The global flavours market is evolving rapidly as food and beverage manufacturers demand increasingly sophisticated taste profiles, shorter product development cycles and greater flexibility in production. In this context, the ability to process complex recipes with precision, hygiene and repeatability has become a strategic requirement for flavour producers.
A recent project developed in Spain by WAMGROUP for Scentium highlights how mixing technology can support these challenges in modern flavour manufacturing. Located in Alhama de Murcia, the Scentium facility is part of the Croda International group and produces a wide portfolio of flavours for the global food and beverage industry, ranging from sweet applications to beverages and savoury products.
Meeting the complexity of modern flavour formulations
Flavour manufacturing is characterised by high formulation complexity. A single plant may need to process hundreds of recipes involving powders, micronized ingredients and liquid flavour components — often in very small proportions. At the new production facility, Scentium required a system capable of managing:
- Two gravimetric production lines
- More than 150 different recipes
- Low-dosage ingredients below 1%
- Liquid flavour additives, including viscous oleoresins
- Food-grade hygienic design and easy cleaning
In addition, the plant was designed with a flexible production layout where mixing and packaging operations could run independently. Finished batches would be temporarily stored in 1 m³ big bags, allowing the packing line to operate separately from the mixing stage.
Designing a mixing solution for flexibility
To meet these requirements, WAMGROUP's MAP division engineered a mixing system centred on a WBH 2000 horizontal ploughshare mixer, designed to deliver high turbulence and rapid homogenisation even when processing very small quantities of flavouring ingredients. Each batch corresponds to approximately 1,000 litres, with a productivity target of 10 big bags per hour. The system layout is organised across three levels:
- Second floor: ingredient loading and feeding
- First floor: mixing stage
- Ground level: discharge and big bag filling
This vertical configuration simplifies gravity-fed material handling while optimising plant footprint and process efficiency.
Ensuring precision for delicate ingredients
Flavour formulations often include highly concentrated components that must be distributed perfectly throughout the mix. Even minimal dosage variations can affect the final sensory profile of a product. To ensure consistent blending performance, the mixer was equipped with several specialised features:
- High-speed choppers to increase turbulence and break agglomerates
- Injection wands for liquid flavour additives
- Variable frequency drive (VFD) to control mixing intensity
- Food-grade seals and stainless-steel contact surfaces
Particular attention was given to handling viscous liquid ingredients such as oleoresins, which tend to adhere to surfaces and require controlled injection to ensure proper dispersion. The machine is powered by a 37 kW drive unit, selected to ensure reliable performance across a wide variety of recipes, including micronized powders and complex ingredient combinations.
Hygiene and cleanability at the centre
In flavour production, hygiene and cross-contamination control are as critical as mixing performance. Many flavour compounds are extremely potent, meaning even small residues from a previous batch can affect the next formulation. For this reason, the system incorporates several design elements aimed at simplifying cleaning operations:
- Food-grade materials and hygienic construction
- Smooth internal surfaces and welded blades
- CIP-ready configuration
- Easy access points for manual cleaning
During commissioning, particular attention was given to cleaning procedures. Some ingredients, such as lactose powder, proved highly adhesive and required dry cleaning methods using sugar or salt to remove residues effectively.
Commissioning and process optimisation
The start-up phase included extensive testing to validate the system's performance under real production conditions. The most challenging recipes were selected to verify:
- Mixing uniformity
- Performance of the choppers
- Liquid injection efficiency
- Residual product levels after discharge
The mixing stage achieved the required quality standards even for the most complex formulations. One challenge encountered during testing involved the injection of highly viscous oleoresin. To address this, WAMGROUP proposed an upgraded injection system combined with a heating solution to reduce the viscosity of the liquid flavour component. Operational adjustments were also made to the plant ventilation system during the big bag filling stage to ensure safe discharge and avoid pressure build-up.
Flexibility as a strategic advantage
The commissioning of the new plant confirmed the effectiveness of the chosen layout and mixing technology. According to project engineers, the system's flexibility is its most valuable feature: the same equipment can manage a wide range of flavour formulations while maintaining high hygiene standards. For flavour manufacturers operating in a market defined by innovation and rapid product turnover, this adaptability is essential.
Supporting the next generation of flavour production
As the food industry continues to evolve, flavour houses must balance creativity with industrial efficiency. Production facilities must be able to handle increasingly complex recipes while ensuring consistent quality and strict hygiene standards. The collaboration between WAMGROUP and Scentium demonstrates how advanced mixing solutions can support this transformation — providing the flexibility, precision and cleanliness required for modern flavour manufacturing.
In a sector where the smallest ingredient can define the success of a product, the ability to mix accurately and reliably is not simply a technical requirement. It is a key ingredient of innovation in the global flavours market.
