Technical Feasibility and Manufacturing Process of Mayonnaise Production

Chapter 3
Technical Feasibility
This aspect includes the product, the manufacturing process
and the raw materials. The raw materials are directly purchased
from suppliers.
The manufacturing process is comprised of three different
parts: the acquisition process, production process and the
packaging process. Production schedule was discussed briefly; the
table representing the production for five years was included as
well. Machineries and equipment were chosen by the proponents
according to its durability and efficiency in functioning for
five straight days.
The direct and indirect materials needed in the study were
also included; these materials will ensure the quality and safety
of the products during production to distribution. Plant building
construction and site as well as the utilities were discussed to
obtain the needed capital in starting up a business.
Location of the site, the size and layout were decided by
the proponents, access to suppliers and potential market were
considered.
10
Product
Mayonnaise is oil-in-water emulsion where oil is the
discontinuous phase and water is the continuous phase obtained by
emulsifying edible vegetable oil in an aqueous phase.
Mayonnaise is an oil-in-water emulsion despite containing
between 70-80% fat. Oil in water emulsions consist of finely
dispersed droplets of oil in a continuous phase of water or a
dilute aqueous solution. Droplet size range is from less than 1μm
to 20μm or more. This emulsion is formed by mixing the eggs,
vinegar and spices, and then slowly feeding the oil, resulting in
a closed-packed foam of oil droplets or coarse emulsion.
Dissimilarly, if the aqueous and oil phases are mixed at once the
result is a water-in-oil emulsion, whose viscosity is similar to
the oil from which it was made (Depreeand Savage2001). Vegetable
oils, the main ingredient in mayonnaise, have an important
function in an emulsion; they contribute to the taste, the
appearance, the texture and the oxidative stability of the
emulsion in a very specific way (Moslavac et al., 2012).
The main role in mayonnaise production is composition ratio
of oil phase and the addition of various emulsifier, stabilizer
and thickener. Texture depends on oil, the more oil is used then
the better texture is resulted. Oil has important function in
characteristic of rheology. Fat as one of the main ingredients,
has positive influence on the rheological properties and sensory
characteristic of final product. High fat intake as associated
11
with increased risk of obesity, some types of cancer,
cardiovascular diseases, and hypertension. The production of low
fat mayonnaise is normally associated with some technical
problems such as poor texture, flavour, appearance stability, and
mouth feel (Amin et al., 2014).
Traditional mayonnaise is a mixture of egg, vinegar, oil and
spices (especially mustard) or eggless mayonnaise also available.
These mayonnaise preparation mixtures of milk solid, oil,
thickener, stabilizer salt and sugar. Despite the high oil
content relative to water, mayonnaise is oil in- water emulsion.
This emulsion is formed by first mixing the eggs, vinegar and
mustard and then slowly blending in the oil. This result in an
emulsion consisting of closely packed „foam‟ of oil droplets
(Singlaet al., 2013).
Mayonnaise is a global consumer favorite that complements
many dishes. We all have our favorite uses of mayonnaise, perhaps
as a spread in sandwiches, a topping for fresh salad or as a dip
for french fries, or mixed with other sauces, spices and
condiments to accompany fish, meat or vegetable dishes.
Mayonnaise is also often used as base for creamy-type salad
dressings. It is formulated to develop characteristics such as
mouthful and spread ability which are considered desirable by the
consumer.
12
Manufacturing Process
The mayonnaise was prepared in Department of Food Chemistry
and Nutrition, CFT, VNMKV, Parbhani. The formulation used for
preparation of flavored mayonnaise. Firstly, the studies on
different ingredients and stages of processing were required to
be standardized. The mayonnaise samples were prepared using food
mixer. A continuous blending system is employed to sustain the
correct degree of emulsification. The blending of all ingredients
moves continuously through a series of positive replacement
pumps. These pumps features cavities fitted with rotary
impellers. The impellers move the blended fluid from one cavity
to another. Pre measured ingredients are piped in through
openings in the sides of the pumps or from spigot overhead.
Mayonnaise is moved through the pumping system to the bottling
station.
13
PLANT LAYOUT
Consumers expect a wide variety of products, including
healthier options. For mayonnaise manufacturers this means
developing recipes that contain less fat, sugar, and fewer
additives, and developing processes for manufacturing top quality
products that don’t compromise on texture, color, taste or shelf
life. Factors also to be considered is to innovate with
healthier, tasty recipes. Our flexible solutions let our
customers respond quickly to market demands, but remain efficient
to reduce costs, resource and energy use.
14
The Process used in existing plants and in similar projects
in the Philippines or abroad are dispersion. It is a way of
distributing evenly of raw materials. Another method is
emulsification. It is a stable suspension of small droplets of
one liquid in another with which it is immiscible. Also,
homogenization can be conclude as a method.
It is the tendency of raw materials to become homogeneous or
to mix as one. Lastly blending, it is the mixture of two or more
materials.
Plant Size and Production Schedule
The designers decided to operate the plant for eight (8)
hours per day and three hundred thirteen (313) days annually. The
plant to be designed produces one hundred (100) Kilograms per
hour.
For the Capacity per day For the Capacity per year
Production: 100 kg/hr Production: 800 kg/day
No. of operating hours/day: 8 No. of operating days/year: 313

