In the food industry, the effectiveness of a surface treatment does not depend solely on the solution used; the method of application is also crucial to achieving a uniform, reproducible distribution that is tailored to the actual conditions of each facility and process.
This aspect is particularly important in ripening chambers, drying rooms, cold stores and fruit and vegetable distribution centres. Cheeses placed on shelves, sausages hanging on hooks, loaded trolleys or pallets stored at height all present a common challenge: ensuring that the exposed surfaces are cleaned evenly without increasing the amount of handling required.
The surface treatment of food by spraying It meets this need by generating a cloud of microdroplets that is dispersed in a controlled manner. In this way, it can facilitate efficient application over large areas and in rooms with a high load density.
Within our range of products for the food industry, DOMCA We approach misting treatments by combining application equipment such as SPRAY PRO with solutions developed for the food industry. The choice of product, concentration and application system must always be determined according to the foodstuff, the technological objective and the relevant conditions of use.
What is the surface treatment of food by spraying?
Surface treatment of food by atomisation is an application system that transforms a liquid solution meeting the appropriate specifications into an aerosol consisting of very fine particles. These microdroplets are dispersed throughout the space and can reach the exposed surfaces of the food.
The treatment may have various technical objectives:
- To promote preservation and stability during storage.
- To help control unwanted moulds and yeasts.
- To help extend the shelf life of food.
- To safeguard the visual quality and consistency of the product.
- To reduce variability between different applications or batches.
How does surface treatment by spraying work?
In cold microdiffusion systems such as SPRAY PRO, the solution is transformed into an aerosol of ultrafine particles, approximately 20 micrometres in size. Their small size helps the microdroplets to remain suspended and follow the air currents within the room where it is applied.
The spray can facilitate application between hanging parts, shelves, trolleys and pallets, which is particularly useful in facilities where manual application is difficult to standardise.
Homogeneity does not depend solely on particle size. Aerosol dynamics vary depending on the enclosure and require the parameters to be adapted to the actual conditions.
Factors affecting the effectiveness of nebulisation
Room volume and geometry
The volume, height and interior layout of the chamber influence the product’s dispersion time. An unobstructed chamber facilitates expansion; a low-ceilinged chamber, or one that is loaded or contains obstacles, may require adjustments to the timing or position of the application equipment.
Load arrangement and density
Trolleys, shelving, hangers and pallets disrupt air flow. With a high load, there may be areas with reduced exposure, so the treatment must be adapted to the usual layout of the product.
Compressed air pressure
Pressure affects the formation and stability of the aerosol. If pressure is limited, it may be necessary to adjust the timing, the location of the equipment or the volume applied.
Temperature, humidity, ventilation/air exchange
Temperature, humidity, ventilation and air exchange affect the behaviour and trajectory of microdroplets. These variables must be analysed in conjunction with one another.
Key benefits of atomisation in the food industry
Fogging is particularly useful when it is necessary to treat an entire room or a batch of product that has already been loaded. Its main advantages include:
- Widespread use of the treatment in facilities handling large volumes.
- Access to areas where direct application may be difficult.
- Less need to move or handle each item individually.
- The ability to set repeatable application times and conditions.
- Can be adapted to different room layouts, trolleys and shelving units.
- Cold application, without introducing heat into the process.
When does it make the most sense to use nebulisation?
Food misting offers greater value when the plant is processing large batches, or when the product is stored on several levels or in different rooms where direct access varies from one shift to the next. It may also be beneficial when seeking to reduce the variability associated with manual application and to establish a reproducible routine.
Before fogging, it is advisable to assess the actual distribution of the load, the availability of compressed air and the compatibility of the solution with the feed. This assessment makes it possible to determine whether the air-based method is the appropriate option or whether it should be combined with washing, immersion or another method of surface application.
Fogging, manual spraying or immersion: which method should you choose?
Fogging does not automatically replace other methods. The choice depends on the foodstuff, the facility, the volume and the purpose of the application.
| Appearance | Aerial spraying | Manual spraying or immersion/washing |
| Coverage | It facilitates a wide distribution across trolleys, shelving, hangers and products stored at height. | It depends to a greater extent on physical access to and the handling of the parts. |
| Consistency | It enables you to establish more consistent application times and routines. | This may vary depending on the operator, the distance, the pressure or the duration. |
| Manipulation | It reduces the need to handle or move the product individually. | It usually requires more direct intervention. |
| Recommended use | Crowded rooms, large volumes and complex layouts. | Localised operations or readily available products. |
Washing, immersion or direct spraying may be more suitable for certain processes. Atomisation is particularly effective when the aim is to cover large volumes, reduce handling and improve uniformity within the production area.
SPRAY PRO: cold micro-diffusion for food environments
SPRAY PRO is the equipment used by DOMCA for aerial micro-diffusion. Its portable design means it can be moved between different areas of the plant and adapted to suit various rooms.
