Be profitable
Squeeze more profit out of your sauces
To boost your profitability within dressings and condiments, it’s vital to manage your costs carefully. You need solutions that are designed to streamline your operations and save on energy and ingredient costs. Whether you produce mayonnaise-based or tomato-based products – or both – our range of mixers optimises utilisation of expensive ingredients and delivers fast and energy-efficient production. Read on to see how – scenario by scenario – you can achieve the lowest production cost per kilogram and lowest total cost of ownership (TCO) compared to benchmark solutions.
Scenario: Save energy and costs in mayonnaise-based production
Use 60% less energy, cut production cost per kg by up to 46%
When you want to save energy and costs, speeding up your mixing and cleaning time is key. With the Tetra Pak® High Shear Mixer for cold emulsions you can:
- Cut heating times in half, thanks to direct steam injection
- Cut cooling times by a third, with flash-cooling option
- Cut batch times in half, by combining direct steam injection and flash cooling
- Mix four to five times faster than standard solutions with vacuum system
In the Batch plus setup, this solution also reduces energy consumption in every CIP cycle by up to 59% compared to the benchmark solution. All this can save you up to 60% on energy and cut your production cost per kilogram of mayonnaise or other cold emulsion by up to 46% compared to benchmark solutions. This also translates to cut CO2 emissions by up to 55%, helping you minimise emissions-related costs where they are in place.
Scenario: Save energy and costs in tomato-based production
Save energy, cut production cost by up to €12,000 annually
With faster mixing times and more energy-efficient homogenization, our solutions save you energy, reducing your production cost for tomato-based products. The Tetra Pak® Homogenizer with HD100 enables producers of tomato-based products like ketchup to lower pressure from, for example, 250 bar to 200 bar, without compromising on quality. This means less energy is required to achieve the same homogenization effect, enabling more energy-efficient operations. Here’s how a typical scenario for hot-break tomato products delivers a savings of up to €12,000 annually in operational costs.
| Homogenization pressure | Energy use per hour | Energy cost per hour at €0.7/kW | Saves €12,000 per year in energy cost1 |
| 250 bar | 37.3 kW | €2,611 | |
| 250 bar | 29.8 | €2,086 |
1 Scenario is based on making tomato ketchup with a Tetra Pak® Homogenizer 250 HD100 for abrasive products with mushroom valves, running 5,000 litres/hour, 20 hours/day, 220 days/yearand with 2 hours of CIP per day.
We help you test the homogenization pressure on your specific product, but in general, optimal homogenization pressure can vary between 50 - 200 bar for tomato products like ketchup with 25 to 35 Brix.
Scenario: Save ingredient costs in mayonnaise-based production
Cut required starch content by 20-30% in low-fat mayo
Thanks to an efficient new system for ingredient intake and highly accurate dosing of shear forces, the Tetra Pak® High Shear Mixer for cold emulsions can save on expensive ingredients like starch stabilisers without compromising on quality. In tests, comparing the production of a 50% salad mayo on a competitor mixer with the Tetra Pak® High Shear Mixer for cold emulsions, our solutions could match the desired viscosity with 40%2 less stabiliser content. That translates to a savings of 20 kilograms of stabiliser for every 1,500 kilogram batch of product. If you were producing 20 batches a day, for 200 days per year, this would give you an ingredient savings on stabilizers of €400,000 every year, while achieving excellent texture.
2 Based on 1,500 kg of 50% salad mayo on a competitor mixer vs. the Tetra Pak® High Shear Mixer for cold emulsions.
Scenario: Save ingredient costs in tomato-based production
Reduce tomato paste by 5%, save €192,000 per year
When producing tomato-based products, our solutions enable you to quickly and accurately dose tomato paste and avoid overshooting on expensive ingredients. You get the flexibility to work with starch and non-starch versions of recipes, while more accurate standardization saves ingredient costs. A solution combining a homogenizer, texturizer and adjustable high shear mixing gives you the ability to adjust target viscosity. In the homogenization step, for example, you can increase viscosity by creating a gel like structure. This viscosity is partly broken down by mechanical shear, so by applying in-line high shear closer to filling you can reinforce the ketchup structure and boost viscosity and glossiness. This opens up the possibility of reducing the amount of tomato paste in the recipe while maintaining desired quality. In a scenario where annual production of 16 million kilograms of ketchup previously required 4.8 million kilograms of tomato paste, this optimisation enables reduction of tomato paste content by 5%, saving €192,000 per year on ingredient costs.
More ways to profit more
Besides big savings on energy costs and ingredient costs, there are more ways to reduce your total cost of ownership and increase your profitability. Since our solutions help you increase the speed of mixing and production, that also means you can produce more within the same time frame, making every hour of production worth more. In addition, we help you calculate where you can save the most and support you in implementing cost-saving steps. For example, we support you in transitioning from batch to continuous process setup when your business grows and you need to increase capacities. Or we can support with moving from hot filling to aseptic ambient filling which removes the need for preservatives, savings ingredient costs, and saves space, time and energy in several ways, for example, by removing the cooling step in the process.
Want to know more about how our solutions have enabled producers to cut costs, increase sales and be more profitable? Contact us or check out our detailed case booklet below and let the numbers speak for themselves.
Bring more flavours to the world
What’s the secret sauce to staying competitive and profitable in the dynamic dressings and condiments segment? It’s bringing more flavours to the world. Find out how we can help you become flexible, consistent and profitable - to the lowest total cost of ownership.