hr/day days/year
15
8 hr
100 kg/hr ( ) = 800 kg/day 800 kg/day (
day
313 day
) = 250,400 kg/year
year
Based from the computed values above, in one day the plant
can produce 800 kg/day and 250,400 kg annually. So, for the next
five (5) years, if the plant is being maintained well the
calculated production is:
Annual Production: 250,400 kg/year
No. of years: 5 years
250,400 kg/year ( 5 years ) = 1,252,000 kg
It is also decided by the designers that the plant is not
operating every Sunday. Sundays are scheduled for the weekly
maintenance of the machineries installed in the plant. It is for
the betterment of the production and to make the life span of the
plant much longer.
The factors used in determining plant size are, the sizes of
the machineries used in operation, the tanks for raw materials,
16
storage for finish products and other stored materials, offices
and solid waste areas.
Machinery
Design Parameters:
Mayonnaise is a water-oil emulsion with eggs. A typical
recipes are as follows:
Oil 70-80 %, preferably Vegetable Oil
Egg 10-11 %
Water 8-10 %
Vinegar 4 %
Table Salt 1.0 %
Sugar 1.0 %
Lemon juice 0.5 %
MANUFACTURING PROCESS
Mayonnaise production can be executed in batches or in-line
with a necessary production rate.
Batch Process:
The production in batch is adequate for low output
production below 1000kg/h.
In-line Process or Continuous Process:
The continuous process is suitable for production
higher than 1000kg/h.
17
SELECTION OF PROCESS
The designers decided to use Batch Process which has a
maximum production rate of only 1,000 kg/hr.
Mayonnaise production can be executed in batches or In-line
with a necessary production rate.
The designers also decided to use 100 kg/hr of mayonnaise
production because of minimum supply of lemon in the area.
INGREDIENTS
There are 4 day tanks with the necessary portions of various
ingredients.
1- Oil. At a low temperature (7-8ºC) if possible
2- Water. With previously dissolved sugar
3- Vinegar. With previously dissolved salt and lemon
juice
4- Eggs. At about 4ºC
USAGE OF DIFFERENT INGREDIENTS USED IN MAYONNAISE PRODUCTION
Eggs are composed of three main parts, egg white (59%), egg
yolk (31%) and the outer shell (10%) (Nys and Guyot, 2011).
However, in mayonnaise only egg yolk and egg white are used as an
emulsifying agent. Egg yolk is more commonly used compared to egg
white because of its greater emulsifier properties.
Vinegar used in mayonnaise contributes to the flavor of the
mayonnaise and it decreases the pH. By keeping the pH of the
18
product low, the microbiological safety and preservation of the
product increases.
Salt contributes to the flavor and to the stability of the
mayonnaise (Depree and Savage 2001). Salt helps to neutralize the
charges of the proteins so they can adsorb more efficiently to
the droplet interface.
The oil content in mayonnaise is usually around 75-80% oil,
where a higher oil content gives a more firm structure.
Sugar contributes to the flavor of the mayonnaise and is
added mainly to counteract the flavor of vinegar. (Duncan, 2004)
Lemon Juice is added for flavour and because acidity is
necessary for the emulsion to properly form.
DESIGN CALCULATIONS:
Solving for the Mass Flow Rate of Recipes needed in the
Production of Mayonnaise:
From Mass Percent Formula
mass of chemical
mass percent = ×100 %
mass of compound
For Vegetable Oil
70-80 % of oil is needed, use 73% of oil needed.
19
mass flow rate of oil
mass percent = × 100 %
mass flow rate of mayonnaise
mass percent ×mass flow rate of mayonnaise

