Mayonnaise production: equipment and technology

The production of mayonnaise has not yet been fully studied, since there are many technologies for preparing the mixture, as the basis for the future product. Everything has been going on since ancient times, when extraordinary methods were used to create this “delicacy” to add piquancy and unusualness to food.

History of production of mayonnaise and sauces

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

Caramé, 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, claimed that the origin lies in the old French word moyeu, which means egg yolk.

Still others insist that creamy sauce was a development of the city of Bayonne in southwestern France. Thus, what was originally called “mayonnaise” was later modified to mayonnaise.

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

In the end, the Hellmans began sorting their mayonnaise into glass jars. In 1913, they built their first mayonnaise factory. Company from California Best Foods Inc. also enjoyed the success of her version of mayonnaise. In 1932, she acquired the Hellman brand and continued production of both versions of the sauce.

A variant of mayonnaise, the production of which was focused on the manufacture of salad dressings, was developed by National Dairy Products in 1933 and presented at the World Peace Exhibition in Chicago. Ultimately, the product became known as Kraft Miracle Whip Salad Dressing.

Mayonnaise production technology - features of each culture

To create mayonnaise, you need only two steps to get the finished product.

Emulsion creation:

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

It turns out a single consistency, which is so important for this type of product. The following is the addition of various components, which are a way of diversity of the base mixture.

Adding Ingredients:

1. Pre-measured ingredients are piped through openings in the sides of the pumps or from the pressure bushings.
2. Mayonnaise moves through the pumping system to the filling station. Pre-sterilized cans move along a conveyor belt and pre-measured quantities of mayonnaise are placed in them. They are sealed with metal screw clamps. At the same time, they are not sealed in vacuum.

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

Raw materials for making sauces and mayonnaise

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

You can add spices and other natural seasonings, with the exception of turmeric and saffron. They gave the mayonnaise a yellow tint, which consumers did not like, so the production line of mayonnaise with them as a part 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 installation. This process is often semi-automated and under vacuum. For research and development, experimental small-scale production is used, typical of the "ready-to-eat" market: sandwich makers, catering establishments and other small companies. For them, mayonnaise must be produced in such a way as to ensure an increase in their sales, but at the same time experiment with the components of the composition.

Some typical recipes would be as follows:

1. At the first stage of production, an egg, which can be used in liquid or powder form, is dispersed in water. It acts as an emulsifier.
2. The residual continuous phase ingredients are then added and mixed until dispersed and hydrated.
3. 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:

“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 volume of liquid. If the egg and other emulsifiers are not properly dispersed and hydrated, the emulsion may break at the stage of oil addition.

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

Due to the high proportion of oil in the recipe, the emulsion may burst if it is not added to the continuous phase correctly. It is very difficult to control when the process is manual.

The droplets of the oil phase should be reduced to a minimum size in order to maximize the surface area of ​​the oil in the continuous stage of mayonnaise production to ensure a stable consistency of the emulsion. This cannot be obtained without special equipment.

Aeration should be minimized or eliminated to ensure maximum shelf life of the product.

Equipment for making mayonnaise

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

1. Water is recycled from the vessel through the system using a specially designed In-Line mixer. An egg (powder or liquid) is added to the vessel and quickly wetted and dispersed in the stream at a high liquid rate.
2. Then the remaining ingredients in the aqueous phase are added to the vessel. Recycling continues until the ingredients are fully dispersed and hydrated.
3. The oil supply valve opens, and it flows from the hopper into the aqueous phase at a controlled speed. The ingredients of the water and oil phases go directly to the working head of the mixer, where they undergo 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 serving of oil.
4. Product recycling continues to provide a uniform 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, the system virtually eliminates operator error. The profitability of raw materials is maximized, as thickeners are fully hydrated, and other ingredients are properly dispersed. Mass production of mayonnaise is a little different. The process is suitable for the manufacture of more than 1000 kg of products per hour:

1. Measuring pumps simultaneously add various ingredients to the tank in the required proportions.
2. The mixture is pumped through the built-in mixer, and mayonnaise is obtained 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 bulk should be installed in accordance with accepted quality standards so that the products can then be tested and tested.

Quality control of finished products

All raw materials are checked for freshness when it arrives at the processing plant. The stored materials are periodically checked. Samples of mayonnaise are taken and tested for taste during the manufacturing process.

A variety of sauces based on mayonnaise

There are many varieties of mayonnaise, including light and low fat. This healthy condiment can be part of a well-balanced diet that satisfies 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 a major source of our daily intake of vitamin E.

Commercial mayonnaise is also one of the safest foods. Salad dressings contain pasteurized eggs, which were subjected to heat treatment to destroy harmful bacteria and ensure the safety of the product, so you can be sure of it. On the basis of mayonnaise create Tatar, spicy, mustard sauces. Since the production of mayonnaise involves the application of basic principles, they can be supplemented. To diversify the taste, and not the consistency or proportion, you can use seasonings.

Russian factories - how do they differ?

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

To replace fat from egg yolk, modified food starches are added. In order for the non-fat mayonnaise to maintain the creamy texture and density of a real mayonnaise, starches from corn or an agar product are used (extraction of seaweed). In Moscow, the production of mayonnaise is carried out by technologists of the highest level. However, the recipe is standard, not changing for years. The Togrus trademark does not change traditions and centuries-old quality standards.

Sometimes, according to recipes, salt is added to enhance the aroma. This amount is approximately 1/16 teaspoon of salt per tablespoon of mayonnaise. Preservatives such as calcium disodium are added to increase shelf life. But the production of mayonnaise in Noginsk was relatively recently formed, but the plant already has many awards for the honorary title "worthy sample."

Dutch mayonnaise sauce recipe

You will need a blender to mix food.

1. Add a double amount of yolks (so that the blender blades are covered with it).
2. Add 2 tsp. salt.
3. Melt the butter in a small saucepan over medium heat. As soon as it starts to separate and still bubbles, pour a little into the blender with the engine running.
4. Add a little more oil, the emulsion should “produce” changes in sound when the blender motor is running.
5. Continue to slowly pour in the butter without adding solid particles of milk.
6. Season to taste with lemon juice, salt and pepper.

Some mayonnaise enterprises have introduced this recipe as the basis for some sauces. You can diversify them with the help of spices and a combination of ingredients in the ratio of proportions.

The recipe for "Tartar"

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

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

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

Benefit

The mayonnaise business is a pretty lucrative business. The basis for such enrichment was created by Africans: they produce sauce in simple cans without inscriptions and brands, using cheap recipes and affordable raw materials. Thanks to such factors, many businessmen can get goods and create their own business for the sale. If we talk about the establishment of production, we should start with small lots, because for a continuous sale of 1000 kg, you need to find outlets. Egg-free mayonnaise is gaining popularity - vegetarians and people who cannot tolerate this product will be the main consumers.