We manufacture equipment for the production of hot and cold mayonnaise both on the basis of UG-UGM and on the basis of conventional vacuum homogenizing devices such as VGA and VGA-GD.

Technological lines for the production of mayonnaise and equipment of our production are widely used in enterprises and workshops for the production of food, can be used in the enterprises of the fat-and-oil, canning and dairy industries.

Technology and equipment for the production of mayonnaise

The technological process for the production of mayonnaise provides for the creation of optimal conditions that make it possible to obtain a homogeneous (close to homogeneous) and stable system of components that are practically insoluble in each other (for example, water and oil). Considering factors such as the concentration of dry components, the conditions for swelling and pasteurization of dry components, the rate of oil supply, the intensity of mechanical action.

The production of mayonnaise consists of the following technological stages:

1. Dosing of components
2. Cooking egg paste
3. Cooking mustard and milk paste
4. Vegetable oil supply
5. Preparation of the vinegar-salt solution
6. Coarse emulsion preparation
7. Preparation of finely dispersed emulsion
8. Packing ready-made mayonnaise
9. Stacking ready-made mayonnaise in a shipping container
10. Transportation of finished products to the warehouse

Dosing of components - VDP-500 Mayonnaise production begins with preparation and dosing of prescription components... Bulk components: egg powder, skimmed milk powder, mustard powder, sugar, salt, soda are supplied to the workshop in bags, stacked on pallets and, as required, unpacked. Dosing of dry components is carried out on a platform technological scale. The deodorized vegetable oil enters the container provided for it, the volume of the oil is determined using a measuring ruler. Dosing the required amount of water into the small mixer further VDP-500, is produced using a flow meter.

Egg paste preparation - VDP-500 and VGA-1000 Mayonnaise production starts with cooking egg paste... To do this, water and egg powder are fed into the VDP-500 (in accordance with the recipe). Mixing with a homogenizer-dispersant lasts no more than 2-3 minutes. Then the mixture is heated to a temperature of 60-65 ° C, kept for 15-20 minutes at a given temperature and pumped into the main mixer further VGA-1000. VGA-1000 is a vacuum homogenizing apparatus. There are several advantages to using a vacuum to make mayonnaise, here are some of them: The introduction of sunflower oil into the product in a thin stream through the circulation channel connecting the disperser and the reactor, which allows to shorten the cooking time of the product and ensure a stable emulsion. The absence of air inclusions in the finished product, which increases the taste and shelf life. Before pumping, a visual sample is taken from the egg paste to determine if it is done. The sample taken on a wooden plate should be completely homogeneous, without lumps, and should drain evenly from the plate. Cooling of egg paste to 20-30 ° C takes place in the main mixer during the preparation and cooling of mustard-milk paste by heat exchange with ambient air.

Preparation of mustard-milk paste - VDP-500

After pumping the egg paste from VDP-500, it starts preparation of mustard-milk paste... For this purpose, water, milk powder, mustard powder, granulated sugar and soda are supplied to the VDP-500 (mass fraction of the components according to the recipe). Water is supplied in the amount recommended in the recipe. Loading and recovery of dry components is carried out in a stream by introducing them through a funnel installed in a circulation channel connecting VDP-500 and a homogenizer - a rotary-pulsation-type dispersant. Then the mixture is heated to a temperature of 80-85 ° C, kept for 15-20 minutes at a given temperature and cooled to 25-30 ° C (according to the passport for a small mixer). Then the mixing system is turned off and the cooled mustard-milk paste is pumped into VGA-1000, according to the scheme similar to egg paste. Before pumping, a visual readiness test is also taken from the mustard-milk paste.

Vegetable oil supply to the main mixer - VGA-1000

The next step in the preparation of mayonnaise is vegetable oil supply into the main mixer. This process is carried out from the provided container using a centrifugal pump or by gravity through a solenoid valve with a vacuum on. It is also possible to supply vegetable oil from a small mixer using the above method. The amount of oil supplied to the main mixer must correspond to the recipe. To ensure uniform distribution, the oil is fed in a thin stream into the circulation pipeline, mixing directly in the flow with the mass previously prepared in the VGA.

