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GEA has expanded its injection portfolio with the launch of the MultiJector 500, a new brine injection system designed for small- to mid-capacity marination lines across meat, poultry and fish applications.

The system, which joins GEA’s MultiJector family and succeeds earlier 450mm-width models, is intended to help processors improve product consistency, line availability and sanitation efficiency.

Developed for operators handling products such as ham, deli meats, bacon, poultry and fish, the MultiJector 500 is aimed at increasing throughput, enabling greater product flexibility and supporting compliance with evolving hygiene, safety and sustainability requirements.

At the core of the system is an application-specific needle configuration, with processors guided towards either 2mm or 4mm OptiFlex needles depending on product type and process requirements. Needle diameter and density determine the injection pattern, which influences how evenly brine is distributed throughout the product. More uniform distribution can help reduce risks linked to uneven curing, including microbiological issues, yield loss and inconsistent quality.

The system also allows for relatively fast changeovers between applications, enabling processors to switch product categories without extended downtime.

Willem Poos, product manager at GEA, said: ““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.”

In meat processing, injection plays a key role in determining product safety, yield and uniformity. Retention – the ability of a product to hold injected brine during subsequent stages such as tumbling or thermal processing – is particularly important. Poor retention can result in drip loss, affecting both product appearance and shelf life.

GEA said the MultiJector 500 has been engineered to address these challenges through an updated drive system, improved brine distribution and continued use of its OptiFlex needle technology. The revised drive concept is designed to reduce mechanical stress on products while supporting consistent injection results.

The system has also been developed in response to changing formulation trends. In bacon production, for example, reduced sodium and nitrite levels in cleaner-label formulations can weaken the curing process, making precise brine distribution more critical. For these applications, GEA offers a 2mm needle option with a tighter injection pattern to improve accuracy.

Poultry processing presents different challenges, as its more delicate tissue structure can lead to faster contamination of recirculated brine. This can increase the risk of needle clogging and unplanned downtime. To address this, the MultiJector 500 can be configured with a ScreenFilter module as part of GEA’s Modular Injector Filter system, designed to maintain brine cleanliness in more demanding applications.

Filtration is positioned as a key element of the system, with clogged needles affecting both product quality and production continuity. According to GEA, the modular filter concept is designed to simplify cleaning while maintaining brine quality.

The machine also features a tool-free belt removal system, enabling cleaning in under ten minutes. This is intended to reduce the time, labour and water typically required for intermediate cleaning, as well as limiting brine waste.

For ham and deli applications, where processors often manage a wider product range and smaller batch sizes, the system offers a 4mm needle configuration. This set-up includes optimised height adjustment and smoother needle head movement to support gentler handling and increased productive time. The hygienic design also allows for quick rinsing and rapid exchange of needles and needle blocks during changeovers.

GEA said the launch comes as processors face ongoing pressure to balance product quality with leaner formulations and more efficient resource use. Common operational challenges include uneven brine distribution, clogged needles, repeated cleaning cycles and time-intensive sanitation processes, all of which can impact throughput, water use and labour.

The company noted that, in some cases, uninterrupted operation over an eight-hour shift without filter cleaning or needle replacement could save one to two hours of production time. Additional efficiencies may come from reduced water consumption and lower brine losses.

The MultiJector 500 forms part of GEA’s wider marination line offering, alongside the MultiJector 700, within systems that can include defrosting, brine preparation, injection, tenderising and tumbling. These integrated lines are designed to allow processors to configure operations around specific capacity requirements and product mixes.