mass flow rate of oil=
100 %
where:
mass flow rate of oil, kg/hr
mass flow rate of mayonnaise, 100 kg/hr
mass percent = 73%
Substituting,
73 % ×100 kg/hr
mass flow rate of oil=
100 %
mass flow rate of oil=73 kg /hr
For Whole Egg
10-11 % of oil is needed, use 10.5% of whole egg needed.
mass flow rate of egg


mass flow rate of egg=
100 %
where:
mass flow rate of egg, kg/hr
20
mass percent = 10.5%
Substituting,
10.5 % ×100 kg/hr

mass flow rate of egg=
100 %
mass flow rate of egg=10.5 kg /hr
For Potable Water
8-10 % of water is needed, use 10% of water needed.
mass flow rate of water


mass flow rate of water=
100 %
where:
mass flow rate of potable water, kg/hr
mass percent = 10%
Substituting,
10 % ×100 kg /hr
mass flow rate of potable water =
100 %
mass flow rate of potable water =10 kg /hr
21
For Vinegar
4 % of vinegar is needed.
mass flow rate of vinegar

mass percent × mass flow rate of mayonnaise

mass flow rate of vinegar=
100 %
where:
mass flow rate of vinegar, kg/hr
mass percent = 4%
Substituting,
4 % ×100 kg /hr
mass flow rate of vinegar=
100 %
mass flow rate of vinegar=4 kg/hr
For Sugar
1 % of sugar is needed.
mass flow rate of sugar


mass flow rate of sugar=
100 %
22
where:
mass flow rate of sugar, kg/hr
mass percent = 1%
Substituting,
1 % ×100 kg /hr
mass flow rate of sugar=
100 %
mass flow rate of sugar=1 kg /hr
For Table Salt
1 % of salt is needed.
mass flow rate of salt


mass flow rate of salt=
100 %
where:
mass flow rate of salt, kg/hr
mass percent = 1%
23
Substituting,
1 % ×100 kg /hr
mass flow rate of salt=
100 %
mass flow rate of salt=1 kg / hr
For Lemon Juice
0.5 % of Lemon Juice is needed.
mass flow rate of lemon juice


mass flow rate of lemon juice=
100 %
where:
mass flow rate of lemon juice, kg/hr
mass percent = 0.5 %
Substituting,
0.5 % × 100 kg/hr

mass flow rate of lemon juice=
100 %
mass flow rate of lemon juice=0.5 kg/hr
24
DESIGN OF STORAGE TANKS
For Egg
The designers decided to supply the storage tank for every
10 days of operation. Mass of egg needed in 10 days is equivalent
to 840 kg.
For the Number of Eggs needed for 10-day Consumption.
From Bake It Right Chart
By Ratio and Proportion
21 whole eggs no . of eggs for 10 days

