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At the heart of transforming raw ingredients into food for human consumption is the mixing operation. Whether small-scale mixing by hand or blending multiple ingredients in high volume, proper mixing is important to establish consistency. Even with the right amount of ingredients and flavors, a great recipe will not transform into good food unless the components are well-mixed.
Taste, texture, color, appearance – these are all crucial parameters intimately influenced by the mixing process. Consumers expect food products will be exactly the same as their last experience. Within the food industry, a high level of consistency is required – not just batch-to-batch but facility-to-facility. In this market, consistency is the backbone of consumer loyalty.
The use and application of various types and styles of mixing equipment are determined by several factors:
- the phases being mixed (liquid-liquid, solid-liquid, or solid-solid)
- physical characteristics of the end product (like viscosity and density)
In reality, many mixing technologies overlap such that certain applications can actually be successfully produced by two or more types of mixing systems. Proper mixer selection is vital to process optimization. In this article, we’ll take a closer look at dry blending equipment options.
Ribbon Blenders
The Ribbon Blender is popularly used in the food and beverage industries for dry blending. The machine consists of a U-shaped horizontal trough and an agitator made up of inner and outer helical ribbons that are pitched to move material axially in opposite directions, as well as radially. The ribbon tip speeds rotate up to approximately 300 feet/min.
When dry blending food products, relatively small amounts of liquid may be added to the solids in order to coat or absorb coloring, flavoring, oils or other additive solutions. Liquid ingredients can be added through a charge port on the cover but for critical applications, liquid addition is best accomplished through the use of spray nozzles installed in a spray bar located just above the ribbon agitator. Liquid flowrate, as well as blender speed, are fine-tuned during liquid addition to avoid flooding or formation of wet clumps of powder.
This blender design is efficient and cost-effective for mixing dry applications such as cake and muffin mixes, flour, bread improvers, cereals, trail mixes, snack bars, spices & herbs, tea (leaves or iced tea powders), coffee (whole or ground beans), and other beverage blends including whey protein shakes, chocolate drinks, powdered juices, and energy drinks.
Although dry blending is its more popular function, the ribbon blender is also used in the preparation of flowable slurries or pastes, such as food extrusion operations. Food extrusion is a processing technology that produces a wide variety of end products, from pasta to ready-to-eat cereals, from snack chips to pet food.
The function of the ribbon blender in the extrusion process is to homogeneously mix two or more grains, flours, oil, sugar, emulsifiers, extrusion aides and other powders. Once the constituents are blended, water is usually added to the batch in order to raise the existing moisture content to the proper level for extrusion.
Paddle, Vertical, and Tumble Blenders
For blends that require a gentler mixing action, food manufacturers may instead use the Paddle Blender, Vertical Blender or Tumble Blender.
A horizontal paddle blender also utilizes a U-shaped trough. The agitator consists of several paddles and has less surface area at the periphery than a ribbon, thus providing lower shear and less heat development.
In comparison, the blending action of a vertical blender’s slow turning auger is far gentler than that of any horizontal blender. The auger screw orbits a conical vessel wall while it turns and gently lifts material upward. As materials reach the upper most level of the batch, they cascade slowly back down in regions opposite the moving auger screw.
The tumble blender is a rotating device that commonly comes in double-cone or V-shaped configurations. Asymmetric vessels designed to reduce blend times and improve uniformity are also available. Generally, tumble blenders operate at a speed of 5 to 25 revolutions per minute. Materials cascade and intermix as the vessel rotates. Mixing is very low-impact.
Evolution through testing
Evolutionary improvements in mixing technologies present an opportunity for food companies to periodically update processes, upgrade efficiencies, improve product consistency and strengthen R&D efforts. A thorough testing program with a reliable and experienced equipment manufacturer can help determine the best type of mixer system for your needs. Confirm your mixing strategy by trying a variety of potential candidates utilizing your own raw materials and simulating operating conditions as close to your actual process as possible. The rewards will be sweet and fulfilling.
About Charles Ross & Son Company:
Charles Ross & Son Company offers individual mixing, blending, drying and dispersion equipment, as well as completely integrated systems including automated controls and storage vessels. Utilizing advanced, computerized engineering and production tools, Ross is equipped to provide a full range of engineering, design and manufacturing services for both large and small-scale capacity.
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Do you have any recommendations regarding adding minor components such as fortification premixes? Is there any information on adding vitamin and minerals ingredients that are required at milligram per serving levels?
This looks some kind of giant machines which can give evolutionary improvements to make this process easier and better production from this technology. Keep up the good post.
we are producing powder dairy blends. we are mixing calcium caseinate, rennet casein, citric acid, sodium citrate, carrgeenan, mono and diglicerides , corn and potatoe starch,etc.
we are looking for equipment . we are producing about 120 tons by month of blend products
Resergene Biosciences is engaged in the marketing of Medical nutrition products, based in Bangalaore. We intend setting up a small plant to manufacture disease specific nutrition supplements – protein powders, in the outskirts of Bangalore.
Kindly advise us the kind of machinery that you have so that we could consider procuring them. We are looking at dry blenders for blending protein powders with fat powders, carbohydrates, Vitamins and Minerals. We will also be requiring automatic pouch sealing machine, and others.
Kindly let me know if we can meet any of your representatives here in India to discuss the matter further.
With kind regards,
Looking for mixing equipment to mix dry powder’s protein
We are mixing seasonings for chips .
We have 2.5 tons of Ribbon mixer.
We have started to have a salt inconsistency problem at our customer
We have cone mill and power sifter after blender
What points in the Blender or in the process I need to check ? Any suggestion
please call me back i m looking for blending machine
please contact on +91-9792866141