What equipment is needed for the production of mayonnaise? Technological line for the production of mayonnaise Equipment for the production of mayonnaise at home.

Many people love dishes with sauces. The inclusion of this ingredient in the recipe can significantly improve the taste of cooked food. For this reason, sauces are very popular. The most popular of them is mayonnaise.

It should be noted that the production of this product, beloved by Russians, is quite profitable. You can organize such a business with a small initial financial investment by purchasing easy-to-use technological equipment.

Production methods

Mayonnaise is a creamy mass made from deodorized and refined vegetable oils. At the same time, a variety of flavoring components and spices can be added to the product. This sauce is used for dressing mainly cold dishes.

There are hot and cold ways to produce mayonnaise. The second option technological process are now rarely used. The fact is that with cold production of the product it is impossible to achieve its high quality.

Concerning hot technology, then simultaneously with the ongoing homogenization of the ingredients, the entire mixture is heated to a certain temperature. In this case, the taste of the product is more pronounced. That is why equipment for the production of mayonnaise is now mostly equipped with heating elements.

Steam is much more economical than electricity. If the enterprise has its source, then it is most advantageous to install a special spiral in equipment for the production of mayonnaise. Through it, the steam will heat the tank.

The use of bulk components

The technology for the production of mayonnaise at its first stage involves the process of dosing and preparing the ingredients specified in the recipe. Bulk components such as mustard and egg powder, salt and granulated sugar, as well as milk powder, are sifted on special vibrating sieves. These devices have cells whose size does not exceed 3 mm.

In addition, they are equipped with special magnets that trap ferrous impurities. During the procedure for preparing dry ingredients, lumps are eliminated. This allows you to increase the moisture capacity and dispersion of products during swelling. Also, dry components increase surface-active and emulsifying characteristics.

Vinegar preparation

The mayonnaise production line allows you to produce the next component of the popular sauce. They are flavored vinegar. This ingredient avoids the undesirable specific pungent taste of the finished product. A flavored analogue of acetic acid is prepared by infusing it.

In this case, a variety of spices are used (allspice and black pepper, bay leaf, etc.). To carry out this procedure, pre-prepared vinegar is poured into a special container. Crushed spices are placed in the liquid, which are in a linen bag. Vinegar is heated to ninety degrees. After cooling, the liquid acquires the status of flavored. Spices in bags can be extracted.

Vinegar-salt solution

Equipment for the production of mayonnaise includes units that prepare another component of the sauce loved by everyone. They are acetic-salt solution. For this, a special container is used. It is fed with a saline solution, which is dissolved with water.

In the same container in the required volumes acetic acid(using a vacuum pump). If there is no special salt solvent in the equipment set, then the acetic-salt solution is prepared in a container equipped with a stirrer.

Mustard production

Cooked mayonnaise should not have an excessive bitter taste. That is why the mustard powder included in the recipe must first be placed in an enameled or stainless steel tank. The dry ingredient is diluted with water, the temperature of which should not be lower than eighty degrees. A day later, the liquid is drained, getting ready-made mustard.

List of required equipment

The production of mayonnaise must be thought out to the smallest detail. Before purchasing equipment, you need to decide on the type of packaging. The most economical option would be a line with packaging in plastic bags. Equipment for the production of mayonnaise should include:

The container in which vegetable oil;

An intermediate tank where the oil is collected before mixing;

Hydrodynamic machine, where the mixture is ground and subjected to heat treatment;

Pump supplying the line with vegetable oil;

An intermediate container in which the product is stored before packaging;

Screw pump supplying mayonnaise to the packaging;

A filling machine that places the product directly into the container.

As for packaging equipment, it can be of automatic or semi-automatic type. The latter type of machines involves the work of an individual worker who installs each individual container, sealing it, and then removing it from the line.

The operation of the machine takes place without human intervention. It's much more productive. However, it is worth considering that the cost of the machine, as a rule, is three to four times more expensive than the semi-automatic.

