Hummus Production Optimized: Ultra-smooth texture with the Fristam Colloid Mixer

Installing the FCM after their Fristam Shear Blender, created market opportunity and a new product

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Introduction to the application and industry overview

Hummus is one of the most competitive food categories in the Middle East and globally. For large-scale hummus producers supplying retail, food-to-go and foodservice markets, texture consistency, particle size control and repeatable quality are critical.

This case study outlines how a leading Israeli hummus producer achieved a completely new product texture – smoother, lighter and more homogeneous – using the Fristam Colloid Mixer (FCM) in combination with a Fristam shear blender and pump system.

Customer brief

A major Middle Eastern hummus producer approached Fristam via its local partner with a clear objective: to develop a new-generation hummus with a noticeably smoother, lighter and creamier texture – without changing the core ingredients.

Hummus in the Middle East is highly differentiated, with strong consumer expectations around mouthfeel and visual appearance. The customer was already producing traditional hummus using cooked chickpeas processed through a shear pump. However, they wanted to:

Significantly reduce particle size
Eliminate coarse peaks in the particle distribution
Create a visibly smoother, almost “fluffier” texture
Maintain full recipe flexibility (plain hummus and hummus with tahini & spices)
Ensure industrial repeatability for high-volume production

The challenge was not functionality — it was product differentiation through texture engineering.

Previous methods

Before trialling the Fristam FCM, the producer transferred cooked chickpeas from a tank to a Fristam shear blender which performed a standard in-line mechanical size reduction.

The Fristam shear blender reduced particle size and created a perfect traditional hummus, however, the customer wanted to create an incredibly smooth hummus – more inline with the texture of a cream, far smoother than a shear blender could reach.

The customer required tighter particle control and a cleaner size cut.

Fristam’s solution

The Fristam FCM 160 Colloid Mixer (30 kW) operating at 50 Hz was installed downstream from the Fristam Shear Blender. To maximize the potential of the shear, the FCM’s patented adjustable shear lever was set to the minimum mill setting, to produce maximum shear.

Trial set-up

1. Product Preparation
Cooked chickpeas were prepared according to the customer’s normal process. Two product variants were tested:

Plain cooked chickpeas, pre-sheared by the Fristam Shear Blender
Pre-sheared chickpeas PLUS additional tahini, water and other ingredients – the final commercial formulation.

2. Pump Feeding
During the product trials, which were held off site rather than at the customers factory – a Fristam FDS double screw pump transferred the hummus from the supply tank to the FCM under controlled flow conditions.

3. Colloid Milling (Single Pass)
The product passed through the FCM 160 at 50 Hz.
At minimal rotor-stator gap, high shear forces were generated, reducing particle size in a single pass.

4. Sampling & Laboratory Analysis
Samples were dissolved in a 50:50 alcohol/water solution and measured using a Beckman Coulter Laser Diffraction Particle Size Analyzer.
Four sample stages were analyzed before and after the FCM.

5. Data Comparison
The results were conclusive:

Mean particle size reduced to 28 µm
Standard deviation significantly improved
Particles >150 µm completely eliminated
No particle peaks

6. CIP Cleaning
After production ended, the system, including the FCM could be cleaned with a CIP cycle. By adjusting the gap in the FCM to the maximum mill setting, a high flowrate of CIP cleaned the colloid mixer thoroughly – without the need for disassembly.

The FCM enabled the customer to create a completely new hummus texture – noticeably smoother, creamier and lighter in mouthfeel, despite identical ingredients. This allowed the customer to tap into a new market of hummus type that the competitors could not offer. The repeatability will enable the customer to run their production without concern for variation occurring batch to batch.

Following the successful trials, the producer purchased two FCM units, which have been operating perfectly with no issues for over 12 months.

The FCM was integrated as an additional processing step after the shear pump, enabling both traditional and premium texture variants depending on gap settings.

Do you have any questions so far?

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Process / Product quality benefits

Drastic reduction in mean particle size
Elimination of particles above 150 µm
Significantly reduced standard deviation
Highly repeatable particle distribution
Adjustable texture via variable gap settings
Ability to produce both standard and ultra-smooth variants

Sustainability benefits

Consistent single-pass particle reduction
Reduced waste from oversized particles
Hygienic CIP-compatible design
Long service life with precision-engineered components

Financial benefits

Premium product positioning in a competitive hummus market
New product category without recipe reformulation
Reduced batch-to-batch variability
Minimized rework caused by inconsistent texture

Other benefits

Plug-and-play installation into existing lines
Suitable for both hot and cold production lines
Industrial scalability
Proven laboratory-verified results

Similar applications

The Fristam Colloid Mixer (FCM) is ideal for industrial food manufacturers requiring precise particle size reduction, ultra-smooth texture and repeatable batch consistency across viscous and semi-viscous products.

Typical applications include:

Bean-based spreads and plant-based proteins – Hummus variants, lentil dips, refried beans and legume pastes for retail and food-to-go production.
Tahini and sesame processing – Fine tahini, sesame pastes and blended dressings requiring controlled particle distribution.
Nut and seed pastes – Peanut butter, almond butter, sunflower seed paste and speciality nut spreads demanding premium smoothness.
Baby food and vegetable purées – Carrot, sweet potato, pea and mixed vegetable purées requiring tight particle size control and consistent texture.
Pestos, sauces and emulsified products – Herb pestos, mayonnaise, aioli and sauce bases where adjustable shear allows texture customization.
Ready-meal and ingredient pastes – Smooth soup bases, plant-based protein blends and semi-finished food ingredients for B2B supply chains.

For engineering, R&D and procurement teams in food production, the FCM provides a hygienic, in-line solution for high-shear mixing, blending and particle size control in modern industrial processing environments.

Frequently Asked Questions

By using a high-shear colloid mixer such as the Fristam FCM, particle size can be precisely reduced in a single pass. This tightens particle distribution, eliminates large peaks and significantly improves mouthfeel — without altering ingredients.

Find the optimal solution for your needs in the food industry

In addition to Mixing & Blending Technology – check out Fristam’s full range of Pumping Technologies suitable for the Food Industry.

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Hummus Production Optimized: Ultra-smooth texture with the Fristam Colloid Mixer