Preparation of acetic-salt solution - VDP-500

The preparation of the acetic-salt solution consists of two stages:

In a specially provided container, a saline solution is prepared as follows. The amount of water prescribed by the recipe with a temperature of 15-16 ° C is poured into the container, the prescription amount of table salt is also added there. The solution is thoroughly mixed with a wooden spatula and allowed to settle (to settle impurities). If the solution has settled, it can be used without filtration, carefully draining from the sediment. The cloudy solution is filtered through two layers of gauze before use.

VDP-500 prepares 10% acetic acid solution... To do this, water is supplied to the VDP-500, in the amount necessary to dilute the solution of 80% acetic acid to 10% solution (mass fraction of the solution in accordance with the recipe).

Further, in VDP-500 with 10% vinegar solution, is added saline solution... The resulting acetic-salt solution is mixed for 5-10 minutes using a stirring system and fed to the VGA (the pumping process is described in detail using the example of mustard-milk paste). The vinegar-saline solution can be started at the same time as the last doses of vegetable oil are added.

Preparation of a homogeneous emulsion - VGA-1000

In VGA-1000, equipped with a mixing device with a low rotation frequency (frame type mixer), a coarse emulsion is prepared. The mixer must ensure uniform mixing in all layers of the mixer without stagnant zones.

The sequence of adding oil and acetic-salt solution to the paste must be strictly observed. This is due to the fact that a one-time or high-speed introduction of them can lead to the receipt of an emulsion of the inverse type, and at a certain stage of emulsification to phase reversal.

The coarse emulsion obtained in the main mixer must correspond to the established type of oil-in-water emulsion, be strong enough and not delaminate before it circulates through the rotary-pulsation apparatus. Visually, such an emulsion has a homogeneous appearance and does not delaminate in a sample taken with slight stirring.

The resulting coarse emulsion must pass through homogenization process, which is carried out using a rotary-pulsating apparatus, the principle of its operation is set out in the passport.

The homogenization process is carried out until a homogeneous emulsion is obtained. A single pass of the coarse emulsion is possible. At the end of homogenization, the rotary-pulsation apparatus is switched off.

After homogenization, samples are taken from the batch of the finished mayonnaise. A sample taken on a wooden plate should be completely homogeneous, without lumps, visible delamination, flow evenly from the plate and have a viscosity characteristic of mayonnaise, as well as color, taste and smell.

Packing mayonnaise

From the container for finished products, mayonnaise is served for packaging. Packing is carried out on any intended for this automatic filling machine.

Packing should be done immediately after production, as contact with air oxygen impairs the taste and preservation of mayonnaise.

Stacking packaged mayonnaise in a shipping container

Finished products are packed in corrugated cardboard boxes in accordance with GOST 13516-86 No. 52-1, which are placed on pallets and transported to the finished product warehouse.

Finished goods warehouse... Finished products must be stored before dispatch to the consumer in the warehouse at temperatures from 0 to + 18 ° С.

Mayonnaise recipes

High-calorie mayonnaise - "Provencal"

№
1		65,40
2	Egg powder	5,00
3	Water	10,00
4	Skimmed milk powder	1,60
5	Mustard powder	0,75
6	Water	10,00
7	Sodium bicarbonate	0,05
8	Sugar (sand)	1,50
9	Table salt	1,00-1,30
10	Acetic acid 80%	0,55-0,75
11	Water	3,75

High-calorie mayonnaise - "Lactic"

(mass fraction of fat not less than 67%)

