multi-step mixing method

The multi-step mixing method describes a multi-stage process for producing high-quality powder mixtures with defined liquid additions. First, selected powdered components are charged into the mixer. The mixing tool then produces a homogeneous powder mixture. Next, a liquid is added. This is done slowly and in small doses while the mixing tool is running so that the liquid is distributed evenly and no localised over-moistening occurs.

Recipes in the food industry are particularly complex. An instant mixture can contain more than 30 different powders and more than five liquid components. The requirements for the end product are high. A mixture should be homogeneous and resistant to separation. It should be dust-free, free-flowing and precisely dosable. It must dissolve quickly and disperse well in water. The product should appear fresh and as natural as possible, especially in the case of coarse ingredients such as herbs, dried fruit or dried vegetables. It should be stable in storage, tasty, digestible and reproducible in production.

Many of these product characteristics are significantly influenced by the mixing process. Certain powder components can absorb liquids well without clumping or becoming overly moist. Other raw materials tolerate high shear energy and can be intensively wetted with highly viscous liquids. Ultra-fine powder components can easily "coat" over-moistened mixtures. In doing so, they bind free moisture, fix dust particles and contribute to the dedusting of the overall mixture. This targeted use of raw material properties is a key advantage of the multi-step method.

The process follows a structured sequence. First, the most robust components are placed in the mixer and moistened. The mixing process is then briefly interrupted, additional powder types are added and the liquid application is adjusted. This increases the filling level in the mixer step by step. This process is repeated until all standard resilient raw materials have been processed. Very fragile ingredients such as vegetables, fruit, croutons, meat preparations, dumplings or potato pieces are only added at the end of the process. They are gently folded in so that their structure is preserved.

Such process chains often arise from the separate preparation of individual premixes in small mixers. These are transferred in sequence to the main or final mixer, where they are combined.