Mayonnaise has the most noble origin. French cuisine is inextricably linked with the use of sauces, of which there are more than three thousand. According to tradition, sauces were named after the inventors or the locality and people to whom the French attributed these culinary traditions. So, for example, Tatar sauce (mayonnaise with cucumbers and capers), Russian sauce (mayonnaise with caviar) were invented. All famous sauces were created in the XVII-XIX century. The authorship of many sauces belongs to the representatives of the titled nobility. Such is the Bechamel sauce, the invention of which is attributed to the Marquis Louis de Bechamel, and the modest onion sauce"Subise" - to the Princess de Soubise.

Mayonnaise is the most common commercially produced sauce. I do not have data for Ukraine, but in Russia its consumption reaches 3 kg per person per year, and this figure tends to increase.

The production of mayonnaise at small enterprises is considered one of the most profitable. In addition, the equipment used is easy to operate, and the production technology is quite simple. All this allows you to fully establish the production process and start making a profit in a short period of 1-2 months.

Mayonnaises are made from refined vegetable oils with the addition of flavors and spices. Mayonnaise is an emulsion: it consists of many microscopic drops of vegetable oil placed in an aqueous mixture of a certain composition.

For the preparation of mayonnaise, the following raw materials are used:
vegetable oil (sunflower, soybean, corn, cottonseed). This is the main component of mayonnaise (from 40 to 60 percent of the weight);
egg powder;
cow's milk;
corn and potato starch;
granulated sugar, salt, acetic acid, baking soda, water.
Other flavoring and stabilizing additives are also used. By the way, taste qualities mayonnaise is determined by the quality of raw materials and recipes.

In the Middle Ages, the recipes for mayonnaises and sauces were the secret of the secrets of European royal cuisine, but even now branded recipes are trade secrets.

Therefore, having decided to engage in the production of mayonnaise, you first need to think about what recipes it will be prepared according to.

Of course, the equipment is supplied with accompanying documentation, including mayonnaise recipes, but it is advisable to find an experienced technologist and develop your own unique recipes.

For equipment selection for a mayonnaise production shop, it is necessary, first of all, to determine the desired production volume, that is, one that would enable the full and fairly quick sale of the product.

Next, you need to decide on mayonnaise packaging method .
The easiest way is packing in plastic containers. In this case, the least expensive set of equipment is used.
However, the shelf life when using this type of packaging is minimal.

Packing in glass jars the most hygienic, gives the maximum shelf life. The equipment is also relatively inexpensive. However, this is the most time-consuming way of packaging.

Finally, the most expensive equipment is used for packaging mayonnaise in plastic bags. At the same time, this method is the least laborious.

For example, I will tell you about the line for the production of mayonnaise with packaging in plastic containers (cups) with aluminum foil lids.

This line consists of the following equipment:
§ Module (mixer) for the preparation of mayonnaise (about 1000 USD) - here the components are mixed and the mayonnaise emulsion is prepared;
§ Capacity for ready-made mayonnaise, 500 liters (150-180 USD) - here at the end of each cooking cycle, ready-made mayonnaise comes from the mixer, after which it is poured into cups;
§ Plant for pouring mayonnaise into cups (about 1500 USD);
§ Installation for sealing cups with foil lids (500 USD);
§ In addition, you can purchase a device for group packing cups with mayonnaise in shrink film (about 500 USD).

So the general cost of equipment - about 3500 USD.

Performance the considered line - 300 kg per cycle (the duration of the mayonnaise production cycle is 2.5 hours).

enough to accommodate it room 15 square meters of production area (plus, of course, storage space - about 50 square meters).

Two workers can serve the line. The director, and most often he is also the owner, bears the administrative and sales burden, negotiates with customers, purchases raw materials, etc.

Practice shows that the real equipment payback period taking into account the time for debugging production and reaching the design performance - three to four months. $$$

Profitability:
Mayonnaise production
Equipment cost: 3500 USD
Payback period: 3-4 months.
Productivity: 300 kg/cycle
Number of employees: 2
Premises: from 65 sq. m.

