A beverage processor developed a premium ready-to-drink cold brew beverage formulated with whole milk powder. The product was manufactured in 12,000-liter batches using a powder mixer with an inline recirculation loop.
While the existing system achieved initial dispersion of the formulation, the processor encountered a shelf-life issue after scale-up. After approximately one month on the shelf, the beverage began to show visible fat separation. To address this, the product label required a “Shake before use” instruction.
This created an additional challenge because the product was stored in glass bottles, where visible separation is more noticeable to consumers at the point of sale. For a premium beverage, this presented a risk to brand perception and reduced the clean, ready-to-drink presentation the processor wanted to achieve.
The processor needed a solution that would improve emulsion stability, eliminate visible fat separation, and fit within the existing production system without major disruption.