№	Name of raw materials for mayonnaise	Mass fraction of components,%
1	Refined deodorized vegetable oil	65,90
2	Egg powder	2,00
3	Water	10,00
4	Skimmed milk powder	1,80
5	Whole milk powder	3,00
6	Mustard powder	0,75
7	Water	10,00
8	Sodium bicarbonate	0,05
9	Sugar (sand)	1,50
10	Table salt	1,30
11	Acetic acid 80%	0,75
12	Water	2,95

Egg mayonnaise

(mass fraction of fat not less than 57.5%)

№		Mass fraction of components,%
1	Refined deodorized vegetable oil	55,00
2	Egg powder	8,00
3	Water	15,00
4	Skimmed milk powder	2,00
5	Mustard powder	0,50-0,75
6	Water	12,00
7	Sodium bicarbonate	0,05
8	Sugar (sand)	1,50
9	Table salt	1,10
10	Acetic acid 80%	0,85
11	Water	3,75

Medium-calorie mayonnaise "Amateur"

(mass fraction of fat not less than 47%)

№	Name of raw materials for mayonnaise	Mass fraction of components,%
1	Refined deodorized vegetable oil	46,00
2	Egg powder	5,00
3	Water	20,00
4	Skimmed milk powder	1,60
5	Water	20,00
6	Mustard powder	0,25-0,75
7	Sodium bicarbonate	0,05
8	Sodium alginate	0-0,50
9	Sugar (sand)	1,50
10	Table salt	1,10
11	Acetic acid 80%	0,65
12	Water	2,85

Low-calorie mayonnaise - "Saladny"

№	Name of raw materials for mayonnaise	Mass fraction of components,%
1	Refined deodorized vegetable oil	35,00
2	Egg powder	6,00
3	Water	25,00
4	Skimmed milk powder	2,50
5	Mustard powder	1,20
6	Water	20,00
7	Sodium bicarbonate	0,05
8	Sugar (sand)	3,00
9	Table salt	1,50-2,00
10	Sodium alginate	1,5-2,00
11	Acetic acid 80%	0,55-0,75
12	Water	2,50

Mustard mayonnaise

(mass fraction of fat not less than 37%)

№	Name of raw materials for mayonnaise	Mass fraction of components,%
1	Refined deodorized vegetable oil	35,00
2	Egg powder	6,00
3	Water	18,00
4	Skimmed milk powder	1,60
5	Mustard powder	2,50
6	Water	25,00
7	Sodium bicarbonate	0,05
8	Sodium alginate	0-0,70
9	Sugar (sand)	3.50
10	Table salt	2,00
11	Acetic acid 80%	1,25
12	Water	3,50

Low calorie mayonnaise(with the use of stabilizers Keltrol and Manukol (UK))

(mass fraction of fat not less than 37%)

№	Name of raw materials for mayonnaise	Mass fraction of components,%
1	Refined deodorized vegetable oil	34,4
2	Egg powder	2,0-2,5
3	Skimmed milk powder	2,5-1,8
4	Mustard powder	0,45-0,5
5	Sodium bicarbonate	0,05
6	Sugar (sand)	1,5-2,0
7	Table salt	1,1
8	Manucol (sodium alginate)	0,3-0,25
9		0,3-0,25
10	Acetic acid 80%	0,55-0,75
11	Water	56,85-56,4

Mayonnaises with a fat mass fraction of at least 47%

№	Name of raw materials for mayonnaise	Mass fraction of components,%
1	Refined deodorized vegetable oil	45,2
2	Egg powder	2,0-2,5
3	Skimmed milk powder	1,8
4	Mustard powder	0,45-0,5
5	Sodium bicarbonate	0,05
6	Manucol (sodium alginate)	0,21-0,16
7	Keltrol (xanthan gum)	0,21-0,16
8	Sugar (sand)	1,5
9	Table salt	1,1
10	Acetic acid 80%	0,55-0,75
11	Water	46,93-46,28

The equipment for the production of mayonnaise, offered by our company, is convenient in operation and reliable. In addition to complete production lines, we can offer individual systems and modules.

