Inject less, retain more quality

You describe GEA OptiFlex needles as a “major step forward in injection quality.” How are OptiFlex needles different?

Bo Wandkær Jensen: GEA OptiFlex needles offer a major advancement in injection technology. Their patented design provides enhanced precision and control, ensuring optimal brine distribution into products. Thanks to their flexible construction, they adapt to different product sizes and types - including bone-in products - making them highly versatile. Made from a patented metal alloy, OptiFlex needles have ‘shape memory’, meaning they return to their original form after bending. In contrast, traditional stainless-steel needles can bend or deflect when hitting bone, compromising injection quality. OptiFlex needles eliminate this issue, delivering higher-quality results and optimal brine distribution.

Since OptiFlex needles are more resistant to damage from bending, does this mean a longer operational life?

Yes, OptiFlex needles last 40–60% longer, reducing maintenance costs while significantly enhancing quality and food safety.

In brining processes, how can using OptiFlex needles promote product quality and safety?

Bo Wandkær Jensen: There are three things to consider. First: the product that is being injected, second, the machine, and third, the operator. When we look at the product, because the needle returns to its shape, it will always inject in the same position. If the needle is bent, when it goes down it will not inject in the same place that it should. So, that’s a major benefit for the product. This is especially important for brine dispersion. If you inject with a bent needle, that needle might penetrate the same place [as another needle] so you are injecting double, which would mean your brine dispersion is not optimum. Causing potential differences in product flavor, coloring, and microbiological product safety, affecting shelf life.

Secondly, from a machine perspective, if you have bent needles, you start damaging your machine, such as the needle guide plates (stripper plate). Thirdly, there is operator safety. If you have bent needles they could start breaking. As OptiFlex needles bend, and return to their original shape, that is very unlikely to happen. 

OptiFlex needles are available in 2, 3, and 4mm diameter, and work in a close pattern. Why is this beneficial?

2mm needles are ideal for tender meats such as poultry, tender beef, pork, and fish. For denser meats, a stronger, more durable 4mm needle is recommended. The 2mm needles follow an overlapping pattern with a needle-to-needle distance of about 7mm, allowing for low-pressure injection. Lower pressure ensures better brine distribution, precise injection levels, and improved product quality. In contrast, high-pressure injection can disrupt meat fibers, potentially causing damage and making the process harder to control.

How does this affect salt distribution? 

Bo Wandkær Jensen: The brine distribution is optimized, in comparison to conventional methods, because of the short distance you need to cover between the two needles. Again, the less pressure you need to use, the easier it will equalize within the product. You get better dispersion of the nitrate salts, and better, faster coloring, as well. This is also important in terms of shelf life. For bacon, it’s important that brine is both evenly injected and distributed, or you might have a problem when slicing later in the process.

With machines such as the GEA MultiJector, how does the filter technology work with the needles to reduce downtime for cleaning?

Our filter technology prevents particles from passing through the needle. We use a specialized, gravity-assisted system called ScreenFilter, which removes proteins when brine is recycled from the injector. This keeps the brine cleaner for longer, reducing both filter and needle blockages. Our newly released Modular Injector Filter offers customizable filtration options, ensuring each customer gets the perfect solution for their application- nothing more, nothing less.

How do MultiShakers, which provide transport, product spreading, brine settling and removal of excess brine in injection lines, work to activate ingredients and reduce yield loss?

In an injection line, the GEA MultiShaker can be placed before the injection process to ensure products are evenly spread in a single layer- without human intervention. A uniform layer is important for maintaining full control over the injection level, brine distribution, and overall product quality. After injection, the GEA MultiShaker helps close needle holes, keeping the brine inside the product. It also removes excess brine and recycles it through a filter tank, reducing brine costs by preventing spillage. This not only minimizes contamination risks but also cuts down on cleaning time and labor.