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Company Cases about Beverage Manufacturer Cuts Batch Time by 87.5% with Inline Dispersing Emulsifier

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Beverage Manufacturer Cuts Batch Time by 87.5% with Inline Dispersing Emulsifier

2025-11-06

Beverage Manufacturer Cuts Batch Time by 87.5% with Inline Dispersing Emulsifier

 

A leading North American beverage company specialized in premium soft drinks faced persistent production bottlenecks. Their traditional process relied on tri-blenders and piston homogenizers to mix gums, sugars, flavor oils, and preservatives into syrups. This method required multiple passes to avoid lumps, took 6 hours per batch, and incurred high maintenance costs for the homogenizers. Additionally, inconsistent oil droplet sizes often caused “color ringing” in bottles, compromising product quality.
To address these issues, the company adopted Aipuweier’s inline high-shear dispersing emulsifier. The equipment’s advanced rotor-stator system and dedicated CIP port enabled lump-free dispersion of powders at 95 lbs/min and efficient incorporation of oil at 9 USGPM—all in a single pass, eliminating the need for recirculation. Its precision engineering achieved oil droplet sizes ≤0.5 microns, forming a stable emulsion that eliminated color ringing. The 316L stainless steel construction also met strict food hygiene standards.
The results were transformative. Batch time plummeted from 6 hours to just 45 minutes, a reduction of 87.5%. Maintenance costs dropped significantly as the piston homogenizer was no longer required. Product consistency improved drastically, with uniform texture and color across all batches. The company scaled production efficiently with Aipuweier’s high-capacity model, handling 400 lbs/min of ingredients, and expanded its premium product line with consumer satisfaction rates rising by 22%.
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