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The Dressings, Mayo & Sauces Industry

Dressings & Sauces are growing and diversifying with more exotic flavors and ingredients. Ethnic products, natural and reduced calorie products,and international sauces are tempting consumers. Besides formula changes to meet consumer demand, the ever volatile prices of sweeteners and oils is driving us to reformulate for cost reduction.  From oil-in-water emulsions to uniformly distributing particulate to milling delicate emulsions, Admix has a variety of mixing, milling and powder induction technologies to creatively solve mixing challenges.

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Question Solution

How do we insure consistent uniformity from the top to bottom of a batch in our high viscosity creamy, whipped and semi-solid emulsified products?

Our approach is that high shear mixers must utilize a design that:

  • Produces high flow rates so that the product is blending and moving from start to finish.  In this way, we can be guaranteed uniformity (especially pH and salt) from top to bottom.
  • Does not depend on an operator to consistently move a mixer around the vessel in order to emulsify or "pull in" the last of the ingredients.
  • Produce high enough shear rates to eliminate milling steps.

The Rotosolver® efficiently combines high flow / good product motion with high shear that is consistent and never overshears keeping emulsions tight as well as robust.

  • Clean-in-Place
  • Meets 3-A TPV Standards #73-01
What will give us good blending in our tank to gently blend in particulate in our high viscosity products as well as maintain suspension and uniformity of spices in low viscosity formulas?

No high shear mixer can uniformly blend in soft particulate in high viscosity emulsions.  What is needed is vortex and gentle flow for particulates and for spice suspension, consistent downward flow, low level mixing is required.

The Rotomaxx™ and Rotomixx® lines offer fixed tank agitation with an all stainless steel drive construction eliminating paint and corrosion above the vessel.  With a variety of impeller options, designs are custom manufactured to your vessel, as well as to your specific process.

We are trying to concentrate the solids level in a batch to reduce mixing times and control costs. The solids are hard-to-wet and create tough fisheyes that clog our filters. How can you help?

The Rotosolver® combines good product motion with efficient pumping blades, a high shear mixing region to break down fisheyes and agglomerates.

  • Clean-in-Place
  • Meets 3-A TPV Standards #73-01

Admix MayoMillWe are having issues with seals on our colloid mills partially caused because we have to manually disassemble them daily for cleaning, as well as when we run high viscosity products like mayonnaise or whipped salad dressing.  The increased line pressure causes our seals to leak.

The Admix MayoMill™, built off the proven Boston Shearmill® platform is truly CIP'able, eliminating the need to disassemble the unit for cleaning.  As standard, the Admix MayoMill has a 700-PSI seal rating, far above any pressures your lines will see, thus eliminating seal failures caused by handling or high pressure.

  • Boston Shearmill meets 3-A TPV Standards #36-01
On our process, we need to premix gums or starches in pure water.  At times, we are at very low levels in our tanks and sometimes don't even reach the mixer.  Because these ingredients require shear, what are our options?

The Fastfeed™ system provides inline, simultaneous powder induction and dispersion from the safety of floor level.  As long as there is enough water to flood the tank outlet, this is a great option.

With its built in shear, the added dries are sheared in less than 1/2 a second of induction so that they never get the chance to form fisheyes or agglomerates.

Some of our materials are very expensive, and testing can be expensive in large volumes. How do we test new recipes without a lot of waste, but ensure that when we go to scale them up in the plant, we will achieve equal results?

At Admix, we believe in true scalability.  The BenchMix™ series of high shear lab mixers can be configured with Rotomixx®, Rotosolver® and Rotostat® impellers for the greatest flexibility and accurate scale-up to full production.

We are so confident in our scale-up methods that we provide a process performance guarantee! Contact Us for details.

I have heard that applying the "correct" shear to my BBQ sauce can enhance viscosity and also reduce cost.  How is that possible?

The Boston Shearmill® high shear wet mill when properly applied will drop the Bostwick on BBQ sauce by up to 14% allowing reduction of starch and/or tomato sauce. 

On ketchup, that Bostwick improvement can be as high as 19%!

Further, coarser pastes (lower costs) can be purchased and then "milled" to the desired "mesh".

Dressings & Sauces Processing Primer "The Admix Primer on Dressings & Sauces" offers useful information regarding ingredients, production and mixing technology. We identify and explain mixing applications and offer solutions to reduce cost while increasing efficiency and quality. Call 800.466.2369 to request your copy and learn how the Admix Advantage can benefit your processing!