Mayonnaise is one of the most common food products and one of the most popular consumer goods. Its consumption in Russia reaches 3 kg per person per year, and this figure is constantly growing. Mayonnaise production is considered one of the most profitable. In addition, it is distinguished by simple technology, which allows you to set up the production process in a short period of 1 - 2 months.

To establish your own production of mayonnaise, you need: firstly, a room that meets sanitary and hygienic requirements, secondly, equipment, and thirdly, an experienced technologist.

Before purchasing equipment, it is necessary to determine the volume of production. And only after that proceed to the selection of a set of equipment. The compositions of the kits are very similar, the differences lie in the design of the homogenizer - units that crush the mass of oil into microscopic drops. However, these differences are not fundamental. The main factors influencing the choice are the price of equipment and the degree of automation of the technological process.

The choice of packaging equipment depends directly on the packaging method that will be used in production. The easiest way is packing in plastic containers, the shelf life when using this type of packaging is minimal. But the equipment used for this type of packaging is the least expensive of all types. Packing in glass jars is the most hygienic and gives maximum shelf life. The equipment is also relatively inexpensive. However, this is the most time-consuming way of packaging. The most expensive equipment is used to pack mayonnaise in plastic disposable bags, this is the least labor-intensive way. In addition, in this case, the cost of storage and transportation of the product is minimal.

The table shows important technical indicators of kits based on IPKS-056 miniplant

The raw materials needed for the production of mayonnaise include: vegetable oil (sunflower, soybean, corn, cottonseed), egg powder, whole cow's milk dry and skimmed milk, corn and potato starch, granulated sugar, salt, acetic acid, drinking soda, water. The taste of the finished product will largely depend on the quality of the raw materials, as well as on the recipe. Recipes are developed by technologists, branded recipes are trade secrets. Therefore, the quality of the product, and hence its success in the market, largely depends on the qualification of the technologist.

Below is a table of the cost of the main components of raw materials (excluding VAT, as of September 1999 in the Moscow region) (note site: prices can be substituted for the current ones - the main principle of calculations)

The mayonnaise production process consists of four main steps:
. Preparation of prescription components
Mayonnaise preparation
Preparation of mayonnaise emulsion
Packing, packaging, labeling

Mustard preparation.

24 hours before the start of mayonnaise production required amount mustard powder placed in an enameled or stainless steel bowl and poured with water at a temperature of 80-100 ° C in a ratio of 1: 2. The mixture is well mixed until a homogeneous consistency with smoothing the top layer. Water with a temperature of 100 ° C, 4-6 cm high, is carefully poured onto a flat surface of the mixture. The container is tightly closed with a lid and left alone for a day. Before use, the top layer of water is carefully drained.

Preparation of egg powder solution.

In a food container, egg powder is dispersed in warm water with a temperature of 40-50 ° C in a ratio of 1: 1, then added to the mass hot water with a temperature of 60-75 about C until the ratio of egg powder and water is 1: 1.5. The composition is thoroughly mixed by hand until a homogeneous mass is obtained.

Preparation of acetic-salt solution.

9% table vinegar according to the recipe and diluted with water.

Mayonnaise preparation

Dry components from the filled volumetric containers are poured into the mixer-emulsifier and filled with boiled water with a temperature of at least 30-40 ° C. The mixture is pasteurized (heated to 80-85 ° C) with thorough mixing for 30 minutes. Sugar is added. At the end of pasteurization, the mass is mixed and cooled to a temperature of 50-55 o C. Then the prepared amount of egg powder and mustard is introduced. The mixture is heated again (up to 60-65 ° C) and kept at it for 25-30 minutes, and then cooled to 30 ° C.

Preparation of mayonnaise emulsion

Vegetable oil is introduced into the mayonnaise paste with further stirring. After receiving the entire dose of oil and obtaining a homogeneous emulsion, an acetic-salt solution is introduced and the mixture is still mixed for 15-20 minutes. At the last stage, the final homogenization of the resulting mixture is carried out using a homogenizer pump, after which the product is poured into flasks or containers of finished products for further packaging and packaging. As we said above, mayonnaise can be packaged in several ways. On small lines, polymer packaging and simple and productive dosing (by volume) devices of the UD-2 type and installations for welding cups made of polystyrene with Al-foil USS-2 are most often used.

