Before we talk about food emulsifying process, we should know what is emulsifying. Emulsifying is the process of forming or producing an emulsion. It is a mixture of two liquids that don’t fully combine or are immiscible. It consists of small droplets or globules of one liquid dispersed in another liquid. For example, mustard helps to emulsify a vinaigrette. An emulsion is a mixture of two or more liquids that are normally immiscible (un-mixable or un-blendable) owing to liquid-liquid phase separation. Emulsions are part of a more general class of two-phase systems of matter called colloids. For example, mayonnaise is an emulsion of oil and vinegar. Some common examples of emulsions are mayonnaise, milk, lotions. Briefly, emulsifying is a process to create emulsions.
Well, we can divide food sauce in two types - Hot food sauce and cold food sauce. Hot emulsion sauces include Sabayon (Zabaglione), Hollandaise sauce and bearnaise sauce etc. Cold emulsion sauces includes vinaigrette and mayonnaise etc. Berbica technology company has different machines apply to different food sauces production.
Mayonnaise, is a basic cold sauce which can be used as a base to make lots of other sauce. Raw materials include egg, food oil (usually sunflower oil or olive oil), vinegar and other flavour additives. Berbica BSP standard emulsifying mixer is suit for mayonnaise, custard cream and other similar food emulsion sauces. Our technicians have done lots test, that the fast process of one batch mayonnaise can be done in 7 minutes in our BSP high efficiency homogenize kettle. BSP emulsifier machine is optional to choose heating system and vacuum system (to remove air bubbles inside of the emulsion). Usually we suggest our customers to get the machine with those optional functions-- On one hand, it can be always ready for future production expending with other types of hot emulsion sauce, on another hand the cost for those functions are not that much.
Chilli sauce, is another cold sauce emulsion, some people can’t live without it (spicy). While the main raw material - dry peppers are solid kind and people can't put it directly into a common homogenizer kettle. Then it comes to the turn of Berbica BC Colloid Mill machine. We have a customer in Singapore use our Colloid mill to produce chilli sauce, and they ordered two more sets of the same machines a few months ago to expand their business. Refers to another post -Two sets of colloid mill machines connected through pipes. The first set of mill machine makes dry peppers into rough sauce, and the second one produce the final fine pepper sauce. People can add additives (flavors like salts etc) through the hopper during the milling process. Some factories pump the fine chili sauces into a blender mixer kettle and add the food ingredients into the kettle and then transfer to the packing working lines. I can eat just a little spicy sauce by the way. lol.
Ketchup, some make it in a hot way. Here only share one of Berbica clients’ experience. We have got a customer from Sudan, they ordered our BH easy stand high shear homogenize mixer machine to process tomato sauce, combines a moveable jackets tank 300kg capacity. The tank equips with electric heating system through jacket water. Put rough tomato paste into the tank, add flavors of sugar and salt etc, turn on heating system and control the temperature at 60C~80C, low down the homogenizer shaft under the paste liquid level, turn on homogenize and speed adjust step by step, maximum 3,000 RPM under 50hz, a few minutes later when the paste changes into a very fine sauce. Anyway, this is a very easy process, economical way which is suit for small batch of business. Of course, if counts from fresh tomatoes, people need to use clean equipment, peal machine and cut machinery, make into rough paste then emulsify into fine ketchup sauce with flavors.
Nowdays, people focus a lot on food health and very strict with a food workshop. BVM high shear homogenize and BSP standard emulsifying plant, even BM mixing tank is more recommended for food sauce process, since it can finish the process in a closed cycled kettle system, reduces the contact air time during the whole production loop. Well, most workshops shall meet GMP standard and the environment in the room is good enough.
