IKA expertise for the food industry

IKA expertise for the food industry


Nature offers a rich supply of all types of food and humans are very creative when it comes to flavorfully refining eatable natural products. Here, the market offers an oversupply. Therefore it comes as no surprise that consumers are spoiled and critical. The quantity doesn't count, quality does. For this reason, food manufacturers are always seeking innovative mixing technologies. At IKA they will find what they are looking for, regardless of the individual technical demands.

With IKA mixing technologies, products retain exclusive organoleptic characteristics and a particularly appetizing look. IKA possesses an extensive know-how when it comes to the food industry's multifaceted mixing processes:
  • emulsifying and homogenizing
  • wet grinding
  • dispersing and powder input
  • drying and mixing of free-flowing solids
IKA offers two powerful machines for the production of high-quality emulsions such as mayonnaise and ketchup: The Master Plant and the Standard Production Plant with a patented dispersing module. Both work under pressure or vacuum. During the everyday production process they ensure maximum flexibility: they can mix, disperse, suck in and moisten solid substances, temper the mixture and eventually discharge it.

IKA colloid mills and inline dispersing machines clear the way for particularly smooth spreads, horseradish and mustard matter. CMS machine developed by IKA enables the instant preparation of starch and sugar solutions in any desired amount.

Additionally, IKA is revolutionizing bread baking. IKA machines make it possible for dough masses to be produced as part of a continuous process. A particular version of the inline machine ULTRA-TURRAX UTL does not only achieve a previously unmatched productivity, but also gives the dough its own special baking characteristics. All of IKA machines and equipment meant for the food industry are made exclusively from high-quality materials. They meet the highest hygienic requirements and are scalable.

With IKA mixing technology are produced:
  • Mayonnaise
  • Ketchup
  • Mustard, horseradish masses
  • Dressings, sauces, pastes
  • Fruit puree
  • Jams
  • Flavourings
  • Spreads
  • Fruit juices
  • Juice concentrates
  • Drinks
  • Pectin-water mixtures
  • Starch solutions
  • Ice cream, milk and chocolate desserts
  • Cheese spread
  • Sugar and fruit syrups
  • Caramel
  • Salt solutions
  • Milk, soy milk
  • Yoghurts, dairy desserts
  • Edible oils
  • Tea blends
  • Spice mixtures
  • Soup powder
  • Baby food
  • Leavened dough, bread dough
  • Animal food


The most popular equipment

ProductgroupMachines and plants
 
Agitators ROTOTRON RTS 115 Motor power: 2.2 kW
ROTOTRON RTS 150 Motor power: 3 kW
 
Inline dispersers / Mills DISPAX-REACTOR® DR 2000/05 Flow rate (max.) : 2500 l/h
DISPAX-REACTOR® DR 2000/10 Flow rate (max.) : 10000 l/h
DISPAX-REACTOR® DR 2000/20 Flow rate (max.) : 20000 l/h
DISPAX-REACTOR® DRS 2000/05 Flow rate (max.) : 700 l/h
DISPAX-REACTOR® DRS 2000/10 Flow rate (max.) : 2500 l/h
Colloid Mill MK 2000/05 Flow rate (max.) : 2500 l/h
Colloid Mill MK 2000/10 Flow rate (max.) : 7500 l/h
ULTRA-TURRAX® UTL 2000/05 Flow rate (max.) : 2500 l/h
ULTRA-TURRAX® UTL 2000/10 Flow rate (max.) : 10000 l/h
 
Batch dispersers UTC 115/KT Batch size max. (H2O): 500 l
UTC 150/KT Batch size max. (H2O): 1700 l
 
Process plants MP 100 Useful volume max.: 100 l
MP 500 Useful volume max.: 500 l
SPP 100 Useful volume max.: 100 l
SPP 500 Useful volume max.: 500 l
SPP 1000 Useful volume max.: 1000 l
 
Pilot plants Labor-Pilot 2000/4 Flow rate (max.) : 300 l/h
magic LAB® with module UTL Motor power: 0.9 kW
PROCESS-PILOT 2000/4 Flow rate (max.) : 350 l/h
 
Vacuum dryers / mixers Conical Dryer CD 100 Useful volume: 100 l
Conical Dryer CD 500 Useful volume: 500 l
Conical Mixer CM 100 Useful volume: 100 l
Conical Mixer CM 500 Useful volume: 500 l
 



Applications

Alginates
Jelly
Mustard or mustard sauces
Native starches
Pectin
Polysaccharides
Processing of vegetable oils
Protein drinks
Salad sauces and dressings


Alginates
Processing in an inline process
Due to their fine particle size (fine powder) hydrocolloids tend to agglomerate and in connection with humidity, to form lumps. Therefore a quick wetting and homogeneous repartition is of great importance. It is known that heat accelerates the swelling behaviour, i.e. the increase of viscosity. It is therefore recommendable to mix the phases homogeneously at low temperature and within short time.