Approximate recipes for the preparation of mayonnaises "Salad", "Provencal"

On prices, production costs, profits and payback periods
(excerpts from technical and economic calculations)

The cost of production consists of the cost of raw materials, materials, fuel, energy, fixed assets, labor resources, as well as other costs for its production and sale.

The results of calculating the cost of 1 liter of products and its selling price are given below.

Initial data:
work is carried out in 3 shifts (8 hours each);
the salary of each worker is 1500 rubles;
25 working days in a month;
sales of products - 100%.
Purchasing wholesale prices for raw materials and ingredients (without VAT, as of September 1999 in the Moscow region) (note site: prices can be substituted for the current ones - the main principle of calculations)
Main conclusions from the calculation results
1. The break-even point in time for all sets is the same and is about half a month (note openbusiness: ???). This is due to the same ratio of fixed and variable costs, taken in the calculations.
2. The performance of the equipment determines its payback period and the amount of net profit. The higher the productivity of the equipment, the higher the net profit and the shorter the payback period.
3. Profitability in these calculations is 10%. But its level depends on the prices for the sale of the final product - if prices significantly exceed the cost of the final product produced, then the planned profit will grow and, accordingly, the profitability of production will increase.

Based on materials from Equipnet.ru

Mayonnaise production equipment has specific requirements. Because the finished product does not undergo complete heat treatment, the equipment on which it is manufactured (from the stage of preparation of raw materials to the process of packaging the packaged product) must be bacteriologically clean.

To do this, in addition to observing the hygienic regime, the equipment must meet the following requirements:

• be protected (sealed) from the ingress of microflora from the external environment;
• do not have stagnant zones in which spontaneous reproduction of bacteria can occur;
• easy to disassemble into separate units for thorough washing and disinfection;
• be made of high-quality materials (with an acceptable cleanliness of the processing of internal surfaces up to 0.1 microns);
• have an automatic washing unit.

Of no small importance is the equipment of equipment for the production of mayonnaise with a deaeration unit, which allows to increase the shelf life of the product, to avoid oxidative damage.

In modern requirements for technological equipment, great importance is attached to the full automation of production.

At the same time, the weighing of ingredients and raw materials, measuring the components in accordance with the recipe, mixing them to the required quality, monitoring and automatically recording the entire course of the product manufacturing process are connected in the technological chain.

It is desirable that cleaning and disinfection of equipment be carried out with solutions in a closed cycle (without the need to dismantle the equipment) - CIP (Cleaning In Place). For this, the following requirements must be met:

• valves must prevent contact between the cleaning solution and the product;
• all surfaces in contact with the product must be accessible to the cleaning solution (in order to achieve complete cleaning);
• it is necessary to exclude the possibility of corrosion of the materials from which the equipment is made.

Equipment types

Depending on the different production schemes, mayonnaise production equipment is divided into high-performance continuous or semi-continuous lines, in which various stages processes are carried out in different apparatuses arranged in series, and small batch units for carrying out all operations in one tank, the productivity of which varies over a wide range (from 30 to 6000 l / h).

Mayonnaise continuous production lines

Continuous and semi-continuous mayonnaise production lines have their own advantages and disadvantages. Benefits include:

1. high performance,
2. the possibility of full automation,
3. guarantee of constant product quality,
4. the ability to easily replace obsolete or faulty modules.

The disadvantages of continuous lines are:

1. the need for large production areas;
2. significant material consumption;
3. high consumption of detergents;
4. increased product losses during sanitary and hygienic measures.

Continuous and semi-continuous technologies are used by automated high-performance Johnson lines (up to 1 t/h), lines by Gilder Corp., Cherry Barrell, Holsum Food Co, Stork SalatOMatic, Schroeder.

Technology system production of mayonnaise and salad dressings on the Johnson line is shown in Figure 1.

