Mayonnaise is a thick, almost solid sauce mainly made of oil, eggs, lemon juice or vinegar, and seasonings. Typically seen in salads and other foods. It is light yellow and isn’t too soft or thick. Mayo has a mildly refreshing smell and a strong aftertaste. Egg yolk phospholipids have a strong emulsifying effect, so they can make a stable emulsion. Fine particles of 2 to 4 microns spread the oil through the vinegar. When you eat, the water phase hits your tongue first and gives you a smooth, refreshingly sour taste. Then, tasting the oil phase.
Mayonnaise is typed as a semisolid emulsion. Egg yolk, vinegar, and salt are the main ingredients used to make it. This recipe can’t be made without any one of these four. Sugar, MSG, mustard, starch, white pepper, and other spices are also non-essential raw materials. Oil makes up at least 65% of mayonnaise, but 77–82% is usually better. There are generally two recipes for the mayonnaise making process. Low-fat mayonnaise and 80% oil mayonnaise. Check out the list below to see how much of each ingredient to use:
|Ingredients||80% Oil Formula||Low–Fat Formula|
|Vegetable Oi l||80%||50%|
How Mayonnaise Production Line Flow?
In the high shear emulsification tank, ingredients like sugar, vegetable oil, vinegar, salt, lemon acid, and starch will be emulsified and mixed before being sent through a rotor pump to a vacuum mixing tank. The vegetable oil and egg yolk or egg liquid will also be put into the mixing and emulsifying tank and mixed well for 20 to 30 minutes. Mixing should be done with cold and in a vacuum. We already have mayonnaise, but it will be homogenized to make the final product smoother and tastier. Finally, it will be filled into retail containers like sachets, bottles, and jars.
Mayonnaise Production Line Machine Overview
Mayonnaise Vacuum Emulsifier
The vacuum emulsifier is the most essential part of the mayonnaise making machines. It has these characteristics:
- Mixing, dispersing, emulsifying, homogenizing, vacuum, heating, and cooling all be done in one unit.
- Efficiency volume ranges from 100L to 2000L.
- The internal process of emulsifying and homogenizing is done by an emulsifying head attached to the top of the tank. All of the mixers have frequency conversion control.
- The triple-layered jacked tank can cool or heat through the cold and hot medium.
- The vacuum system makes sure that there is no air or bubbles in the mixing and homogenizing process. This can also make the shelf life of the finished products longer.
- The tanks are made of SUS304 or SUS316L, and they can come with loading cells to ensure that the right amount of each ingredient is used.
- The emulsifier has a manhole, inlets, and outlets for material, a sample valve, a CIP cleaning ball, and inlets and outlets for both cold and hot mediums.
- The anchor stir in the high shear mixer mixes the oil and other ingredients efficiently.
SSHE (Scrape Surface Heat Exchanger) Mayonnaise Pasteurization Machine
After vacuum emulsification, the SSHE is used to heat and cool the mayonnaise. The SSHE has the following qualities:
- High efficiency at transferring heat.
- Fit for products with high viscosity.
- The whole surface is constantly scraped to ensure nothing will stick to it.
- The machine is built of SUS304/316L stainless steel and features a CIP function.
- Steam and hot water are used for heating. Glycol or chilled water is used to cool the system.
- From 0.08 to 1.40 m2 of heat exchange surface per cylinder.
After vacuum emulsification, most mayonnaise will be filled into small containers like jars, bottles, cans, or sachets. When mayonnaise is filled into glass jars or metal cans, vacuum sealing technology is used to keep it fresh longer. When mayonnaise is filled into PET bottles, aluminum foil sealing or liquid nitrogen is used to keep it fresh.
How Does the Mayonnaise Production Line Finish?
After mixing and homogenizing with mayo making machines, mayonnaise is packed in many different ways, such as in metal cans, glass bottles, flexible pouches, sachets, and aseptic bags in box containers.
What Are the Most Essential Parts of Making Mayonnaise?
- Emulsification is important because it keeps the oil and water from separating when making mayonnaise. We use emulsification equipment that works in a vacuum to process. This multifunctional mayonnaise mixer has a high-shear device that can make tiny oil droplets, keep the product from trapping microbubbles, and keep it from clumping and settling. It uses a vacuum to put the ingredients below the surface of the liquid. This makes the emulsion happen immediately, stops clumping and “fish eyes,” and cuts down on air mixing and foaming.
- Because liquid egg yolk can’t handle temperatures above 65°C (egg yolk’s proteins will break down), blending and making an emulsion must be done at 5°C. Heat sterilization isn’t done because if the egg yolk is heated, it will coagulate and lose its ability to keep the ingredients mixed together. This will also cause the mayonnaise to separate.
- Plant-based emulsifiers are also added to ensure the final product is thoroughly mixed. You can change how thick the final mayonnaise is by adding colloid or starch.
- The technology for handling the raw materials can manage all ingredients that go into mayonnaise making machines, like liquid egg mixture and egg yolk. The automatic weighing equipment is connected to a control system that ensures each ingredient can be weighed correctly and stored in perfect conditions.
- The sanitary system’s design ensures that the mixer empties completely between batches. This cuts down on waste, keeps product loss to a minimum, and speeds up cleaning. The mixer uses an effective cleaning-in-place (CIP) design, which means it can mix better and take less time.
- Mix proof valves can be put on the whole production line to keep the product from leaking into the cleaning line and causing contamination or wasting the product.
- The mayonnaise production line can make between 500LPH and 5000LPH of mayonnaise, which can then be filled into small bottles and pouches.
- Because making mayonnaise involves cold processing, raw ingredients like egg yolk or liquid egg must be pasteurized before they can be stored in aseptic containers or cold places.
- After vacuum mixing, some manufacturers pasteurize the mayonnaise. Because of the high viscosity of the final products, the pasteurizer will heat treat them.
- Mayonnaise has a pH of about 4.0 and a level of acetic acid of between 0.3% and 0.7%. When vinegar and salt are added to water, the acetic acid level increases significantly. This makes the water resistant to the growth of microbes. So, even if the mayonnaise is vacuum cold emulsified and filled without being sterilized, it can still last between 2 to 6 months.
- When making mayonnaise, the emulsification and filling steps are all done under a vacuum, effectively making the product last longer.