For the inline process, the IKA® inline powder wetting and dispersing machine of the type CMS 2000 is an ideal machine.

For continuous processes and very high concentrations, we recommend to use the IKA® mixing and dispersing machine of the type MHD 2000.


Alginates
Processing in a batch process
Due to their fine particle size (fine powder) hydrocolloids tend to agglomerate and, in connection with humidity, to form lumps. Therefore a quick wetting and homogeneous repartition is of great importance. It is known that heat accelerates the swelling behaviour, i.e. the increase of viscosity. It is therefore recommendable to mix the phases homogeneously at low temperature and within short time.

For the batch process, the IKA® ULTRA-TURRAX® UTC is an ideal machine.


Jelly
Production in a circulating inline process
In order to solve the sugar and for quick wetting and thus avoiding pectin agglomerates it is necessary to mix the components quickly under controlled shear stress. The IKA® mixing and dispersing machine of the type CMS 2000 is the perfect machine to meet these requirements.

The necessary quantity of fruit juice is in the cooking vessel, first at ambient temperature in order to avoid a too early thickening. The solid quantities corresponding to the recipe are fed to the CMS 2000 via a funnel. The CMS is sucking the solids and solves resp. disperses them in the fruit juice, free of agglomerations. It has to be taken care that the sugar is solved in approx. the same time period that is needed for thickening due to the pectin. For this purpose the product is cooked and preservatives, colorants and flavour enhancers may be added.


Mustard or mustard sauces
Production in a batch process
Sauces, dressings and pastes can generally be prepared in the following way:
1. Giving the liquid components acc. to recipe into a mixing vessel
2. The solids - in most cases starting with the mustard powder - are directly dosed into the DBI 2000/.. via a funnel and intensively mixed and dispersed in a circulating process. Care has to be taken regarding the viscosity and the speed may have to be adjusted.


Native starches
Processing in an inline process
Due to their fine particle size (fine powder) hydrocolloids tend to agglomerate and, in connection with humidity, to form lumps. Therefore a quick wetting and homogeneous repartition is of great importance. It is known that heat accelerates the swelling behaviour, i.e. the increase of viscosity. It is therefore recommendable to mix the phases homogeneously at low temperature and within short time.

For the inline process, the IKA® inline powder wetting and dispersing machine of the type CMS 2000 is an ideal machine.

For continuous processes and very high concentrations, we recommend to use the IKA® mixing and dispersing machine of the type MHD 2000.


Native starches
Processing in a batch process
Due to their fine particle size (fine powder) hydrocolloids tend to agglomerate and, in connection with humidity, to form lumps. Therefore a quick wetting and homogeneous repartition is of great importance. It is known that heat accelerates the swelling behaviour, i.e. the increase of viscosity. It is therefore recommendable to mix the phases homogeneously at low temperature and within short time.

For the batch process, the IKA® ULTRA-TURRAX® UTC is an ideal machine.


Pectin
Batch processing
Due to their fine particle size (fine powder) hydrocolloids tend to agglomerate and, in connection with humidity, to form lumps. Therefore a quick wetting and homogeneous repartition is of great importance. It is known that heat accelerates the swelling behaviour, i.e. the increase of viscosity. It is therefore recommendable to mix the phases homogeneously at low temperature and within short time.

For the batch process, the IKA® ULTRA-TURRAX® UTC is an ideal machine.


Pectin
Inline processing
When contacting water, pectin tends to form lumps that are very difficult to solve again. Therefore wetting should be made as quickly as possible while dispersing at the same time, so that the lump formation is avoided.

The best machine for this purpose is the inline mixing and homogenizing machine of the type IKA® MHD 2000/.., which at the same time mixes, disperses and homogenizes water and pectin in defined quantities.

