate and required excessive downtime for
equipment cleaning. In  addition, the chocolate compound was over-applied and increased the calorie
count of the cannoli.

Solution:
An AccuCoat Fully Jacketed Heated Spray System is now used to coat the inside of the cannoli
shells. The system maintains the chocolate at 175°F (79.4°C) from the 10-gallon (38-L) tank until
it exits the nozzles. A sanitary Model 63600 Spray Manifold, equipped with three air atomizing
nozzles, is secured on both sides of a conveyor. Shells index three at a time and stop briefly so
the nozzles can deliver a precise volume of chocolate to the inside of each shell.