Mayonnaise production: equipment and technology

2024 Author: Howard Calhoun | [email protected]. Last modified: 2023-12-17 10:16

The production of mayonnaise has not yet been fully studied, since there are many technologies for preparing the mixture as the basis for a future product. Everything comes from ancient times, when extraordinary ways were used to create this "delicacy" to make food spicy and unusual.

History of mayonnaise and sauces

Food historians offer four possible theories for the origin of mayonnaise. The most popular story dates from June 28, 1756, when the French Duke of Richelieu captured Port Mayon on the Spanish island of Menorca. In preparation for the victory celebration, the duke's chef was forced to replace the olive oil with cream in the sauce. Unexpectedly pleased with the result, the chef dubbed the final sauce "mayonnaise" in honor of the place of victory.

Karame, French writer and author of Cuisinier Parisien: Trarte des Entries Froids believed that the word was derived from the French verb "manier", which means to mix. Another food expert, Prosper Montagnier, has argued that the origin lies in the old French word "moyeu", whichmeans egg yolk.

Thirds insist that the creamy sauce was the own development of the city of Bayonne in southwestern France. Thus, what was originally called "mayonnaise" was later modified to be mayonnaise.

Regardless of its origin, mayonnaise quickly gained popularity, so it is not surprising that its appearance in all European cuisine. In the early 1900s, a German immigrant named Richard Hellmann discovered the delicacy in New York. The salads his wife made with homemade mayonnaise were especially popular. When customers started asking if they could buy the mayonnaise itself, Hellmans decided to make it in bulk and sell it by weight in small wooden oil-measuring jars.

Eventually the Hellmans began sorting their mayonnaise into glass jars. In 1913 they built their first mayonnaise factory. California company Best Foods Inc. also enjoyed the success of its version of mayonnaise. In 1932, she acquired the Hellman brand and continued to produce both versions of the sauce.

A variant of mayonnaise, whose production was focused on making salad dressings, was developed by the National Dairy Products Company in 1933 and presented at the World's Fair in Chicago. The product eventually became known as the Kraft Miracle Whip Salad Dressing.

Mayonnaise production technology - features of each crop

To create mayonnaise, you need only two steps to get readyproducts.

Emulsifying:

1. To maintain the correct degree of emulsification, a continuous mixing system is used. An emulsion (technically known as a colloid) occurs when mixing two liquids, in this case vinegar and oil, causes one of them to form small droplets that disperse throughout the other liquid.
2. The mixture of vinegar and oil is continuously moved through a series of pumps that mix the ingredients. These devices have a cavity or set of cavities with rotating impellers. The adjustable pumping action causes the cavities to fill and empty. The impellers move the mixed fluid from one cavity to another.

It turns out a single consistency, which is so important for this type of product. Next comes the addition of various components, which is a way to diversify the base mixture.

Adding ingredients:

1. Pre-measured ingredients are fed into the pipelines through holes in the sides of the pumps or from the pressure bushings.
2. Mayonnaise moves through the pumping system to the bottling station. Pre-sterilized jars move along a conveyor belt and pre-measured amounts of mayonnaise are placed in them. They are sealed with metal screw clamps. However, not vacuum sealed.

This mayonnaise production technology is used by almost 80% of enterprises and factories. The standard scheme did not change for a long time untilvarieties of sauces with additives did not appear.

Raw materials for making sauces and mayonnaises

Mayonnaise is an oil-in-water emulsion that can contain up to 80% oil. Thickeners such as starches are used in low-fat products to replace the natural viscosity and bulk effect of butter, and to improve mouthfeel and ensure stable emulsion formation.

Spices and other natural seasonings can be added, with the exception of turmeric and saffron. They gave mayonnaise a yellow tint, which consumers did not like, so the mayonnaise production line with them in the composition did not last long.

Vinegar is also used, which is distilled from distilled alcohol, lemon or lime juice (diluted with water). Soybean oil is the most common type of ingredient used in the production of mayonnaise.

Large scale production is usually carried out using a specially designed plant. This process is often semi-automated and under vacuum. For research and development, pilot small-scale productions are used, typical of the “ready-to-eat” market: sandwich makers, food service companies and other small companies. For them, mayonnaise must be produced in a way that will increase their sales, while experimenting with ingredients.

Some typical recipes would be:

1. At the first stageproduction, the egg, which can be used in liquid or powder form, is dispersed in water. This acts as an emulsifier.
2. Then add the remaining ingredients of the continuous phase and mix until dispersed and hydrated.
3. The oil is added so quickly that the continuous mixing phase immediately raises it. This leads to a sharp increase in the viscosity of the product during the formation of the emulsion.

Problem:

The "continuous phase ingredients" make up only a small fraction of the total composition, but they perform vital functions. Mixing equipment must be able to disperse and moisten them properly with a relatively low liquid volume. If egg and other emulsifiers are not properly dispersed and hydrated, the emulsion may break during the oil addition step.

Hydration of stabilizers and thickeners is one of the most complex mixing operations. You may need to stir the ingredients for a long time to fully hydrate.

Due to the high proportion of oil in the recipe, the emulsion may break if it is not added to the continuous phase correctly. This is very difficult to control when the process is done manually.

