Mayonnaise Processing

Mayonnaise, commonly known as mayo, is a cold emulsion-based sauce originating from French cuisine. It is an oil-in-water (O/W) emulsion, where the oil is the dispersed phase, and water forms the continuous phase. Stabilized by emulsifiers like egg yolk, mayonnaise is crafted using ingredients such as oil, vinegar, salt, sugar, mustard, and water.

Understanding the Science of Emulsification

What is Emulsification?

Emulsification is the process of mixing two immiscible liquids—typically oil and water—into a uniform suspension. These two do not blend naturally, so an emulsifier is required.

Role of Emulsifiers in Mayonnaise

An emulsifier is a molecule with both fat-soluble and water-soluble parts. In mayonnaise, egg yolk (rich in lecithin) acts as the emulsifier, surrounding oil droplets and preventing separation. This is essential for producing a stable, high-quality emulsion in industrial food production.

Key Ingredients in Mayonnaise Manufacturing

1. Oil

Primary component of mayonnaise (up to 70–80% by weight).
Influences texture, creaminess, and stability.
Recommended oils: sunflower oil, rapeseed oil, or grapeseed oil for their neutral taste.

2. Egg Yolk

Industrial mayonnaise often uses pasteurized liquid or powdered egg yolk.
Provides emulsifying properties via Low-Density Lipoproteins (LDL).
More effective than egg white in maintaining emulsion stability.

3. Vinegar

Adds flavor and lowers pH, enhancing food safety and shelf life.

4. Salt & Sugar

Salt enhances flavor and emulsion stability.
Sugar balances acidity from vinegar and contributes to taste.

5. Mustard

Adds flavor and color.
Contains isothiocyanates, which influence the sharpness of the product.

Mayonnaise Production Process in Food Manufacturing Facilities

Step-by-Step Mayonnaise Manufacturing Process:

Egg yolk is added to a mixing tank.
Water (with dissolved sugar) is added.
Agitator is switched on and oil is slowly incorporated, forming the pre-emulsion.
Vinegar, along with salt and lemon juice, is added.
The pre-emulsion is recirculated until a stable mayonnaise is formed.
The product is transferred to a buffer tank and prepared for packaging.

💡 Note: Operational speeds during mixing significantly impact emulsion quality. Improper speed or temperature can lead to phase inversion—producing a water-in-oil (W/O) emulsion and resulting in broken mayonnaise.

Common Challenges in Mayonnaise Production

Factors Influencing Emulsion Quality:

Stirring speed
Temperature control
Egg quality (type and content)
Oil addition rate

Improper handling of any of these can lead to emulsion instability or product separation, which impacts shelf life and consumer acceptance.

Consult PMG Engineering for Food Technology Consulting

At PMG Engineering, we specialize in food business consultancy, including mayonnaise processing plants, food factory design, and end-to-end project execution. Our team of food industry consultants ensures compliance with HACCP, FSSAI, and other global food safety standards.

Whether you're planning a greenfield food processing plant or upgrading an existing food manufacturing unit, our engineering and consulting services are tailored to your needs.

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