PL Powder Dissolver Cuts Syrup Production Time by 50% and Improves Safety

Application Overview
A major North American producer of flavored malt beverages and hard seltzers was expanding production to meet rapidly growing consumer demand. Their process involved creating concentrated flavor syrup batches containing sweeteners, acids, preservatives, flavors, and other powdered ingredients that would later be blended with water and alcohol to create finished beverages.

The Challenge
Traditionally, syrup production required operators to work from elevated platforms or mezzanines, manually dumping bags of ingredients into large tanks to be mixed by an impeller agitator. This process created several challenges, including operator safety concerns, dust generation, ingredient loss, and lengthy mixing times while powders were incorporated into the batch.

As the company designed a new production facility dedicated to supporting continued growth, they sought a better way to handle powder incorporation and syrup preparation.

The processor required a solution capable of:

1. Safely incorporating powdered ingredients without requiring operators to work from elevated platforms.
2. Rapidly mixing ingredients such as citric acid, malic acid, sodium citrate, potassium sorbate, flavorings, and sweeteners into syrup batches.
3. Reducing dust, ingredient loss, and housekeeping issues associated with traditional tank charging methods.
4. Supporting high-volume production while maintaining batch consistency.
5. Improving operator ergonomics and simplifying ingredient handling.

Solution: The Fristam PL Powder Dissolver
Working with their process equipment supplier, the beverage manufacturer selected Fristam PL03 Powder Dissolvers for the new production facility. Six PL units were installed, including one dedicated to preparing dextrose solutions used for secondary fermentation and five dedicated to producing concentrated flavor syrup batches.

The PL Powder Dissolver allows operators to add powdered ingredients at a convenient waist-level induction hopper while the product is recirculated through the system. Rather than lifting ingredients to elevated platforms and dumping them into the top of a tank, operators can introduce powders safely and efficiently from ground level.

The concentrated syrup batches contain a variety of ingredients, including citric acid, malic acid, sodium citrate, potassium sorbate, natural flavors, lemon juice, gums, and sweeteners. The PL Powder Dissolvers quickly incorporate and disperse these ingredients, creating consistent syrup concentrates that are later blended with water and alcohol to produce finished beverages.

The PL03 Powder Dissolver is capable of handling up to 4,000 kg/hr (150 lb/min) of powder induction. For key ingredients such as citric acid and sodium citrate in this application, the PL03 achieved induction rates of up to 1,100 kg/hr (approximately 40 lb/min), enabling rapid batch preparation while maintaining consistent product quality.

Although the installation included long recirculation piping runs and numerous elbows that reduced available suction, the PL systems consistently achieved high powder induction rates and supported production requirements.

Results

1. Improved Operator Safety: Operators no longer need to routinely work from elevated platforms while handling bags of powdered ingredients, reducing safety risks and improving workplace ergonomics.

2. Faster Batch Preparation: Powder addition and blending times are estimated to have been reduced by approximately 50% compared to traditional tank charging methods. The high induction capability of the PL enabled operators to quickly incorporate key powdered ingredients without the delays associated with conventional tank mixing.

3. Reduced Dust and Ingredient Loss: The inline induction process minimizes powder blowback, airborne dust, and ingredient waste commonly associated with dumping powders into open tanks. By introducing ingredients directly into the liquid stream, the PL Powder Dissolver helps keep powders contained and product where it belongs.

4. Increased Production Capacity: The new facility was built to support growing demand for hard seltzers and flavored malt beverages. Multiple PL systems allow the manufacturer to prepare numerous syrup batches each day while maintaining consistent product quality. The facility operates five syrup-production PL units and can produce approximately five to six batches per machine per day during peak production periods.

5. Simplified Operations: By eliminating the need to transport ingredients to elevated platforms and manually charge large mixing tanks, the PL Powder Dissolvers streamlined ingredient handling and created a safer, more efficient production environment.

Conclusion: Safer, Faster Syrup Production for High-Growth Beverage Manufacturing
By implementing Fristam PL Powder Dissolvers, the beverage producer modernized its syrup preparation process while supporting significant production growth. The combination of improved operator safety, simplified powder handling, reduced ingredient loss, rapid powder induction rates, and faster batch preparation has helped the company efficiently produce the concentrated flavor syrups required for today’s fast-growing flavored malt beverage and hard seltzer market.

With six PL Powder Dissolvers installed and operating successfully, the manufacturer continues to rely on Fristam technology to support high-volume beverage production while improving ergonomics, efficiency, and product consistency.

Contact Fristam or one of our Authorized Distributors to learn how the PL Powder Dissolver can improve safety, reduce mixing times, and streamline powder incorporation in your beverage manufacturing process.