=
1 kg 840 kg
no . of eggs for 10 days=17,640 eggs
For Vegetable Oil
25
The mass of vegetable oil for 10 days consumption is
equivalent to 5,840 kg.
Density of Vegetable Oil
From SPX Fine Food Production p. 5, the density of vegetable
oil is equal to 0.920 kg/l (920 kg/m3)
Solving for Volume of Vegetable Oil Tank
From the basic formula,
mvo
V VO =
ρ vo
Where:
V = volume of vegetable oil
m = mass of vegetable oil
ρ = density of vegetable oil,
Substituting,
5,840 kg
V VO =
920 kg
m3
V VO =6.35 m3 (1,678 gallons)
26
SELECTION OF VEGETABLE OIL STORAGE TANK
From Norwesco Catalogue
Capacity 1,700 gallons
Dimensions
Diameter 87 inches
Height 74 inches
Material Polyethylene
1,700 Gallons Above Ground Water Storage Tank
27
For Potable Water
The mass of potable water for 10 days consumption is
equivalent to 800 kg.
Solving for Volume of Potable Water Tank
m pw
V pw =
ρ pw
Where:
V = volume of potable water
m = mass of potable water
ρ = density of potable water, 1000kg/m3
Substituting,
800 kg
V pw =
1000 kg
m3
V PW =0.8 m3 (211.34 gallons)
SELECTION OF STORAGE TANK FOR POTABLE WATER
From Dura-Cast Vertical Plastic Potable Water Storage Tank
Capacity 220 gallons
Dimensions
28
Diameter 42 inches
Height 44 inches
220 Gallon Above Ground Water Storage Tank
For Vinegar
The mass of vinegar for 10 days consumption is equivalent to
320 kg.
Solving for Volume of Vinegar Storage Tank
m pw
V pw =
ρ pw
Where:
V = volume of vinegar
m = mass of vinegar
ρ = density of vinegar, 1050 kg/m3
Substituting,
320 kg
V pw =
1050 kg
m3
29
V PW =0.3048 m 3 (80.52 gallons)
SELECTION OF STORAGE TANK FOR VINEGAR
From Dura-Cast Storage Tank
Capacity 90 gallons
Dimensions
Diameter 23 inches
Height 63 inches
90 Gallon Above Ground Vinegar Storage Tank
For Sugar
The mass of sugar for 10 days consumption is equivalent to
80 kg.
Solving for Volume of Sugar Storage Tank
30
mS
V S=
ρS
Where:
V = volume of sugar
m = mass of sugar
ρ = density of sugar, 1,590 kg/m3
Substituting,
80 kg
V ST =
1,590 kg
m3
V ST =0.05031 m 3 (13.3 gallons)
From INOXPA Catalogue, it is stated that the sugar is previously
dissolved in water.
From
The solubility in water of sugar is 204 grams/ 100ml of
water. Therefore, by ratio and proportion
204 grams m sugar

