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Visit Sauce Page 

Over 20,000 organic monthly users find us when searching for production technology in Google. We rank top #3 positions in Google globally for keywords like <em>sauce-making equipment</em>, <em>industrial cookers</em>, <em>or mayonnaise technology</em> and had over 35000 pageviews related to sauce mixing, cooking, and packaging in the last year.

Making.com is a growing platform for finding production technology

Texture and consistency are critical to foods with delicate compositions like dressings and fruit juices. But the base ingredients do not always mix into a homogenous recipe, especially in the case of emulsions such as mayonnaise.


<h3>Disperse the components uniformly into the mix</h3>
The Standard Production Plant (SPP) from IKA is a high-shear mixer for fine foods and beverages, including ketchup, plant-based cheese, and hummus. The system incorporates a two-stage unit that blends the ingredients and, secondly, disperses them homogeneously across the medium.

A rotor-stator solution achieves dispersion with a narrow particle size distribution, ensuring stable emulsions and suspensions with the longest possible shelf-life. Meanwhile, the dispersing chamber produces a vacuum to maintain a constant flow rate regardless of viscosity level.

The SPP is available in batch volumes from 25 to 4,000 liters and is equipped with spray nozzles for quick and easy clean-in-place without additional pumps.

Homogenization and emulsifying system for fine foods

When processing alternative proteins or making products such as smoothies and sauces that require multiple production steps such as cutting and dispersing, having a single system that can combine the different processes in one, makes production more practical and efficient, saving costs and time.


<h2>Fine cutting and emulsifying of food products in one solution</h2>
The Stephan Microcut from ProXES is a multifunctional food processing system for fine cutting and homogeneous emulsifying. It can provide stable emulsions and disperse solids in liquids. The unit has a pre-cutter that can reduce product sizes of 100mm down to 1-2mm. It can be installed with a single or double cutting system consisting of cutting head(s) as the rotor, cutting ring(s) as the stator, and a feeding disc. The cutting rings are equipped with knives of specific gap sizes from 0.05 to 3mm, and the feeding discs are available in different designs. Product applications include meat emulsions, marinades, sauces, vegetable, and fruit grinding, and nut grinding. The system has a unique layout for cutting vegetables, fruits, frozen products, and rework of bakery products.

Multifunctional cutting and dispersing machine

Successful innovators in the food, chemicals, and plastics industries need reliable mixing and aeration equipment for producing high-quality consistent foams. Developing new products and processes in these industries requires laboratory equipment with production-level features like automatic gas dosing and precise control of process variables to ensure results that are reproducible. Here is laboratory equipment for the development of processes that are ready to be scaled to production levels.


<h2>A fully automatic aerator/foam generator for the laboratory</h2>
The Pico-Mix from Hansa Mixer comes in two distinct variants, one for the food industry, and one for non-food industries such as plastics and chemicals processing. The machines are essentially the same as the food industry variant including design options for compliance with food industry standards and regulations. Pico-Mix is a fully automated mixing and aerating/frothing system for pumpable liquids designed for flexibility, and accuracy. The process is tightly controlled to assure reproducible results in a production setting. Typical foam densities generated are between 50 a 900 g per liter. The mixing head is temperature-controlled and includes a double-action floating ring seal. The systems provide automatic gas dosing precisely conforming to your recipe. Air volume/foam weight are displayed and controlled via a user-friendly touch control panel. Contrary to other laboratory aerators, Hansa Mixer's Pico-Mix includes a gasket-free eccentric spiral pump and temperature-controlled receiver tanks.

Laboratory aerator for food products

Large volume producers of sauces and ready meals continuously pack different product sizes into cartons. Intelligent and flexible infeed systems are needed to ensure your products integrate smoothly into the carton line at higher speeds.


<h2>Integrates packaging automation into your process seamlessly</h2>
The VENTO Cartoner from Mpac is a carton packaging system with a smart infeed system suitable for smaller single-serve packs as well as standard sauces and dressings packaging formats such as bottles, cans and pouches. The fully automatic cartoning and handeling of different product sizes at higher speeds is what Mpac is known for it the market.

The system has an open design for easy visibility of product flow and quick access to the components in case of maintenance and cleaning and is made of hygienic stainless steel. The cartoner is servo-driven and coupled directly to its components for minimum maintenance and long operating life. Their advanced intelligent machine interface that provides information on machine status, maintenance, and changeover controls based on product applications. From carton erecting, loading, transportation, and closing, Mpac ensures  production of upto 500 cartons per minute and  changeover for different carton sizes in less than 1o minutes.

