Two heat exchangers and a homogenizer have allowed a smooth beverage processing transition for this dietary supplement manufacturer.
Anna Webber/Stringer via Getty Images
When a company takes on new processing endeavors, challenges can derail momentum. But with the right equipment, processors can make progress and put out quality products. Superior Supplement Manufacturing uses tools to do just that, citing the use of heat exchangers and a homogenizer as important pieces to its juice and viscous-liquid operations.
The Fountain Valley, Calif.-based company primarily functions as a dietary supplement contract manufacturer but has dived into the world of beverage processing with intention.
“At Superior Supplement Manufacturing, we’ve expanded into functional beverage manufacturing over the past few years, and having the right processing equipment has been key to our success,” says CEO Jake Hyten.
Exchanging heat for juices and blending for thick liquids
For temperature treatment of its juice products, Superior is making use of an Alfa Laval plate heat exchanger, which Hyten says is “one of the most critical pieces” the company relies on.
“We use it primarily for pasteurizing juices and cooling beverages before bottling,” Hyten adds. “Its ability to precisely control temperature helps us maintain both flavor and nutrient content, which is a big deal for the health-focused products we make.”
The heat exchanger works by efficiently transferring heat between two fluids through a series of thin, corrugated metal plates, helping achieve the precise temperature control Hyten speaks of.
In addition, the company has implemented a Waukesha Cherry-Burrell scraped-surface heat exchanger for processing fiber-rich or viscous drinks. These drinks include plant-based smoothies and products fortified with inulin, a soluble dietary fiber. Hyten says the scraped-surface heat exchange setup prevents fouling, or product buildup, which used to be a “constant headache with traditional systems.”
Contrary to plate or tubular heat exchangers, scraped-surface heat exchangers mechanically scrape the heat transfer surface during operation, which makes them effective for tough-to-handle beverage products.
To achieve smooth textures and retain nutrients, Superior has also added an ultrasonic homogenizer from Hielscher, which Hyten touts as “a game-changer for emulsifying fat-soluble ingredients and delivering a clean mouthfeel without using gums or synthetic additives.”
Ultrasonic homogenizers differ from conventional homogenization methods in five ways.ProFood World
Operational and workforce benefits, challenges
Hyten acknowledges the challenges the equipment presents, including expenditure and effort toward care.
“Of course, there are always tradeoffs. These systems require a significant upfront investment and ongoing maintenance. Scraped-surface units, for example, have moving parts that need routine care, and ultrasonic homogenizers can overprocess delicate ingredients if not tuned properly,” Hyten says. “But the benefits far outweigh the challenges.”
The heat exchangers and homogenizer provide well-rounded benefits to Superior’s operations and workforce.
“Collectively, these technologies have significantly increased production efficiency while improving overall product consistency,” Hyten says. “Because the systems are highly automated and CIP-compatible, less time is spent manually monitoring or cleaning equipment and more time on quality control, product development, and process optimization. This shift has not only helped scale operations without the expansion of labor force but also opened up opportunities for cross-training and internal advancement.”
Moreover, the production efficiency ultimately helps Superior save and make more money.
“Financially, the equipment investments pay themselves off through reduced ingredient waste, minimized downtime, and being able to launch new SKUs faster, leading to both cost savings and new revenue streams. It's been a win across the board for both operations and the workforce,” says Hyten.
Superior Supplement Manufacturing’s equipment choices are partially a result of staying aware of its needs. Hyten recommends processors keep the specifics of their operations in mind when considering tools.
“If I had one piece of advice for other beverage manufacturers, it’s this: don’t just buy based on volume or brand name,” Hyten says. “Think about the types of ingredients you’re using, your CIP requirements, and the consistency you want across your product line. The right equipment won’t just streamline your production; it’ll elevate your product quality and brand reputation in a crowded market.”
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