GEA Introduces ProCoater for Consistent Wet Coating and Improved Processing Efficiency

GEA has introduced the GEA ProCoater, a new wet coating system designed to help food manufacturers achieve stable batter flow, consistent coating application and improved production efficiency. The machine is intended for processors producing coated poultry, pork, fish, cheese, plant-based and hybrid food products.

Improved Batter Flow and Coating Consistency

Demand for coated convenience foods continues to evolve, with consumers seeking appealing textures, crisp finishes and innovative product formats. For manufacturers, maintaining consistent quality while managing production costs, complex recipes and labour challenges remains a key priority.

The GEA ProCoater addresses these requirements through precise control of batter application. Its patent-pending guided return flow system is designed to reduce air entrainment and foam formation by up to 80%, helping create a more stable batter flow and uniform coating curtain. This can minimise defects such as voids and white spots while supporting consistent results across extended production runs and different batter viscosities.

Features Designed for Reliable Production

The system incorporates several features to improve process control and simplify operation. Adjustable scrapers allow operators to make fine adjustments during production without stopping the line. Smart air knives provide uniform blow-off across the conveyor belt, helping maintain accurate coating weights and a consistent product appearance.

An optimised infeed transfer supports smooth product movement into the coating process. In addition, a patent-pending batter retention plate and an optional bottom batter layer supply device help ensure complete underside coverage while keeping products stable and preventing floating or drifting during coating.

These features are designed to deliver reliable coating performance throughout the production cycle, from start-up to shutdown. Consistent batter pickup can help reduce rework, lower the number of downgraded products and minimise product giveaway. More efficient batter use can also improve yield and support cleaner production operations.

The GEA ProCoater is available in belt widths of 400, 600 and 1,000 mm, enabling food processors to select a configuration suited to their production capacity, line layout and product requirements.

“GEA ProCoater has been developed to give processors dependable control over a critical stage of coated food production,” says Ben Kop, Application Specialist at GEA. He adds that stable batter flow and simpler adjustments help operators achieve consistent results with less intervention.

Technical Support from Development to Production

Alongside the equipment, GEA offers application expertise, food technology assistance and access to its Technology Centers for product trials, process validation and new product development under production-relevant conditions. Supported by its global service network, these capabilities help manufacturers optimise recipes and coating parameters, maintain equipment performance and manage risks when scaling up new coated food products.