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.

Yangzhou Aipuweier Automatic Equipment Factory have more than 20 years experience. We can produce the machine according to your requirement. And our machines are all passed GMP compliant and have complete certificates. Our main products are vacuum homogeneous emulsifying machines, reverse osmosis water treatment machines, liquid soap making machine, semi-automatic filling machines and all kinds of stainless steel tanks. All of our products are of reliable quality and good effect. We have more than twenty years' experience in machinery manufacturing and our products have been entered into domestic and overseas markets. The diverse products of high quality can meet various needs of industries mentioned above.