GEA unveils new brine injector for smaller meat processing lines
GEA has added the MultiJector® 500 to its injection portfolio, a brine injection system targeting small- to mid-capacity marination lines processing ham, deli meats, bacon, poultry, and fish. The machine was unveiled at interpack 2026 in Düsseldorf, Germany, which ran from 7 to 13 May.
The MultiJector 500 succeeds earlier systems in the 450 mm width category and is positioned for processors looking to increase throughput, expand their product range, or update equipment in response to stricter hygiene, safety, and sustainability requirements.
Application-specific needle configuration at the core
Central to the system is a choice between 2 mm and 4 mm OptiFlex® needles, selected according to product type and process objective. In injector technology, needle diameter and density determine the injection pattern, meaning the distribution of injection points across the product surface. A denser pattern improves brine dispersion, which is particularly critical where uneven curing may lead to microbiological risks, yield loss, or inconsistent product quality.
The system is also designed to permit relatively rapid conversion between applications, enabling processors to switch product categories without extended changeover times. According to Willem Poos, Product Manager at GEA: “Processors in the small- and mid-capacity range are under pressure due to greater recipe variation, that results in more and shorter runs and tighter operating margins at the same time. The MultiJector 500 was developed to provide a more adaptable injection platform while optimising the process factors that most often affect uptime, retention, and cleaning effort.”
Why injection matters in meat processing
Injection is not simply a dosing step. It has direct consequences for product safety, yield, brine retention, and final product uniformity. Retention describes how well the product holds injected brine during downstream stages such as tumbling, thermal treatment, or packaging. Poor retention leads to drip loss or purge, the release of free liquid after injection, which affects both appearance and shelf life.
The MultiJector 500 addresses these outcomes through a revised drive concept, improved brine distribution, and continued use of OptiFlex needle technology. The drive concept controls the injector head and has been made flexible to accommodate both 2 mm and 4 mm needle execution, reducing mechanical stress on the product and supporting a more consistent injection result.
In bacon processing specifically, the shift towards cleanerlabel formulations reducing sodium and nitrite levels is placing additional demands on brine distribution. Reduced sodium and nitrite levels can weaken the osmotic effect, the natural movement of water and dissolved substances through meat tissue during curing. Uneven distribution under these conditions risks under-curing, visible colour differences, lower yield, and elevated microbiological risk. GEA’s 2 mm needle option with a tighter injection pattern is intended to address this.
Poultry presents a different technical challenge. The comparatively delicate tissue structure promotes faster protein release during processing, contaminating recirculated brine more rapidly. Where filtration is insufficient, needle clogging follows, causing unplanned downtime and reduced line availability.
Filtration gets a modular overhaul
To manage brine quality more effectively, GEA has introduced the Modular Injector Filter, with the ScreenFilter module available for 2 mm needle configurations in demanding applications such as poultry. Poos notes: “Filtration performance has a direct impact on process stability. When needles begin to clog, the consequences extend beyond maintenance. It affects injection accuracy, shift continuity, and ultimately product consistency. The modular filter concept was developed to simplify cleaning while keeping brine quality under control.”
A tool-free belt removal system enables cleaning in under 10 minutes, reducing the labour burden, water consumption, and brine disposal associated with intermediate cleaning.
Ham and deli flexibility
For ham and deli applications, where shorter batch runs and wider product variation are common, a 4 mm needle configuration is offered. This version includes optimised height adjustment and smooth needle head movement, alongside GEA’s stripper plate technology for gentler product handling. Needle blocks and needle heads can be exchanged rapidly, supporting operations with frequent product changeovers.
Production efficiency gains
GEA cites one operating scenario in which uninterrupted production over an eight-hour shift, without stopping for filter cleaning or needle replacement, could recover one to two hours of lost production time. Additional gains may arise from lower water and brine losses and reduced disposal of contaminated brine. The patented needle block system and OptiFlex needle design are engineered for mechanical robustness, with the aim of extending replacement intervals and reducing associated operating costs.
The MultiJector 500 and its larger counterpart, the MultiJector 700, sit at the centre of GEA’s broader marination line offering, which spans defrosting, brine preparation, injection, shaking and tenderising, and tumbling, allowing processors to configure complete lines around specific capacity targets and product mixes.
For more information, visit: gea.com
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