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Production Halted, a Quick, Effective Solution Was Demanded

Quality control is perhaps the most crucial issue in food processing operations. Typically, when a problem occurs, it must be analyzed and solved as quickly as possible to avoid expensive downtime and maintain quality standards. Here's how a pizza crust manufacturer solved a quality problem with spray technology.

PROBLEM: The Midwestern food processor assumed their process would eliminate any mold formation problems on their pre-packaged pizza crusts. However, after receiving a customer complaint, they needed to reevaluate their process and develop steps to ensure better application of mold retardant.

The production line, which operates two shifts, four days a week, was shut down. The company determined that the solution to this problem was to spray the tops and bottoms of the crusts with potassium sorbate to eliminate mold formation. They needed a precise spray system for this application . . . and they needed it immediately.

SOLUTION: The food manufacturer contacted their Spraying Systems Co. sales engineer who recommended air atomizing spray nozzles. These nozzles deliver a finely atomized drop which provided the light, even coating needed on the crusts. The order was placed, the spray nozzles and accessories delivered and the entire system installed in three days. Expensive production downtime was minimized. Extra precautions were taken to eliminate future downtime as well. Two 10-gallon (37.9 liter) Spraying Systems Co. pressure tanks were installed. When one tank runs empty, the standby tank, filled with potassium sorbate, is ready to go. This allows production to continue while the operator opens and refills the empty tank.

The system was also equipped with an air pressure regulator and a liquid pressure regulator. The regulators allow air and liquid pressure adjustments and achievement of the exact drop size required.

The installation was fast . . . the solution effective. The air atomizing spray nozzles solved the mold problem. Plus, the system's flexibility provides better application thereby increasing production and improving quality control.

Air atomizing spray nozzles are available in a variety of sizes, body designs and materials. There are hundreds of complete spray set-ups, which consist of specific air cap and fluid cap combinations, for a wide range of applications.

Spraying Systems Co. offers several basic air atomizing models.

• Low Capacity Series. Our 1/8J and ¼J models range in capacity from 0.13 to 72 gph (0.49 to 280 l/h).
  
• Low Capacity Compact Series. Our 1/8JJ models range in capacity from 0.13 to 25.7 gph (0.49 to 88 l/h).
  
• Medium Capacity Series. Our ½J models range in capacity from 4.1 to 306 gph (15.5 to 1,158 l/h).
  
• High Capacity Series. Our 1J models range in capacity from 24 to 1,740 gph (91 to 6,586 l/h).

These models operate at air pressures ranging from 10 to 60 psi (0.7 to 4.0 bar) and can be specified with pressure or siphon/gravity liquid feed spray set-ups. A full range of air atomizing accessories are available including liquid strainers, solenoid valves, pressure tanks, air and liquid pressure regulators, gauges and air filters.