Case Study

New Spray Nozzles Increase Beef Processor’s Daily Revenue by US$29,000

Case Study

New Spray Nozzles Increase Beef Processor’s Daily Revenue by US$29,000

A major international beef processor needed to chill steer carcasses in a more efficient manner. A combination of full cone and wide-angle flat spray nozzles are now used to provide complete, mist-free water coverage on the carcasses for effective cooling.

Problem:
A major international beef processor needed to chill steer carcasses in a more efficient manner. The process, which involved spraying the carcasses with over 50,000 gallons (189,271 liters) of chilled water over an 18-20 hour period, is used to prevent weight loss and shrinkage.

The previous system was not providing complete coverage of the carcasses and required long chilling times. As a result, carcass mass and size were reduced causing unnecessary revenue loss. In addition, excess mist was generated by the spray system creating ice build-up on the rails and the facility structure. The nozzles required frequent maintenance and constant monitoring in order to keep the chill rooms operational and safe.

The beef processor sought a better spray system to increase chill room efficiency, ensure complete carcass coverage and lower maintenance needs.

Sprühanwendung zur Kühlung bei der Rindfleischverarbeitung

Solution:
Spraying Systems Co. converted one of the processor’s 11 chill rooms to ProMax® QuickJet® nozzles. A combination of full cone and wide-angle flat spray nozzles are now used to provide complete, mist-free water coverage on the carcasses for effective cooling. A third-party review validated that chill time had decreased, and water consumption and ice build-up on the rails and refrigeration equipment was significantly reduced. It was also verified that carcass weight loss was minimal during the cooling process.

Results:
With cooling time cut in half, a significant drop in water usage and a product yield increase due to a reduction in carcass shrinkage, the remaining 10 chill rooms were also converted to the ProMax® QuickJet® nozzles. The company now processes an average of 1750 steer a day with each carcass weighing approximately 450 lbs (204 kg). The 2% increase in production yield and 44% decrease in water consumption have resulted in a daily revenue upturn of nearly US$30,000. In addition, the new system enhances the processor’s sustainability efforts by saving a total of 4.3 million gallons (16.2 million liters) per year. The estimated payback period for the conversion to ProMax QuickJet nozzles is less than three weeks.

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