mixing raw fruits and vegetables

 How to manufacture a smoothie using the Wahal’s Machinery 

Smoothies are made by mixing raw fruits and vegetables with water, fruit juice, and milk. It may also contain other ingredients such as grains, herbs, and proteins.

In general, smoothies are more viscous than juices due to their high solid content and the natural thickening effect of some ingredients such as bananas and mangoes.

Process

1. smoothies are manufactured in a variety of batch sizes, from the single food service industry to mass production.

2. Some manufacturers use whole fruits and vegetables, while others buy and mix ready-made purees. As a result, there are many different ways to make smoothies, and many different types of equipment are used. However, the processing requirements are about the same.

3. When making a smoothie from puree and juice, the mixing system must be able to mix liquids of different viscosities.

4. When processing whole fruits and vegetables, especially when using frozen solids, hard or fibrous raw materials, various equipment may be required to chop the solids into the puree. 

5. The mixing system must be able to disperse all powdered ingredients, such as milk powder and other dietary supplements.

6. After the initial disintegration stage, further processing may be required to achieve the required smooth texture and mouthfeel.

Problem

There are many problems with the manufacturing process.

1. The small mixing plant widely used in this process does not have comparable production. Therefore, duplication of results from laboratory or pilot production can be very problematic during scale-up. 

2. Reproducibility between lots is difficult to achieve.

3. Inadequate treatment can result in inadequate texture and mouthfeel.

4. Traditional stirrers cannot easily mix liquids with very different viscosities.

5. Long mixing times may be required to achieve uniform mixing.

6. Powdered materials can be difficult to formulate and disperse, especially when added to high-viscosity smoothies.

Solution

These problems can be overcome with Wahal Engineer's high shear mixer. The high shear of the rotor/stator workhead allows for quick shredding and shredding of fruits and vegetables of all shapes and sizes, including hard solids. The operation is as follows:

Liquid Power Mixer (Powder Induction Mixer) LPM

Stage 1

The tank is filled with liquid and the mixer starts. Fruits and/or vegetables are placed in the hopper and pulled into the rotor/stator workhead, where they are rapidly shredded.

Stage 2

Centrifugal force pushes the material around the workhead, applying strong high shear in the gap between the rotor and stator walls. The product is extruded from the stator and radially returned to the body mix .

Stage 3

At the same time, new material is sucked into the workpiece head. In one short mixing cycle, all materials pass through the work head many times to achieve a smooth and uniform mixing.

Benefits

• Rapid shredding and shredding of solids and incorporation of powder components.

• Can mix liquids with different viscosities.

• Replaceable work head. Available from coarse shredder heads to ultra-fine sieves, users can achieve their desired consistency.

• Consistent and reproducible results.

• Wahal Engineer scalable results across the product range

The batch size, formulation, ingredient type, and viscosity of the final product will determine which Wahal model is best suited to your processing needs:

high shear mixer homogenizer

• Manufactured with the same tolerances as the production model, it provides a simple and accurate product. 

• Function Duplex assembly available for solids collapse

High shear batch mixer

• Suitable for batches up to 300 US gallons

• Can be used on mobile floor stands

• Duplex mixer available for larger solids collapse

High shear In-line Homogenizer 

• For larger batches than ideal

• Suitable for mixing puree through a distributor just before the inlet

• Gives uniform consistency to the product

• Easy retrofit to existing equipment

• Self-pumping

• Aeration Free

• High Viscosity Model Available Designed for

• Cleaning In Place

Wahal Blending Plant

• A complete system that can be decomposed as large as this lid without pretreatment

• Bottom Entry Mixer provides initial softening of solids

• Inline Mixer further refines the product to achieve the required smooth consistency

Filtration Aid Powder Dispersion for Beer

 Powder Dispersion using Filtration aid 

Most beers, especially lagers, are filtered to remove yeast and other suspended solids. This reduces the storage time required for the natural clarification of beer, improving stability and shelf life. The most commonly used filter media (or filter media) is synthetic amorphous silica (silica), commonly referred to as diatomaceous earth, which is available under a variety of trade names.

Process

An aqueous suspension of powdered diatomaceous earth is prepared in a separate container before being fed to the filter. The solid content can be varied depending on the dosage required for each type of beer.

The general manufacturing process for diatomaceous earth production using a conventional stirrer is as follows:

• The container is filled with water.

• The stirrer arranged to generate a vortex starts.

• The powder is slowly fed into the vortex.

• Continue mixing to completely disperse the powder and keep the solids in suspension.

Problems

• Using a traditional stirrer can cause some problems. 

• Diatomaceous earth is very low density and can emit large amounts of dust.

• The powder is easy to float. Incorporating the powder into the water requires vigorous agitation, exacerbating the dust problem and increasing oxygenation. The rate of addition of powder should be carefully controlled to avoid lump formation.

• Aggregates need to break down to fine particle size to create a stable suspension. 

• The cleaning effect of the stirrer cannot do this 

• A long mixing time is required to complete the dispersion/suspension.

Solution

Wahal Flashblend can be used to significantly reduce processing time and improve product quality.

