Mayonnaise is an oil-in-water emulsion that can contain up to 80% oil. Starch-based thickeners are used in low-fat products to replace the viscosity and bulking effect of the oil and ensure a stable emulsion.
This process is often carried out semi-automatically and under vacuum. There are many applications for mayonnaise. It is very common to use mayonnaise in large volumes for the production of salad dressings and in small volumes for manufacturers of ready meals, salads and sandwiches. Therefore, mayonnaise must be produced in a way that allows for much greater flexibility.
Mayonnaise production process
In the first stage of production, eggs, which are used in liquid or powder form, are dissolved in water, which acts as an emulsifier.
The ingredients of the aqueous phase are added and dissolved in the water.
Oil is then added, which significantly increases the viscosity of the product by forming an emulsion.
Manufacturing Challenges
The water phase ingredients are only a small part of the total formulation, but they perform critical functions in the process. The mixing equipment must be able to disperse and homogenize these ingredients well in a relatively small volume of water. If the eggs and other emulsifiers are not properly dispersed and homogenized, the emulsion can easily break during the oil addition stage.
Dispersing and homogenizing stabilizers and thickeners is one of the most difficult operations in the mixing process. To complete this process, the solution is to run the dispersion operation for a longer period of time. Bubbles can easily form and cannot be removed by stirring alone.
Because of the high oil content in the mayonnaise recipe, the emulsion can break if the oil is not added to the water phase correctly. This is very difficult to control when adding oil manually.
The oil droplets must be as small as possible to maximize the oil level in the water phase to ensure a stable emulsion. This is not easily achieved without specialized equipment.
To maximize product shelf life, the amount of bubbles in the product must be minimized or completely eliminated.
Solution provided by Arkan Felez Company
Arkan Felez Company offers a vacuum homogenizer mixer to produce mayonnaise for the market and solve production challenges. This unit is capable of performing the entire process including rapid preparation of the mix, dispersion of thickening and stabilizing agents, and preparation of the final oil-in-water emulsion.
Ideal for small volumes intended for immediate use.
Due to the fact that the mixer is under vacuum, it prevents the formation of bubbles in the mix and its deterioration.
The fully automatic PLC system virtually eliminates operator errors.
The consistency and stability of the mayonnaise produced in the factory without spending high costs puts it in the top mayonnaise producers in Iran (most of them use mixers manufactured by Arkan Felez Company).
The performance of the raw materials is maximized, as the thickening agents are fully hydrated and other ingredients are properly dispersed.
Vacuum homogenizer mixer is designed to achieve high viscosity products without the need for additional pumps or auxiliary equipment.
Easily adapts to changes in product type and recipe.