Smart Industrial Sauce Cartoning System

Our Sauce Making Favorites 

Mayonnaise is created by blending oil with eggs, and then flavoring with vinegar, mustard, herbs, and spices. The eggs are a natural emulsifier that creates a uniform mixture. Ingredients are pumped into mayonnaise manufacturing equipment. First, a dynamic mixer maintains the desired level of emulsification of the mixture, which then moves on to packaging and bottling once reaching a satisfactory consistency.

Mayonnaise 

Tomato sauce is a popular ingredient for adding a sweet, slightly acidic touch of flavor to food and recipes. Sauce production involves cooking the tomatoes, removing the seeds and stems with a strainer, using a grinder or milling machine, and then further cooking to the desired consistency. Tomato sauce making equipment is used in industrial production to speed up the various preparation steps while maintaining the quality of the sauce.

Tomato sauce

Can you think of anything better than a slice of bread with some spreadable cheese for a snack? Production of cheese spread is similar to other types of processed cheese, but it contains more moisture to be soft and spreadable. Cheese spread starts with one or more types of cheese along with other ingredients and food additives such as stabilizers and emulsifiers. After mixing and vacuum cooking these ingredients, you can pour them into molds for cooling before packaging.

Cheese spread

Hummus processing begins by blending chickpeas, tahini, lemon juice and olive oil to create the simple yet versatile dip loved by so many around the world. To prove their love for hummus, the Lebanese, in 2010, made the largest plate of hummus that weighed over 10 tonnes! To produce hummus industrially, you need a hummus production line that includes processing equipment such as cookers, industrial grinders, pasteurizers and packaging equipment.

Hummus

Chili sauce is produced worldwide, but each is augmented by the cultural elements of where it is made. Most chili sauces consist primarily of chilis, though some preparations include tomato as the primary ingredient. Vinegar, sugar, and salt are added to the chili sauce making machinery, and the mixture is thickened mainly by cooking.

Chili sauce

Guacamole

Salad dressing has found its way onto dinner plates for millennia as a quick way to liven up leafy dishes. Experimentation with oil, vinegar, wine, salt, and other ingredients developed into the broad selection of dressings we enjoy today. Through a process of emulsifying the basic formula, adding additional elements, and then bottling and labeling the final mixture, consumers have easy access to reliable tastes on demand.

Salad dressing

To put into perspective, the average number of peanuts that you use to make a 12-ounce jar of peanut butter is 540 pieces. Peanut butter is widely used as a spread for most bread and biscuits. To make it, use raw peanuts and process them using peanut butter making machines.

Peanut butter

White, black and brown seeds from the mustard plant are the key constituents of this colorful and classic condiment. The various mustard production technology includes a mixer that mixes the mustard seeds with a handful of other ingredients and a mill that finely grinds the seeds to impart their characteristic flavor.

Mustard

Made from bananas, apples, strawberries and other tasty fruits, fruit purees are beloved by both children and adults around the world. Fruits that make it into the puree go through a strict selection process. Fruit puree processing line incorporates all machinery used for selecting, washing, cleaning, crushing and sieving the fruit which ensures the quality of the fruit puree.

Fruit puree

What sauce can your technology make better? 

Moliere famously said that slow-growing trees bear the best fruit. Clearly, the 17th-century playwright never ran a mayonnaise production facility.

In food manufacturing, once the recipe is developed and reproducible, every minute lost is an extra cost.

“<em>Time is money</em>,” reminds us Rolf Schmidt, “<em>But time efficiency means the highest quantity at the highest quality.</em>”


<h2>Superior dispersal starts with the droplets</h2>
As a food processing expert at <a href="https://www.linkedin.com/company/ika-works">IKA Process Equipment</a>, Rolf isn’t simply throwing around platitudes. The processing equipment firm existing for more than 110 years, has developed a unique dispersing machine for uniformly dispersing the oil phase in the aqueous phase at high speed.

“<em>We have put our very long experience in dispersing techniques into our dispersing machine DBI</em>,” says Rolf as he explains the technology of the Standard Production Plant (SPP) series. Conventional machines add the oil to the water and then often need to further homogenize the mixture, whereas the IKA machine allows to shorten this process.

The IKA technique comminutes oil materials directly when distributing them into the circulating water. The heart of the system is the rotor-stator. As the oil phase travels through the high-shear mechanism, it breaks down into uniform fine droplets.

