Process / Product quality benefits
- Uniform single-digit micron oil droplet size for stable emulsions
- Consistent shelf stability without phase separation
- Repeatable batch-to-batch emulsion quality
- Reliable single-pass inline high-shear emulsification
Previously unsuccessful methods
The dressing was produced in 600 lb batches using an in-tank high-shear mixer, where all ingredients were loaded from the top and mixed until final consistency was reached. However, in-tank shear created uneven energy distribution, meaning:
- Portions of the batch received insufficient shear
- Oil droplets were not uniformly reduced in size
- Emulsion stability varied between bottles and batches
- Shelf separation remained unresolved
This highlighted the limitation of tank-based shear versus full-flow inline processing.
Fristam’s solution
Fristam recommended installing an FS inline shear blender downstream of the existing positive displacement pump. The FS rotor-stator system applies intense, controlled high shear to 100% of the product in continuous flow – with this method, none of the product could “hide”.
Flow rate and FS rotor speed were adjustable, allowing engineers to dial in precise emulsification performance for each formulation.
Trial set-up
1. Dressing ingredients were first combined in the existing batch tank agitator to create a pre-mix, just as before.
2. The pre-mix was transferred using a Fristam positive displacement pump toward the filling line.
3. An FS inline shear blender was installed downstream of the pump within the transfer line.
4. The product passed through the rotor-stator shear zone, where oil droplets were reduced to single-digit micron size.
5. The positive displacements pump flow rate and FS rotor speed were adjusted to achieve the target emulsion stability.
6. The fully emulsified dressing proceeded directly to filling, where shelf stability and visual consistency were confirmed.
A successful outcome with the Fristam FS Shear Blender
By integrating the FS shear blender, the manufacturer achieved a uniform, fully stable emulsion that remained blended through storage and retail shelf life.
Crucially, this improvement required no change to the overall production process or existing equipment, delivering rapid quality resolution with minimal CAPEX.
The processor now relies on tank pre-mixing followed by single-pass inline emulsification, ensuring consistent droplet size, batch uniformity and reliable product performance.
Sustainability benefits
- Lower product waste from unstable emulsions
- Reduced energy consumption compared with extended tank mixing
- Efficient use of existing processing infrastructure
Financial benefits
- Resolution of retail shelf quality failures
- Avoided major equipment replacement or process redesign
- Reduced product rejection and rework
- Cost-effective retrofit installation
Other benefits
- Hygienic inline design suitable for condiment manufacturing
- Seamless integration with Fristam positive displacement pumping systems
- Adjustable shear enabling multi-recipe flexibility
- Strong value for OEMs, integrators and CAPEX decision-makers