Mixing is a critical and deceptively complex step in food and beverage production. While the core of the process is relatively straightforward, ensuring a consistent, homogeneous blend can become challenging on an industrial scale. Improper mixing is more common than it may seem and can cause significant food quality issues.
Since mixing-related errors can arise from many factors, there are several ways to optimise the process. Understanding where issues occur and how to address these risks is the first step to ensuring higher food quality in mixing.
Use the right mixer for the batch
Matching batches and mixing equipment is one of the most important steps in proper blending. The industry’s emphasis on scalability may lead many companies to use larger mixers, but a tank that’s too large will create just as many issues as one that’s too small.
If a batch falls below a mixer’s minimum operating volume, it will result in excessive mixing intensity. The components will move faster than necessary because of the reduced resistance, leading to a larger surface vortex.
While some vortexes are beneficial, a larger one can introduce issues like foaming. In addition to impacting mixture texture and quality, more foam translates into more wasted ingredients. Manufacturers are already responsible for 1.5 million tonnes of food waste — 16% of the U.K.’s total — so minimising this figure is essential.
Rethink the order of ingredients
The order in which manufacturers add ingredients to the mixture can also impact its quality. Even if any order of ingredients will produce an identical result, how long it takes them to reach the same end will vary. Consequently, manufacturers can streamline the process by considering each element’s impact on mixture viscosity.
Generally speaking, it’s easier to mix a high-viscosity liquid into a less viscous one than the other way around. If manufacturers added a highly viscous ingredient like corn syrup before a less dense one like water, the slurry would get thick and cause excess friction. That friction will hinder the mixing intensity, impacting the quality and time of the final mix.
Similarly, fine powders should enter the mix before larger solids or viscous liquids to enable a more cohesive blend. Manufacturers should also pre-mix minor ingredients in a portion of a major one before adding them to the solution.
Consider unique ingredient qualities
Food and beverage companies must also consider how their ingredients’ unique qualities may impact the mix. Viscosity is the most obvious factor to gauge when determining when to add an element, but some components may have other characteristics that affect the final blend.
Acidic ingredients like citrus could hinder the viscosity of the mix, resulting in a different final texture and higher mixing intensity. Some temperature-sensitive solids can clump together instead of forming a free-flowing powder if the equipment gets too hot or mixes too quickly. Qualities like these may require pre-processing or unusual ingredient orders to minimise their impact.
Manufacturers can address some unique ingredient qualities with counteractive additives, but companies should approach these with caution. If businesses sell their products in the U.S., all ingredients must meet approved additive standards to avoid regulatory complications.
Implement a proactive maintenance programme
It’s also important to address the state of the mixing equipment itself. Machine issues can impact mixing speed, temperature and other factors, making it difficult to consistently produce a quality solution. If businesses don’t have a regular maintenance program, narrowing down the cause of these problems may be challenging, wasting time and money.
Instead of running equipment to failure, manufacturers should implement a proactive maintenance schedule. Regular inspections and fixes may disrupt operations slightly, but they’ll prevent larger breakdowns, saving time in the long run. Preventive repairs will also ensure issues don’t gradually build, providing more consistent performance.
Predictive maintenance is even more beneficial than schedule-based preventive approaches. This strategy uses connected sensors to predict when a machine needs repairs. Consequently, it reduces maintenance-related downtime on top of preventing breakdowns, resulting in a 25% increase in productivity and a 25% cost reduction on average.
Optimise upstream processes
Processes outside of mixing can impact mixing-related food quality changes, too. If all the ingredients aren’t in optimal condition before going into the mixer, they won’t blend together as well. By the same token, better pre-processing will result in a more effective mixing process.
Ensuring uniformity is the ultimate goal of optimising upstream workflows for more consistent mixing. Automating repetitive processes like breaking solid ingredients into smaller pieces will improve consistency by minimising human error. Manufacturers can also use physical stops like sieves and filters to ensure only particles of a certain size go through to the mixer.
Pre-mixing minor ingredients and breaking dissolved solids into a finer powder will also ensure a faster and more consistent final blend. Manufacturers may also need to adjust pre-mixing workflows to align better with the order of ingredients, producing the first-added ones first while giving more time for later additions.
Train employees thoroughly
As with any process, mixing can also benefit from a reduction in human error. Since the mixing process involves more complex considerations than it may initially seem, it can be easy to make mistakes. Human error also plays a larger role in manufacturing than in any other industry, so addressing these risks is crucial.
Workers running mixing equipment should understand how other factors impact the blender’s intensity, speed, temperature and consistency. That way, they can narrow down the cause of any unexpected outcomes easier and adapt accordingly. Similarly, they should be familiar with the machines they’re using, including their rotational speed, recommended batch volumes and maintenance needs.
Regular refresher training can help prevent mistakes from complacency, ensuring the initial training doesn’t go to waste. Holding employees accountable for human error-related quality issues can also help.
Optimising the mixing process has far-reaching impacts
The mixing process plays a critical role in determining the final product’s taste, mouthfeel, downstream processing and even health and safety. Consequently, food and beverage companies must address quality issues and their root causes in this step.
These six strategies will help any food manufacturer optimise their mixing process. They can then ensure higher-quality, safer and more consistent products for their customers.
