CASE STUDY

Bakery Reduces Scrap by 40% with Automated Spray System


Problem:
Manually coating gingerbread cookies with butter flavoring prior to baking was creating issues for a large commercial bakery. Workers were applying the flavoring using handheld spray guns. The process was time-consuming, and the results were inconsistent. The bakery was  experiencing a high scrap rate due to the application of too much or too little flavoring.  An alternative to the existing industrial baking equipment was needed.


Solution:
An AutoJet® 1550+ Modular Spray System and an electrically-actuated PulsaJet® spray nozzle provided the bakery with the precision coating required. As cookies pass through the spray station, the proper volume of coating is applied. The system uses Precision Spray Control (PSC) to cycle the food-grade PulsaJet nozzle on and off very quickly to control flow rate without affecting spray performance. Flow rate adjustments are automatic and made when operating conditions, such as line speed, change. The compact AutoJet 1550+ Modular Spray System is mounted on a mobile cart for easy use on other conveyor lines.


Results:
The bakery has reduced its scrap rate by 40% since the installation of the AutoJet® 1550+ Modular Spray System. In addition, workers have been deployed to other tasks and flavoring waste has been eliminated. The bakery recouped the cost of the new system in just under 10 months.

For complete details of this case study, click here to see the PDF version.

A Closer Look at the System

PulsaJet Nozzles

Electrically-actuated nozzles deliver advanced spray performance.

AutoJet Spray Controller

Provides precise flow rate and spray timing, eliminating overspray and waste

Precision Spray Control (PSC)

PSC technology enables precise flow rate control without changing pressure.

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