autojet® antimicrobial spray systems - Spraying Systems Co.
autojet® antimicrobial spray systems - Spraying Systems Co.
autojet® antimicrobial spray systems - Spraying Systems Co.
You also want an ePaper? Increase the reach of your titles
YUMPU automatically turns print PDFs into web optimized ePapers that Google loves.
AUTOJET ® ANTIMICROBIAL<br />
SPRAY SYSTEMS<br />
PRECISE APPLICATION OF<br />
ANTIMICROBIALS HELPS ENSURE<br />
MEAT AND POULTRY SAFETY<br />
Experts in Spray Technology
ENSURE FOOD SAFETY,<br />
INCREASE PRODUCTIVITY<br />
AND REDUCE CHEMICAL USE<br />
SYSTEM OVERVIEW:<br />
Meat and poultry processors all have a common goal —<br />
to ensure the highest level of food safety possible while<br />
minimizing production costs. AutoJet ® Antimicrobial Spray<br />
<strong>Systems</strong> help processors achieve these goals by eliminating<br />
slower, more expensive post-pasteurization techniques.<br />
AutoJet Antimicrobial Spray <strong>Systems</strong> apply a predetermined<br />
volume of <strong>antimicrobial</strong> agent onto each product or into<br />
each package. An AutoJet <strong>spray</strong> controller monitors liquid<br />
pressure and flow from PulsaJet ® automatic <strong>spray</strong> nozzles<br />
to ensure the proper volume of <strong>antimicrobial</strong> is delivered to<br />
each product.<br />
Used successfully with several commercially-available<br />
topical <strong>antimicrobial</strong>s, the efficacy of this technology has<br />
been established by the USDA/ARS.<br />
The <strong>systems</strong> have a proven track record of effectively<br />
controlling pathogens including E. coli, Salmonella and<br />
Listeria monocytogenes while reducing operating costs<br />
for processors. Using this technology, some customers<br />
have eliminated the need for lactates, diacetates and other<br />
internal <strong>antimicrobial</strong>s entirely.<br />
AutoJet Antimicrobial Spray <strong>Systems</strong> can be incorporated<br />
into existing HACCP plans. An optional auto-refill/ratio panel<br />
is available to continuously monitor the fluid level in the<br />
pressure tank and trigger a refill cycle when necessary. The<br />
auto-refill/ratio panel also dilutes concentrated <strong>antimicrobial</strong><br />
to the proper ratio for application.<br />
2 <strong>spray</strong>.com | 1.800.95.SPRAY | Intl. Tel: 1.630.665.5000
BENEFITS:<br />
• Closed-loop control ensures precise application of <strong>antimicrobial</strong><br />
for consistent performance and minimal waste<br />
• Different shot sizes and timing intervals can be<br />
pre-programmed for automatic batch changes<br />
• Pressure tank is easy to assemble/disassemble and clean<br />
• Easy integration in existing product lines<br />
• Unattended operation – alarms notify workers if intervention<br />
is required<br />
• Optional auto-refill/ratio panel triggers tank refill and<br />
maintains proper <strong>antimicrobial</strong> concentration<br />
SYSTEM MODULES:<br />
Application requirements determine the actual<br />
configuration of an AutoJet ® Antimicrobial Spray System.<br />
Key components include PulsaJet ® electric <strong>spray</strong> nozzles<br />
with FDA-compliant finishes, an Allen-Bradley PLC and a<br />
pressure pot.<br />
IDEAL FOR:<br />
• Bagged whole muscle products<br />
• Hot dogs, links and formed products<br />
• Fresh meats – subprimals and trim<br />
• Packaged poultry products<br />
• Sliced meat and poultry products<br />
<strong>spray</strong>.com | 1.800.95.SPRAY | Intl. Tel: 1.630.665.5000<br />
3
Trigger sensor<br />
PulsaJet ® nozzle<br />
Antimicrobial<br />
PulsaJet nozzles<br />
Thru-beam<br />
photo-eye<br />
PulsaJet nozzles<br />
BAGGED WHOLE MUSCLE<br />
PRODUCTS AND HOT DOGS<br />
FRESH MEATS<br />
Antimicrobials are <strong>spray</strong>ed into the vacuum packages<br />
before sealing. Vacuum-sealing of the packages<br />
distributes the <strong>antimicrobial</strong> evenly around the product.<br />
The efficacy of this SLIC ® (Sprayed Lethality in <strong>Co</strong>ntainer)<br />
process has been established by the USDA/ARS.<br />
<strong>Co</strong>nveyorized meat and poultry products are <strong>spray</strong>ed<br />
with multiple PulsaJet nozzles within an enclosed<br />
<strong>spray</strong> station, typically located before injectors/<br />
tenderizers or immediately prior to packaging.<br />
4 <strong>spray</strong>.com | 1.800.95.SPRAY | Intl. Tel: 1.630.665.5000
PulsaJet nozzles<br />
Antimicrobial<br />
TUMBLERS, MIXERS AND<br />
BLENDERS<br />
SLICED PRODUCTS<br />
Meat trim pieces inside tumblers, mixers and blenders<br />
are <strong>spray</strong>ed with multiple PulsaJet ® nozzles to ensure<br />
even coating of all pieces before the grinding process.<br />
Tests have shown consistent coverage throughout<br />
ground meat packages using the AutoJet ® Antimicrobial<br />
Spray System.<br />
Integrated into the most advanced slicing <strong>systems</strong> on<br />
the market and synchronized with blade movement, high<br />
speed PulsaJet automatic <strong>spray</strong> nozzles apply precise<br />
<strong>antimicrobial</strong> doses to each sliced product prior to<br />
packaging. Additional <strong>antimicrobial</strong>s are added to each<br />
