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
smoothies are manufactured in a variety of batch sizes, from the single food service industry to mass production.
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.
When making a smoothie from puree and juice, the mixing system must be able to mix liquids of different viscosities.
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.
The mixing system must be able to disperse all powdered ingredients, such as milk powder and other dietary supplements.
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.
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.
Reproducibility between lots is difficult to achieve.
Inadequate treatment can result in inadequate texture and mouthfeel.
Traditional stirrers cannot easily mix liquids with very different viscosities.
Long mixing times may be required to achieve uniform mixing.
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:
Manufactured with the same tolerances as the production model, it provides a simple and accurate product.
Function Duplex assembly available for solids collapse
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
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