It is powered by compressed air and does not require an electrical connection at the point of use. This makes it easy to use in wet rooms, drying rooms and other demanding environments.
Its key features include:
- Cold microdiffusion using ultrafine particles of approximately 20 micrometres.
- Three outlet nozzles designed for wide distribution.
- Adjustable height to suit the product layout.
- Portable design for moving around the plant.
- Operates via the installation’s compressed air line.
It is particularly useful in high-ceilinged rooms, crowded rooms or spaces where manual application can be time-consuming or difficult to replicate.
Common applications in the food industry
Cheese dairies and maturing rooms
In the maturing rooms, the cheeses are usually arranged on trolleys or on wooden or stainless-steel shelves at different heights. Fogging facilitates the treatment of exposed surfaces, such as the rind, and can help to reduce the proliferation of unwanted microorganisms, such as “Penicillium spp. or Aspergillus spp.”, among others (subject to verification of the conditions at each plant).
Drying rooms for sausages and cured meat products
In drying rooms, the high density of hanging produce makes it difficult to apply the solution evenly by hand. An overhead spray system can facilitate the distribution of the solution across the pieces and walkways, whilst also reducing the need for individual handling. This can help to prevent areas of microbiological shadow, promote the desired fungal growth and reduce the formation of dry crusts or unwanted moulds during curing.
Fruit and vegetable distribution centres and post-harvest facilities
In the case of fruit and vegetables, misting can be incorporated into preservation and shelf-life strategies within cold stores, warehouses or processing rooms, and can support preservation strategies against dehydration and deterioration caused by post-harvest fungi (such as“Botrytis cinerea or Monilinia spp.”.), depending on the solution applied (subject to validation of the conditions at each plant).
Ready-to-eat products
In the case of fresh cut fruit and vegetables, misting can act as a complementary tool within an overall preservation strategy, helping to maintain the turgidity and freshness of the plant tissue without saturating the raw produce with water.
Packaging rooms and cleanrooms
The solution must always be applied to the surface of the food. In cleanrooms, it can be incorporated into the environmental protocols for slicing or packaging rooms, either beforehand or as part of the process, in accordance with the treatment specifications, to help reduce the microbial load and enhance food safety.
How does DOMCA tailor its treatment to each plant?
Every installation is different and there is no single correct configuration. To design a tailored treatment plan, it is necessary to assess:
- The food to be processed.
- The technological objective of the application.
- The product to be applied.
- The volume, height and geometry of the room.
- The arrangement and density of the load.
- The available air pressure.
- Temperature, humidity and ventilation.
- The plant’s normal operations.
Using this information, the technical team can determine the concentration, timing and positioning of the equipment to facilitate the integration of fogging into quality, preservation and food safety procedures.
Frequently asked questions about food misting
In which types of premises is misting most useful?
In large-volume facilities or those with a high spatial density of product, such as vertical ripening chambers, meat drying rooms with multi-level hanging racks and compartmentalised storage facilities. This also applies where the cost of manual application and the risk of inconsistent treatment may be high.
Can you use a nebuliser when the room is full of people?
Yes, it is one of its main operational advantages. The overhead conveyor system can facilitate the handling of batches placed on trolleys, shelves, hangers or pallets, minimising the need for individual handling of the items.
« (Note: Fogging in rooms containing product must always be carried out in the absence of unprotected personnel or in accordance with the safety and ventilation times set out in the protocol). »
What factors influence the outcome?
The result depends on the equipment, the solution and the installation. Volume, pressure, temperature, humidity, ventilation and the layout of the product all influence the distribution. Therefore, each installation requires specific adjustment.
Does SPRAY PRO need to be plugged in?
No mains power supply is required at the point of use. The unit operates by being connected to the installation’s compressed air supply. This makes it easier to use in damp rooms, drying rooms and environments where it may be less practical to work with electrical equipment near the treatment area, thereby reducing the associated risks.
Does misting cause excess moisture to build up on the food?
Microdiffusion produces finer particles than conventional spraying. The result depends on the solution, the dosage, the duration, the load and the environment, so the parameters must be set correctly.
How is fogging incorporated into HACCP plans?
DOMCA assesses each case individually, taking into account the nature of the food, the volume and layout of the load in the chamber, the target microbiological parameters and the existing airflows. Based on this data, a bespoke protocol (fogging time, adjuvant concentration and equipment positioning) is defined for integration into the client’s HACCP plans.
A tailored, secure and reproducible application
In short, fogging adds value when it is tailored to the food product, the characteristics of the production area and the objective of the treatment. Correctly defining the solution, the equipment and the application parameters enables it to be integrated as a controlled, documented and repeatable stage within the production process.
At DOMCA, we assess each facility to facilitate the integration of the treatment process into the plant’s food safety and quality procedures. This approach is underpinned by our food safety management system, which is certified in accordance with FSSC 22000 V.6.
Would you like to know whether atomisation is suitable for your process?
Please contact the DOMCA technical team and we will examine the characteristics of its installation.
