• Flavours
• Dressing and sauces
• Jams and spreads
• Fruit Juices, concetrates, pulps and soft drinks
• Seeds and mustards
• Ice cream
• Cheese spreads
• Sugar
• Hydrocolloids
• Milk solids
• Salts
• Edible oils

Flavors are added to a wide variety of the foods we eat. Although they may take several forms, flavors are commonly concentrated in an oil based liquid. Food processors must often emulsify this oil in an aqueous system using high shear mixing technology coupled with gums or other stabilizing agents to improve product quality and shelf life.

IKA® Works, Inc. has a wide range of solutions to improve product quality and process efficiency. The two steps to this process involve forming an emulsion (dispersing and reducing the droplet size of the liquids) and hydrating a stabilizer to help maintain the emulsion. Neglecting either of these steps will result in a reduced shelf life for the product.

Emulsions are formed when two immiscible liquids (oil and water) are dispersed within one another. Stability of the emulsion will depend on several characteristics of the product, most notably viscosity (thickness) and droplet size.

The higher the viscosity of the liquids, generally, the more stable the emulsion. This is because the phases cannot easily move within one another (picture an air bubble trying to rise in honey versus water). Therefore, the stabilizers often used in the manufacture of flavor emulsions include gums or other thickening agents. These ingredients, often a powder, act to increase the viscosity and thus keep the oil and water phases from separating. The challenge to the manufacturer is to effectively blend these often difficult to disperse powders. IKA® Works range of high shear mixers can rapidly and efficiently disperse these stabilizers using rotor / stator technology. The intense mixing action breaks down the agglomerates (lumps) that often form when hydrating these powders and increases the surface area exposed to the liquid, improving functionality.

IKA® Works’ value to the customer is not limited to dispersing a stabilizer. The shelf life of the product and stability of the emulsion will also depend on the droplet size of the liquids or how finely they are dispersed within one another. Illustrating this point, picture a small air bubble that sits in a glass of water for hours versus a large bubble which instantly rises to the surface. IKA®Works’ customers utilize a range of interchangeable Generators (rotor / stator tools) to tailor a single mixer to achieve a very narrow droplet size distribution of the ideal size for maximum shelf life. The multiple rows of rotors and stators coupled with the ability to utilize up to three distinct rotor / stator sets allow IKA® Mixers to overcome the forces (i.e. interfacial tension) that hinder the formation of stable emulsions. IKA® has experience forming emulsions with droplet sizes as low as 0.25m m and very tight size distributions.

1. Increased viscosity from a given amount of gum / stabilizer, due to increased functionality. This allows customers, in many cases, to decrease their raw materials usage.
2. Less wasted product. Lumps of gum do not need to be filtered out.
3. Decreased operator input. Operators must finely sift gums into a batch tank when using conventional methods, which takes a considerable amount of time. Also, filter changes / maintenance are common, as even the best operators cannot avoid some agglomeration when using these methods.
4. Increased efficiency. Conventional methods take a considerable amount of time (often hours) to hydrate a gum or stabilizing agent. IKA® Works Mixers achieve almost instantaneous hydration.
5. Fine droplet sizes / improved shelf life or stability. IKAv Works Mixers produce the finest emulsions of any rotor / stator mixer with the tightest particle size distribution.
6. Decreased process time. Alternate high shear devices will often require long process times or may not even be capable of forming the emulsion. IKA® Works’ innovative Generator designs ensure a tight, stable emulsion is quickly formed.
   

Dressings and sauces may take many forms and consistencies from thick bleu cheese dressings to light soy sauces to low calorie versions. The challenges to the manufacturer often include dispersing a gum or other thickening agent, emulsifying oil and water phases, dispersing spices or additives, and possibly milling solids (i.e. spices).

IKA® Works range of high quality mixing equipment is ideally suited to all of the above applications. We will address these in terms of dispersing the thickening agent, forming an emulsion, and dispersing / milling spices or other additives.

Smoothly dispersing and hydrating a thickening agent is one of the most difficult powder / liquid mixing applications for a food processor. These powders often form difficult to disperse agglomerates (lumps) when exposed to water. These agglomerates often take hours of process time, filtration, or application of a high shear mixer to remove. The application of a high shear mixer is the preferred method, as this results in faster process times, increased product utilization, and improved product quality. The intense shear created in a rotor / stator mixer (click on Tech Info tab for more information) breaks down these agglomerates exposing a greater surface area of the gum to the liquid phase. Thus, hydration is improved, production time is reduced, and the need for filtration is eliminated.

Emulsions are formed when two immiscible liquids are dispersed within one another. The phases (commonly oil and water) will quickly separate unless the droplet size of the liquids are reduced sufficiently. The exact droplet size required will depend on the particular characteristics of the product, but will often require use of a high shear mixing device to obtain. IKA® Works manufacturers mixers suitable for producing any type of emulsion from coarse (relatively large droplet size) to extremely fine (sub micron droplet size). IKA® Works rotor / stator mixers utilize multiple rows of rotor and stator teeth and up to three distinct stages, assuring droplet size reduction. We also offer colloid mills for even higher energy input. These devices also have three distinct shear zones and allow the operator to fine tune the shear rate with a simple adjustment.

