A leading Asian sauce manufacturer specializing in chili and tomato sauces faced persistent challenges in its production line. For years, the company relied on traditional stirrers to blend ingredients, resulting in two major issues: inconsistent texture—sauces often had unblended spice particles—and short shelf life (only 6 months) due to air bubbles trapped during mixing. Additionally, the slow stirring process limited daily output to 800kg, struggling to meet rising market demand.
Seeking a solution, the manufacturer invested in a 1,000L high-speed emulsifier with a 12,000rpm shear head and temperature control system. The machine’s high-speed shear force broke down spice particles to ≤10μm, ensuring a smooth, uniform texture. Its vacuum-assisted mixing also removed 98% of air bubbles, preventing oxidation that caused spoilage.
Within a month of implementation, the results were remarkable. Sauce texture uniformity reached 99%, eliminating customer complaints about gritty consistency. Shelf life extended to 12 months, reducing waste from expired products by 35%. Daily output surged to 2,000kg, a 150% increase, allowing the company to fulfill 2 new large retail orders. Labor costs also fell by 20% as the emulsifier automated mixing, reducing the need for manual stirring and rework.
“The high-speed emulsifier didn’t just fix our problems—it opened new growth opportunities,” said the company’s operations director. Six months later, the manufacturer launched a new line of low-sugar sauces, leveraging the emulsifier’s precision to maintain flavor and texture, further expanding its market reach.
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