1 - bunker for egg powder; 2 - hopper for dry ingredients; 3 - oil container; 4, 13 - containers for water and vinegar; 5 - deaerator; 6, 15, 23 - pumps; 7, 10 - dosing pumps; 8, 9 - votators; 11 - votator supply tank; 12 - starch hopper; 14 - tank for preparing starch suspension; 16 - finished product tank; 17 - filling machine; 18 - seaming machine; 19 - homogenizer; 20 - feed tank of the homogenizer; 21 - tank of sanitary marriage; 22 - filter; 24 - mixer
Figure 1 - Technological scheme for the production of mayonnaise and salad dressings on the Johnson line

Batch equipment

The advantages of periodic lines are compactness, cost-effectiveness, a wide range of performance. However, it should be said that batch lines only work effectively if there is full automation.

In the production of mayonnaise, the main devices of the technological line are homogenizers (or dispersants), which should ensure the creation of homogeneous finely dispersed emulsions with a given particle size. The main working elements are high-speed stirrers, high-pressure homogenizers, colloid mills, rotor-stator systems, homogenizing devices, which are combined with product evacuation in a hermetically sealed apparatus and pumping the product “to the return” at high speed, which allows achieving the desired degree of dispersion. finished product.

Let's imagine the equipment for the production of mayonnaise of some leading German companies.

"BUT. Stefan & Sons GmbH & Co. manufactures modern machines and systems for use in many areas of the food industry. For the production of mayonnaises, universal machines of the UMM/SK type, a universal vacuum-mixer of the VM/MC type and a Stefan microcut MCH 10/2 homogenizer are of interest. These batch machines can operate both in manual, semi-automatic and automatic modes of process control according to a given program.

The Stefan UMM/SK unit has a rational design, suitable for integration into existing equipment, it is easy to maintain and clean, it is multivariate, and it allows obtaining a stable quality of the product. The machine is a sealed container equipped with a double jacket, into which an elongated shaft is lowered, which serves to attach a working tool - sharp knives or mixing blades. The kit also includes a transport blade for removing especially viscous materials from the walls and directing them to the center of the container. Simultaneously with mechanical processes, thermal processes can take place in the machine: heating can be carried out either by direct supply of steam or through a jacket. All processes can take place under vacuum conditions. A mini-variant is also produced for small batches of experimental products in laboratories - UMM / SK 5.

The technical data of these machines are given in table 1.

The Stefan Vakuterm plant is designed for the production of sauces, mayonnaises, food emulsions, as well as pureed soups, various meat and fish products. The basis of the modular vacuum system (Figure 2) is a diagonally mounted hermetic working container with an attached motor-reducer, on which a stirrer with a scraper is fixed. The drive shaft is sealed on the side of the container with a double-acting mechanical seal, which is steamed during sanitary measures. The circulation pump is used to uniformly supply the product through the homogenizer and recirculation system back to the working tank. At the end of the emulsification and homogenization cycle, additional components and in the final stage there is a process of homogeneous mixing. The circulation of the product can be carried out optionally through a homogenizer or bypassing it. The circulation pump is also the unloading pump.

1 - STEFAN vacuterm; 2 - loading opening DN 200; 3 - viewing window DN 125; 4 - vacuum connection; 5 - unloading fitting; 6 - unloading pump; 7 - STEFAN microcut MSN; 8 - dosing funnel - dry substances; 9 - dosing funnel - liquids; 10 - control cabinet
Figure 2 - Module "Stefan vakuterm"

Modular vacuum systems are equipped with a jacket for indirect heating and cooling of the tank contents. However, the supply of live steam and inert gases is also provided for rapid heating and cooling in a gentle mode.

The vacuum system of the installation consists of a vacuum pump and an adjustment unit operating in an automatically set mode. The main working element of the plant is Stefan's homogenizer with a rotor-stator system, which can be equipped with various rings with a gap of 0.1 to 3 mm and thereby regulate the process of homogenization and emulsification.

The technical data of the Stefan Vakuterm units are shown in Table 2.