Dispersing and / or milling a spice or other additive is another area where IKA® Works Mixers benefit food processors. Customers may select a coarse or medium shear Generator to rapidly disperse solids without degredation of particle size. However, many companies would like to purchase spices unground and wet grind them during addition to their product. This allows the customer to save money on the raw material, while getting the most flavor (think of purchasing ground or whole bean coffee). IKA® Works selection of Generators and colloid mills allow a customer to tune their IKA® Mixer to produce the perfect particle size for whatever spice they are blending into whatever dressing or sauce(s) they may manufacture.

1. Smooth, agglomerate free dispersion and hydration of gums without need for filtration.
2. Reduced raw material costs through full hydration of gums and ability to wet grind spices on site.
3. Stable emulsions and suspensions increase shelf life and improve visual appeal to consumers.
4. Perfect grind and dispersion of spices or other additives allow manufacturers to produce a product with a fresher taste.

1. Complete hydration of pectin decreases manufacturing costs through reduced process time, no wasted raw materials (no need for filtration), and full ingredient utilization.
2. bility to produce a wide range of products. Customers may use a single mixer to produce jams, jellies, or other materials by simply optimizing residence time and Generator selection.

1. Nutritional Supplements.
2. Improved product quality. These additives are often difficult to disperse and suspend. IKA® Mixers input significant energy into the product, assuring a uniform, stable dispersion.
3. Decreased process time. IKA® Works equipment allows customers to quickly and effectively add solids including inline, single pass designs!
4. Dissolving Sugar or Artificial Sweeteners.
5. Reduced heat / cooling requirements. Manufacturers must often heat the liquid to adequately dissolve the sugar when using conventional methods. IKA® Mixers high shear action allow the sweeteners to be dissolved at ambient temperature.
6. Reduced process time. Conventional methods often require hours of blending time to dissolve the sweeteners. IKA® Works High Shear Mixers not only significantly reduce the dissolving time by increasing the surface area of the solids exposed to the liquid, but also reduce the time required for heating.
7. Hydration of gums.
8. Reduced raw materials requirements. Manufacturers must often add larger percentages of gums and filter the final product due to the poor hydration common with conventional mixing techniques. IKA® Works Mixers ensure complete hydration / ingredient functionality and the high shear mixing action eliminates lumps, agglomerates, or fish-eyes. Thus, the percentage of gums may often be decreased and filtration eliminated, while maintaining product quality.
9. Hydration of flavorings or other additives.
10. Decreased production time. IKA® Works technology allows customers to blend powders into liquids inline, often in a single pass.
11. Reduced aeration. IKA® manufactures systems which allow rapid incorporation of solids into liquids without aeration or foaming.
12. Reducing particle size / pulping solids.
13. Improved product consistency. IKA® Works Mixers can handle a wide range of initial particle sizes and through the use of various Generators produce the desired size reduction within a narrow distribution.
14. Reduced capital costs. Due to the versatility of IKA® Works Mixers, a single unit may perform the functions currently done with several other machines.

1. Agglomeration of gums is eliminated. The intense high shear zones created by an IKA® Mixer break down any agglomerates, exposing fresh powder to the liquid.
2. Improved ingredient functionality. Subjecting the product to high shear ensures that all of the powder is exposed to the liquid and thus hydrated. This complete hydration eliminates waste and ensures full ingredient functionality.
3. Elimination of foaming. IKA® Works MHD powder / liquid mixer utilizes a positive powder feed, unlike the vacuum or venturi designs of competitive equipment. Vacuum or venturi systems can draw air into the system and cause foaming, especially with ingredients such as milk powder.
4. Elimination of bridging. IKA® Works MHD powder / liquid mixers employ an anti-bridging bar to ensure smooth powder feed.
5. Single source responsibility. IKA® Works will work with your engineers to tailor anything from a single component to a complete system to your process.
6. Reduced process time. Conventional methods often require hours of blending time to dissolve the sweeteners. IKA® Works High Shear Mixers not only significantly reduce the dissolving time by increasing the surface area of the solids exposed to the liquid, but also reduce the time required for heating.
7. Hydration of gums.
8. Reduced raw materials requirements. Manufacturers must often add larger percentages of gums and filter the final product due to the poor hydration common with conventional mixing techniques. IKA® Works Mixers ensure complete hydration / ingredient functionality and the high shear mixing action eliminates lumps, agglomerates, or fish-eyes. Thus, the percentage of gums may often be decreased and filtration eliminated, while maintaining product quality.
9. Hydration of flavorings or other additives.
10. Decreased production time. IKA® Works technology allows customers to blend powders into liquids inline, often in a single pass.
11. Reduced aeration. IKA® manufactures systems which allow rapid incorporation of solids into liquids without aeration or foaming.
12. Improved product consistency. IKA® Works Mixers can handle a wide range of initial particle sizes and through the use of various Generators produce the desired size reduction within a narrow distribution.
13. Reduced capital costs. Due to the versatility of IKA® Works Mixers, a single unit may perform the functions currently done with several other machines.