Mayonnaise is around 80% oil, whereas making mayonnaise on an industrial scale starts with a 100% water phase and introduces oil droplets at high intensity until they reach the accurate recipe ratio. Directly dispersing the oil in the mixture shortens the processing time and increases the dispersal efficiency.
<h2>Process 500 liters of mayo in 5 minutes</h2>
Rolf points out that it’s not only the way of downsizing drops that make the technique faster: “<em>Our solution actively pumps the oil into the dispersing machine, injecting it with a higher speed than in common systems.</em>”

The unique design of the dispersing machine facilitates the efficient dispersal of the droplets. It allows to integrate the oil faster and more efficiently than in common systems. In Rolf’s customer experience, this often decreases the processing time by more than half. In fact, the SPP 500 system can produce 500L of mayonnaise in just 5 minutes.

With new varieties launched every year, the mayo market has been evolving rapidly since the original recipes of 18th-century France. That was long after Moliere’s time, but had he tried the condiment, he would have discarded his own advice and advocated instead for faster production.

Make a batch of mayo before you can finish a bag of fries

Caboc? Nope. Crowdie? Nope. Lanark Blue? Nope. Bonchester cheese? Nope. Oh, wait… Did we say Scottish cheese?

We meant the Scottish Sheese!



From the beautiful Isle of Bute in Scotland, <a href="https://www.buteisland.com/" target="_blank" rel="noopener">Bute Island Foods</a> was the first company in the UK to produce vegan cheese alternative Sheese in 1988. The company’s first vegan cheese was a cheddar style soya-based cheese alternative.

Made with coconut oil and without hydrogenated fat or palm oil, Sheese products are gluten and lactose-free.

Winning is hard work and determination, and that’s why, with over 30 years of experience, the company received more awards than you can imagine. One of the latest examples was the victory of Smoked German Style as the Best Vegan Cheese 2019.

Over the years, the company increased its range of Sheese blocks, Creamy Sheese, Grated Sheese, and Sheese slices with different formats and flavors.

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#Changemaker: From Scotland, the award-winning vegan cheese that is taking the market by storm

There was a period when ketchup bottles looked more like poster colors than condiments. The fad filled retail shelves with edgy ketchup palettes of purple, blue, green, pink. But the introduction coincided with a growing appetite for unprocessed food ingredients, and producers quickly reverted to red ketchup.

Most consumers will not be aware of lycopene, the compound that gives tomatoes their pigment. However, they know that the natural color of ripe berries is a rich red. The era of multicolor ketchup was, alas, short-lived.

But ketchup is more than tomato sauce. The classic recipe combines vinegar, sugar, and seasoning into the base sauce. Cooking combines the aromas and reduces the sauce into a denser liquid. But while it enriches the taste and texture, the rise in temperatures turns the glowing red of the tomatoes into a fading brown.


<h3>Natural pigments on red alert</h3>
“Conventional industrial cookers subject the ketchup mixture to temperatures up to 100°C,” explains Maurizo Pettini from Frigojolinox. The elevated heat diffuses the natural pigmentation and makes the orange and yellow undertones of lycopene more pronounced.

The discoloration can be corrected with food-grade additives, often Allura Red AC (E129 / FD&amp;C Red 40). However, preserving the original red pigment of the tomato sauce minimizes the degree of color adjustment required.

The trick is to balance temperatures with atmospheric pressure. Cooking the ketchup mixture under a vacuum reduces the thermal stresses considerably, circumventing the 'burn’ effect caused by traditional high-heat cookers.

“Vacuum cooking is conducted at around 50°C and removes a significant measure of the thermal burden from tomatoes,” Maurizio tells us. The decreased pressure lowers the boiling point of the moisture content in the sauce and the water in the vacuum cooker.
<h3>Take the pressure off color, texture, and taste</h3>
Lycopene perishes under intense heat, but the vacuum technique treats them gently. While the ingredients combine and thicken into ketchup, the tomatoes retain vivid redness.

But that is not the whole story, Maurizio points out. Besides the color, vacuum cooking develops other organoleptic qualities. It controls the extraction of water which regulates the viscosity levels. Meanwhile, the low temperatures prevent the caramelization of sugars that often produce off-tastes.

The vacuum technique protects the natural color of tomatoes and produces more authentic ketchup hues. However, that is no guarantee that the polychromatic craze will not make a comeback.

Ketchup shows its true colors with vacuum cooking

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