Toothpastes are usually either white abrasive pastes or clear gels. Although the formulation varies, many of their ingredients are common. These may vary from country to country, depending on the laws regarding the use of ingredients, etc. Manufacturing process The processing methods vary depending on the type of product and the ingredients used. A typical process can be described as follows: First, the base liquid is prepared – water, sorbitol/glycerin and other liquid ingredients Rheology modifiers may be pre-mixed with a non-aqueous liquid such as glycerin or flavoring oil or mixed with other powdered ingredients to aid dispersion. The active ingredient, sweetener and preservative are added and dispersed. Abrasive/filler is added, which may be prepared as a water slurry or pre-mixed with water to make it compatible with the liquid base. Flavoring, color and essence are added. In the last step, the detergent is gradually added with slow, rapid mixing to minimize foaming. This step is typically done in solid form, so avoid adding water to the formulation at this stage.   Process Challenges Bubbling is a major problem in toothpaste production. All powders contain a certain amount of air and detergents can exacerbate the problem. To overcome this, mixing is usually done under vacuum. Other problems that can be seen include: Rheology modifiers cause lumps to form that are difficult to break up with a mixer. Adding the compound to other liquid or powder ingredients increases process time and costs. Some rheology modifiers require high shear stress to achieve maximum efficiency. Some ingredients, such as hydrated silica, have low densities and are very difficult to mix and wet. Conventional mixers, especially when mixing powders, introduce air into the mix. Abrasives such as calcium carbonate can be supplied as a slurry and the mixing equipment must be able to break them apart. Solution provided by Arkan Felez Company Manufacturing of all types of toothpaste can be done using Arkan Felez Company’s vacuum homogenizer mixer. The high viscosity and abrasiveness of toothpaste make it necessary to use high-power homogenizers as well as high-speed lump breaker mixers manufactured by Arkan Felez Company. Key points Prepare the liquid base before adding fillers and abrasives. Before adding detergents and thickeners, mix the mix thoroughly, especially in cases where fillers such as calcium carbonate are used as water dough. Advantages of using a vacuum homogenizer mixer Manufacturing time is significantly reduced. Rapid mixing and wetting of powders. Product quality and stability are greatly improved. With the vacuum operation of the homogenizer mixer, the possibility of product bubbling can be minimized. At the end of the process, deaeration of the process components is possible.

Tomato sauce is used in many food products, including frozen foods, pasta sauces, sandwiches, pizzas, and as one of the most common food condiments. A tomato sauce is usually made entirely from tomatoes or from tomato paste. It also contains water, sugar, vinegar, salt, and seasonings. The desired viscosity is usually achieved by using starch-based thickeners. Ketchup is a type of condiment made from similar ingredients, although tomato paste is used in its production instead of tomatoes. Highly concentrated ketchup sauces obtain their viscous content from a combination of water trapped in the fibrous strands in the tomato paste and the gel-like effect of the pectin substance present in the tomatoes. A homogenizer is used to obtain the desired viscosity. This is common with lower concentration ketchups, which may also contain starch-based thickeners. Ketchup and tomato sauce manufacturing process The process recipe and the appropriate viscosity for ketchup and tomato sauce can vary depending on the intended use of the final product, but typical process requirements are as follows: The mixing equipment must be capable of completely dissolving the powdered ingredients in the water so that the product does not clump. If the product is made entirely from tomatoes, it must be thoroughly ground before being added to the mix. Insoluble particles in the tomatoes must be thoroughly dispersed and ground to achieve a smooth, uniform texture. The carotene pigments in the tomatoes must also be thoroughly dispersed to provide the proper color. To increase the water-holding capacity, the fibrous strands in the tomatoes must be thoroughly dispersed, which increases the viscosity. After mixing, the product may be passed through a homogenizer to achieve the required consistency. Production Challenges Manufacturers face challenges when using conventional mixers and agitators: Additives added to the product to increase the consistency of the product become lumpy when dissolved, and conventional mixers are unable to disperse them. Incompletely dissolved materials may stick to the walls of the tank or mixer. It takes a long time to achieve the final mix