Line Components and Technologies
Mixer-saturator: how stable carbonation is achieved
The saturator determines what the drink will be like when it reaches the consumer: the gas level, the taste consistency from batch to batch, and whether the line will foam during filling.
What the unit does
A mixer-saturator solves three tasks in sequence: it deaerates water, mixes it with syrup in a set ratio and saturates the finished beverage with carbon dioxide. All three operations run in-line, so quality depends on flow meter accuracy and pressure stability.
Deaeration is mandatory: dissolved oxygen interferes with carbon dioxide absorption and accelerates oxidation of flavor components. Without it, the gas level fluctuates and shelf life drops.
Blending can be by mass or by volume. Mass flow is more accurate and does not depend on syrup temperature; volumetric is cheaper and sufficient for stable recipes.
Carbonation levels by product
| Product | CO2, g/L | Saturation temperature |
|---|---|---|
| Strongly carbonated water | 6-8 | 4-8 °C |
| Lemonade, cola | 5-7 | 4-8 °C |
| Kvas | 4-6 | 2-6 °C |
| Lightly carbonated water | 2-4 | 6-10 °C |
| Sparkling wines | 7-9 | 0-4 °C |
What to check when selecting
- Flow capacity
- Should exceed the filler capacity by 10-15% so the line never starves.
- Mixing type
- Mass dosing for wide assortment, volumetric for one or two recipes.
- Carbonation range
- One unit should cover both strongly carbonated and lightly carbonated products.
- CIP compatibility
- Cleaning without disassembly, including the syrup circuit.
- Buffer tank
- Smoothes filler stops and reduces gas loss during startups.
FAQ
Can carbonation be done in a blending tank without a saturator?
For very small volumes this scheme exists, but gas level is unstable and CO2 consumption is higher. For an industrial line it is not a working option.
How does the saturator affect foaming during filling?
Directly. Properly deaerated and cooled product fills calmly. If the line foams, the cause is usually in the saturator and temperature, not the filler.
Is a syrup cooking section needed?
If the recipe is prepared on-site — yes: cooking kettle, filtration and syrup cooling. When working with ready concentrates, a tank with agitator is enough.
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