Precision Potassium Sorbate Spraying with the F1850+ Controller
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PROBLEM
A leading cheddar cheese producer faced challenges with their existing potassium sorbate spraying process. The previous system relied on air atomizing hand guns, which created excessive misting during application, uneven coating of the cheese surfaces, but also resulted in unnecessary chemical loss and higher potassium sorbate consumption.
As a result, the customer was looking for a more controlled, efficient, and sustainable spraying solution that could improve coating quality while reducing waste and operating costs.
SOLUTION
By choosing Spraying Systems Co.®, our customer partnered with a trusted global expert with more than 85 years of experience in spray technology innovation.
To address their challenges, we implemented a hydraulic, food-contact-approved PulsaJet® spray system specifically designed for precise application.
The installation configuration consists of an AutoJet® F1850+ spray controller providing Pulse-Width Modulation (PWM) paired with 6 hydraulic PulsaJet® spray guns. Three guns positioned for the top surface and three positioned for the bottom surface.
By switching from air atomizing technology to hydraulic spraying combined with PWM control, the system enabled accurate regulation of spray timing, flow rate and duty cycles. This ensured that potassium sorbate was applied exactly where needed, in the right amount, without producing mist or overspray.
RESULTS
The new potassium sorbate spraying system delivered immediate and measurable improvements in both product quality and operational efficiency. Key results included:
- A homogeneous and uniform coating across all cheese surfaces.
- Complete elimination of misting tanks to hydraulic spray technology.
- Reduced potassium sorbate consumption through precise PWM control.
- Improved process efficiency and more consistent product quality.
With an investment of €18.000, the cheddar cheese producer successfully optimized its preservative application process, reduced waste, and strengthened quality control demonstrating how precision spray technology helps food manufacturers make every drop count.
A CLOSER LOOK AT THE SYSTEM
The AutoJet® F1850+ controller provides full independent control of your paired nozzles. The spray system can be used as an autonomous spray system or can be integrated into any existing process control system and is completely food-safety compliant.
Our air atomizing PulsaJet® spray nozzles deliver the release agent with accuracy and precision.
Precision Spray Control (PSC) involves turning nozzles on and off very quickly to control flow rate. This cycling is so fast that the flow often appears to be constant. With traditional nozzles, flow rate adjustments require a change in liquid pressure, which also changes the nozzle's spray angle, coverage and drop size. With PSC, pressure remains constant enabling flow rate changes without changes in spray performance. PSC requires the use of electrically-actuated spray nozzles and an AutoJet® spray controller.
Your process could be next! Reach out to see what precision spraying can do for you.