Application: Mole Paste Production – Tradition Perfected with PerMix Sigma Mixers

Few foods carry as much cultural weight and culinary complexity as mole — that deep, fragrant blend of chilies, nuts, spices, chocolate, and oil that defines Mexican cuisine. Whether for retail jars, restaurant bases, or frozen sauces, modern manufacturers face a challenge that’s as much art as engineering: how to reproduce the handmade texture and flavor of mole, while scaling to industrial volumes with consistent quality and hygiene.

Understanding the Mole Process

At its core, mole is a carefully balanced emulsion of solids and fats — thick, sticky, and incredibly aromatic. The production process unfolds in several key stages:

  1. Ingredient Preparation
    Dried chilies (ancho, mulato, pasilla, guajillo), nuts, seeds, and spices are roasted or fried to build flavor through Maillard reactions. After cooling, these ingredients are ground or milled into fine powders using DP Pulverizers’ pin or hammer mills, ensuring uniform particle size for smooth dispersion.
  2. Pre-Mixing and Fat Phase
    In the PerMix Z-Blade Sigma Mixer, the fat phase — oils or lard — is heated via a jacketed bowl to 60–70 °C. Ground solids are then gradually folded in, starting with the roasted chili and nut base, followed by cocoa, sugar, and seasonings.
    The Sigma’s dual Z-blades, rotating at differential speeds, knead and stretch the mass, recreating the texture traditionally achieved with a stone metate — only with precision, speed, and scalability.
  3. Kneading, Emulsifying & Texture Development
    As the blades work, friction and controlled heating melt the natural oils, allowing the water and oil phases to emulsify. Optional high-speed choppers break down stubborn chili fibers and spices for a velvety, cohesive paste.
    Operators can monitor torque and temperature trends in real time, knowing exactly when the paste has reached perfect consistency — glossy, smooth, and rich.
  4. Vacuum Deaeration & Cooling
    Applying vacuum at −0.8 bar removes air bubbles, prevents oxidation, and deepens the characteristic dark color. Once the desired texture is reached, cooling water circulates through the jacket to bring the product to 40–45 °C, locking in structure and flavor.
  5. Discharge & Packaging
    The finished mole can be tilt-discharged or pressed out through a discharge screw for direct transfer into bins, pails, or fillers. Many producers finish the paste with a colloid mill loop for ultra-fine polishing before packaging for retail, foodservice, or export.

Why PerMix Sigma Mixers Lead the Industry

PerMix Sigma Mixers (Empastadoras) are engineered precisely for high-viscosity, sticky pastes like mole, nut butters, caramel, and confectionery fillings. Every detail supports efficiency, cleanliness, and product integrity:

  • Food-Grade Construction: 304 or 316L stainless steel with mirror polish and crevice-free welds.
  • ASME-Rated Jacket: For heating and cooling with steam, hot water, or glycol.
  • Vacuum Capability: For deaeration and oxidation control.
  • Powerful Dual Motors: Independent drives with variable speed for both blades.
  • CIP-Ready Design: Rounded corners, spray nozzles, and lift-up lids for complete cleanability.
  • Automation Options: PLC/HMI control, torque monitoring, batch data logging, and recipe storage.

PerMix delivers a repeatable mole every time — same aroma, same body, same shine — while reducing labor, shortening cycle times, and meeting global food safety standards.

Beyond Mole: Total Process Integration

PerMix partners with manufacturers to design turn-key mole production systems, integrating:

  • DP Pulverizers for spice and nut grinding,
  • PerMix Sigma Mixers for paste formation,
  • Vacuum discharge presses for automatic product transfer, and
  • Colloid mills or inline homogenizers for final finishing.

The result: a compact, high-efficiency system that captures the soul of handmade mole while meeting the throughput demands of the modern food industry.

The Tradition Lives On — Engineered by PerMix

Making mole has always been about patience, heat, and harmony. With PerMix Sigma Mixers, those same principles live on in stainless steel and precision control — bringing artisanal authenticity to industrial scale. From small artisan producers to global food brands, PerMix helps you turn heritage into high-volume perfection.