Dry Blending Services
Henry Broch Foods has run contract dry blending and filling for CPG brands, private-label retailers, and foodservice suppliers since 2006, when we added blending and milling capabilities to our co-packing operation. Today, our Waukegan, Illinois, campus spans 374,000 sq. ft square feet across more than 30 production lines, giving us the scale and equipment to take a dry formulation from raw ingredients to a finished, filled package under one roof. From a single pilot batch to a recurring contract blending program at commercial volume, our team builds the process around your product.
Dry Blending Across Difficult Ingredient Formats
Not every ingredient blends the same way. Fine powders clump under the wrong shear rate, and oleoresins behave differently from dry granulates. Leafy herbs fracture easily if handled too aggressively. Our blending lines run ribbon and paddle mixing, along with high shear mixing, so each format gets the process it needs:
- Fine powders and micro-ingredients, blended without clumping or segregation
- Salts and granulates, mixed to a consistent particle distribution
- Leafy herbs and botanicals, handled gently to preserve structure and flavor
- Oleoresins, incorporated evenly into dry bases
- Dry sauces and seasoning systems, built to your formulation specifications
Our contract blending and filling services use bulk handling for super sacks and totes, plus bulk bags for the largest volume ingredients. Raw materials move into blending without manual transfer steps that slow production or introduce contamination risk.
Filling Technology Matched to Your Product and Package
Food and powder blending services are only as good as the filling process that follows. We match the fill mechanism to how your product flows, rather than forcing every formulation through one machine type:
- Auger filling for fine powders and free-flowing ingredients
- Volumetric filling for consistent fill weights across large batches
- Scale-based filling for high-precision, weight-critical products
- Hybrid filling methods for blends that combine multiple textures or densities
Every fill connects to a packaging format built for your channel:
- Pouches, including stand-up and gusseted styles
- Cartons and rigid containers for retail shelf presentation
- Cups for individual and foodservice portions
- Bulk formats for industrial and foodservice accounts
Certification Standards Built Into Every Blending Run
Every blending and filling run takes place in a facility built to the food safety standards that buyers in this category expect. Our BRC certification sits among the highest grades issued under the standard. We also hold USDA certification for shelf-stable proteins, a distinction most contract blenders cannot claim. Beyond those two, our facility maintains additional certifications that let your formulation carry the credentials your retail or foodservice partners already require:
NSF Certified
Organic
Non-GMO
Gluten-Free
Kosher
Halal
80+ Years of Experience at Commercial Scale
Henry Broch Foods has been serving clients since 1941. Our campus has grown over the years, and we now employ over 350 team members. More than 140 active customers rely on that scale today, from growing CPG brands to enterprise-tier private-label retailers, and our ingredient sourcing team keeps formulations stocked and moving, so a blending schedule never stalls while waiting on raw materials.
Start Your Contract Blending Project Today
Henry Broch Foods provides contract dry blending and filling for CPG brands and private-label retailers, as well as foodservice suppliers that need a certified partner capable of handling complex formulations at commercial scale. Our team reviews your ingredient formats, fill requirements, and packaging goals before your first production run, so there are no surprises mid-run. Submit our contact form, and a member of our blending and filling team will follow up within one business day.
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Frequently Asked Questions About Dry Blending Services
Can we run a small pilot batch before committing to full-scale contract blending?
Yes. New formulations move through our in-house R&D team and Culinary Kitchen before reaching production. We start with concept development and prototyping, then validate the formula through sensory evaluation and pilot trials before committing to a full commercial run.
How does Henry Broch protect our formulation during a contract blending project?
We treat every formulation you bring to us as proprietary information. Your recipe and ingredient specifications stay confidential to your project team and ours, and we can put a formal confidentiality agreement in place before any formulation details change hands.
Is there a minimum order size for contract blending and filling projects?
We don’t apply a blanket minimum to every formulation. Run size depends on your ingredient formats and packaging format, plus how often you plan to produce, so our team scopes minimums during your project review rather than quoting a flat number upfront that doesn’t reflect your production plans.
What is a typical turnaround time for a contract blending and filling project?
Timeline depends on where your project starts. A pilot batch using an existing formulation can usually move onto our schedule faster than a new formulation that needs R&D and sensory validation first. Once a formula is approved, commercial run scheduling depends on your ingredient formats, packaging line requirements, and how that project fits alongside our existing production calendar. We’ll give you a specific timeline during project scoping rather than a general estimate that does not account for your formulation and packaging needs.