=
100 mL V water
Where:
m sugar =mass of sugar ,80 kg
31
V water =Volume of Water needed ∈liters
Substituting,
1000 grams
80 kg ×
204 grams 1 kg
=
1 liters V water
100 mL ×
1000mL
V water =39.2 liters(10.4 gallons)
For the Storage Tank of Dissolved Sugar
V sw =V ST +V water
Where:
V sw =total volume of mixed sugar∧water
V ST =volume of sugar , 13.3 gallons
V water =volume of water , 10.4 gallons
Substituting,
V sw =13.3 gallons+10.4 gallons
V sw =23.7 gallons
SELECTION OF STORAGE TANK FOR
DISSOLVED SUGAR
32
From Mixer Direct Catalogue
Capacity 30 gallons
Dimensions
Diameter 24 inches
Height 42 inches
Leg Length 12 inches
SELECTION OF AGITATOR MOTOR
From Binks Quick-Mixers Catalogue
Container Sizes 5 to 55 gallons
Shaft Length 40 inches
Shaft Diameter ½ inches
Material Stainless Steel
For Salt
The mass of salt for 10 days consumption
is equivalent to 80 kg.
Solving for Volume of Salt
33
mST
V ST =
ρST
Where:
V = volume of table salt
m = mass of table salt
ρ = density of table salt, 2,160 kg/m3
Substituting,
80 kg
V ST =
2,160 kg
m3
V ST =0.037 m 3 (9.8 gallons)
From INOXPA Catalogue, it is stated that the salt is previously
dissolved in water.
From
The solubility in water of salt is 36 grams/ 100ml of water.
Therefore, by ratio and proportion
36 grams m salt
=
100 mL V water
Where:
34
m salt =mass of salt , 80 kg
Substituting,
1000 grams
80 kg ×
36 grams 1 kg
=
1 liters V water
100 mL ×
1000mL
V water =222 liters(58.7 gallons)
For the Storage Tank of Dissolved Salt
V sw =V ST +V water
Where:
V sw =total volume of mixed salt∧water
V ST =volume of salt , 9.8 gallons
Substituting,
V sw =68.5 gallons
35
SELECTION OF STORAGE TANK FOR DISSOLVED SALT
Capacity 80 gallons
Dimensions
Diameter 30 inches
Height 49 inches
Top Head Open
Solving for the Lemon Juice Storage Tank
The mass of lemon juice for 10 days consumption
is equivalent to 40 kg.
36
For the Number of Lemons needed for 10-day Consumption
From Canadian Living Test Kitchen. (2012) Fruits and vegetables:
A buying guide.
1 lb (500 g) = 2 to 3 lemons, say use 2.5 lemons
By Ratio and Proportion in which 10-day consumption of lemon is
equal to 40 kg
0.5 kg 40 kg
=
2.5lemons number of lemons for 10 days
number of lemons for 10 days=200 lemons
For the Storage Life and Temperature of Lemon
From Cargo Handbook
Freshness Facts of Lemon

Optimum carrying temperature 10°C to 11°C (yellow lemons)
12°C to 14°C (green lemons)

Highest freezing point -1,4°C
Optimum humidity 90%

Storage life 2-3 months
Solving for Volume of Lemon Juice
37
m LJ
V LJ=
ρLJ
Where:
V = volume of lemon juice
m = mass of lemon juice
ρ = density of lemon juice, 1,031 kg/m3
Substituting,
40 kg
V LJ=
1,031kg
m3
V LJ=0.0388 m3 (38.8 liters)
SELECTION OF STORAGE MATERIAL FOR LEMON
The designers decided to
store the lemons on a
refrigerator to keep the lemon
fresh for 10-day consumption
From Alibaba.com
Capacity 40 liters
38
Dimensions
Length 437 mm
Width 402 mm
Height 537 mm
DESIGN OF DAY TANKS
For Whole Egg
From Bake It Right Chart
39
By Ratio and Proportion
21 whole eggs no . of eggs per day

=
1 kg 84 kg
no . of eggs needed per day=1,764 eggs
Selection of Egg Breaking Machine
From Allance Machinery Catalogue
Model ALEB-3
Capacity 3,600 eggs/hr
Material Food Grade 304
Stainless Steel
Dimensions
Length 1,650 mm
Width 850 mm
Height 1,400 mm
FOR THE DAY TANK FOR EGG
Solving for Volume of Whole Egg
m egg
V egg =
ρegg
Where:
V = volume of egg
40
m = mass of egg
ρ = density of egg , 1031kg/m3
Substituting,
84 kg
V egg =
1031 kg
m3
V egg =0.0815 m3 (21.53 gallons)
Selection of Whole Egg Day Tank
From Mixer Direct Tank
Capacity 30 gallons
Dimensions
Diameter 24 inches
Height 42 inches
Selection of Agitator Motor of Whole
Egg Day TankFrom Tacmina Agitators Catalogue
Model GTO-0.065A
Maximum Agitator Capacity 400 Liters
Shaft Length 600 mm
Shaft Diameter 13 mm
41
For Vegetable Oil
Solving for Volume of Vegetable Oil
m vo
V vo =
ρ vo
Where:
V = volume of vegetable oil
m = mass of vegetable oil
ρ = density of vegetable oil , 920 kg/m3
Substituting,
584 kg
V vo =
920 kg
m3
V vo =0.635 m 3 (167.7 gallons)
Selection of Vegetable Oil Day Tank
From Precision Tank Catalogue
Model CWT-200
Dimensions
Diameter 38 inches
Height 48 inches
42
Selection of Agitator Motor of Vegetable Oil
Day Tank
From Tacmina Agitators Catalogue
Model GTO-0.065A
Maximum Agitator Capacity 1,200 Liters
Shaft Length 1,000 mm
Shaft Diameter 16 mm
Solving for Volume of Sugar
mS
V S=
ρS
Where:
V = volume of sugar
m = mass of sugar
ρ = density of sugar, 1,590 kg/m3
Substituting,
43
8 kg
V ST =
1,590 kg
m3
V ST =0.005031 m3 (1.33 gallons)
From INOXPA Catalogue, it is stated that the sugar is previously
dissolved in water.
From
The solubility in water of sugar is 204 grams/ 100ml of water.
204 grams msugar

