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The marinade was produced in a small batch tank by mixing approximately 1 gallon of salt and seasonings with 4 gallons of water using a wand‑style in‑tank mixer. Although this circulated the ingredients, seasoning particles were still large enough to block injector needles.
The manufacturer suffered repeated shutdowns for cleaning and maintenance, losing hundreds of processing hours and injecting the meat with inconsistent seasoning.
Fristam recommended installing an FSI Inline Shear Blender between the existing mix tank and the injection skid. The FSI’s intermeshed rotor‑stator geometry generates intense mechanical shear and turbulence as rotating teeth pass near stationary teeth at high speed. This action reduces particle size, ensures thorough ingredient dispersion before discharge. The center of the rotor stator shear head incorporates an impeller that provides additional pumping energy. The retrofit solution improved performance without requiring replacement of upstream mixing equipment.
Trial set-up
1. Marinade continued to be prepared using the existing batch tank.
2. Product flowed from the tank through the Fristam FSI shear blender.
3. Rotor‑stator shear reduced salt and seasoning particle size within the flowing stream, creating a homogeneous marinade.
4. The product exited the blender, pumped towards the injector system, where meat was injected with a well blended, evenly dispersed seasoning and salt mix.
Following installation, seasoning particle size was sufficiently reduced, which prevented injector clogging. Eliminating repeated stoppages and restoring continuous production.
The process optimization saved an estimated four hours of downtime per day- equivalent to roughly 28 hours per week or 1,460 hours annually!
