What a sauce making machine does
In a Wahal sauce line, vacuum and high shear work together in one vessel.
- Even texture and flavour. The high shear mixer disperses every ingredient uniformly, so texture and flavour are consistent through the batch.
- No trapped air. Vacuum processing removes air bubbles. That limits oxidation, helps shelf life and gives a smoother, better-looking sauce.
- Stable emulsions. Vacuum and high shear together improve the stability of emulsions such as dressings and mayonnaise, so they do not separate over time.
- Faster batches. High shear speeds up mixing, and under vacuum the sauce boils at a lower temperature, which saves energy and shortens the process.
One line can be adapted to many sauces, from ketchup and mayonnaise to salad dressings.
The Thermoshear vacuum unit: the core sauce making machine
The Thermoshear is Wahal's vacuum processing unit for mixing, cutting, homogenizing, emulsification and texture improvement, and it is also our vacuum cooking system.
- Direct steam injection (DSI) for efficient heating of the sauce.
- Vacuum homogenization in a hermetically sealed vessel: solids are drawn straight into the liquid stream under vacuum, for a very fine texture.
- Contra-rotary agitator with perforated blades, scrapers and a vortex breaker.
- Triple jacket with insulation, for heating and cooling.
- PLC panel with actuated valves and recipe storage; ingredients dosed by flow meters, load cells or dosing stations.
- Adjustable shear rate for shear-sensitive products.
- Recirculation for mixing and homogenizing, and a discharge function for products with chunks or bits.
- Clean-in-place (CIP) models with residue discharge valves, a dosing trolley with lift and tilt conveyor, and an automated lifting top lid.
More on the Thermoshear vacuum emulsification unit. When a sauce must cook gently, the vacuum lowers its boiling point, so heat-sensitive products cook faster and under gentler conditions: see our vacuum cooking machines.
Sauces our lines make
We build sauce lines for:
- Chilli and schezwan sauces
- Pizza and pasta sauces
- Sandwich spread and dressings
- Dips and spreads
- Ready-to-eat curries, and other cooking applications such as sauce preparation
Some products have their own page:
- Tomato ketchup and tomato sauce: our tomato ketchup plant makes both, from fresh tomatoes to filling; tomato sauce making machines are covered there.
- Mayonnaise: mayonnaise processing plant.
- Mustard: mustard preparation.
- Ginger, garlic, chilli and onion pastes: vegetable paste processing plant.
- Nut butters and chocolate spreads: our peanut butter plant and chocolate spread plant, which share equipment.
Machines in a sauce production line
A line is built from the machines your recipe needs. Each one has its own page.
| Stage | Machine | What it does |
|---|---|---|
| Grinding whole ingredients | Multiprocessor | Grinds chillies, garlic, ginger, onion and other vegetables to a paste at 9,600 rpm, with no heat generated in grinding. Chilli sauces and condiments are listed uses |
| Breaking down dense pastes | Duplex disintegrator dissolver, bottom mounted homogenizer | Break down coarse solids and dense pastes, then blend them into a smooth, consistent product. Used for tomato sauces and ketchups and ginger-garlic paste |
| Thickeners and powders | Liquid powder mixer | Wets gums such as xanthan and guar in a controlled shear zone before the viscosity builds, so no fisheyes form. Also used for starch solutions and sugar syrups |
| Cooking, mixing and homogenizing | Thermoshear vacuum unit | Direct steam injection, homogenization under vacuum, contra-rotary scraper agitator, triple jacket, PLC recipes |
| Fine texture | Colloid mill, inline homogenizer | Colloid mill: smooth texture and uniform consistency in sauces and dressings. Inline homogenizer: one, two or four rotor-stator stages in the pipeline, used for sauces and emulsions |
| Transfer | Shear pump | Pumps and shears in one inline unit, and handles high-viscosity lines |
| Filling | Partner fillers | Supplied with the line through our partner filler manufacturers, matched to your pack format |
For the full range, see our high shear homogenizers and mixers.
Capacity, startup lines and recipe trials
Wahal sauce lines are typically 100–500 kg/hr, sized to your recipe and daily output.
For startups and small food manufacturers we build customised small-scale sauce lines. Batch size and floor space are fixed once the product and the equipment are chosen.
Before you order, trial your own sauce recipe in our fully equipped laboratory, or rent a machine pre-configured to your requirements for as long as you need: see trials and rentals.
Wahal Engineers makes sauce making machines in India at its factory in Bhigan (Murthal), Sonipat, Haryana; the head office is in New Delhi. Tell us your sauce, recipe and daily output, or trial your recipe on a Wahal machine before you decide.
Frequently asked questions
What is a sauce making machine?
A machine that heats, mixes, homogenizes and de-aerates sauce ingredients into a smooth, stable sauce. Wahal's is the Thermoshear vacuum unit: direct steam injection, a contra-rotary scraper agitator, homogenization under vacuum, a triple jacket and PLC recipe control. Grinders, colloid mills, powder mixers and pumps are added around it as the recipe needs.
Which sauces can one line make?
One line can be adapted to a wide range of sauces. We build lines for chilli, pizza, pasta and schezwan sauces, sandwich spread, dressings and dips. Tell us every sauce you plan to make, so the line covers all of them.
Why are sauces made under vacuum?
Vacuum removes air bubbles, which limits oxidation and gives a smoother sauce, and together with high shear it keeps emulsions such as dressings from separating. Under vacuum the sauce also boils at a lower temperature, which saves energy and shortens the batch.
What capacity are your sauce lines, and is there a small machine for startups?
Lines are typically 100–500 kg/hr. For startups and small food manufacturers we build customised small-scale lines; batch size and floor space are fixed once the product and the equipment are chosen.
Do you supply filling machines?
Yes, as part of the line. The fillers come from our partner filler manufacturers and are matched to your pack format.
Do you make tomato sauce making machines?
Yes. Tomato sauce and tomato ketchup are made on our tomato ketchup plant, from fresh tomatoes to filling.
Can I trial my sauce recipe before buying?
Yes. Trials with your own recipe are available for our sauce lines in our fully equipped laboratory, and a rental program lets you keep a machine pre-configured to your requirements.
What does a sauce production line cost?
Price on request. It depends on your sauces, recipe and daily output, and on the stages you need, from grinding to filling.