and complete the production process. Dissolving tomato paste in water takes a long time, because conventional mixers cannot mix liquids of different viscosities. To pass the mix through the homogenizer, the product particles must be completely dispersed. Conventional mixers are not able to do this process. Several operations may be performed through the homogenizer to obtain the desired product. Excessively long mixing time destroys the texture of the product and damages the water holding capacity, resulting in the desired color not being achieved. The homogenization and mixing process can damage the texture of the final ketchup sauce product. The mixing process of products that are completely made from tomatoes may cause the final product to become bitter. The solution provided by Arkan Felez Company The Arkan Felez Company’s vacuum homogenizer mixer can solve these problems and eliminate the need for additional processes such as crushing, defoaming, and some additional homogenization steps. The vacuum homogenizer mixer can be used in all stages of the production of tomato sauces and ketchup. Some of the advantages of using these mixers are listed below: It significantly reduces the process time. Rapid dispersion of thickeners and stabilizers and prevention of their caking Improved performance of the raw ingredients Smooth and uniform texture and improved product consistency Improved color The product fed to the homogenizer is uniform and uniform and its particle size is small, allowing for faster processing through the homogenizer. Since the entire manufacturing process is under vacuum, the baking process takes place at a lower temperature than atmospheric mixers, so the final product has a better color.

Mayonnaise is an oil-in-water emulsion that can contain up to 80% oil. Starch-based thickeners are used in low-fat products to replace the viscosity and bulking effect of the oil and ensure a stable emulsion. This process is often carried out semi-automatically and under vacuum. There are many applications for mayonnaise. It is very common to use mayonnaise in large volumes for the production of salad dressings and in small volumes for manufacturers of ready meals, salads and sandwiches. Therefore, mayonnaise must be produced in a way that allows for much greater flexibility. Mayonnaise production process In the first stage of production, eggs, which are used in liquid or powder form, are dissolved in water, which acts as an emulsifier. The ingredients of the aqueous phase are added and dissolved in the water. Oil is then added, which significantly increases the viscosity of the product by forming an emulsion. Manufacturing Challenges The water phase ingredients are only a small part of the total formulation, but they perform critical functions in the process. The mixing equipment must be able to disperse and homogenize these ingredients well in a relatively small volume of water. If the eggs and other emulsifiers are not properly dispersed and homogenized, the emulsion can easily break during the oil addition stage. Dispersing and homogenizing stabilizers and thickeners is one of the most difficult operations in the mixing process. To complete this process, the solution is to run the dispersion operation for a longer period of time. Bubbles can easily form and cannot be removed by stirring alone. Because of the high oil content in the mayonnaise recipe, the emulsion can break if the oil is not added to the water phase correctly. This is very difficult to control when adding oil manually. The oil droplets must be as small as possible to maximize the oil level in the water phase to ensure a stable emulsion. This is not easily achieved without specialized equipment. To maximize product shelf life, the amount of bubbles in the product must be minimized or completely eliminated. Solution provided by Arkan Felez Company Arkan Felez Company offers a vacuum homogenizer mixer to produce mayonnaise for the market and solve production challenges. This unit is capable of performing the entire process including rapid preparation of the mix, dispersion of thickening and stabilizing agents, and preparation of the final oil-in-water emulsion. Ideal for small volumes intended for immediate use. Due to the fact that the mixer is under vacuum, it prevents the formation of bubbles in the mix and its deterioration. The fully automatic PLC system virtually eliminates operator errors. The consistency and stability of the mayonnaise produced in the factory without spending high costs puts it in the top mayonnaise producers in Iran (most of them use mixers manufactured by Arkan Felez Company). The performance of the raw materials is maximized, as the thickening agents are fully hydrated and other ingredients are properly dispersed. Vacuum homogenizer mixer is designed to achieve high viscosity products without the need for additional pumps or auxiliary equipment. Easily adapts to changes in product type and recipe.