Mayonnaise Manufacture

Mayonnaise is an oil-in-water emulsion which can contain up to 80% oil. Gums and thickeners such as starches are used in low fat products to replace the viscosity and bulking effect of the oil, to enhance mouthfeel, and to ensure that a stable emulsion is formed. Large scale production is normally carried out using a specifically designed plant. This process is often semi-automated and usually under vacuum. For R&D, pilot scale and small scale production typical of the “ready-to-use” market - sandwich producers, caterers and other low-volume applications-mayonnaise needs to be produced in a manner which allows much more flexibility, especially when changing formulation.

The Process

• In the first stage of production, the egg, which may be used in either liquid or powder form is dispersed into the water. This acts as the emulsifying agent.

• Remaining continuous phase ingredients are then added and mixed until dispersed and hydrated.

• The oil is added as rapidly as the continuous phase will take it up. This results in a dramatic rise in product viscosity as the emulsion is formed.

The Problem

• Continuous phase ingredients are only a small proportion of the total formulation,but they perform vital functions. The mixing equipment must be capable

of dispersing and hydrating these properly in a relatively low liquid volume. If the egg and other emulsifying agents are not properly dispersed and hydrated

the emulsion can break during the oil addition stage.

• Hydration of stabilizers and thickeners is one of the most difficult mixing operations. The solution may have to be agitated for a long period to complete

hydration.Agglomerates can easily form; these cannot be broken down by agitation alone.

• Due to the high proportion of oil in the recipe the emulsion can break if the oil is not added to the continuous phase correctly. This is very difficult to

control when the oil addition is done manually.

• Oil phase droplets must be reduced to the smallest size possible to maximize the surface area of oil within the continuous phase to ensure a stable emulsion.

This is not readily achieved without specialized equipment.

• Aeration must be minimized or eliminated to maximize product shelf life.

The Solution

Arkan Felez has developed a unit for manufacture of mayonnaise for the ready- to-use market, R&D and pilot scale production. The unit is capableof carrying out the entire process, including rapid preparation of premixes, hydration of thickening and stabilizing agents and preparation of the final oil-in-water emulsion.

The Advantages

• Ideal for small batches that are intended for immediate use.

• Aeration is minimized.

• The system practically eliminates operator error.

• Offers the batch-to-batch consistency and stability of mayonnaise manufactured in turnkey plant without the high capital expenditure.

• Yield of raw materials is maximized, as thickening agents are fully hydrated and other ingredients are correctly dispersed.

• The system is designed for handling high viscosity products without the need for additional pumps or auxiliary equipment.

• Easily adapted to variations in product type and recipe.

Vacumm Mixer Homognizers of Arkan Felez Company

VMH Series

VC Series

Vacumm Mixer Homognizer - LAB Series