< Previous30 Food & Drink International www.fdiforum.net MIXING AND BLENDING Mixing and blending are responsible for everything from texturizing and emulsification to incorporating powders, flakes and pellets into food products. Yet selecting the right option is paramount for process optimisation. F rom a glance, much of the equipment and machinery utilised in food plants looks similar. Yet drilling down into these processes, one can see the complex array of machines needed for different products. This is perhaps most keenly seen when it comes to mixing and blending. Mixing dry goods together, for example, requires different speeds and machinery from what’s required when mixing wet or viscous ingredients together. Understanding the difference – and installing the right equipment accordingly – is vital to process optimisation. Industrial blenders introduce different amounts of energy and high shear and high impact blending systems, all of which can have an effect on a product’s particle size, influencing consistency and texture. This is advantageous for emulsification, powders and thickeners. The latter is especially useful as stabilising and thickening agents are crucial to the end texture and quality of many products – such as salad dressings, gummy confectionery, syrups and ice creams. But incorporating these gums into a product mix can cause problems during the manufacturing process, and they can be difficult to disperse and hydrate correctly and efficiently. When added to water, most gums form agglomerates which conventional Mixing things up Food & Drink International 31 www.fdiforum.net MIXING AND BLENDING agitators struggle to rapidly break down. But by using high shear equipment, manufacturers can avoid these agglomerates from forming and achieve the desired texture, consistency and mouth feel of their products. Industrial blenders aren’t suited to every application and, in some cases, can be of detriment to a product rather than beneficial. Other options include ribbon blenders which boast dual action ribbon-shaped agitators which creates an intimate blend in a short cycle time. Thanks to the nature of this mixer, it’s ideally suited for powder blending applications where thoroughly incorporating products together is paramount. For blends requiring a gentler mixing action, there’s paddle, tumble and vertical blenders. The latter is ideal for a product that is shear sensitive, or where process parameters are critical. The blending action is gentler than the agitators seen in the ribbon blender, so for loose mixers and those of a more delicate nature, this is a better fit. Tumble blending is a rotating mixing 32 Á © stock.adobe.com/Sergey Bogomyako © stock.adobe.com/Volodymyr Herasymov © stock.adobe.com/nordroden32 Food & Drink International www.fdiforum.net MIXING AND BLENDING WORLD RENOWNED SHAKERS AND SIEVES ENDECOTTS.COM 9 Lombard Road ƒ London, SW19 3UP ƒ UK ƒ Tel.: +44 (0)208 542 8121 ƒ sales@endecotts.comEndecotts Ltd ƒ 9 AND MORE...! Consistometers Sample Dividers Laboratory Shakers & Sieves machine that, as one can deduce, mixes through a tumbling rotating action. These machines come in a variety of styles depending on the requirements, from intermediate bulk container blender, the V-shaped blender and the double-cone configuration. Agitation is often conflated to mean all types of mixing processes, but this is an oversight, eclipsing the purpose of agitation in food processing. Agitators ensure the mixing process achieves a homogenous mix faster. Given that there’s dozens of different kinds of products that require this specific kind of mixing, it’s no surprise that there are different kinds of agitators. From low shear to high shear, agitators can be used to mix, disperse and emulsify making them common on production lines. As we’ve already explored, ensuring the correct mixer or blender is in place can result in huge efficiency and process optimisation gains. This can be taken Food & Drink International 33 www.fdiforum.net MIXING AND BLENDING How to manufacture batter mixes with Silverson high shear mixers In Silverson Machines’ latest ‘How to’ video, viewers can see how high shear mixers can easily create an agglomerate-free 50/50 powder/liquid batter mix. The vigorous movement created by a Silverson Ultramix in-tank mixer ensures powders that tend to float on the liquid surface, such as flours, milk proteins and powdered egg, are quickly wetted out and a homogeneous, smooth mixture is rapidly obtained. The Ultramix can also be used to incorporate any oil or other liquids in the formulation and will rapidly disperse and hydrate thickening or emulsifying agents. The single-piece workhead is easy to clean, offering improved process hygiene. For bulk production, the Silverson Flashmix and Silverson In-Line mixers are suitable for manufacturing the batter mixes. In-Line mixers can be installed between holding tanks and subsequent processes maintaining a uniform consistency and preventing lumps from blocking the system. To find out more visit the Silverson website: www.silverson.com further still. With continuous mixing and blending, a manufacturer can meet the demand for ever more efficient processes and increase batch throughput. This can be accomplished by using several mixing receptables arranged in such a way that a batch is always being worked on at any given time. However, opting for multiple off- the-shelf options might have the opposite effect and compromise efficiency rather than enabling it. For that reason, manufacturers might be better off opting for a bespoke approach. This equipment is built to exacting customer standards and optimise specific individual processes, meaning they’re purpose-built to a manufacturer’s unique needs. With the growing number of food and drink manufacturers moving towards more specialised optimised processes to maximise quality and minimise cost, no doubt these bespoke options will