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Before implementing the Fristam solution, the manufacturer processed different powdered ingredients using separate mixing technologies. This approach had developed over time because the various powders all had different properties, such as their solubility, bulk density, wettability etc…
To manage these differences, the production line relied on a combination of agitator-based tank mixing, competitor inline blending equipment and venturi induction systems.
While each method could handle certain ingredients, the use of multiple technologies was not an efficient solution increased processing time, energy consumption, and production complexity.
Fristam supplied an Fristam PM Powder Mixer – an integrated powder mixing system that combines a self-priming centrifugal pump to draw in liquid, a hopper to pour powders and a high-performance FS Shear Blender to blend wet and dry ingredients.
This compact, waist height, hygienic system would enable all powdered ingredients to be dissolved into liquid using the same inline process, simplifying production while delivering rapid mixing, full homogeneity and reliable batch-to-batch consistency.
Trial set-up
1. The liquid base is drawn into the mixer by the Fristam FZ Liquid Ring Pump, this liquid is circulated through the Fristam Powder Mixer to establish stable flow conditions.
2. Powdered ingredients – such as sugar, caffeine, taurine, citric acid, flavourings and hydrocolloid stabilisers were introduced via the mixers hopper and drawn into the liquid stream below where they are immediately wetted.
3. The Fristam FZ passes the premixed combination of liquid and powders to the Fristam FS Shear Blender – which fully disperses and incorporates powders and liquids into a lump-free and uniform energy drink base.
The Fristam powder mixing system enabled complete dissolution of all powdered ingredients within a single inline process while reducing batch mixing time by up to 90% compared to the other technologies being used previously (venturi, in-tank agitation, competitor inline mixing). The manufacturer achieved a fully homogeneous product, simplified production, and improved overall process efficiency.