You can buy equipment for the production of mayonnaise according to previously agreed options, dimensions and performance. The price of equipment for the production of mayonnaise is always negotiable due to the unpredictability of costs.

A few introductory words

Mayonnaise is the most common industrially produced sauce. Its consumption in Russia reaches 3 kg per person per year, and this figure tends to increase. Mayonnaise is a creamy oil-in-water emulsion made from refined vegetable oils with the addition of flavors and spices, and is used as a seasoning to improve the taste of meat, fish, vegetable, cereal and flour dishes. The production of mayonnaise at small enterprises can be distinguished as one of the most profitable, which is facilitated by the increased interest of the population in small-scale production, which clearly differs from the usual standards of mass production. Another feature of small production, favorable for small producers, is that the equipment used is easy to operate, while the technology mayonnaise production and sauces is simple enough. And this allows you to set up the production process in a short period of 1 - 2 months.

Several questions and answers

- What is mayonnaise? What does it consist of?

Mayonnaise is an emulsion: it consists of many microscopic drops of vegetable oil, placed in an aqueous mixture of a certain composition.

- What is the raw material for making mayonnaise?

The main component of mayonnaise is vegetable oil (40 to 60 percent by weight). Olive or highly refined sunflower oil is used. The other part of the mayonnaise is an aqueous mixture that includes salt, vinegar, mustard, egg powder, starch, and flavorings.

- What do you need to start the production of mayonnaise?

First, you need a room that meets sanitary and hygienic requirements and is appropriately equipped. Secondly, a certain set of equipment. And, finally, it is imperative to have a sufficiently experienced technologist.

- What is the main thing in the technology of mayonnaise production?

The most important thing is strict adherence to the developed recipes and regimes. Any violation will affect, first of all, the real shelf life.

- How to choose equipment?

First of all, you need to determine the desired production volume. The main selection criterion is the possibility of a complete and fairly quick implementation of the product. This is followed by the choice of one of the kits offered by various firms. The compositions of such sets are very similar, however, differences in design are possible - units that crush the mass of oil into microscopic droplets. 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.

- How to choose a method of packing mayonnaise and equipment for this?

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 is the most hygienic, it gives the maximum shelf life. The equipment is also relatively inexpensive. However, this is the most time consuming packaging method. Finally, the most expensive equipment is used for packaging mayonnaise in plastic disposable bags. At the same time, this method is the least time consuming. In addition, in this case, the costs of storing and transporting the product are minimal.

- What determines the quality of mayonnaise?

The main indicators of quality are taste and stability during storage. Taste qualities are determined by the quality of raw materials and recipes. Formulation development is a function of highly qualified technologists, proprietary recipes are trade secrets. Thus, the taste of mayonnaise depends entirely on the technologist. The main indicator of durability is the absence of delamination and oil release. This indicator depends on adherence to technology and storage conditions.

- What is the payback period of the equipment?

The exact calculation results are shown below. Practice has shown that the real term, taking into account the time for debugging production and reaching the design productivity, is three? four months.

About raw materials and ingredients

Table mayonnaises such as "Provencal", "Amateur", medium-calorie type "Milk" and low-calorie type "Moscow" are produced in accordance with GOST R-50174-92 "Mayonnaise" on technical equipment for the preparation of liquid nutritional mixtures of the AMZ-0.8 type.

The following raw materials are used for the preparation of mayonnaise:

• vegetable oil (sunflower, soybean, corn, cottonseed);
• egg powder;
• whole milk powder and skimmed cow milk;
• corn and potato starch;
• granulated sugar, salt, acetic acid, baking soda, water.

Other flavoring and stabilizing additives are also used. More details about raw materials and ingredients, as well as about the characteristics and requirements for the products of the mayonechny workshop, are described in the brochure "Mayonnaise lines: technical and economic calculation", prepared and published by Dialog Plus on the basis of calculations performed by the company's specialists.

