Application: Bouillon Tablets & Seasoning Powder Manufacturing

PerMix — Engineering Turnkey Solutions for Bouillon Tablet & Powder Production

The production of bouillon cubes and seasoning powders is an artful balance of precision mixing, fat integration, and uniform compression. Behind every flavorful cube lies a complex process of blending up to fourteen ingredients — salt, starch, sugar, spices, MSG, and fats such as Sterane solid fat or Olaine liquid fat — into a homogenous, free-flowing, and compressible mass.

PerMix understands the science behind this process and provides complete turnkey systems that take your bouillon line from raw material to finished tablet or powder sachet — with consistency, efficiency, and hygiene.

The Process: How Bouillon Tablets Are Made

1. Ingredient Preparation

The process begins with accurate dosing and conditioning of ingredients. Salt, starch, sugar, and flavor enhancers are sieved or milled to achieve a consistent particle size distribution, ensuring smooth flow and even mixing. Fats are handled separately:

  • Sterane solid fat is melted in a PerMix Fat Fusion Tank with precise PID temperature control (typically 60–70°C).
  • Olaine liquid fat is stored in a heated jacketed tank with a metered dosing system.

Both fats are transferred to the mixer through jacketed pipelines and heated spray injectors that maintain the ideal viscosity and deliver precise quantities during the mixing phase.

2. Homogeneous Mixing and Fat Coating

At the heart of the process is the PerMix Fluidized Zone Mixer (PFB / PFBSD) or PerMix Plow Mixer (PTS / PTSD). These mixers are engineered to disperse fats into the powder matrix with absolute uniformity.

Inside the mixer:

  • Dry ingredients are first blended for uniformity.
  • Melted or liquid fat is sprayed directly into the moving powder bed, creating fine droplets (50–200 microns) that coat every particle evenly.
  • High-speed choppers break up any agglomerates, ensuring no “wet spots” or lumps.
  • The fluidized motion of the mixer prevents smearing, creating a perfectly blended, free-flowing mass.

For solid fat systems, the mixer jacket maintains gentle heat during injection and then cools the mixture afterward to stabilize the fat coating. When the cycle completes, the blend is uniform in density, color, and fat distribution — the foundation for high-quality bouillon tablets.

3. Conditioning and Cooling

The blended product is discharged into a PerMix Ribbon Conditioner or cooling conveyor, where it is gently tumbled to bring the temperature down to ambient. This conditioning step “sets” the fat coating, locks in texture, and ensures consistent compressibility during tablet pressing or flowability for sachet filling.

Tablet Compression: Transforming the Blend into Flavor Cubes

After conditioning, the powder blend is ready for direct compression into bouillon tablets. The material flows from a surge hopper into a rotary tablet press equipped with a force feeder to maintain even die filling.

During compression:

  • Pre-compression removes entrapped air and locks the fill bed.
  • Main compression applies 10–40 kN (depending on tablet size) to form dense, uniform cubes.
  • Tablets are released with consistent weight, thickness, and hardness, meeting friability targets of ≤1% and disintegration times under 2 minutes in hot water.

Lubricants such as magnesium stearate or sodium stearyl fumarate are added in micro-quantities to prevent sticking. Advanced tooling with TiN or CrN coatings further enhances surface performance for fatty blends.

The finished tablets then pass through dedusters, metal detectors, and cooling conveyors before final packaging.

Powder Sachet Production

The same formulation can also be used for seasoning powders packed into sachets. The PerMix-blended powder flows seamlessly into auger fillers or multi-lane sachet machines, maintaining precise fill weights and clean seals. Flowability is optimized with fine anti-caking agents and controlled fat content, ensuring the product remains free-flowing even in humid climates.

Why Bouillon Manufacturers Choose PerMix

1. Turnkey Process Expertise

PerMix provides complete bouillon production systems, including:

  • Ingredient weighing & dosing systems (macro and micro)
  • Fat fusion & storage tanks
  • Heated & metered fat injection lines
  • High-performance mixers (fluidized zone or plow)
  • Conditioning & cooling systems
  • Integration with tablet presses or sachet fillers
  • PLC/HMI automation for recipe management and batch reporting

From raw material handling to finished product packaging, PerMix designs and delivers fully integrated, turnkey lines.

2. Precision Fat Integration

Our fat fusion and injection systems allow seamless processing of both Sterane and Olaine fats, with adjustable temperature control and droplet size for perfect coating uniformity — eliminating fat streaking, segregation, or clumping.

3. Rapid Mixing & Short Cycle Times

PerMix mixers achieve complete homogeneity in as little as 3–5 minutes per batch, reducing energy consumption and maximizing throughput.

4. Sanitary Construction & Easy Cleaning

All contact parts are available in 304 or 316 stainless steel, with CIP (Clean-In-Place) or dry air cleaning options for quick flavor changeovers and allergen control.

5. Scalable from R&D to Full Production

PerMix designs systems that scale predictably from lab-size mixers for product development to industrial lines exceeding 3,000 kg/hr, maintaining the same process dynamics and product quality.

Process Flow Overview

  1. Ingredient Preparation (sieving, milling, dosing)
  2. Fat Fusion (Sterane/Olaine)
  3. Mixing & Fat Injection (PerMix Mixer with choppers)
  4. Cooling & Conditioning
  5. Tablet Compression or Sachet Filling
  6. Inspection & Packaging

PerMix — Your Partner in Bouillon Production

From seasoning powders to pressed flavor cubes, PerMix delivers engineering excellence, process knowledge, and turnkey integration unmatched in the industry. Our systems are designed to handle multi-ingredient formulations, solid or liquid fat systems, and high-volume production with repeatable, automated precision.

Whether you’re expanding an existing bouillon line or building a new facility from the ground up, PerMix has the expertise, equipment, and innovation to make it happen — efficiently, cleanly, and cost-effectively.

Discover how PerMix can design your complete bouillon manufacturing system today.
PerMix — Mixing Perfection, Since 1954.