Sauces & Dressings

Dressings, sauces and other culinary condiments may take many forms and consistencies from thick hummus to light mayonnaise and to smooth barbecue sauce. The challenges to the manufacturer often include dispersing a gum or other thickening agent, emulsifying oil and water phases, dispersing spices or additives, and possibly milling solids. Mixing, heating and pumping solutions are often mandatory in the production of such condiments.


The Process

Dressings, dips and mayonnaise are generally oil-in-water emulsions and are manufactured in a similar manner. A typical method would be as follows:

The vessel is charged with water (the continuous phase) and the mixer is started.

Powdered and liquid ingredients such as emulsifying agents, stabilizers, thickening agents, flavorings, preservatives and coloring are dispersed in the water. In some instances these are pre-mixed in dry form.

The oil phase (the dispersed phase) is added to the mix and an emulsion is formed.

Mixing is continued until a smooth, agglomerate-free product is obtained

Sauces, hummus, ketchup and mustard are a blend of water, spices and solid ingredients that requires dispersing and milling to achieve small particle size for improving yield and obtain a smooth and uniform texture. Some processes will involve heating or cooling and multiple mixing stages where coarse or fine ingredients must be kept in suspension in product, or if sub-micron size particles is required (for example the release of natural pectin present in tomato paste)

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The Challenge

There are several challenges and factors to consider for these processes:

  • Product viscosity est la première considération majeure et influence le type et la taille de la pompe/mélangeur. La viscosité affecte également l'efficacité du transfert de température entre le fluide de refroidissement chauffage et le produit, déterminant ainsi la technologie nécessaire.
  • The ingredients in the recipe will also dictate several design choices. Certain powdered ingredients, like starch or spices, tends to create small clumps of unmixed material with dry centers that require powerful mixing action to disperse. Other ingredients will foam if air is incorporated and requires delicate agitation.
  • Unique product conditions can also impact the vessel performance and mixing method needed. For instance, barbecue sauce cooked and blended in the vessel demand scrape-surface sidewall agitation to prevent burn-on during cooking.
  • Mixer type may be the most important processing consideration. The mixer or agitator used will alter processing time and consistency, plus influence product separation over time.
  • Cost of ingredients drives everyday manufacturer choices in sourcing raw ingredients. Sometimes the equipment used to produce a condiment will limit manufacturer choice by having to favor costlier ingredients that comes already grounded or pre-treated for easy dilution.
  • Product integrity is key to market the best product possible. Once a recipe is done, the process equipment must preserve product thickness/viscosity and mouth feel texture, and control temperature for packaging sterility or preventing bacteria growth.

The Advantages

Jetequip is your ideal partner for sourcing single components such as pumps, mixers, mixing tanks and heat transfer solutions. Our expertise in mixing along our process knowledge drives us into integrating process equipment in turn-key solutions. We are proud to offer solutions with the following advantages:

  • Laboratory, pilot and full production scale equipment available
  • Batch-to-batch consistency and stability manufactured in turnkey solutions without the high capital expenditure
  • Systems are designed for handling low or high viscosity products
  • Stable emulsion
  • Yield of raw materials is maximized, as thickening agents are fully hydrated and other ingredients are correctly dispersed
  • Dramatically reduced processing times
  • Rapid dispersion of thickeners and stabilizers
  • Agglomerate-free mix
  • Easily adapted to variations in product type and recipe