Custard Sauce Production Line

Custard Sauce Production Line

Production Video: https://www.youtube.com/watch?v=AkAcycJx0pI

A custard sauce production line involves a series of automated and semi-automated processes to manufacture custard sauce efficiently, consistently, and hygienically. Below is a detailed breakdown of the typical stages in a custard sauce production line:

1. Ingredient Handling & Preparation

• Milk Reception & Storage
  • Raw milk is received, tested for quality, and stored in refrigerated silos.
  • Alternative: Reconstituted milk powder + water (for longer shelf life).
• Sugar & Sweetener Handling
  • Sugar, corn syrup, or alternative sweeteners are weighed and dissolved.
• Egg & Egg Powder Processing
  • Liquid eggs (pasteurized) or egg powder is mixed with water.
• Starch & Stabilizers
  • Cornstarch, modified starch, or thickeners (e.g., carrageenan) are pre-mixed to prevent clumping.
• Flavorings & Additives
  • Vanilla, caramel, or other flavors, along with preservatives (if needed), are prepared.

2. Mixing & Blending

• Batch or Continuous Mixing
  • Ingredients are combined in a high-shear mixer or premix tank under controlled temperatures (to avoid premature thickening).
  • Homogenization may be applied for smooth texture.

3. Cooking & Pasteurization

• Continuous Cooking (Scraped Surface Heat Exchanger)
  • The mixture is heated to 75–85°C (167–185°F) to activate starch gelatinization and thicken the sauce.
• Pasteurization (HTST or Batch)
  • High-Temperature Short-Time (HTST) at 72°C (161°F) for 15-20 sec or batch pasteurization to ensure microbial safety.
• Cooling Phase
  • Rapid cooling to 4–10°C (39–50°F) to stop further cooking and maintain texture.

4. Homogenization (Optional)

• High-Pressure Homogenizer
  • Used for ultra-smooth texture (prevents graininess).

5. Filling & Packaging

• Automatic Filling Machines
  • Pouch filling (for retail) or bulk filling (for foodservice).
  • Aseptic filling (for long shelf life) or hot-fill (for ambient storage).
• Packaging Formats:
  • Plastic bottles, cartons, pouches, or cans.
  • Nitrogen flushing may be used to extend shelf life.

6. Cooling & Storage

• Blast Chilling (if required)
  • For refrigerated custard, rapid cooling to 4°C (39°F).
• Cold Storage
  • Stored at 4°C (39°F) for fresh custard or ambient for UHT-treated products.

7. Quality Control & Testing

• Viscosity Checks (using viscometers).
• pH Monitoring (target: ~6.0–6.5).
• Microbiological Testing (total plate count, yeast/mold).
• Sensory Evaluation (taste, texture, color).

Key Equipment in Custard Sauce Production Line

1. Storage Tanks (for milk, liquid ingredients).
2. Weighing & Dosing Systems.
3. High-Shear Mixers & Premix Tanks.
4. Pasteurizer (HTST or Batch).
5. Scraped Surface Heat Exchanger (for cooking).
6. Homogenizer (optional).
7. Filling Machines (piston, volumetric, or aseptic).
8. Cooling Tunnels.
9. Packaging Machines (sealing, labeling).

Types of Custard Sauce Produced

• Refrigerated Custard (short shelf life, fresh taste).
• UHT Custard (long shelf life, sterilized).
• Powdered Custard Mix (for reconstitution).

Automation & Efficiency

• PLC Control Systems for precise temperature and mixing control.
• CIP (Clean-in-Place) Systems for hygiene.