=
100 mL V water
Where:
msugar =mass of sugar ,8 kg
Substituting,
1000 grams
8 kg ×
204 grams 1 kg
=
1 liters V water
100 mL×
1000mL
For the Storage Tank of Dissolved Sugar
V sw =V ST +V water
44
Where:
V ST =volume of sugar , 1.33 gallons
Substituting,
V sw =2.37 gallons (0.009 m3)
For the Potable Water Day Tank
Solving for Volume of Potable Water
m pw
V pw =
ρ pw
Where:
V = volume of potable water
m = mass of potable water
ρ = density of potable water, 1000kg/m3
45
Substituting,
80 kg
V pw =
1000 kg
m3
V PW =0.08 m3 (21.134 gallons)
For Total Volume of Sugar and Water Mixture
V sw =V ST +V water
Where:
V ST =volume of dissolved sugar , 2.37 gallons
Substituting,
V sw =( 2.37 gallons+21.134 gallons )
V sw =23.504 gallons (0.089 m3)
SELECTION OF STORAGE TANK FOR DISSOLVED
SUGAR WITH WATER
46
Capacity 30 gallons
Dimensions
Diameter 24 inches
Height 42 inches
For Mixture of Vinegar, Salt and Lemon Juice
Solving for Volume of Vinegar
mv
V v=
ρv
Where:
V = volume of vinegar
47
m = mass of vinegar
ρ = density of vinegar, 1,050 kg/m3
Substituting,
32 kg
V ST =
1,590 kg
m3
V ST =0.020126 m 3 (5.32 gallons)
Solving for Volume of Salt
mST
V ST =
ρST
Where:
V = volume of table salt
m = mass of table salt
ρ = density of table salt, 2,160 kg/m3
Substituting,
8 kg
V ST =
2,160 kg
m3
V ST =0.0037 m 3 (0.98 gallons)
48
From INOXPA Catalogue, it is stated that the salt is previously
dissolved in water.
From
The solubility in water of salt is 36 grams/ 100ml of water.
36 grams m salt
=
100 mL V water
Where:
Substituting,
1000 grams
8 kg ×
36 grams 1 kg
=
1 liters V water
100 mL ×
1000mL
For the Volume of Dissolved Salt
V dsa =V ST + V water
Where:
V sw =total volume of mixed salt∧water
V ST =volume of salt , 0.98 gallons
49
Substituting,
V dsa =0.98 gallons+5.87 gallons
V dsa =6.85 gallons (0.026 m3)
Solving for the Volume of Lemon Juice
m LJ
V LJ=
ρLJ
Where:
V = volume of lemon juice
m = mass of lemon juice
ρ = density of lemon juice, 1,031 kg/m3
Substituting,
4 kg
V LJ=
1,031kg
m3
V LJ=0.00388 m3 (1.025 gallons)
From Canadian Living Test Kitchen. (2012) Fruits and vegetables:
A buying guide.
1 lb (500 g) = 2 to 3 lemons, say use 2.5 lemons
50
0.5 kg 4 kg
=
2.5lemons number of lemons for 10 days
number of lemons for per day=20 lemons
For Total Volume of Vinegar, Dissolved Salt and Lemon Juice
V vsl =V v +V ds +V LJ
Where:
Vvsl= total volume
V v =volume of vinegar , 5.32 gallons
V ds =volume of dissolved salt ,6.85 gallons
V lj =volume of lemon juice , 1.025 gallons
Substituting,
V vsl =( 5.32 gallons+6.85 gallons+1.025 gallons )
V vsl =13.2 gallons (0.05 m3)
SELECTION OF STORAGE TANK OF VINEGAR, DISSOLVED SALT AND LEMON
JUICE
Capacity 15 gallons
Dimensions
51
Diameter 18 inches
Height 16 inches
For the Total Volume of Pre-Emulsion Tank
The designers use a pre-emulsion tank with an hourly
production rate of 100 kg of mixed ingredients.
52
m egg m water m vinegar m sugar m vo m lj m salt
V PET = + + + + + +
ρegg ρ water ρvinegar ρsugar ρvo ρlj ρsalt
Where:
megg=mass of egg, 84 kg
