Hydrocolloids such as thickeners, stabilizers and proteins are sensitive to shear. When mixed into a liquid, agglomerates are formed initially, which must then be broken down by dispersion. During the dispersion of the agglomerates, the polymer structure of the gel that has been hydrated is destroyed. The viscosity and texture decrease irreversibly.

The solution to this problem is a technology in which the primary particles of hydrocolloid powder are separated by vacuum expansion before entering the liquid, are completely wetted when they first contact the liquid, and then dispersed in situ under vacuum conditions and hydrate the agglomerates . Freedom under overpressure. The powder dissolves completely immediately. No agglomerates are formed. No further dispersion is required. The texture is not damaged.

The Conti-TDS powder wetting and dispersing machine is different from other systems on the market. The powder is directly introduced into the liquid from the bag, hopper, container, big bag or silo without any dust and loss, and is wetted and dispersed within a few seconds. The machine works according to the rotor/stator principle. It is installed outside the process tank and connected to it like a pump. The machine recirculates the liquid together with the tank. Due to the special geometry of the rotor, a strong vacuum is generated in the dispersion chamber. Using this vacuum, the powder can be sucked directly from the powder container without dust and loss. The liquid stream is dispersed in the dispersion chamber under high shear. Under these conditions, the surface of the liquid into which the powder is introduced is greatly enlarged.

The powder always contains air in the space between the particles. The air expands under vacuum. As the vacuum increases in the process of entering the dispersion zone, the air between the particles expands. Therefore, the particles release each other. The wide distance allows each particle to be wetted easily and completely. The powder and liquid enter the dispersion chamber through completely different paths, and only gather in the dispersion zone under a defined shear gradient. It is impossible to form uncontrolled aggregates. These are ideal conditions for wetting individual particles. Compared with standard powder addition, this process helps to achieve fine distribution during wetting and ensures that the product performance is significantly better.

According to the formula, several different raw materials can be dispersed continuously and fully automatically, which can be sensed from different containers. After the solid induction is completed, additional dispersion and homogenization can be performed until the desired particle size distribution is achieved or the dissolution process is completed.

Emulsion can be produced using the same machine. Introduce and emulsify the oil phase in a solution or suspension without agglomerates. The high flow rate in the recirculation and the fine distribution of the high shear zone can produce a very fine, uniform and stable emulsion, so no additional high pressure homogenization is required in most cases.

Compared with traditional processes, powder induction and dispersion are constant and independent of the operator. This guarantees repeatability. As a result of the definition process, characteristics such as droplets and particle size distribution can be set to be reproducible.

In addition to the option of integrating Conti-TDS into existing systems, a compact turnkey system with the smallest footprint can also be provided. The possibilities here extend to fully automated process systems with automatic recipe control and documentation, including batching, weighing, monitoring and quality control.

As another feature, the Conti-TDS disperser can also be used as a CIP pump. It can carry out the tank cleaning process in recirculation and can be integrated into the online pipeline cleaning program. The machine is designed in accordance with hygienic design standards, is fully drainable and has passed 3A certification.

Not only suitable for easy powders, even the most viscous, viscous and thickened powders, such as pure milk protein, auto-soluble xanthan gum, PVP or high-concentration guar gum, can be dispersed without any problems. Liquids such as oil or syrup can also be introduced directly from the drum and emulsified or diluted. The maximum pectin concentration is possible.

For example, in the production of yogurt, ice cream premix or dessert, different thickeners and stabilizers are used. By using Conti-TDS, these hydrocolloids can be dispersed more effectively without agglomeration immediately. Their thickening effect will not be destroyed by the additional dispersion of agglomerates like traditional processes. This inevitable dispersion in the traditional process not only destroys the already hydrated thickener, but also destroys the protein structure, which requires more thickeners. Using Conti-TDS, users can save protein structures. The concentration of thickener can be significantly reduced, and the quality of the final product is higher. The saving of raw materials is very high. Lower thickener concentration and lower protein shear have a positive effect on taste and improve stability and mouthfeel.

In the traditional salad dressing production process in the vacuum process system, the hydrocolloid has never been dispersed in the form of colloids. The product passes through the downstream plate heat exchanger. After five or six batches, it will inevitably get stuck and then have to be cleaned. The reason is the gel clumps that can never be completely dissolved. These interruptions have been completely eliminated by using Conti-TDS. In addition, in addition to the related hydrocolloids, all other powder materials can now also be processed with the same machine.

When using Conti TDS, there is usually no need to pre-mix the powder. The ingredients of the formula can be weighed layer by layer in a hopper or container. Choose the layer that is most beneficial to the process.

Ystral is represented in Australia by Technomik Pty Ltd — https://www.technomik.com.au.

Image source: ©stock.adobe.com/au/fahrwasser

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