About recipes

In the Middle Ages, the recipes for mayonnaise and sauces were the secret of the secrets of European royal cuisine, and few dignitaries could boast of their inventive chef - the creator of these exquisite spices. Nowadays, the most popular mayonnaise "Provencal", "Saladny" and "Amateur", the approximate recipes of which are given below.

№	name of raw materials	Mass fraction of components,%
		"Provencal"	"Amateur"	"Salad"
1.		65,40	46,00	35,00
2.	Egg powder	5,00	5,00	6,00
3.	Skimmed milk powder	1,60	1,60	2,50
4.	Mustard powder	0,75	0,25 - 0,75	1,20
5.	Sodium bicarbonate	0,05	0,05	0,05
6.	Sugar (sand)	1,05	1,50	3,00
7.	Table salt	1,00 - 1,30	1,10	1,50 - 2,00
8.	Sodium alginate	-	0-0,50	1,5 - 2,00
9.	Acetic acid 80%	0,55 - 0,75	0,65	0,55 - 0,75
10.	Water	24,15 - 23,65	43,85 - 42,85	24,15 - 23,65

About technique (equipment of mini-lines)

In the brochure "Mayonnaise lines: technical and economic calculation" the main equipment of the kits (lines) is considered in detail, here are only the most important technical indicators of the kits based on the IPKS-056 mini-plant described in the brochure, for which technical and economic calculations were performed.

About mayonnaise production technology

The principles of the technology for making table mayonnaise, set out below, are based on their recipe. On its basis, a technical process or technological instruction can be drawn up for the production of a specific name of mayonnaise, taking into account the process of preparing spices and gelling additives.

The mayonnaise production process consists of four main stages:

Preparation of recipe components

1. Packing, packaging, marking

The sequence of operations can be described in the following order:

Preparation of recipe components. Preparation of bulk components (milk powder, granulated sugar, egg powder, salt): sieving and dosing by weight in accordance with recipes, and then loading into food containers.

Cooking mustard. 24 hours before the start of the production of mayonnaise, the required amount of mustard powder is placed in an enamel or stainless steel dish and poured with water at a temperature of 80-100 ° C in a ratio of 1: 2. The mixture is well stirred to a uniform consistency with smoothing of the top layer. Water with a temperature of 100 ° C and a height of 4-6 cm is carefully poured onto the 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 off.

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 1: 1 ratio, then hot water with a temperature of 60-75 ° C is added to the mass 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 an acetic-salt solution. 9% table vinegar according to the recipe is poured into an aluminum tank, previously filled with the amount of salt corresponding to the recipe, and diluted with water.

Making mayonnaise paste

Dry components are manually poured from measuring containers filled in accordance with the recipe into the mixer-emulsifier and filled with boiled water at a temperature not lower than 30-40 o C. The mixture is pasteurized (heated to 80-85 o C) with thorough mixing for 30 minutes. At the same time, granulated sugar is added. At the end of pasteurization, the mass is mixed and cooled to a temperature of 50-55 o C. Then a prepared amount of egg powder and mustard is introduced. The mixture is heated again (up to 60-65 o C) and kept at it for 25-30 minutes, and then cooled to 30 o C.

Preparation of mayonnaise emulsion

Vegetable oil is added to the mayonnaise paste with further stirring. After the entire dose of oil has been received and a homogeneous emulsion is obtained, an acetic-salt solution is introduced and the mixture is stirred for another 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 into containers of finished products for further packaging and packaging. Packing mayonnaise can be carried out in several ways: in glass or polymer containers (glass jars with a capacity of 200-250 and 500 ml with metal lids, polymer cups with polymer lids or sealed with foil, polymer 1 - 2 x-liter cans, PET bottles of various volumes and shapes with screw covers, and so on). The equipment used at this stage is distinguished by a wide variety both in purpose and in design features, performance and price. On small lines, polymer packaging is most often used and quite simple and efficient dosing (in terms of volume) devices of the UD-2 type and installations for welding polystyrene cups with Al-foil USS-2 are used.

