Pet food processors apply a wide range of palatants, antioxidants, and other additives at different stages of production to enhance product quality and extend shelf life. Manual application is prone to errors and inconsistencies. Often, those errors are only identified in the final product, generating high volumes of scrap.

As a result, processors struggle with:

• Over-application, which is wasteful and costly

• Inconsistent application, which results in product quality issues, elevated scrap, and production slowdowns

• Misting, which increases downtime and causes worker safety issues

Trends in pet humanization are also driving pet food processing requirements to meet standards similar to that of human food production. And when it comes to food safety, there is no room for risk-taking. The Food & Drug Administration (FDA) is also establishing guidelines for pet food manufacturers to meet ingredient and labeling standards, similar to those enforced with human food regulatory requirements.

Improve consistency and safety, increase throughput, decrease scrap, and protect your reputation.
There is a more efficient and cost-effective way to apply coatings, additives, mold inhibitors, and release agents while boosting production. Automated spray systems are revolutionizing pet food processing by ensuring the proper volume of additive is applied uniformly and directly. The result is better quality products, minimal waste, lower operating costs, and increased production.

PRECISION SPRAY CONTROL – DRAMATICALLY REDUCE THE USE OF ADDITIVES & INCREASE EFFICIENCIES WITHOUT COMPROMISING QUALITY
Precision Spray Control (PSC) systems provide exceptional accuracy and consistency with minimal waste by ensuring the proper amount of coating is uniformly applied. PSC systems automate flow rates by turning electrically actuated spray nozzles on and off to match pet food production speed variations in real time. This cycling is so fast that the flow often appears to be constant.

In the past, flow rate was typically controlled by manually adjusting spray pressure. However, adjusting pressure can dramatically change the spray angle and drop size. With PSC systems, the flow rate from a single nozzle can be varied without changing pressure. Flow rate changes are based on operating conditions, such as line speed and product weight in the tumbler/coater. The flow rate changes almost instantaneously to ensure the proper application rate. Changing the flow rate without changing the angle and drop size results in uniform application.

PSC SYSTEMS ARE AN IDEAL SOLUTION WHEN YOUR OPERATION REQUIRES:

• Using costly coatings or chemicals

• Consistent, precise, and uniform coverage

• Intermittent and variable spraying

• Flexibility – ability to adjust spray performance based on line speed, temperature, humidity, or product changes

• Manual monitoring and supervision during production

• Frequent maintenance

PRECISION SPRAY CONTROL SYSTEM COMPONENTS

IMPROVE PRODUCT QUALITY & CONSISTENCY – REGARDLESS OF BATCH, SHIFT, EMPLOYEE OR VARIATIONS IN RECIPES OR FORMULAS
You can improve product quality and minimize costs, while uniformly applying flavorings, oils, palatants, vitamins, and other supplements. Processors are often shocked to discover how much coating material they waste within their operations.

OVER-APPLICATION & MISTING ARE THE PRIMARY CAUSES OF WASTED COATINGS & OCCUR WHEN:

• More coating is applied than necessary

• Coating is poorly applied and sprays on areas surrounding the target

• Coating is dispensed continuously instead of intermittently when needed

• Misting, which increases downtime, waste, and creates worker safety issues

Precision spray control processes eliminate coating waste through the automatic adjustment of the application rate. PSC systems cycle on/off to maintain a consistent flow rate ensuring the exact amount of coating is applied and not a drop more.

There is no need to spray continuously, even if the product is in close proximity. By applying the coating directly on the target, PSC systems deliver accurate, consistent spray coverage, applying the coating only when and where it is needed.

ADDITIONAL BENEFITS OF PRECISION SPRAY CONTROL SYSTEMS:

• Eliminate manual application or adjustment of flow rate
• Eliminate the need for compressed air, reducing energy costs
• Efficiencies in applications result in wastewater savings

A PEDIGREE IN AUTOMATED & PRECISION SPRAY CONTROL
Food processing plants around the world depend on our spray technologies for applications ranging from coating and cleaning to tank washing and lubrication. Our experts help customers optimize performance while maximizing food safety.

Spraying Systems Co. has been the world’s leading manufacturer of spray nozzles for more than 85 years. With tens of thousands of standard products, we have the right nozzle for your application.

Our engineering and manufacturing resources can help solve your toughest spray technology challenges. Local spray technology experts provide fast, hands-on service and we offer quick delivery from strategically located manufacturing facilities on six continents. Backed by our factory Technical Services staff, they are your first resource for all spray technology questions.

IS PRECISION SPRAY CONTROL RIGHT FOR YOUR OPERATION?
If your operations involve spraying coatings, flavorings, and additives, or applying mold inhibitors and release agents, the answer is ‘yes.’ For many pet food manufacturers, uniform coating alone can be a gateway to reduced scrap, improved worker safety, lower operating costs, and increased production.