GEA Fresh Enhanced Line


Injected and marinated fresh poultry products are gaining market share quickly. It is providing a “win-win-win” situation for producers, resellers and end consumers alike. If you do it right. GEA's solutions for fresh injecting in combination with marinating as an optional second step enables impressive long term brine retention, guarantees the smallest possible variances and reduces brine and marinade losses. All while improving product appearance and juiciness.

GEA Fresh Enhanced Line

Working principle
The GEA Fresh Enhanced Line Solution not only includes equipment, it also draws on stateof-the-art knowledge about running and
controlling fresh application processes and measuring yield.

• Configured from a range of machines
• From brine mixing up to including freezing and packaging 

Injecting too much is not permitted and should be avoided at all time, whereas too little is the same as meat give-away. Injection levels must remain with the smallest possible bandwidth. It is precisely this bandwidth that GEA minimizes to ensure that yield is as close to agreed specification limits as possible. We do this by: 1) constant control over brine pressure at the needle tip, 2) stabile brine temperature, 3) even belt load, 4) consistent brine mixing, and 5) accurate brine distribution – all parameters that have a significant impact on standard deviation.

• Smart yield measurement system
• Accurate injection control
• Dense needle pattern for optimal brine distribution
• 2mm GEA OptiFlex injection needles
• Unique 50 Hz shaker technology 

Output quality
To decrease drip after injecting and in the package, GEA uses a number of methods: 1. An extremely dense injection pattern (see below images for comparison): this allows a high number of injection points. When combining this dense pattern with relatively low pressure injection, the meat fiber remains 100% intact and absorbs the brine efficiently 2. Thin and sharp needles: GEA’s exclusive OptiFlex 2mm needles with extremely sharp needle tips do not cut, rip or pierce meat. The sharp tip simply moves meat fibers aside when it is inserted. When the needle is retracted from the meat, the fibers move back in place, leaving no cut and no channels for the brine to leak back out. 3. Temperature control: warm brine is less effective. It causes more drip loss after injection. If brine does not stay cool (between 2 – 4 degrees Celsius) at the point of injection, yield differences may add up to 0,2%. The GEA solution assures the best possible brine distribution and retention. For fresh products, unsightly 'pools' of excess brine in the package are avoided. And with frozen products, less free moisture means no icing up fans, avoiding unnecessary freezer downtime.

• Better looking packaged products
• No post-packaging drip loss and no needle marks
• Higher perceived value 


Cosistent results and maximum yield

GEA is the technological market leader in the fresh enhanced business. It specializes in processes that minimize deviation, safeguard product quality and reduce drip percentages, both directly after injection and in retail packages. Its Fresh injection line solutions reduce labor costs, deliver unmatched capacities and experiences virtually no downtime.

• Highly controlled in-line process
• Cosistent results and maximum yield
• Efficient processing and high capacity 

Return on investment
A pro-active R&D department and superbly equipped Technology Centers to test new ideas, recipes and processes have yielded many process enhancements.

• Reduced labor
• Faster cleaning
• Less freezer maintenance and higher freezer effectiveness
• Reduced give-away
• No wasted brine 

The GEA solution also uses shaker technology to eliminate the need to manually load, orient and spread products at the infeed. This has the added benefit of reducing human contact with the product, improving the food safety. Due to the elimination of needle marks, it is no longer necessary to position poultry parts on fresh-packed injection lines (for frozen this remains required to avoid products freezing together and belt marks in the freezing process).

• Enhanced food safety
• Reduced human contact


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