Cover StoryPrecision
Cover StoryPrecision Cleaning instead of Flooding:Efficient Tank Cleaning with MinimalWater WasteFrom softdrinks to toothpaste: Cleaning tanks with agitators presents a major challenge forplant operators. The undersides of agitator blades are often difficult to reach and remain in thespray shadow, making full cleaning difficult. This results in inefficient processes, high waterconsumption, and excessive use of chemicals. The new GEA Direct Sprayer DS 25 provides apatented solution that delivers targeted cleaning while conserving valuable resources.The challenge: Cleaning tankswith agitatorsThe cleaning requirements in the foodand beverage industry are constantlyincreasing. High hygiene standards,prevention of product contamination,and efficient resource management arecritical for plant operators. Tanks withrotating agitators, baffels and pipes posea particular challenge: the undersidesof the agitator blades often remain inthe spray shadow, making them hardto clean with conventional cleaners.As a result, operators face inefficientcleaning cycles, increased water consumption,and a higher demand forcleaning chemicals.A patented solution: The GEADirect Sprayer DS 25GEA has developed the Direct SprayerDS 25 to specifically target the undersidesof agitator blades, eliminating sprayshadow without interfering with agitatorThe GEA Direct Sprayer DS 25 is installed flush with the tank wall and opens into the cleaner body.This prevents any parts of the cleaner from protruding into the vessel and interfering with themoving agitators.movement. “Previously, operators oftenflooded these tanks up to the height ofthe agitators to ensure complete cleaning– a costly and unsustainable approach,”explains Jana Zimpel, Product SalesManager for Cleaning Technology atGEA’s Separation and Flow Technologiesdivision. “With our new technology, weclean precisely where needed, savinglarge amounts of water and chemicals.”Innovative technology formaximum efficiencyThe GEA Direct Sprayer DS 25 isintegrated directly into the tank wall.Its patented design allows for a flushmountedinstallation that does notrestrict agitator movement. The keyinnovation is the movable valve plate,which opens right into the cleaner whenactivated to produce a precise spraypattern.Agitator blades are difficult to clean, even for a high-performance main cleaning system in processor storage tanks. The GEA Direct Sprayer DS 25 completes the cleaning solution by producing apowerful full-cone jet to clean the bottom sides.Through a gap, the cleaning liquidis released as a full-cone spray – an6
Cover Storyimportant advantage over conventionalspray cones, which often leave a hollowspace in the center. This innovationensures uniform coverage and efficientresidue removal.Maximum spray force and reachOne of the standout features of the GEADirect Sprayer DS 25 is its powerfulmechanical cleaning action. With a sprayforce of up to five kilograms, the full-conespray effectively removes even stubbornresidues. Its cleaning reach of up to fivemeters makes it ideal for large tanks,ensuring that all critical areas receivethorough cleaning.“A major advantage over traditionalretractors, which often have a hollowcone in the middle or operate with a fanspray, is the flexible positioning,” explainsJana Zimpel. “Our sprayer opens inwardthe cleaner and produces a precisefull-cone spray, whereas conventionalsystems often provide only a limited fanspray. This allows us to clean every areain the tank efficiently and sustainably.”The inward-opening valve plate ensuresthat the agitator mechanism remainsunaffected.Yogurt production: 84.5% lesswater consumptionA practical example demonstrates thepotential of this new technology. Atypical yogurt production tank is sixmeters tall and three meters in diameter,with multiple agitator blade levels. In thisexample, there are three levels up to fourmeters in height. Previously, such tankshad to be flooded with up to 29 cubicmeters of cleaning liquid – a process thattook two hours.“With the new GEA system, we wouldintegrate three Direct Sprayer DS 25 unitsinto the tank wall, precisely cleaning theundersides of the agitator blades,”says Zimpel.“This saves 84.5% water and reducescleaning time by 87.5% – from two hoursdown to just 15 minutes.”Versatile applications: Fromyogurt to toothpasteThe GEA Direct Sprayer DS is designedfor use in the food, beverage, dairy,and pharmaceutical industries. It isparticularly effective in demandingapplications, including:• Yogurt production: Tanks with multipleagitator blade levels require precisecleaning at different heights. TheDirect Sprayer DS 25 significantlyreduces cleaning effort.• Toothpaste manufacturing: In thehome and personal care (HPC)industry, tanks with multiple agitatorsare common. In toothpaste production,where thick pastes are processed,effective cleaning is crucial.Sustainability and resourceconservation“The advantages of our new technologyextend beyond cleaning efficiency,” emphasizesJana Zimpel. “We drasticallyreduce water consumption, which translatesinto lower costs for our customersand a reduced environmental impact.”Beyond water savings, the targeted useof cleaning agents reduces chemicalwaste and improves the overall CO 2footprint of plant operations.The GEA Direct Sprayer DS 25 can beeasily integrated into existing tanksystems. Variants designed to meet3-A sanitary standards are alreadyin development to enhance globalapplicability.Conclusion: Precise cleaningsaves resourcesWith the GEA Direct Sprayer DS 25, GEAintroduces a groundbreaking solutionfor industrial cleaning. The patentedfluid dynamics ensure targeted spraycoverage, minimize water and chemicalconsumption, and enable more efficienttank cleaning.“Our goal is to provide plant operatorswith the best possible technology tomeet the highest hygiene standardswhile protecting the environment,” concludesJana Zimpel. “With the DirectSprayer DS 25, we’ve taken a major stepin that direction.”GEA has developed the Direct Sprayer DS25 to specifically target the undersides ofagitator blades, eliminating spray shadow withoutinterfering with agitator movement. Source: GEAJana Zimpel, Product Sales Manager CleaningTechnology at GEA Division Separation andFlow Technologies. Source: GEAdrinkworld Technology + Marketing · March 20257