Stefan Mikrokut homogenizers for grinding and emulsifying soups, sauces, desserts with a capacity (depending on the degree of grinding) from 3000 to 6000 l/h also have a disintegrator as the main working body.

FRYMA manufactures equipment for the production of food emulsions, purees, jams and marmalades, pasty products.

For the production of mayonnaise and salad dressings, the company has developed the MZM/VK "Delmix" plant (Figure 3).

Figure 3 - Processing
installation MZM/VK "Delmix"

The product passes through the emulsifying head and returns to the tank through the recirculation pipe to achieve the required degree of emulsification. The emulsifying head consists of a rotor and a stator, the gearing of which is selected taking into account the desired degree of dispersion of the product. Delmix units are produced in 10 modifications, with a capacity from 7 to 3000 liters.

Since 1970, KORUMA has been producing plants for the production of dispersed and homogenized food products. For the production of mayonnaise emulsions, DISHO plants (DISperses and HOmogenizes) are offered with a working capacity of 85 to 1300 liters (table 3). The units are equipped with a rotor-stator homogenizer, recirculation and vacuum systems.

Mixing of a product is carried out in horizontal and vertical directions. Process control is automatic in accordance with the program.

Domestic equipment

Russian manufacturers also produce machines for the manufacture of mayonnaise products, which are very easy to install and operate.

For example, the MAIS mini plant manufactured by Stroyvest SPKF (Dzerzhinsk, Nizhny Novgorod Region) is intended for the production of food emulsions (mayonnaise, creams, pastes, jams, sauces, jams and other food mixtures of various recipes) at public catering establishments, dairy and fat-and-oil plants, small and medium-sized businesses.

The principle of operation of the installation is based on the successive two-stage production of mayonnaise: first, dispersion of all mayonnaise components except oil, then slow oil supply and homogenization of the mixture.

The unit can be equipped with a batcher and an electric seaming machine with interchangeable heads.

The FLIGHTM mayonnaise plant is equipped with an original Bulgarian-made homogenizer with a capacity of 1500 l/h. Plant productivity up to 3000 kg/shift.

Chopper mixers IS-160 and IS-80 are offered by CONSITA for the production of sauces and mayonnaises. The unit is equipped with a stirrer, a jacket, a vacuum chamber, a live steam injection manifold, and automatic control.

The Elf-4M company produces a mayonnaise module IPKS-056 with a capacity of 3000 kg / day, equipped with a rotary pulsation unit RPA-1.5-5, as well as a mini-plant for the production of mayonnaise based on this module.

In the plant for the production of mayonnaise MA-0.5, offered by OAO Tveryagroprodmash, with a capacity of 500 l/h, the homogenizer is a colloid mill of an original design, which consumes three times less electricity compared to piston-type homogenizers.

Sets of equipment for the production of mayonnaise with a capacity of 300, 500, 800 and 1000 kg/shift, in which dispersion and homogenization are provided by a rotary-pulsation apparatus, are offered by AGRO-3 JSC. The equipment provides pasteurization of raw materials and finished mayonnaise. The duration of the cycle does not exceed 2.5-3 hours.

The mayonnaise production unit offered by Ekomash is designed for the preparation and packaging of various varieties of mayonnaise in polystyrene cups and glass jars. The set includes a tank mixer, a rotary pulsation apparatus, a pump, a set of locking equipment and a semi-automatic filling machine.

Manufacturers of equipment in Russia and the CIS offer customers both sets of equipment for the production of mayonnaise, as well as individual homogenizers of well-known brands, mainly designed for the dairy industry. For example, the AGRO-3 company offers OGV homogenizers, the Odessa Mechanical Plant - K5-OG2A and A1-OG2M homogenizers, the FlightM company - Bulgarian-made MDH-401 homogenizers, the Stupino plant of the Moscow region - RPA homogenizers.

Packaging of mayonnaise in order to avoid deterioration of quality and reduction of shelf life is carried out immediately after production. To do this, various packaging equipment is used depending on the containers used, the choice of which, in turn, is dictated by the features of the technological process, the calorie content of the product and its shelf life.

