GEA Direct Sprayer DS 25: Efficient cleaning for tanks with agitators

With the GEA Direct Sprayer DS 25, GEA introduces a pioneering solution for industrial tank cleaning in the food and beverage industry, specifically designed for tanks with rotating installations. The patented spray technology effectively removes residues from the undersides of agitators, pipes, and flow breakers. A case study from yogurt production shows that this method cuts water use by 84.5% and shortens cleaning time by 87.5% compared to traditional tank flooding.

Targeted cleaning instead of inefficient flooding

Strict hygiene standards, contamination prevention, and resource efficiency are key challenges in food and beverage production. However, cleaning tanks with internal installations poses a particular challenge: the undersides of agitator blades often remain in the spray shadow and are not adequately cleaned by conventional methods. The most common solution has been to completely flood the tank with cleaning liquid – a resource-intensive and time-consuming process.

The Direct Sprayer DS 25 sprays directly onto the undersides of the agitator blades while ensuring that the agitator mechanics remain unaffected. The cleaner is flush-mounted into the tank wall and can be positioned flexibly, ensuring full coverage inside the tank. The patented valve disc only opens when activated, ensuring an even distribution of the cleaning fluid. Since the valve plate opens inward, it does not interfere with the agitator.

Maximum spray power and reach

The mechanically powerful full-cone spray targets the undersides of the agitators and efficiently removes residues. “Unlike alternative retractable cleaners, which often have a hollow cone or operate with a fan spray, our spray pattern is a true full cone,” explains Jana Zimpel, Product Sales Manager for Cleaning Technology at GEA.

With a spray force of up to five kilograms, the GEA Direct Sprayer DS 25 effectively removes even tough residues. Conventional cleaning systems often operate at lower forces, requiring longer exposure times or additional chemicals. The full-cone spray of the DS 25 cleans more efficiently while reducing resource consumption. With a cleaning range of up to five meters, the full-cone spray is also suitable for large tanks and reaches areas that previous solutions often left uncleaned.

Case study: Yogurt production – 84.5% less water consumption

A real-world example from yogurt production highlights the potential of the GEA Direct Sprayer DS 25. A typical tank in this industry is six meters high with a diameter of three meters and contains agitator blades arranged on three levels up to four meters above the tank floor. The conventional cleaning method involves flooding the tank with caustic solution and using rotation to clean the surfaces. This process, including flooding, circulation, and draining, takes two hours and consumes 29 cubic meters of cleaning liquid.

With the new Direct Sprayer DS 25, one cleaner per agitator blade level is integrated into the tank wall. This targeted cleaning approach drastically reduces fluid consumption to just 4.5 cubic meters, while the cleaning time shrinks to 15 minutes – an 84.5% reduction in water use and an 87.5% decrease in cleaning time.

“This time saving can be directly used for additional production capacity,” explains Jana Zimpel. “In yogurt production, for example, this means more batches per day or faster recipe changes without compromising efficiency.” The savings in water and chemicals make the Direct Sprayer DS 25 one of the most efficient cleaning methods for tanks with agitators.

Versatile applications for maximum efficiency

The GEA Direct Sprayer DS 25 has been developed for use in the beverage, food, dairy, pharmaceutical, and home and personal care industries. It is particularly advantageous in production environments with frequent recipe changes, strict hygiene standards, and demanding cleaning requirements. The system delivers fast, efficient cleaning while minimizing water use and keeping production running smoothly. It can also be easily integrated into existing systems.