ρegg =density of egg, 1,031 kg/m3
m water =mass of water , 80 kg
ρwater =density of water , 1,000 kg/m3
m vinegar =mass of vinegar , 32 kg
ρ vinegar =density of vinegar , 1,050 kg/m3
m sugar =mass of sugar , 8 kg
ρ sugar=density of sugar , 1,590 kg/m3
m vo =mass of vegetable oil , 584 kg
ρ vo=density of vegetable oil , 920 kg/m3
m lj =mass of lemon juice , 4 kg
ρlj =density of lemon juice , 1,031 kg/m3
53
ρ salt=density of salt , 2,160 kg/m3
Substituting,
84 kg 80 kg 32 kg 8 kg 584 kg 4 kg 8 kg
V PET = + + + + + +
kg kg kg kg kg kg kg
1,031 3 1,000 3 1,050 3 1,590 3 920 3 1,031 3 2,160 3
m m m m m m m
V PET =0.84 m3 (222 gallons)
SELECTION OF PRE-EMUSION TANK
From Precision Tank Catalogue
Dimensions
Diameter 44 inches
Height 60 inches
Type 304 Stainless Steel
54
Container Sizes 20 to 1,000 gallons
Shaft Diameter 1.0 inches
FOR CONVERSION OF MIXED RECIPES INTO MAYONNAISE
From the Handbook of Food Processing Equipment by George D.
Saravacos and Athanasios E. Kostaropoulos, p. 188
In homogenization, uneven particles of liquid foods are
reduced into smaller, more uniform units. Homogenization retards
the separation of mixed liquids into separated groups and
eliminates consistency variations. Homogenization enables better
55
viscosity control and supports jelling at low temperatures. It
facilitates cell rupture and comminution of fibrous materials
dispersed in liquids.
Homogenization is a further step of emulsification.
Homogenizers and emulsifiers are often used interchangeably with
respect to equipment of emulsification (Fellows, 1990). In
emulsification of liquids, one or more liquids forming the
internal phase, are dispersed in another liquid, which forms the
external continuous liquid phase, provided the liquids are
immiscible
For the Equipment needed for the Homogenization of the
Ingredients
From the Handbook of Food Processing Equipment by George D.
Saravacos and Athanasios E. Kostaropoulos, p. 193, it was stated
that “In liquid homogenization, colloid mills are used when the
viscosity of the product is relatively high (> 1 Pa s) (Brennan
et aI., 1990) such as mayonnaise, containing about 80% oil and
meat paste.”
From Alibaba.com
Model KF04-PN-50W
Output 0.01 to 0.1 t/hr
56
Rotated Speed 2,800 rpm
Power 1.1 Kw
Machine Dimension 600x330x650mm
Application:
Widely used for grinding all kinds of materials to make
paste, such as chili paste, pepper paste, sesame paste, peanut
butter, beans paste, jam, vegetable paste, onion paste, ginger
paste, garlic paste, mayonnaise, etc.
Feature:
Colloid Mill products are fine fluid materials processing
machinery. It combines a homogenizer, a variety of performance
mill, three roll machine, shearing machines, blenders and other
machinery, with superior ultrafine grinding, dispersing and
emulsifying, homogenizing, mixing and other effects. After the
material through processing, particle size of 2 to 50 microns,
more than 90% homogeneity, is the ideal equipment for processing
for ultrafine particles.
57
58

