Can changing spray nozzles really deliver an 80% reduction in water use and save millions of Rands for a snack food producer?
Yes – and the results speak for themselves. A leading international snack food producer (with strong sustainability goals that resonate perfectly with South African water-scarcity challenges) achieved an 80% reduction in water consumption simply by replacing oversized spray nozzles on their corn chip production lines.
The change across all plants delivered total savings of more than 500 million gallons (approximately 1.9 billion litres) of water per year. That translated into millions of Rands saved on water purchases, wastewater treatment, and the energy required to heat cleaning water. Best of all, the entire investment in the new spray nozzles paid for itself in less than 5 days. This real-world example shows that nozzle audits and upgrades are one of the fastest, most cost-effective ways for South African food plants to cut costs and meet environmental targets.
What exactly did the solution involve, which nozzles were used, and why were they the optimal choice?
It started with a no-charge spray system audit by the experts at Spraying Systems Co , represented in South Africa since 1950 by Monitor Engineering (the company behind www.spray-nozzles.co.za). They discovered that the existing nozzles on the corn chip cleaning lines were oversized – delivering far more water than necessary for effective cleaning.
The customer tested smaller-capacity VeeJet® flat spray nozzles and confirmed there was no loss in cleaning performance. These nozzles simply use less water while maintaining the same uniform, high-impact flat-fan pattern needed for conveyor and equipment cleaning.
Because the VeeJet nozzle design provides precise flow control at typical operating pressures (around 20 bar / 26 L/min in the original setup), each plant immediately cut water use by up to 80%. The nozzles are also easy to install, clog-resistant, and available in a wide range of capacities – making them the ideal, drop-in replacement for any South African food and processor looking for quick wins.
What are the different types of spray nozzles commonly used in food production, and what specific functions do they serve?
Food plants use a variety of specialized nozzles from Spraying Systems Co. (exclusively available in Southern Africa through Monitor Engineering / www.spray-nozzles.co.za). Each is engineered for a precise task to maximize cleaning, cooling, or drying while minimizing water and energy use:
- VeeJet® Flat Spray Nozzles – Ideal for conveyor and equipment cleaning. They deliver a uniform, high-impact flat fan spray for thorough washing with minimal overspray.
- WashJet® Spray Nozzles – Designed for high-pressure cleaning up to 250 bar. Perfect for tough residue removal while still controlling flow.
- SpiralJet® Nozzles – Used in recirculated CIP (Clean-In-Place) systems. Their full-cone pattern ensures complete coverage with low clogging risk.
- FullJet® Nozzles – Excellent for product cooling. They produce a full-cone spray for uniform temperature control on snacks, baked goods, and more.
- TankJet® Spray Balls and Rotating Nozzles – The go-to solution for tank and vessel cleaning. They provide 360° coverage and dramatically reduce water and chemical consumption compared to manual methods.
- GunJet® Spray Guns – For manual clean-up. Far more efficient (and safer) than open pipes or hoses.
- WindJet® Air Nozzles and Blower Systems – Used for conveyor and product drying or blow-off. They replace compressed air or inefficient fans, cutting energy costs and eliminating water carry-over.
All these nozzles are stocked locally and backed by Monitor Engineering’s factory-trained engineers and in-house spray laboratory in Johannesburg.
Why should South African food processors contact spray-nozzles.co.za (Monitor Spray / Monitor Engineering) right now?
Because no other company in Southern Africa has the same 75+ years of expertise or direct access to Spraying Systems Co. technology. As the sole agents since 1950, Monitor Engineering offers:
• Free on-site spray audits (exactly like the one that delivered the 80% savings above)
• Local stock, fast delivery, and technical support from offices in Johannesburg, KZN, Cape Town and beyond
• Proof-of-concept trials in their Johannesburg spray lab
• Custom calculations showing your exact Rand savings on water, chemicals, and energy
Whether you run a snack plant, bakery, dairy, beverage line or meat processor, our engineers will show you how the right nozzles can slash water use, meet sustainability targets, and deliver payback in days – not years.
Ready to start saving thousands of Rands and million’s of liters of water and chemical?
Visit www.spray-nozzles.co.za or call 011 618 3860 today. Ask for a no-obligation site audit – your first step toward 80% water savings could be just a phone call away.
Monitor Engineering – Solving spray applications across Southern Africa since 1950.