1. Decreased production time. Traditional methods will require solids to be finely sifted into an agitated batch tank to avoid agglomeration or foaming. IKA® Works Mixers overcome these issues with innovative Generator and powder feed designs which rapidly disperse powders smoothly and without foaming.
2. Improved product quality. The intense mixing action created by an IKA® Works Mixer ensures a uniform dispersion of all additives and a stable emulsion with a tight droplet size distribution.

1. Lower process temperatures. Sugar is traditionally processed at 180oF or higher to increase solubility. However, the intense energy and shear imparted by an IKA® Works Mixer allows customers to solubilize sugar at lower temperatures.
2. Decreased process time. Traditional methods require a long agitation time coupled with the high temperature noted above to achieve solubilization. IKA® Works Mixers can simultaneously reduce the temperature and process time required. Complete solubilization can often be achieved in a single pass through one of our high shear devices. We even offer systems to add and dissolve the sugar inline, eliminating the batch tank.

1. Rapid process time. The intense shear exerted by an IKA® rotor stator mixer ensures that any agglomerates that may form are rapidly broken down, exposing the full surface are of the powder to the liquid. Thus, operators may add powders faster and hydration occurs more rapidly.
2. Decreased operator input. IKA® Works CMS and MHD mixers will feed the powder into the liquid at a controlled rate, inline. Systems may be fully automated and include all ancillary equipment including pumps, powder feed systems, PLC controls, etc.
3. Reduced production costs. Hydrocolloids are often one of the most expensive ingredients, per pound, added to a recipe. The complete hydration experienced with an IKA® Mixer reduces waste and often results in a reduction in raw material requirements. Gum manufacturers also offer "easy to disperse" versions of popular hydrocolloids at a price premium. IKA® Works Mixers are capable of hydrating any gum, allowing manufacturers to purchase a less expensive grade of the hydrocolloid.

1. Elimination of foaming and aeration. Traditional methods involve adding the solids to the vortex of an agitated vessel or inline through a vacuum (venturi) device. These methods all allow air to enter the product and cause foaming. The IKA® Works MHD powder / liquid mixer uses a positive powder feed design, which eliminates aeration and foaming.
2. Improved product consistency. The high shear imparted on the product ensures a uniform dispersion while eliminating the agglomerates that often form when using conventional methods.
3. Reduced operator input. IKA® Works CMS and MHD mixers allow inline addition of solids to the liquid stream and may be integrated with existing plant controls.

1. Decreased process time
2. Dissolving (water based). Traditional methods often require long process times to dissolve salts. IKA® Works Mixers utilize a high shear action which rapidly breaks down the solid particles, exposing a large surface area to the liquid and speeding solubilization.
3. Dispersing (oil based). Traditional methods require batch tanks and adequate residence time to ensure a uniform dispersion. The intense shearing action of an IKA® Mixer ensures an instantaneous dispersion.
4. Higher concentrations of solids
5. Dissolving. Traditional methods are limited on the percentage of solids that can be dissolved. However, the intense energy input from an IKA® W
6. Dispersing. Traditional methods will suffer from settling / sedimentation when a certain solids loading is reached. Utilizing an IKA® Works mixer allows intimate contact between the salts and oil, forming a more stable dispersion even at higher concentrations.orks Mixer allows higher solids loading. We have accomplished over 60% solids in a single pass!

1. Degumming. This involves treating the crude oil with water and / or acid (typically phosphoric acid) to hydrate phosphatides and allow separation through centrifugation.
2. Alkali refining. The degummed oil is then treated with an alkali solution (i.e. NaOH) to reduce the free fatty acid content and remove other impurities through conversion to water soluble soaps. These soaps are removed from the oil with a water wash.
3. leaching. The oil is purified further and colors removed through bleaching. Typically, diotomaceous earth or clay is used to absorb color affecting substances. The clay and absorbed impurities are then filtered out.
4. Deodorization. Vacuum steam distillation is then used to remove volatile compounds that may affect taste, color, or odor.
5. The oil can then be either subjected to fractionation, hydrogenation, interesterification, esterification, or simply packaged depending on the properties desired in the final product.

1. Reduced additive quantities. The intense high shear mixing action (see Tech Info for more details) of an IKA® Mixer ensures intimate contact between the oil and any additives (i.e. phosphoric acid, caustic soda) allowing a smaller quantity of additive to treat a larger quantity of oil.
2. Decreased processing times. Utilizing innovative Generator designs and up to three distinct stages of rotors and stators, IKA®Mixers ensure that all components are intimately blended together. This allows additives to work more rapidly and a higher purity oil is produced more quickly.
3. Improved filtration efficiency. The IKA® CMS and MHD mixers are capable of rapidly and effectively dispersing the clay or diatomaceous earth throughout the oil. This allows a more effective bleaching process and lowers the occurrence of clogged filters.
4. Versatility. The modular concept of the IKA® Works 2000 Series Mixers allows a single unit to be adapted to a wide range process requirements.