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Dissolving spray-dried milk, yoghurt powders, salt, starch and pectin

in margarine production using Fristam Powder Mixers & Shear Blenders

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Introduction to the application and industry overview

A German dairy required a reliable way to incorporate different functional ingredients, at different stages of production when manufacturing margarine. Many dairies prefer to work with dried powders as opposed to fresh ingredients due to hygiene issues – but they must ensure these powders are dissolved quickly, uniformly and effectively. This case study outlines how both the Fristam Powder Mixer and Fristam Shear Blender supported controlled dissolution and dispersion enabling consistent processing and improved product functionality for the production of margarine.

Customer brief

The dairy has 2 main requirements:

  • To dissolve multiple powdered ingredients into aqueous or semi-viscous phases during production for flavour positioning, stabilisation and texture control.
  • To dissolve starch – whilst keeping their current in-tank set up, as they had recently just invested heavily in this area.

Previously unsuccessful methods

The customer previously used a in-tank mixing to dissolve spray-dried milk, yoghurt powders, salt, starch and pectin powders, but this left undissolved particles or lumps at the end of the cycle and limited the functional performance of stabilising components such as starch and pectin.

Previously unsuccessful methods

Fristam’s solution

Fristam looked at the process in 2 parts. A Powder Mixer was required for dissolving spray-dried milk or yoghurt powders, salt, and pectin. A Shear Blender was required for the starch production process – so the customer could add the shear blender to their existing cycle, rather than modify the whole process.

Trial set up

Powder mixing applications (Fristam Powder Mixer)

Multiple margarine ingredients were dissolved using the same Fristam Powder Mixer process:

  1. Liquid was circulated through the Fristam Powder Mixer to establish stable flow conditions for powder induction.
  2. The dry ingredients were introduced via the Powder Mixer hopper.
  3. A vacuum generated by the induction pump drew the powders directly into the liquid stream for immediate wetting.
  4. This premix then passed through the Fristam shear blender which dispersed and dissolved the powders uniformly, preventing floating material, reducing clumping risk and ensuring consistent ingredient incorporation.
  5. For certain phases continuous circulation was required – which allowed the target concentration or functional performance before integration into margarine production.
  6. The Powder Mixer was cleaned with CIP in-between different cycles and phases to prevent cross contamination and keep the system hygienic.

 

High-shear blending application (Fristam FS Shear Blender)

For starch stabilisation, the customer continued dissolving starch in hot water within an existing tank system due to prior equipment investment.

After leaving the tank, the hot and highly viscous starch solution was passed through a fast-running Fristam FS Shear Blender to provide final inline homogenisation.

This additional high-shear stage destroyed remaining lumps and undissolved particles, improved dispersion and stabiliser activation.

Fristam’s solution

A successful outcome with Fristam Mixing Technology

The Fristam powder mixer provided a rapid and reliable way to dissolve key ingredients in margarine production. By improving dispersion and stabiliser activation, the system created a faster, more consistent process that significantly reduced waste. The customer was impressed to find a single solution that could blend multiple powders across different production phases.

The addition of the FS Shear Blender into the existing in-tank mixing process meant the customer could keep their existing set-up – but homogenize the product much more effectively. The product was blended so well that the customer was able to switch to a cheaper brand of starch without compromising the quality of the end product.

Do you have any questions so far?

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Process / Product quality benefits

Process / Product quality benefits

  • Reliable dissolution of milk, yoghurt, salt, starch, and pectin ingredients
  • Improved dispersion and reduction of undissolved particles or lumps
  • Enhanced stabiliser functionality supporting consistent margarine texture
Sustainability benefits

Sustainability benefits

  • No more raw material wastes due to agglomerates sitting on tank walls
  • Faster production that uses less energy
  • Retention of current tank set up – modifying the system rather than a total replacement
Financial benefits

Financial benefits

  • Potential use of more cost-effective starch due to improved activation from better homogenisation with the FS Shear Blender
  • Eliminated product inconsistency and associated processing losses
  • Enabled the customer to improve a failing process (starch tank mixing) without scrapping the entire kit
Other benefits

Other benefits

  • Avoidance of hygienic risks linked to fresh dairy ingredients through use of spray-dried powders
  • Health and safety improvements – the process is now less manual for workers – as they do not need to climb ladders with powder bags

Similar applications

  • Dissolution and dispersion of powdered dairy, salt, and stabilising ingredients in spreads, emulsified sauces, and fat-based food systems
  • Preparation of brines, hydrocolloid stabiliser systems, and viscous starch solutions across food processing sectors where consistent texture and functional activation are required
  • Powder-into-liquid incorporation of functional ingredients in broader food manufacturing environments requiring hygienic handling, controlled shear, and repeatable product structure

Frequently Asked Questions

The most effective way to eliminate “fish-eyes” and lumps is by using an inline high-shear device like the Fristam FS Shear Blender. Unlike traditional in-tank mixing, the FS Shear Blender provides intense mechanical shear that destroys agglomerates instantly, ensuring 100% starch activation and a perfectly smooth texture.

In addition to mixing & blending technology – check out Fristam’s full range of pumping technologies suitable for the dairy industry.

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