Solving Challenges in SNCR | Clog-Resistant Spray Nozzles for Efficient NOx Reduction
Technical Library
- HOME
- Technical Library
- Achieving Uniform Chocolate Coating with an External-Mixing Pneumatic Spray Nozzle
Achieving Uniform Chocolate Coating with an External-Mixing Pneumatic Spray Nozzle
Solutions or Products Featured
in This Case Study
Key Reasons for Implementation
Selecting a pneumatic spray nozzle capable of atomizing matcha (green tea) chocolate into a uniform spray while mitigating two clogging risks: high viscosity and foreign particles.
- Not sure which product is right for you?
- Curious about the total cost?
- Wondering where to start?
- We’re here to help – reach out with any questions.
Challenges Faced by the Customer
At a confectionery plant, the customer faced a challenge in the chocolate coating process.
When they coated freeze-dried strawberries in a drum coater by pouring melted matcha chocolate over them, lumps formed easily, leaving many coated pieces with an uneven, unattractive finish.
To improve the finish, the customer explored whether atomizing the melted matcha chocolate and applying it as a fine spray could achieve a more uniform coating. They contacted IKEUCHI to discuss suitable spray nozzles for the process.
Solutions Proposed by IKEUCHI
Internal-mixing pneumatic spray nozzles, which mix compressed air and liquid inside the nozzle to atomize the liquid, are commonly used to achieve fine sprays. However, with viscous melted chocolate, clogging inside the nozzle was a concern.
IKEUCHI therefore selected the clog-resistant SETOJet Series—an external-mixing pneumatic spray nozzle that mixes air and liquid outside the nozzle to reduce clogging.
Clog-resistant SETOJet Series nozzle
In addition, the chocolate was recirculated, so seeds from the freeze-dried strawberries could enter the line and further increase the clogging risk. To address this, IKEUCHI specified a model with a larger free passage diameter* (2.0 mm), allowing particles to pass through more easily.
*The free passage diameter refers to the narrowest part of the liquid flow path inside the nozzle, indicating the maximum particle size that can pass through without clogging. A larger value means particles are less likely to get trapped inside the nozzle, reducing the risk of clogging.
Benefits Achieved
By spraying atomized matcha chocolate using the SETOJet, the customer achieved a uniform coating on the dried strawberries. Variations in the finish were minimized, the intended appearance was consistently attained, and overall yield improved.
They also realized measurable cost savings by reducing product waste, rework, and the labor required to dispose of rejects and remake products.
No nozzle clogging has occurred.
Today, IKEUCHI’s spray nozzles continue to support the stable production of matcha chocolate–coated strawberries.
Note: For food-processing applications, ensure that parts used for our products comply with applicable food safety regulations and standards.