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

A person or a group of entrepreneurs who have decided to engage in food production, as a rule, will be primarily interested in the following questions:

1. The cost of a set of equipment.
2. How much money will be spent on the purchase of raw materials, consumption of electricity, heat, etc. - current production costs.
3. How soon this production will bring profit and the amount of this profit.
4. Equipment payback period.
5. Sales market.

These and many questions are answered in detail in our brochure. "Mayonnaise lines: technical and economic calculation". Here are some excerpts from it.

Production cost represents a cost estimate of the raw materials, materials, fuel, energy, fixed assets, labor resources used in the production process, as well as other costs for its production and sale.

Total cost- the total cost of production per month (including taxes - 4%).

Payback period equipment is a period of time after which the total value of depreciation deductions and the company's net profit will be equal to the book value of the purchased equipment.

Net profit- the difference between the volume of planned sales (revenue) and the total cost of production.

Break even- the amount for which it is necessary to release products to cover their own production costs. Knowing the selling price of the manufactured products, you can determine what time frame will be needed to start breakeven production. Therefore, the break-even point is often defined in units of time (days, months). For the calculations, it was assumed that the equipment is located in a newly created small enterprise and that this enterprise enjoys certain well-known tax incentives.

Initial data:

• work is carried out in 3 shifts (8 hours each);
• the salary of each worker is 1,500 rubles;
• in a month there are 25 working days;
• sales of products - 100%.

Wholesale purchase prices for raw materials and ingredients (excluding VAT, as of September 1999 in the Moscow region)

Raw materials	Unit rev.	Price
Refined deodorized vegetable oil	1 l	RUB 19
Potable water	1 m 3	13 rubles 82 kopecks
Egg powder	1 kg	RUB 63
Skimmed milk powder	1 kg	RUB 30
Mustard powder	1 kg	RUB 13
Sugar (sand)	1 kg	RUB 7
Salt	1 kg	RUB 1.2
Electricity	1 kWh	45 kopecks

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

Options	Unit rev.	Kit number
		№1	№2
Material costs (based on 1 liter of finished product)	rub / l	16,25	16,25
Wage fund	rub / l	0,25	0,19
Depreciation deductions	rub / l	0,08	0,11
Other costs	rub / l	2,47	2,47
Tax attributable to cost	rub / l	0,76	0,76
Cost price	rub / l	19,82	19,77
Selling price without VAT	rub / l	21,80	21,75

Below, in the final table, are the results of calculating the breakeven point of production, net profit and payback periods for equipment for each of the three lines (sets).

Summary table

Main source and settlement items	Kit (line) number
	№ 1	№ 2
Equipment cost including VAT (rub)	135000	245000
Break-even point (months)	0,63	0,63
Net profit (rubles)	148 621	197 643
Equipment payback period (months)	0,8	1,1

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. This is due to the same ratio of fixed and variable costs adopted 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. When calculating, the same relative value of the planned profit was laid down, therefore, the profitability of production for all sets is also the same and amounts to 10%. If the prices on the market for products sold will significantly exceed the cost of the final product produced, then the projected profit will grow and, accordingly, the profitability of production will increase.

In this article:

The production of mayonnaise and ketchup is rightfully considered one of the most profitable. The production of mustard is slightly inferior in economic efficiency, therefore it is recommended to consider it as an auxiliary product. There is an increased interest of the population in small-scale production, which differs from the standards of mass production. This trend can be of great service to a budding entrepreneur.

On average, the population consumes about 3.5 kilograms of pasty products per year (mayonnaise, mustard and ketchup). Thus, the product will be in demand, and its production will be economically profitable.

Organizational nuances of the food business

1. Determine the organizational form of management

For the operation of a mini-plant for the production of pasty products, it is recommended to register an LLC on the general taxation system. Strategic partners are wholesalers, food warehouses and supermarkets, which often prefer to work with a reliable company.