Oil phase droplets should be reduced to a minimum size to maximize the surface area of the oil in the continuous mayonnaise production step to ensure a stable emulsion consistency. It cannot be obtained without special equipment.

Aeration must be minimized or eliminated to maximize product shelf life.

Equipment for making mayonnaise

To achieve the desired result, you need to choose the best equipment for making mayonnaise. The devices work according to the following principle:

1. Water is recirculated from the vessel through the system using a specially designed In-Line Mixer. An egg (powder or liquid) is added to the vessel and is rapidly wetted and dispersed in a high liquid velocity stream.
2. Then the remaining ingredients in the aqueous phase are added to the vessel. Recirculation continues until the ingredients are completely dispersed and hydrated.
3. The oil supply valve opens and oil flows from the hopper into the water phase at a controlled rate. The ingredients of the water and oil phases enter directly into the working head of the mixer, where they are subjected to intensive mixing. This process finely distributes the oil in the aqueous phase, immediately forming an emulsion. Vinegar or lemon juice is added with the last portion of oil.
4. Product recirculation continues to provide consistent consistency as viscosity increases. After a short period, the process ends and the finished product is unloaded.

The method is ideal for small batches intended for immediate use. Aeration is minimized and the system virtually eliminates operator error. The yield of raw materials is maximized becausethickeners are fully hydrated and other ingredients are properly dispersed. Mass production of mayonnaise is somewhat different. The process is suitable for making more than 1000 kg of products per hour:

1. Measuring pumps simultaneously add different ingredients to the tank in the required proportions.
2. The mixture is pumped through the built-in mixer, and the mayonnaise is received only through one compartment, and all ready at once, and then pumped into the buffer tank and prepared for packaging.

Equipment for the production of mayonnaise in mass quantities should be installed according to accepted quality standards, so that products can then be checked and tested.

Quality control of finished products

All raw materials are checked for freshness when they enter the processing plant. Stored materials are also checked periodically. Mayonnaise samples are taken and taste tested during the production process.

Variety of sauces based on mayonnaise

There are many varieties of mayonnaise, including light and low fat. This he althy seasoning can be part of a well-balanced diet to meet any dietary need. Mayonnaise is made from pure oils such as soy and canola. They are a natural source of alpha-linolenic acid, an essential omega-3 fatty acid. In addition to essential fatty acids, these oils are also the main source of our daily intake of vitamin E.

Commercial mayonnaise is also one of the safest foods. Salad dressings contain pasteurized eggs that have been heat-treated to kill harmful bacteria and ensure product safety, so you can be sure of them. On the basis of mayonnaise, Tatar, spicy, mustard sauces are created. Since the production of mayonnaise involves the application of basic principles, they can be supplemented. You can diversify the taste, and not the consistency or proportions, with the help of seasonings.

Russian factories - how are they different?

The production of mayonnaise in Russia is somewhat different from foreign production due to technology and equipment. So many technologists use basic recipes, creating only “shades” of fat and acid compositions.

To replace egg yolk fat, modified food starches are added. In order for low-fat mayonnaise to retain the creamy texture and density of real mayonnaise, starches from corn or agar product (seaweed extraction) are used. In Moscow, top-level technologists are engaged in the production of mayonnaise. However, the recipe is standard, not changing over the years. Trademark "Togrus" does not change the traditions and age-old quality standards.

Sometimes, according to recipes, s alt is added to enhance the flavor. This amount is about 1/16 teaspoon of s alt per tablespoon of mayonnaise. Preservatives such as calcium disodium s alt are added to increase shelf life. But the production of mayonnaise in Noginsk was relatively recently formed, but the plantalready has many awards for the honorary title of "worthy example".

Mayonnaise Hollandaise Sauce Recipe

You will need a blender to mix the products.

1. Add double the amount of egg yolks (to coat the blender blades).
2. Add 2 tsp. s alt.
3. Melt the butter in a small saucepan over medium heat. Once it starts to separate and is still bubbling, pour some into the blender with the motor running.
4. Add some more oil, the emulsion should make a change in sound as the blender motor runs.
5. Continue to slowly pour in the butter without adding milk solids.
6. Spice with lemon juice, s alt and pepper to taste.

Some mayonnaise companies have introduced this recipe into the base of some sauces. You can diversify them with the help of spices and a combination of ingredients in the ratio of proportions.

Recipe "Tartar"

There are recipes for "Tartar" based on mayonnaise. It is done simply, given that the base is already ready:

1. Mayonnaise - 300g
2. Sour cream - 200g
3. Pickled cucumber - 1 piece.

Mix the products until a uniform consistency is formed. Add garlic and herbs to taste. Sprinkle with lemon juice before serving.

Benefit

The mayonnaise business is a pretty profitable business. Africans created the basis for such enrichment: they produce sauce in simple jars without inscriptions and brands, usingcheap recipe and affordable raw materials. Thanks to such factors, many businessmen can secure goods and create their own sales business. If we talk about setting up production, then we should start with small batches, because for continuous sales of 1000 kg, we need to find sales points. Egg-free mayonnaise is gaining popularity - vegetarians and people who cannot tolerate this product will be the main consumers.