In mayonnaise processing today, there are many different ways to make mayonnaise with varying amounts of ingredients. But the fat content is what makes this product what it is. Based on European standards, the product is called mayonnaise when it has 80% fat, salad mayonnaise when it has 70–50% fat, and salad dressing when it has 49–20% fat.
Egg powder, milk powder, mustard powder, and vegetable oil come together to form the fine oil-in-water emulsion known as mayonnaise. Boost the flavor by adding spices, emulsifiers, and flavorings. So, in this case, our main job is to get a stable, homogenous substance by adjusting the flow of oil and the level of mechanical and hydro-mechanical equipment. This is done by considering how concentrated the dry components are and how much they swell.
Mayonnaise Processing
Mayonnaise manufacturing has several essential sets: The ingredients’ resting section, steam treatment tanks, the main mixer tank, and a colloid mill or homogenizer.
To start the mayonnaise process, mix the egg yolk, water, and one-third of the vinegar until it reaches a high viscosity. A cold process is one in which the temperature never exceeds 5°C. Then gradually add the remaining oil and vinegar. While the hot process combines a hot-filling temperature and 70°C.
For making a high-quality product, the raw materials must meet standards. For instance, if vegetable oil is one of the key ingredients, then it must go through a refining process that includes deodorization and use within a month.
Dry components: egg powder, powdered milk from cows (whole or skim), sugar, salt, and mustard powder. Vinegar, or acetic acid solution, is often at a concentration of between 9 and 10%.
In prepping the mayonnaise, we must follow a number of steps. Follow the recipe to get all of the ingredients ready. Use a scale to measure the egg, mustard powder, dry milk, sugar, salt, and baking soda. Sift the dry ingredients through a fine-mesh sieve. Sifting in a sieve gets rid of big lumps and makes the powders better at holding on to water. The suitable storage tanks are then filled with the right amounts of water and vegetable oil.
It is common to cook first the egg paste. To do this, fill the mixing tank with water and egg powder. For between two and ten minutes, mix the mixture using a paddle-style mixer. For around 2 to 10 minutes, mix the mixture using a paddle-style mixer. Heat then the mixture to 60 to 65°C and store for 15 to 20 minutes before feeding it through the homogenizer and into the main mixing tank for cooling to 20 to 30°C.
Prepare the mustard and milk mixture in the second tank. The homogenizer spreads the dry ingredients out evenly in the water, and if necessary, a colloid mill grinds up the solid parts. The resulting mixture can cool for 20 minutes at 80 to 85°C. This helps dissolve and pasteurize the ingredients before cooling to 20 to 30°C. Then, after cooling the mustard and milk paste, pump them into the primary tank for mixing.
Blend the egg paste and mustard-milk paste in the main mixing tank for 5 to 10 minutes using a paddle-type agitator to get a homogenous mixture. Mayonnaise with a high-calorie count has a mustard-milk-egg paste weight ratio of 1 to 2:1, while mayonnaise with a medium or low-calorie count has a balance of 2 to 2:8.
The main mixing tank receives vegetable oil in the next step. To ensure uniform dispersion, spread the oil with a fine jet into the homogenized mixture of egg and mustard milk pastes. At the same time, add the rest of the vegetable oil and cold vinegar-salt solution (15 to 16°C).
The order and speed with which you add the vegetable oil and vinegar-salt solution to the paste are very important. The emulsion can get lumpy or mushy if you add them all at once or quickly.
Finally, after pumping from the mixer tank, homogenize the mayonnaise emulsion to smooth out any rough spots. As long as the emulsion remains stable, homogenization will continue. To get this consistency, homogenize the mayonnaise emulsion at least twice.
If the sample product is completely smooth, has no lumps, flows evenly, and has a viscosity, color, taste, and smell that are typical for mayonnaise, then it is ready for filling and packaging.
Store mayonnaise between 3 and 7 °C. Keep in mind that freezing and overheating can destroy the mayonnaise’s composition. And extreme temperatures can significantly shorten the product’s shelf life.
Note: All the steps mentioned above may still vary depending on your unique mayonnaise processing and recipe.
Mayonnaise Filling and Packaging
The piston pumps the mayonnaise from the material cylinder into the measurement cylinder. The piston then moves to deliver the mayo to the filling pipe. The filling head lowers to begin filling as the bottle travels down the conveyor belt and into the filling device.
This equipment sets the liquid level in vacuum-sealed bottles. It works by timing normal pressure filling, dispensing the right amount to a certain level, then turning on the vacuum and sucking the extra material back into a storage cylinder. After filling bottles, they will then send to the capping station through the conveyor belt.
A fully automatic piston-type mayonnaise filling line has a bottle unscrambler, capping and labeling devices, as well as other auxiliary machines. It has a built-in protection cover and can automatically unscramble, fill, cap, seal, label, and QR code filled bottles. This allows mayonnaise processing, and the manufacturing process is automatically manageable. Providing you with stability and efficiency. Most importantly complies with safety, environmental, and intelligence regulations.
Design Your Production Line Equipment
Our liquid food filling and packaging solutions can handle thick liquid products such as mayonnaise, ketchup, sauce, olive oil, barbecue sauce, jams, and many more. With 15 years of filling and packaging expertise, we are proud to offer you the latest mayonnaise production line today.
Choose from a wide selection of fillers, cappers, and labelers to fulfill the demands of your liquid food packaging needs. To complete your packaging system, we provide customization to accommodate your desired machine size, setups, and configurations. You can rely on our team of experts to advise you on, install, and maintain the machinery that best suits your production line’s needs.
Get in touch with us if you need help designing and installing a whole system of liquid food filling machines and other equipment. Partner with us, and we will maximize your packaging system’s lifespan and profitability!