package to cover all surfaces of the stack.<br />
<strong>spray</strong>.com | 1.800.95.SPRAY | Intl. Tel: 1.630.665.5000<br />
5
RESULTS EXPERIENCED BY<br />
PROCESSORS<br />
OLD WORLD PROVISIONS: ANNUAL SAVINGS OF $300,000<br />
Old World Provisions, a meat processor specializing in whole<br />
muscle products and roll stock products, decided to use the<br />
AutoJet ® Antimicrobial Spray System to reduce the expense<br />
of the functional ingredients used as <strong>antimicrobial</strong> agents. A<br />
single system is being used on a roll stock line and a bagger<br />
operating at six packages per minute.<br />
The outcome has exceeded expectations.<br />
• The use of an <strong>antimicrobial</strong> agent that cost $0.025 to $0.030<br />
per pound was eliminated. Lauric arginate diluted in a clarified<br />
liquid smoke is now used at an application cost of just<br />
$0.015 per pound<br />
• Typical log reductions ranging from 1.8 to 2.8 for roll stock<br />
and whole muscle products<br />
• Product quality and shelf life have remained stable<br />
• Product labels are clean<br />
• The use of lower cost <strong>antimicrobial</strong>s saves the company<br />
$300,000 each year<br />
6 <strong>spray</strong>.com | 1.800.95.SPRAY | Intl. Tel: 1.630.665.5000
JOHN MORRELL & CO.: ELIMINATED USE OF<br />
LACTATES/DIACETATES<br />
John Morrell & <strong>Co</strong>., a subsidiary of Smithfield Foods, Inc., is<br />
the largest vertically integrated producer of processed meat<br />
and fresh pork in the United States. <strong>Co</strong>ncerned about the flavor<br />
of certain hams containing lactates/diacetates, the company<br />
opted to treat them externally with lauric arginate using<br />
an AutoJet ® Antimicrobial Spray System.<br />
The results are impressive.<br />
• Improved product flavor<br />
• 1 to 2 log kill against Listeria monocytogenes<br />
• The process is even more efficacious on products that<br />
include other <strong>antimicrobial</strong>s, such as a cured product containing<br />
nitrite<br />
• Product labels are clean<br />
NORTH COUNTRY SMOKEHOUSE:<br />
40% INCREASE IN SHELF LIFE, ALT-2 STATUS<br />
ACHIEVED<br />
North <strong>Co</strong>untry Smokehouse, a family-run smokehouse, has<br />
been using the system on a wide variety of meat products.<br />
The results include:<br />
• An increase in product shelf life to 70 days from 45 to 50 – a<br />
40% increase<br />
• Achievement of ALT-2 status at a cost of $0.015 per pound<br />
on products using a lauric arginate and liquid smoke flavor<br />
<strong>antimicrobial</strong><br />
• Typical log reductions range from 2.3 for hams to 4.0 for<br />
kielbasa<br />
• Clean label on products maintained – lauric arginate is a<br />
bacteriocide that is also considered a processing aid and<br />
does not need to be labeled at the levels being used<br />
NORTH COUNTRY<br />
SMOKEHOUSE<br />
<strong>spray</strong>.com | 1.800.95.SPRAY | Intl. Tel: 1.630.665.5000<br />
7
AUTOJET ® ANTIMICROBIAL SPRAY<br />
SYSTEM DETAILS<br />
SPECIFICATIONS:<br />
<strong>Co</strong>ntrol Module<br />
• 6 in. (15.24 cm) touch screen provides easy user interface to Allen-Bradley PLC<br />
• Adjustable <strong>spray</strong> timing for volumes ranging from 0.25 cc/shot to 45 cc/shot<br />
• Wall-mount, NEMA 4X rated panel<br />
• Optional 2- and 4-channel capability provides independent control for multiple <strong>spray</strong> stations<br />
• NEMA 4X sensors for product detection and for triggering <strong>spray</strong><br />
Supply Modules<br />
• Polished stainless steel 25-gallon (95-liter) pressure pot with tri-clover sanitary fittings. Also available with stainless steel<br />
washdown rated pumps<br />
• Liquid level sensor notifies operator when refill needed<br />
• Optional automatic refill panel triggers pressure tank refill when sensor falls below threshold without disturbing pressure<br />
level<br />
• Pressure relief valve provides safety release<br />
• Pressure transmitter allows operator to view the operating pressure<br />
Delivery Module<br />
• PulsaJet ® high-speed automatic electric <strong>spray</strong> nozzle provides accurate, rapid, repeatable dose sizes<br />
• Multiple mounting options are available for roll stock and bagging machines from Cryovac ® , Multivac ® , RapidPak ® , VC999 ®<br />
and others<br />
• Fully adjustable armature allows precise vertical and horizontal positioning<br />
Alarm<br />
• Stack light on top of control panel provides multi-colored lights for general alarms and tank low level<br />
Experts in Spray Technology<br />
North Avenue and Schmale Road, P.O. Box 7900, Wheaton, IL 60187-7901 USA<br />
Tel: 1.800.95.SPRAY Intl. Tel: 1.630.665.5000<br />
Fax: 1.888.95.SPRAY Intl. Fax: 1.630.260.0842<br />
www.<strong>spray</strong>.com<br />
<strong>Spraying</strong> <strong>Systems</strong> <strong>Co</strong>., AutoJet and PulsaJet are registered<br />
trademarks of <strong>Spraying</strong> <strong>Systems</strong> <strong>Co</strong>. All other logos and<br />
trademarks are the property of the respective trademark<br />
owners. ® and denote registered trademarks in the<br />
United States and other countries.<br />
Bulletin No. 647C ©<strong>Spraying</strong> <strong>Systems</strong> <strong>Co</strong>. 2013