The range of currently used containers and packaging is very large: from flasks with a capacity of 18 and 25 kg to plastic bags weighing 150 g. Both traditional glass 200-gram "mayonnaise" jars and glass jars with a "twist-off" lid are widely used. Mayonnaise is packaged in plastic cups and buckets, tubes, plastic jars with various lids, plastic bags of various capacities, Pure-Pak packages, etc. The materials from which these types of containers are made have high chemical resistance to mayonnaise and its components, and hygiene indicators do not exceed the current sanitary standards.

Equipment for packing mayonnaise products into polyethylene, polypropylene, laminated, glass containers with various types closures are produced by many foreign and domestic firms.

Firm "Istok" offers automatic lines "Alta-4" for packing and capping of homogeneous viscous products in polystyrene cups with a lid made of aluminum foil with a thermo-lacquer, with a capacity of 100 to 500 ml (capacity 900-1400 packs per hour).

Automatic machines AV50F(Zh) - vertical packing in polypropylene bags weighing from 0.1 to 1.0 kg, with a capacity of 35 packs per minute, are supplied by Flight-M.

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 has been going on since ancient times, when extraordinary methods were used to create this "delicacy" to add spice and unusualness to food.

The history of the production 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 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.

Carame, 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 expert on food products, Prosper Montagnier, claimed that the origin lies in the old French word "moyeu", which means egg yolk.

Still others insist that cream sauce was an 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 its appearance in all European cuisine is not surprising. In the early 1900s, a German immigrant named Richard Hellmann discovered the delicacy in New York. The salads his wife made with 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.

The production of which was focused on the manufacture of 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 culture

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

Creating an emulsion:

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 are dispersed 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. The 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 quantities of mayonnaise are placed in them. They are sealed with metal screw clamps. However, they are not vacuum sealed.

Such 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 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 oil, as well as to improve mouthfeel 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 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 off 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, 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, but at the same time experiment with the components of the composition.

Some typical recipes would be:

1. In the first stage of production, the egg, which can be used in liquid or powder form, is dispersed in water. This acts as an emulsifier.
2. The remaining ingredients of the continuous phase are then added and mixed until dispersed and hydrated.
3. The oil is added so quickly that the continuous mixing phase immediately lifts 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. The 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.

The hydration of stabilizers and thickeners is one of the most complex mixing operations. It may be necessary 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.

The oil phase droplets must 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. This is impossible to obtain 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 optimal 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. or liquid) is added to the vessel and rapidly wetted and dispersed in the high velocity liquid flow.
2. The remaining ingredients in the aqueous phase are then 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. Recirculation of the product continues to provide a consistent consistency as the 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. Raw material yield is maximized as thickeners 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 various ingredients to the tank in the required proportions.
2. The mixture is pumped through the built-in mixer, and the mayonnaise is obtained through only one compartment, moreover, 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 the 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 manufacturing process.

Variety of sauces based on mayonnaise

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

Commercial mayonnaise is also one of the most safe products. 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 they create Tatar, spicy, mustard sauces. 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 do they differ?

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

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

Sometimes, according to recipes, salt is added to enhance the flavor. This amount is about 1/16 teaspoon of salt per tablespoon of mayonnaise. Preservatives such as calcium disodium salt 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 of "worthy sample."

mayonnaise hollandaise sauce recipe

You will need a blender to mix the products.

1. Add double the 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. Once it starts to separate and is still bubbling, pour some into the blender with the motor running.
4. Add a little more oil, the emulsion should "give" changes in sound when the blender motor is running.
5. Continue slowly pouring in the butter without adding milk solids.
6. Season to taste lemon juice, salt and pepper.

Some mayonnaise enterprises have introduced such a recipe into the basis 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 - 300 g.
2. Sour cream - 200 g.
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 fairly lucrative business. Africans created the basis for such enrichment: they produce the sauce in simple jars without inscriptions and brands, using cheap recipes and affordable raw materials. Thanks to such factors, many businessmen can secure goods and create own business on sale. 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 can't stand it this product, will be the main consumers.