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dressings and sauces case study

Dressing Processor Boosts Output 56% with Admix Rotosolver® High Shear Mixers

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INDUSTRY
Prepared Foods
Application
High-viscosity dressings and sauces
KEY PRODUCT
Rotosolver® High Shear Mixer
CHALLENGE
Inefficient batch sizes, inconsistent mixing, downtime, and underutilized capacity.
SOLUTION
Tank-mounted Rotosolver® high shear mixers.
Admix-Rotosolver-head-HR-flipped

 

56% increase in output
17% capacity recovered
33% energy savings per tank
100% elimination of milling step

CHALLENGES

A leading manufacturer of dressings and sauces was operating with six 750-gallon (2,839.06-liter) processing tanks. Four 150-horsepower mixers, each mounted on hydraulic lifts, serviced two tanks each. As demand increased, the processor planned to  expand with eight additional tanks—but their existing mixing technology posed several limitations:

  • Inconsistent product quality: To fully incorporate high-viscosity ingredients, operators had to raise the mixer near the surface. This led to variable mixing results between batches and between operators.
  • Reduced capacity: Despite using 750-gallon tanks, operators were limited to producing only 625 gallons (2,365.88 liters) per batch due to mixing limitations—a 17% capacity loss.
  • Operational bottlenecks: One mixer served two tanks, causing frequent delays when the second tank sat idle waiting on the shared mixer.
  • Single point of failure: If the shared mixer went down, both tanks were out of commission, cutting production capacity significantly.

THE SOLUTION

The processor evaluated alternative mixer technologies and selected the Admix Rotosolver, a high shear mixer known for its efficient, vigorous mixing and superior batch consistency. After installing six Rotosolvers on the new tanks, the processor saw immediate improvements:

  • Lower energy consumption: Horsepower dropped from 150 HP to 100 HP per tank, delivering significant energy savings.
  • Increased batch sizes: The processor could now run full 750-gallon  (2,725.5 liter) batches on every formula, maximizing tank capacity.
  • Improved consistency: The Rotosolver’s high flow and shear performance eliminated the need to raise the mixer for ingredient incorporation, ensuring homogeneity throughout the batch.
  • Reduced capital cost: Installing one fixed Rotosolver per tank was more cost-effective than purchasing fewer mixers on lifts serving multiple tanks.
  • Increased reliability: Each tank operated independently. If maintenance was needed, only one tank was affected—keeping production moving.
"Not all high shear mixers are created equal.
The Rotosolver stands apart with its performance, reliability, and cleanability."

- Dressing Processor

THE RESULTS

After two years of running the six new Rotosolver-equipped tanks, the  processor scrapped their eight existing ram-lift systems and replaced them with eight more Rotosolvers.

Key outcomes:

  • 56% more output per two-tank Rotosolver kitchen compared to their previous generic mixers
  • Eliminated milling for all dressings
  • Higher percentage of “Right First Time” batches due to improved batch-to-batch consistency
  • Reduced overall equipment footprint by switching to a fixed tank system

WHY ROTOSOLVER

Admix-Rotosolver-full-head2bThe Admix Rotosolver has set the standard for high shear mixing in the
food, beverage, and chemical industries. Its patented one-piece mixing
chamber ensures efficient emulsification, powder dispersion, and particle
reduction, while the open design guarantees hygienic clean-in-place (CIP)
compatibility.

With its high shear, high flow design, the Rotosolver delivers:

  • Faster batch times
  • Energy savings
  • Improved product quality
  • Unmatched batch-to-batch consistency
  • Compliance with 3A sanitary standards

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