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    F Mayonnaise Manufacture 2016 US

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    Jahangir Milton
    This document discusses mayonnaise production and provides solutions for mixing using Silverson equipment. It describes the typical mayonnaise formulation including high oil and low fat varieties. The mixing challenges are outlined such as properly dispersing and hydrating ingredients to form a stable emulsion. Silverson's in-line mixer is presented as a solution for small scale production, allowing the entire process from premixing to final emulsion. Advantages include minimizing aeration and operator error while maximizing raw material yield. Larger scale options from Silverson are also presented.

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    © All Rights Reserved
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    F Mayonnaise Manufacture 2016 US

    Uploaded by

    Jahangir Milton
    58 views4 pages
    This document discusses mayonnaise production and provides solutions for mixing using Silverson equipment. It describes the typical mayonnaise formulation including high oil and low fat varieties. The mixing challenges are outlined such as properly dispersing and hydrating ingredients to form a stable emulsion. Silverson's in-line mixer is presented as a solution for small scale production, allowing the entire process from premixing to final emulsion. Advantages include minimizing aeration and operator error while maximizing raw material yield. Larger scale options from Silverson are also presented.

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    Mayonnaise

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    This document discusses mayonnaise production and provides solutions for mixing using Silverson equipment. It describes the typical mayonnaise formulation including high oil and low fat varieties. The mixing challenges are outlined such as properly dispersing and hydrating ingredients to form a stable emulsion. Silverson's in-line mixer is presented as a solution for small scale production, allowing the entire process from premixing to final emulsion. Advantages include minimizing aeration and operator error while maximizing raw material yield. Larger scale options from Silverson are also presented.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    58 views4 pages

    F Mayonnaise Manufacture 2016 US

    Uploaded by

    Jahangir Milton
    This document discusses mayonnaise production and provides solutions for mixing using Silverson equipment. It describes the typical mayonnaise formulation including high oil and low fat varieties. The mixing challenges are outlined such as properly dispersing and hydrating ingredients to form a stable emulsion. Silverson's in-line mixer is presented as a solution for small scale production, allowing the entire process from premixing to final emulsion. Advantages include minimizing aeration and operator error while maximizing raw material yield. Larger scale options from Silverson are also presented.

    Copyright:

    © All Rights Reserved
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    of 4

    Solutions for Your TOUGHEST

    MIXING Applications in

    FOOD

    Mayonnaise Manufacture

    THE FIRST NAME IN HIGH SHEAR MIXERS


    Mayonnaise Manufacture
    Mayonnaise is an oil-in-water emulsion which can contain up to 80% oil. Some typical
    recipes would be as follows:

    80% Oil Formula Low Fat Formula


    Vegetable oil 80% Vegetable oil 50%
    Egg yolk 6% Egg yolk 4%
    Other thickeners 4%
    Vinegar 4% Vinegar 3%
    Sugar 1% Sugar 1.5%
    Salt 1% Salt 0.7%
    Spices (e.g. mustard) 0.5% Spices 1.5%
    Water 7.5% Water 35.3%

    Gums and thickeners such as starches are used in low fat products to replace the
    viscosity and bulking effect of the oil, to enhance mouthfeel, and to ensure that a stable
    emulsion is formed.
    Large scale production is normally carried out using a specifically designed plant. This
    process is often semi-automated and usually under vacuum. For R&D, pilot scale and
    small scale production typical of the “ready-to-use” market - sandwich producers,
    caterers and other low-volume applications - mayonnaise needs to be produced in a
    manner which allows much more flexibility, especially when changing formulation.

    The Process
    • In the first stage of production, the egg, which may be used in either liquid or powder
    form is dispersed into the water. This acts as the emulsifying agent.
    • Remaining continuous phase ingredients are then added and mixed until dispersed
    and hydrated.
    • The oil is added as rapidly as the continuous phase will take it up. This results in a
    dramatic rise in product viscosity as the emulsion is formed.

