By Diane Silcock
The baking industry, not unlike other manufacturing sectors, continually faces competitive pressures. In their ongoing efforts to improve quality, boost productivity and control costs, commercial bakeries are finding that spray technology can be a very effective tool in meeting a number of persistent challenges.
MD Grant Orsmond of Monitor Engineering – an expert in spraying technology – discusses how this technology is proving to be effective in solving problems in bakery operations, primarily related to consumables, where closely controlling application rate and location can reduce waste of costly ingredients and boost overall efficiency and effectiveness.
“The four primary concerns in baking, and in the food production industry as a whole,” says Orsmond, “are food safety, employee health and safety, sustainability and doing more with less.
Major technological advances over the last decade are enabling us to play a significant role in helping bakeries address these concerns. This is especially true with regard to automation, the adoption of which has steadily enabled bakeries to do more with less while also improving product consistency. Automated spray systems provide bakeries with an array of options for reducing waste and increasing product quality and shelf life. Automation reduces waste of costly coatings, ensures uniform application to reduce quality problems and contributes to sustainability efforts through efficient use of resources.”
He explains how their AutoJet® Precision Spray Control systems consisting of an AutoJet spray controller, work in concert with nozzles selected for each particular application.
Although there is great variation among systems, the underlying objective is the same: apply a precise amount of material at the proper time in the proper location.
He says that this approach addresses the cost of consumables head on, because many standard bakery operations result in over- or under-application, both of which drive up costs.
Choosing to spray improves quality and cuts waste
In addition to saving on consumables, the work environment is also improved through the frequent reduction of waste.
Eliminating the misty overspray that compromises air quality and causes slippery surfaces contributes to an overall safer working environment.
Gaining control over unwanted misting also reduces – and may well eliminate – the need for personnel to be permanently assigned to keep floors and equipment clean in the operating area.
Controlling material application by ensuring an optimal application of a release agent, for instance, results in less sticking and fewer rejections, thereby enhancing product quality.
Using only the amount of coating necessary extends the time between pan glazing and pan and conveyor cleaning.
Where coatings are being applied to food products, automatic control results in better product consistency, which may also mean better consumer appeal or more predictable shelf life.
Orsmond refers to a particular case study where a manufacturer wanting to apply a precise amount of extra virgin olive oil on each bread slice before toasting, replaced its old system of air atomizing nozzles with an AutoJet spray control panel and PulsaJet® automatic flat spray nozzles.
This eliminated the need for compressed air as well as misting and overspray problems. The new system resulted in improved product quality while reducing olive oil consumption by nearly 75%. The company’s monthly oil savings were significant and paid for the system in just a little more than one month.
Monitor Engineering is the sole agent in southern Africa for Spraying Systems Co. and has been importing quality spray nozzles, automated spray systems, customised fabricated shower headers, spray lances and accessories for 75 years.
Learn more at: www.spray-nozzles.co.za