In case of high concentrations up to approx. 8% solids it results in a nearly plastic, but already homogeneous mixture, which may subsequently be diluted again in a buffer vessel.

The moisture expansion also takes place in this vessel under medium stirring.


Polysaccharides
Processing in an inline process
Due to their fine particle size (fine powder) hydrocolloids tend to agglomerate and, in connection with humidity, to form lumps. Therefore a quick wetting and homogeneous repartition is of great importance. It is known that heat accelerates the swelling behaviour, i.e. the increase of viscosity. It is therefore recommendable to mix the phases homogeneously at low temperature and within short time.

For the inline process, the IKA® inline powder wetting and dispersing machine of the type CMS 2000 is an ideal machine.

For continuous processes and very high concentrations, we recommend to use the IKA® mixing and dispersing machine of the type MHD 2000.


Polysaccharides
Processing in a batch process
Due to their fine particle size (fine powder) hydrocolloids tend to agglomerate and, in connection with humidity, to form lumps. Therefore a quick wetting and homogeneous repartition is of great importance. It is known that heat accelerates the swelling behaviour, i.e. the increase of viscosity. It is therefore recommendable to mix the phases homogeneously at low temperature and within short time.

For the batch process, the IKA® ULTRA-TURRAX® UTC is an ideal machine.


Processing of vegetable oils
Processing in an inline process
Vegetable oils are processed in following steps:

A) Degumming
Part of the phosphatides in the raw oil are hydrogenizable with water and can thus easily be separated. The remaining non-hydrogenizable phosphatides can be separated by adding acid.
The untreated oil is heated up to 60°C - 70°C and thoroughly mixed with up to 1% of phosphoric acid. The acid is reacting with the phosphatides, thus enabling a settlement of the water. The phosphatides can then be separated by filtration or centrifuging. This results in a "degummed" oil and gum resin, from which, under certain conditions, lecithin can be produced. For a thorough mixing of acid and oil, the IKA® dispersing machine of the type DISPAX-REACTOR® DR 2000 proved to be very suitable.

B) Neutralization
Free fatty acids (FFA) are influencing the taste of the oil and accelerate its spoiling. For neutralization of the FFA the oil is intensively mixed with sodium hydroxide at a temperature of approx. 90° to 100°C. The FFA are settling as soaps and can be separated by centrifuging. The DISPAX-REACTOR® DR 2000 as well as the single stage dispersing machine of the type ULTRA-TURRAX® UTL 2000 proved to be the right machines for the neutralization of FFA.

C) Bleaching
In order to remove remaining impurities like colour and oxidation products the oil can finally be bleached. For this purpose it is intensively mixed with bleaching clay. For this process we recommend the IKA® inline mixing and dispersing machine of the type MHD 2000.


Protein drinks
Production in a batch enrichment process
Milk drinks for sportsmen are ideally produced in a batch enrichment process. The liquid ingredients like skimmed milk and water are supplied in a container. The powdery ingredients are dispersed into the liquid flow by means of a powder incorporation dispersing machine. This avoids agglomerations and the solving process is accelerated.
The solids are fed into the powder incorporation machine via a funnel. Special funnel geometries help avoiding a so-called "creation of chimneys" in the dosing vessel. This minimizes the introduction of air to the quantity enclosed in the powder, which avoids a building of foam. After the complete incorporation of the solids, the final product can additionally be circulated in the machine for further homogenisation. Depending on the recipe resp. the product viscosity a pump may be connected to the powder incorporation machine for support of the flow. The material in the vessel may additionally be mixed by means of a stirrer. After the mixing process itself, the protein drink is sterilised and bottled.


Salad sauces and dressings
Production in a batch process
Emulsions for salad sauces and dressings are usually produced in 2 steps.

First salt, colorants, preservatives, spices, etc. are dispersed into the continuous phase, i.e. water with vinegar. Preferably high shear dispersing machines of the type IKA® ULTRA-TURRAX® UTL 2000 or DBI 2000 are used for this purpose.

Adding the disperse phase, i.e. oil and a suitable emulsifier, results in an emulsion. For further stabilisation and thickening stabilisers like e.g. guar gum, pectin or xanthane may be used. Often so-called "visible" spices are added at the end of the emulsifying process.