Technical Feasibility and Manufacturing Process of Mayonnaise Production

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Technical Feasibility and Manufacturing Process of Mayonnaise Production

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Chapter 3

This aspect includes the product, the manufacturing process

The manufacturing process is comprised of three different

parts: the acquisition process, production process and the

packaging process. Production schedule was discussed briefly; the

table representing the production for five years was included as

well. Machineries and equipment were chosen by the proponents

according to its durability and efficiency in functioning for

five straight days.

The direct and indirect materials needed in the study were

of the products during production to distribution. Plant building

construction and site as well as the utilities were discussed to

obtain the needed capital in starting up a business.

Location of the site, the size and layout were decided by

the proponents, access to suppliers and potential market were

Mayonnaise is oil-in-water emulsion where oil is the

discontinuous phase and water is the continuous phase obtained by

emulsifying edible vegetable oil in an aqueous phase.

Mayonnaise is an oil-in-water emulsion despite containing

between 70-80% fat. Oil in water emulsions consist of finely

dispersed droplets of oil in a continuous phase of water or a

to 20μm or more. This emulsion is formed by mixing the eggs,

a closed-packed foam of oil droplets or coarse emulsion.

result is a water-in-oil emulsion, whose viscosity is similar to

the oil from which it was made (Depreeand Savage2001). Vegetable

oils, the main ingredient in mayonnaise, have an important

function in an emulsion; they contribute to the taste, the

appearance, the texture and the oxidative stability of the

emulsion in a very specific way (Moslavac et al., 2012).

The main role in mayonnaise production is composition ratio

of oil phase and the addition of various emulsifier, stabilizer

the better texture is resulted. Oil has important function in

characteristic of rheology. Fat as one of the main ingredients,

has positive influence on the rheological properties and sensory

characteristic of final product. High fat intake as associated

cardiovascular diseases, and hypertension. The production of low

fat mayonnaise is normally associated with some technical

problems such as poor texture, flavour, appearance stability, and

mouth feel (Amin et al., 2014).

Traditional mayonnaise is a mixture of egg, vinegar, oil and

spices (especially mustard) or eggless mayonnaise also available.

These mayonnaise preparation mixtures of milk solid, oil,

thickener, stabilizer salt and sugar. Despite the high oil

content relative to water, mayonnaise is oil in- water emulsion.

This emulsion is formed by first mixing the eggs, vinegar and

mustard and then slowly blending in the oil. This result in an

emulsion consisting of closely packed „foam‟ of oil droplets

(Singlaet al., 2013).

Mayonnaise is a global consumer favorite that complements

many dishes. We all have our favorite uses of mayonnaise, perhaps

as a spread in sandwiches, a topping for fresh salad or as a dip

for french fries, or mixed with other sauces, spices and

condiments to accompany fish, meat or vegetable dishes.

Mayonnaise is also often used as base for creamy-type salad

dressings. It is formulated to develop characteristics such as

mouthful and spread ability which are considered desirable by the

The mayonnaise was prepared in Department of Food Chemistry

and Nutrition, CFT, VNMKV, Parbhani. The formulation used for

preparation of flavored mayonnaise. Firstly, the studies on

different ingredients and stages of processing were required to

be standardized. The mayonnaise samples were prepared using food

mixer. A continuous blending system is employed to sustain the

correct degree of emulsification. The blending of all ingredients