Industrial Mayonnaise Production Process

1. ‌Raw Material Preparation‌

• ‌Ingredients‌:
  • Vegetable oil (70-80%), egg yolk (or pasteurized liquid egg yolk), vinegar, water, salt, sugar, mustard, stabilizers (e.g., xanthan gum).
• ‌Equipment‌:
  • Liquid Ingredient Storage Tanks: Pre-measured water, vinegar, and egg yolk are stored at controlled temperatures.
  • Dry Ingredient Mixer: Blends salt, sugar, and stabilizers uniformly.

2. ‌Premixing & Emulsification‌

• ‌Process‌:
  • ‌Phase 1 (Aqueous Phase)‌: Egg yolk, vinegar, water, and dry ingredients are mixed in a high-shear mixer (e.g., ‌IKN Triple-Stage Homogenizer‌) to form a uniform base.
  • ‌Phase 2 (Oil Phase)‌: Vegetable oil is gradually added to the aqueous phase under vacuum in a vacuum emulsifying tank (‌ER2000 Vacuum Emulsifier‌) to prevent air incorporation.
• ‌Critical Parameters‌:
  • Temperature: Maintained at 10–15°C to avoid oil crystallization.
  • Shear Rate: 8,000–12,000 rpm for optimal droplet size reduction.

3. ‌Homogenization‌

• ‌Equipment‌:
  • High-Pressure Homogenizer (e.g., ‌JPS Series Homogenization Unit‌): Further reduces oil droplet size (<5 μm) to stabilize the emulsion.
• ‌Quality Check‌:
  • Viscosity and pH (target: 3.6–4.2) are monitored in real-time using inline sensors.

4. ‌Pasteurization & Cooling‌

• ‌Equipment‌:
  • Plate Heat Exchanger: Heats mayonnaise to 65–70°C for 2–3 minutes to eliminate pathogens.
  • Scraped Surface Cooler: Rapidly cools the product to 10–15°C to preserve texture.

5. ‌Filling & Packaging‌

• ‌Equipment‌:
  • Automated Filling Machine: Dispenses precise volumes into jars, pouches, or tubes.
  • Labeling & Capping System: Integrates date coding and batch tracking.
• ‌Packaging Materials‌: Glass jars, PET bottles, or laminated foil pouches (oxygen barrier properties).

6. ‌Quality Assurance‌

• ‌Tests‌:
  • ‌Microbial Analysis‌: Total plate count, yeast/mold detection.
  • ‌Texture Analysis‌: Back-extrusion test for firmness and spreadability.
  • ‌Shelf-Life Testing‌: Accelerated stability trials (e.g., 30°C/75% RH for 90 days).

Key Equipment Highlighted in the Process:

• ‌Vacuum Emulsifiers‌ (e.g., ER2000 Series): Prevent oxidation and ensure smooth texture.
• ‌High-Pressure Homogenizers‌: Critical for emulsion stability.
• ‌Automated Filling Lines‌: Ensure hygiene and throughput (up to 10,000 units/hour).

Sustainability Considerations:

• ‌Waste Reduction‌: Reclaim oil/water from CIP (Clean-in-Place) systems.
• ‌Energy Efficiency‌: Heat recovery from pasteurization for preheating ingredients.