become more popular still. Whatever the processing capabilities of mixing and blending equipment, one issue still remains – hygiene. Without a thorough washdown and sanitation routine in place between batches, mixers and blenders become a major health risk. When high viscosity food ingredients are mixed together, ingredients closest the vessel walls tend to move slower which affects the overall efficiency of the mixing process. Scrapers are purposefully designed to come into contact with the vessel walls to scrape away sticky ingredients and incorporate them back into the mix. But some particles can become embedded in the scraper itself, creating abrasion on the vessel walls which leads to wear. Ingredients can also collect on the scraper arm, where they can contaminate the next batch. This is just one example, highlighting the wider need for mixing and blenders to be regularly and thoroughly cleaned between batches. This does result in periods of downtime, which can be avoided if a company embraced continuous mixing operations, as outlined previously. Innovation never sleeps for food processing, and updates in mixing and blending technologies offer food manufacturers the chance to regularly evaluate and update their processes which, in turn, helps boost efficiency, process optimisation and improve product consistency. © stock.adobe.com/Renar34 Food & Drink International www.fdiforum.net FRUIT AND VEGETABLES T he COVID-19 pandemic brought about an unexpected silver lining in the form of heightened awareness of healthy eating among British consumers. With a newfound emphasis on well-being, the consumption of fruits and vegetables saw a significant uptick. According to a study conducted by the European Institute of Innovation and Technology, fresh fruit consumption increased by 33%, while vegetables saw a 31% rise in consumption within the United Kingdom during the pandemic. Consumers became more discerning, seeking out food and beverage items that not only tasted delicious but also conferred health benefits. This shift in consumer preferences is particularly evident in the popularity of products catering to specific diets such as keto A growing appetite for fruit and veg In recent years, the fruit and vegetable industry has witnessed decent growth, marked by a surge in fruit production that nearly doubled in value since 2010. The fruit production sector, which has been thriving, attained a valuation exceeding £910 million in 2021, showcasing an impressive contrast with the vegetable sector’s modest increase to £1.6 billion over the past decade. Food & Drink International 35 www.fdiforum.net FRUIT AND VEGETABLES and gluten-free, as well as those with broader immunity-boosting and mood- enhancing effects. The surge in the foodservice industry’s requirements, coupled with the increasing appetite for convenient dining options, is a significant driver of growth in the fresh fruits and vegetables market. Moreover, the soaring popularity of vegan diets has contributed significantly to the market’s expansion. When it comes to product types, organic fruits have consistently claimed the largest share in the fresh fruits and vegetables market throughout its history. Looking at the European market generally, it’s poised for steady demand, primarily attributed to the rising consumer interest in fruits like avocados, blueberries, sweet potatoes, and mangoes. The region’s health-conscious population and the quest for diverse flavours are key factors propelling market growth. Despite the promising growth in fruit production, the sector experienced a minor setback in recent years. In 2019, fruit and vegetable production in the UK totalled 3,288.5 thousand tons, a figure that dipped to 3,263.9 thousand tons in 2020. The culprits? Hot summers and unpredictable climatic conditions disrupted crop yields across the board, including vegetable crops. Furthermore, changing consumer dietary habits influenced by Western culture have spurred the demand for processed fruits and vegetables. Companies are racing to develop innovative products like cold-pressed juices and preserved fruits and vegetables to meet this demand. Consumers are increasingly drawn to products offering longer shelf lives and convenient storage options compared to traditional fresh produce. Companies are therefore continuing to focus on processing fresh goods. In the pursuit of efficiency and sustainability, key players in the food industry are making strides toward energy-efficient and multifunctional © stock.adobe.com/Alexander Raths 36 Á36 Food & Drink International www.fdiforum.net FRUIT AND VEGETABLES food processing equipment. By reducing operational costs and facilitating sustainable product development, these advancements are reshaping the industry. Leading companies like Tetra Pak have introduced cutting-edge equipment solutions that enable cost-efficient carbonation in consumables manufacturing. Energy efficiency, equipment safety, and maintenance cost reduction are critical factors propelling the growth of the food processing machinery market. Flexibility in design and the ability to switch between products with minimal downtime are also increasingly important for beverage processing. Convenience is paramount in today’s fast-paced world, and processed fruits and vegetables have emerged as preferred options for consumers seeking to maintain their nutrient intake. This shift in consumer preferences is anticipated to drive the growth of the fruit and vegetable processing market in the years to come. Private labels are seizing the opportunity to expand their economical ranges within the fruit and vegetable industry, as consumers grapple with the effects of rising inflation. However, despite these budget-friendly options, many consumers still fall short of their recommended daily fruit and vegetable www.kanegrade.com Tel: +44 (0) 1438 742242 Email: info@kanegrade.com NATURAL FOOD INGREDIENTSFood & Drink International 37 www.fdiforum.net FRUIT AND VEGETABLES intake, highlighting the need for concerted efforts to encourage healthier eating habits. Industry leaders working with health professionals to disseminate appropriate health advice could be key. For example, canned fruits represent a valuable reservoir of essential vitamins and minerals. Within the fruit and vegetable processing sector, segmentation occurs based on both product type and the type of processing equipment employed. It’s essential to dispel a common misconception about irradiation: it does not render foods radioactive and has no detrimental impact on their nutritional content, taste, texture, or appearance. The fruit and vegetable industry are doubling down on sustainability efforts, with a heightened focus on eco-friendly packaging. As 37% of UK consumers express their intent to purchase more own-label products due to rising prices, this represents a significant opportunity for private labels in the market. To unlock further growth, the industry must pivot its product development and marketing strategies. Embracing new demographics, tapping into social media trends, and promoting the allure of local and seasonal produce can all play pivotal roles in encouraging consumers to opt for fresh produce. In the United States, a survey reveals that 56% of fruit and vegetable users find it challenging to use up their produce before it spoils. This highlights an opportunity for the industry to develop products and packaging solutions that extend shelf life and reduce waste. Looking ahead, the future of the fruit and vegetable industry is closely intertwined with the continued investment in vertical farming and other forms of controlled agriculture. As technology evolves, scaling indoor farming becomes more feasible, and gene editing opens new frontiers. These developments promise tastier produce and broader accessibility to exotic fruits and vegetables, ultimately increasing access to fresher versions of consumer favourites. Whilst the fruit and vegetable industry continues to experience growth, it is increasingly diverging from fresh produce only. This is driven by changing consumer preferences, climate challenges, and advancements in processing and farming techniques. As it continues to adapt and evolve, this industry is poised to meet the demands of a health-conscious and sustainability-minded consumer base. The future promises exciting innovations and a reimagining of how we experience the “fruits” of the sector. Apply Now… 0044 (0) 20 8446 7127 info@halalfoodauthority.com www.halalfoodauthority.com London - Ireland - Belgium EXPLORE OPPORTUNITIES Get Halal Certified Halal Food Authority is an industry leading Halal Food Certification Company. We specialise in Halal Certification of Food and Non-Food items including cosmetics, logistics, chemicals, additives & aromas, cleaning substances, packaging, pharmaceutical, ingredients and much more. Our certification is globally recognised including GCC countries and other developing markets such as Saudi Arabia, UAE, Qatar, Oman, Bahrain, Kuwait, Jordan, Egypt, Malaysia, Indonesia, Singapore, Turkiye, Pakistan and rest of the world. © stock.adobe.com/MVProductions38 Food & Drink International www.fdiforum.net FOOD SCIENCE Proper hygiene, handling and storage go a long way when upholding food safety. But for the gaps in our knowledge, investigations are being made into more effectively harnessing microbiology. HarnessingFood & Drink International 39 www.fdiforum.net FOOD SCIENCE © stock.adobe.com/Pixel-Shot M icrobial contamination can occur at various stages of the food supply chain, from production and processing to distribution and consumption. In the complex web of food and drink industry, the paramount concern is ensuring that the products that reach consumers’ tables are not only delicious but also safe for consumption. Practicing rigorous hygiene in every step of the food production process is the first line of defence against microbial contamination. From the moment raw ingredients arrive at the facility to the packaging and distribution stages, clean hands, sanitised equipment and sterilised workspaces are essential. Implementing proper handling techniques ensures that at no point are harmful microorganisms given an opportunity to flourish. Whether it’s preventing cross- contamination by separating raw meats from ready-to-eat products or ensuring that machinery and surfaces are washed down between tasks, these practices form an impenetrable barrier against potential contaminants. When we ignore the importance of preventative measures such as cold and dry storage, or strict temperature control in cooking, microorganisms have free reign to cause many unpleasant and dangerous illnesses. Any imbalance or flaw in processing or storage at any stage can lead to outbreaks of salmonella, E. coli, listeria and other consequences that prove disastrous both to public health and business reputation. Vulnerable populations—including the elderly, pregnant women, children, or individuals with weakened immune systems—can be especially susceptible to contracting these illnesses and experiencing them at their most severe. Food manufacturers can implement many strategies to combat microbial threats such as campylobacter. While implementing thorough washdown procedures and appropriate cooking and storage are crucial, these alone cannot guarantee complete protection. Companies may therefore rely on laboratory testing, imaging, and other scientific methods to examine food and beverage products, as well as production lines, for any signs of contamination. Outside of common practice however, new methods of detecting microbial contamination are continuously being developed. Advanced molecular techniques, like polymerase chain reaction and next-generation sequencing, allow for more rapid and accurate 40 Á © stock.adobe.com/GorodenkoffNext >