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Before engaging Fristam, the processor had relied on:
These approaches failed to achieve the required viscosity range or batch consistency, and hygiene challenges due to manual cleaning further undermined production efficiency.
Fristam’s application specialists recommended the installation of a custom Powder Mixer Skid combining a Fristam FS Shear Blender with a Fristam FDS 2-3 Twin-Screw Pump. This hybrid skid was selected to:
This solution was designed to integrate seamlessly with the existing production line and replace inefficient batch methods with a continuous, inline blending approach.
Trial set-up
1. System installation and integration
The Powder Mixer Skid was installed inline in the gravy production process, allowing cooked vegetables, powders, and liquids to flow directly through the shear pump and twin-screw pump configuration.
2. Process configuration
Pump and rotor-stator settings were calibrated to handle the wide particle size range — from vegetables to spice particulates — ensuring balanced shear without breakage.
3. Flow testing and optimization
Actual product formulations were passed through the skid during trial runs to evaluate flow stability, shear performance, and product texture.
4. Line tuning and operator training
Piping was optimized for free inlet and outlet flow, performance tests confirmed consistency, and operators received on-site training covering routine operations and maintenance.
The Fristam Powder Mixer Skid transformed the gravy production process. Mixing times were reduced from 4–5 hours to approximately 1–2 hours per batch, significantly boosting throughput and enabling faster product release cycles.
Product consistency improved markedly, with uniform texture and stable viscosity achieved across all production runs. The integration of high-shear mixing and twin-screw transfer eliminated the inconsistencies caused by previous methods, ensuring repeatable quality for every batch.
Hygiene performance saw substantial gains through fully CIP-compatible design, reducing manual cleaning effort and associated downtime. Maintenance requirements dropped due to robust equipment selection and reduced wear.
Following the successful implementation, the customer plans to roll out the Powder Mixer Skid to additional gravy production lines, using the proven configuration as a benchmark for future expansion.