    The Problem
    • Continuous phase ingredients are only a small proportion of the total formulation,
    but they perform vital functions. The mixing equipment must be capable of dispersing
    and hydrating these properly in a relatively low liquid volume. If the egg and other
    emulsifying agents are not properly dispersed and hydrated the emulsion can break
    during the oil addition stage.
    • Hydration of stabilizers and thickeners is one of the most difficult mixing operations.
    The solution may have to be agitated for a long period to complete hydration.
    Agglomerates can easily form; these cannot be broken down by agitation alone.
    • Due to the high proportion of oil in the recipe the emulsion can break if the oil is not
    added to the continuous phase correctly. This is very difficult to control when the oil
    addition is done manually.
    • Oil phase droplets must be reduced to the smallest size possible to maximize the
    surface area of oil within the continuous phase to ensure a stable emulsion. This is
    not readily achieved without specialized equipment.
    • Aeration must be minimized or eliminated to maximize product shelf life.

    The Solution
    Silverson has developed a unit for manufacture of mayonnaise for the ready- to-use
    market, R&D and pilot scale production. The unit is capable of carrying out the entire
    process, including r­apid preparation of premixes, hydration of thickening and stabilizing
    agents and preparation of the final oil-in-water emulsion. Operation is as follows:

    recirculation process
    control panel pipework vessel

    hopper for
    oil addition

    modified high
    shear In-Line
    mixer

    Stage 1 Water is recirculated from the vessel through the system by the specially designed
    In-Line mixer. The egg (either powder or liquid) is added to the vessel and is
    rapidly wetted out and dispersed into the high velocity liquid stream.

    Stage 2 The remaining aqueous phase ingredients are then added to the vessel.
    Recirculation continues until the ingredients are fully dispersed and hydrated.

    The oil feed valve is opened and oil is drawn from the hopper into the aqueous
    Stage 3 phase at a controlled rate. The aqueous and oil phase ingredients pass directly
    into the workhead of the In-Line mixer where they are subjected to intense high
    shear. This finely disperses the oil into the aqueous phase, immediately forming an
    emulsion. The vinegar (and/or lemon juice) is added with the last of the oil.

    Recirculation of the product continues to ensure a uniform consistency as the


    Stage 4 viscosity rises. After a short recirculation period the process is completed and the
    finished product is discharged.
    The Advantages
    • Ideal for small batches that are intended for immediate use.
    • Aeration is minimized.
    • The system practically eliminates operator error.
    • Offers the batch-to-batch consistency and stability of mayonnaise manufactured in
    turnkey plant without the high capital expenditure.
    • Yield of raw materials is maximized, as thickening agents are fully hydrated and other
    ingredients are correctly dispersed.
    • The system is designed for handling high viscosity products without the need for
    additional pumps or auxiliary equipment.
    • Easily adapted to variations in product type and recipe.

    Large Scale Manufacture


    Silverson also offer mixers for production of mayonnaise on a larger scale:

    M Agitator High Shear In-Line Mixers

    • Ideal for larger batches


    Jacketed
    vessel • Aeration free
    • Easily retrofitted to existing plant
    • Self-pumping
    Discharge
    • HV In-Line mixers available for
    higher viscosity mixes
    • Can be used to discharge vessel
    • Designed to be Cleaned-In-Place
    Recirculation

    UHS - HV In-Line Mixer

    M Agitator Silverson Flashmix

    Jacketed
    • Suitable for batches with large volumes of
    vessel powders
    • Suitable for high viscosity mixes
    • Minimized aeration
    Discharge
    • Minimized cleaning requirements
    • Minimum user input required

    Recirculation

    Flashmix Powder/Liquid Mixer

    For more information click here to go to www.silverson.com


    Silverson Machines, Inc. 355 Chestnut Street, East Longmeadow, MA 01028
    Ph: (413) 525-4825 [email protected]
    Information contained in this report is believed to be correct and is included as a guide
    only. No warranty is expressed or implied as to fitness for use or freedom from patents.
    Issue No. 52FA4
    Silverson Machines reserve the right to change product specification without notice.

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