Overcoming dip and sauce manufacturing challenges through advanced innovation and process development

The dips and sauces market continues to soar as time poor consumers look to replicate international cuisines at home. With this opportunity in mind, manufacturers need to ensure that their products pack a punch on flavour, whilst ticking all of the boxes in relation to shelf life, the even distribution of particulates, positive mouthfeel, repeatable quality and of course nutrition.

Consumer spending is under threat and sustainability objectives are high on the agenda, dictating that these objectives need to be achieved cost effectively, whilst minimising the use of water and energy.

Alongside our market leading technology partners, we’ve been working with some of the UK’s leading dip and sauce manufacturers to develop technology and process solutions that not only achieve the financial objectives of the business, but also meet or exceed consumer expectations in terms of product quality.

These are just some of the projects that we’ve been working on:

A sustainable batch process to maximise the shelf-life of pouched sauces = Lagarde Autoclaves

A vegetable sauce manufacturer were looking for a cost-effective and sustainable batch process to pasteurise their pouched product, ensuring the best quality outcome with maximum shelf-life. Lagarde’s retorting technology provided the ultimate solution, resulting in a delicious and nutritious product that meets the needs of a premium foodservice customer.

An efficient cooking solution to integrate with an existing line = Perfinox Perficooker

Perfinox’s Perficooker was the ideal solution for a leading manufacturer that was looking to consolidate production of their stocks and sauces to a single site. Integrated with their existing line, this installation offers a high efficiency cooking solution that has the flexibility of feeding into a Perfinox buffer vessel and/or Fillfast’s hot fill solution.

Upscaling production whilst ensuring consistency and positive mouthfeel for a plant-based range = Roboqbo
 The natural creamy texture and significant nutritional benefits of cashew nuts meant that they were the ideal base for Origin Kitchen’s new range of plant-based sauces.

The manual, labour intensity of their homebased process restricted production capacities and limited the growth potential of the business, whilst also potentially causing issues with product variances. Roboqbo’s universal processing system enabled them to complete all parts of the manufacturing process in one single vessel in less than a quarter of the time, whilst extending product shelf-life. The flavours were more intense and the greater shear of the Qbo enhanced the creamy mouthfeel of the product range even further.

Transferring hot-filled sauces for cold storage = Fillfast Piston Filler.    
A globally recognised manufacturer was looking for a hot-fill solution for the transfer of sauces for cold storage and then onward distribution to food service customers. Integrating with a Perficooker and / or buffer vessel, Fillfast offered the best solution in terms of sustainability and flexibility.

Every dip and sauce project is different, from the enzymatic reactions and process requirements of raw ingredients, through to the available factory space and existing lines. With almost 50 years of application experience and a market leading portfolio of sustainable technology solutions, we’re able to offer a bespoke solution for each and every project.