The structure of dry mix products
Instant soups, sauce powders, bouillons and meal mixes bring ingredients of different particle size and density together in a single pack. Consumers expect a lump-free product with the right consistency and balanced flavour when prepared with water. Achieving this requires thickener, flavour components, carriers and flow properties to be designed together.
Thickener: choosing the starch
Starch is the main source of body in soup and sauce powders. Native or modified starches are used in products cooked on the hob, where they gelatinise during cooking. Potato starch gives high viscosity and clarity, rice starch a creamy, smooth texture. Modified corn starch withstands long cooking and acidic conditions. Instant products prepared by adding hot water need pregelatinised starches.
Lump-free dispersion
When starch is added directly to hot water its surface can gel rapidly and form lumps. Dispersing starch well with ingredients such as salt, sugar and maltodextrin in the dry mix separates the particles so they wet evenly. Agglomerated ingredients and a small amount of fat coating also aid dispersion. Water temperature and stirring steps in the preparation instructions should be written accordingly.
Flavour base: spices
Onion powder and garlic powder form the flavour base of almost every soup and sauce. Onion granules are used where visible particles are wanted. Black pepper, or white pepper in light-coloured products, ground cumin, red chili powder, dried parsley and thyme define the product's character. The cut size of dried herbs affects both appearance and texture after cooking.
Protein and fibre enrichment
Pea protein and rice protein can be added for high-protein soups; pea protein also contributes to a creamy mouthfeel. Citrus fibre or pea fibre can be used for fibre enrichment; as these also contribute to body, the starch level should be readjusted.
Blending and segregation
Ingredients of different size and density can segregate during transport and filling. Choosing similar particle sizes, validating blending time and reducing drop height on the filling line limit segregation. Salt and spice distribution should be checked by sampling packs after filling.
Moisture and shelf life
When dry mixes pick up moisture they cake, lose flowability and microbiological risk rises. Low-moisture ingredients, a controlled production environment and moisture-barrier packaging protect shelf life. The microbiological quality of spices is especially important because the product is consumed after short cooking.
Sourcing notes
PERDIST supplies potato, rice and modified starches, onion powder and granules, garlic powder, black pepper, white pepper, dried parsley, thyme, pea protein and fibres to dry mix manufacturers from a single source.
Frequently asked questions
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