Stage 1:

Water is drawn from the reservoir by a centrifugal pump and sent to an in-line mixer via a venturi assembly. The high-speed flow through the venturi creates a vacuum in the chamber below the powder hopper. Water is returned to the container via a self-pumping in-line mixer.

Stage 2:

The powder is fed to a specially designed hopper. As soon as the water circulates, the powder supply valve opens. The powder is sucked into a Venturi tube, where the water and powder flow are immediately mixed and immediately sent to the inlet of the Inline High Shear Mixer.

Stage 3:

Liquids and solids are subjected to strong high shear forces at the work heads of in-line mixers. When the powder addition is complete, the bypass valve opens and the flush blend is in fast recirculation mode. The entire contents of the bottle pass through the flash blend in a short mixing cycle, ensuring rapid completion of hydration.

Benefits

Wahal Bead Mill machine has many advantages over traditional systems.

• Processing time is greatly reduced.

• The rapid uptake of large amounts of powder.

• Improved consistency and reproducibility.

• Controlled powder addition rate

• Requires minimal operator input.

• Minimized cleaning requirements LIQUID POWDER MIXER is designed for Cleaned In Place (CIP).

• Designed to facilitate automation and connection to process computers.

• Dust Emission Reduction Flashblend can also be integrated into a dust extraction system.

• The Powder Incorporation system can be custom-built to meet the requirements of individual customers.

• Can be integrated into powder administration systems such as large bags (flexible containers). 

• The optional Funnel Flow Aid can be used on difficult powders.

Soft Drink Manufacturer : Sugar Syrups - Liquid Powder Mixer

 Soft Drink Manufacturer - Preparation of Sugar Syrups

The sugar content of carbonated and still soft drinks varies depending on whether the product is delivered ready for consumption, or as a concentrate (commonly referred to as “syrup”). Common formulas may contain concentrated spice or fruit juice, acidity controls, preservatives, solvents, antioxidants, and pigments. By “Food,” and other “sugar-free” sugary drinks are replaced by sweeteners such as Aspartame.

The process

One of the first stages in the normal production process is to prepare sugar syrup. Sugar is used in granulated or liquid form. Liquid sugar simply needs to be mixed with water, but when granulated sugar is used, many aspects of the processing must be considered:

Small-scale production of low-sugar syrups may be done at ambient temperature. However, with certain concentrated products, 60% or more sugar solutions are rare, requiring hot water to help dissolve.

For large operations, temperatures of up to 95 ℉ (35 ℃) may be generated to accelerate melting.

Some powdered ingredients may be dry mixed with half the sugar, which helps prevent the mixing and "weight" of the simple powder that often floats.

The problem

1. Liquid sugar may be more expensive than granulated sugar.

2. The melting of powdered sugar with a simple movement is a slow process.

3. Ordinary agitators are unable to dissolve high sugar levels at local temperatures.

4. Heating water for convenience adds to the cost and does not save energy.

5. The cooling process also adds to the cost and processing time.

6. Crystallization of syrup may occur during heating/cooling.

7. Incomplete solubilization may lead to loosening or even blockage of vessels.

Solution

The Wahal Engineer High Shear Mixer may significantly reduce mixing times and eliminate the need for water heating. This may be achieved with Batch Mixers in the tank or by adding a Wahal Engineer In-Line Mixer to the existing system. This works as follows:

Stage 1

The high-speed rotation of the rotor blades creates a strong absorption of water and sugar granules on the vessel to the work surface.

Stage 2

Centrifugal force drives objects into the work area around the head when they are under the grinding action in the space between the rotor and the stator wall.

Stage 3

The product is forced out of the stator as new materials enter the subject matter. In a short mixing cycle, all substances pass over the work head, gradually reducing the particle size and exposing the growing area of ​​sugar to the surrounding liquid, speeding up the dissolution process.

Benefits

1. The combination of reducing granule size and strong mixing significantly reduces mixing times.

2. 66% sugar syrup may be produced at ambient temperature. 

3. Various flexibility allows the manufacturer to use sugar in the form of granulated or syrup.

4. The Wahal Engineer mixer may also disassemble and apply water solubility and stabilizing agents such as CMC and Xanthan gum in part of the time taken by other means.

There are several products in the Wahal Engineer range that are suitable for this application, their selection is determined by the requirements of each process including the size of the collection.

High Shear Batch Mixers

1. Suitable for bulk sizes 

2. Many units may be used on low-moving floors

3. Smaller units are available for R&D and driver production

Top Shear In-Line High Shear Mixers

1. Suitable for large collections

2. Aeration is free

3. It is easily transplanted to an existing plant

4. Self-pumping

5. It may be used to pull a ship

6. Ultra Sanitary models are available

7. High viscosity models are available

8. More about this Mixer

Wahal Engineer Powder Liquid Mixer (LPM)

1. Suitable for large collections

2. It can quickly assemble large quantities of powders

3. Reduced ventilation

4. Reduced cleaning requirements

5. Suitable for high viscosity mixtures

6. Suitable for working at high temperatures

7. Small operator input is required

8. More about this Mixer

Wahal Engineer Liquid Powder  Mixer 

1. Design of Ultra Sanitary CIP

2. Excellent movement in the tank

3. It can quickly assemble large quantities of powders

4. Suitable for high viscosity mixtures

5. Low maintenance