Smarter liquid application in bakeries

In modern bakery and snack production, the smallest process variables often have the biggest impact on quality, yield and compliance. Whether it’s oiling baking trays, applying release agents, lightly coating surfaces, or applying preservatives before packaging, liquid application is a deceptively critical step.

Traditional spray systems can struggle with consistency, especially when line speeds fluctuate or when extremely low, precise flow rates are required. This is where electrically controlled, liquid-only atomising nozzles are gaining attention as an alternative to conventional pneumatic-controlled spray systems.

Bakeries operate under constant pressure to improve efficiency while meeting strict food safety and hygiene standards. However, many liquid application systems face common challenges:

• Over-application of oils and coatings, leading to unnecessary product waste
• Inconsistent coverage when conveyor speeds change
• Poor control at low flow rates, especially when fine, repeatable dosing is required
• Cleaning and hygiene challenges in food-contact environments

In applications such as oiling baking trays, applying light surface coatings to dough, or applying preservatives to pizzas or snacks before packaging, even minor inconsistencies can affect product quality, shelf life and operating costs.

Precision control with electrically operated liquid atomisation

Electrically controlled hydraulic atomising nozzles are designed to deliver highly repeatable, finely controlled liquid application without the use of compressed air. The technology converts incoming liquid into fine droplets and allows flow rates to be electronically controlled through pulse width modulation (PWM) or ON/OFF pulsing modes.

This means production teams can vary the volume of liquid applied without changing nozzle pressure or hardware, enabling consistent coating even when belt speeds change, ultra-low flow rates for light applications, and repeatable dosing across batches — all of which reduce product and oil waste.

In bakery environments, this is particularly valuable for applications such as oiling baking trays, light surface oiling of dough, application of preservatives prior to packaging, and controlled liquid application for decorative or functional finishes.

Reducing waste and improving process efficiency

Food and beverage environments place strict demands on equipment design. Electrically controlled atomising nozzles designed for food processing are typically manufactured using food-compatible materials such as stainless steel and are suitable for use with common bakery fluids including water, oils, sugar solutions, milk and disinfectants.

The ability to control spray timing and volume precisely also helps reduce overspray and misting, improving hygiene outcomes and reducing residue build-up on surrounding equipment.

One of the biggest advantages of precision liquid application is material efficiency. By applying only the volume required — and only when required — bakeries can significantly reduce oil and release agent consumption. Over time, this can translate into meaningful cost savings, especially in high-volume production environments.

From a sustainability perspective, reducing excess liquid application also means:

• Less product waste
• Reduced cleaning chemical usage
• Lower water consumption during washdown
• Improved housekeeping around production lines
• An alternative to traditional pneumatic spray systems

Electrically controlled liquid atomisers are increasingly being considered as an alternative to conventional pneumatic-based spray systems where fine control and low flow rates are critical. Unlike traditional systems that may struggle to maintain spray quality at very low outputs, electronically controlled nozzles maintain spray consistency while varying flow digitally.

This makes them well suited to modern bakeries and snack manufacturers looking to improve consistency, reduce waste and future-proof their processing lines as automation and digital control become more prevalent.

Advanced spray technologies developed for European food manufacturing environments are now becoming more accessible in Australia. Local suppliers are increasingly partnering with global manufacturers to bring liquid application solutions into Australian food production facilities, supporting upgrades in efficiency, hygiene and process control without requiring full line replacements.

As bakeries continue to modernise, precision spray technologies are becoming a quiet but powerful contributor to improved product quality, reduced waste and smarter manufacturing practices.

Image credit: iStock.com/zorazhuang