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Volume Scaling

Hi there, Im having a problem with recipe scaling and though Im sure there is an easy answer to this I cant seem to find it on the internet and it has me fairly baffled.
 
I started making my sauce batches fairly small, 20-30 oz at a time. Recently demand has picked up and I am making 100 oz at a time (the size of my largest pot.) I bottle in conventional 5 oz woozys, and measure all units out down to grams and 1/8 oz. So I took my original recipes and divided all ingredients down to the amount in 5 oz. essentially
 
20 oz recipe:
 
10 parts A
8 parts B
6 parts C
 
So divide everything by 4 to find the amount in a 5 oz woozy, thus
 
5 oz recipe
 
2.5 parts A
2 parts B
1.5 parts C
 
I figured I would use this recipe and just multiply it based on the orders Im getting. So to make a 100 oz batch I would just multiply everything by 20 and get
 
100 oz recipe
 
50 parts A
40 parts B
30 parts C
 
However when I use that recipe, I consistently get much more volume than expected, as much as an extra 30 oz. I assume this has to do with the amount of liquid (vinegar/juice) I am using, as the recipes tend to be slightly more liquid than usual, and that it should be multiplied in a direct correlation to the rest of the ingredients, but I have no idea why. Does anybody else have experience with this? Im hopping to go to a CoPacker with my recipes soon and need to get this figured out first. Any and all advice would be greatly appreciated, thanks so much!
 
Hello SaucyJ,
 
Something that could help (especially with your copacker) is to convert all your recipes to grams - which I believe you said you already do.  Ounces are tough when scaling recipes - ounces of peppers versus ounces of vinegar, etc.  If you're using fresh peppers the water in those peppers should be accounted for and might be part of why your larger batches are thinner than you'd like.  You can counteract that by cooking down for a bit longer.
 
All my recipes are in grams and I've had little trouble scaling from 1 gallon batches to 5 gallons batches and then onto 10 gallon batches.  
 
One note though:  I have found as I've scaled up batch size that salt does not need to be scaled up in exact proportions.  If my 1 gallon batch has 15 grams of salt the 5 gallon batch does not need 75 grams - it actually needs 45 grams.  Hope this helps and keep going!  :)
 
Thanks man, thats a great point on the salt, Ill have to look into that as I move forward. As for the weights, I have all the liquids in oz's and everything else (peppers, spices) in grams, so I don't see why it would change much. But the extra water weight in fresh ingredients could be the factor, particularly with water heavy peppers like bells. Ill have to look into cooking it down more, Ive just been doing a 10 minute pasteurization to keep the recipes as efficient as possible, But there may not be another way around the water weight outside of using purely dried ingredients.
 
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