For the preparation of periodic reporting, it will be more economically profitable to use the services of an outsourcing company.

During the registration process, a novice entrepreneur will need the following OKVED code: 15.87 Production of spices and seasonings

2. We study regulations

Before the release of the first batch of pasty products, it is recommended to study the state standards:

• GOST R 53590-2009 Mayonnaise and mayonnaise sauces. General technical conditions.
• GOST R 52141-2003 Ketchups. General technical conditions.
• GOST 9159-71 Mustard seeds.

3. Product certification

To organize the production of any kind of sauce, it is imperative to undergo certification and receive the necessary package of documents that will confirm the quality of the product.

The above-mentioned GOSTs or TU (technical conditions) developed by oneself can act as normative documents.

Mayonnaise production technology

There are various recipes for mayonnaise, but the main ingredients are the same - eggs and vegetable (soybean) oil. Only yolks are taken from eggs, only whites, or both together. Eggs must be pasteurized to kill salmonella and other bacteria. Eggs are brought to large enterprises in metal tanks in liquid form.

The eggs are pumped through a hose into a cooling collecting tank.

The second main ingredient is soybean oil. All tanks or other containers that come from the supplier must be hermetically sealed and not open until arriving at the mini-plant. The pump also transfers oil to storage tanks. Further, additional ingredients are weighed - spices, which must be added according to the company's secret recipe.

The resulting mixture is poured into a tank at room temperature. As a result of mixing all the components, a mayonnaise paste is obtained.

Meanwhile, raw eggs are poured into a large refrigerated tank. Thus, the production hall houses 3 containers: with pasta, eggs and soybean oil. Further, in a certain ratio (according to the recipe of the enterprise), all components are sent to the mixing vat.

After 5 minutes of operation of the unit, eggs, paste and oil are mixed into a homogeneous mass - mayonnaise.

Periodically, product samples from the mini-factory are sent to the laboratory for quality control.

Laboratory technicians evaluate parameters such as color, consistency and odor. After checking the finished product for quality, the packaging machine pours it into a plastic container. It is recommended to place a foil inside the lid, which is attached by induction heating. It is she who will protect the mayonnaise from heating, and also indicate that the can was not opened after shipment from the factory.

The quality control laboratory performs another check - the consistency of the product is measured.

Ketchup production technology

Ketchup production begins by adding a mixture of sugar and salt to a giant cauldron of water. The components are thoroughly mixed.

The factories often use ready-made concentrated tomato paste as the main raw material, which is pumped into a large digester.

A sugar-salt solution is placed in it.

Cooking pot

The mixture is thoroughly mixed in a giant cauldron. Steam is supplied between the inner and outer walls of the unit, which prevents the mass from burning. The stirrers are constantly turning and make the ketchup homogeneous, i.e. the mixture is homogenized.

Cooking pot device

The finished factory sauce is sent for laboratory testing, where the mass fraction of soluble solids is measured using a refractometer - i.e. find out if there are enough tomatoes in ketchup.

If all the parameters suit the specialist (consistency, aroma, color, etc.), then the batch is sent in bottles.

Containers can be made in a nearby workshop. They are based on PVC granules, of which many plastic products are composed. Then a dye is added - so the container will acquire a noticeable red color.

The granules are heated and ground in a device that is similar to a meat grinder - extruder.

Hot red "sausages" are squeezed from both sides by the walls of the forms.

Then the syringe injects a portion of air into the plastic blank and the semi-finished product becomes a "pot-bellied" bottle.

It is noteworthy that a standard bottle for ketchup weighs only 42 grams; it goes to the filling directly from the conveyor, barely cooled down.

At the same time, ketchup is bottled using hot technology, when the temperature of the finished product should not be less than 80 degrees. In this case, the appearance and growth of bacteria in the sauce is prevented. Next, the bottles are supplied with lids, labels and packaged in boxes.

Mustard seed production technology

The initial ingredients for the production of the product are: seeds of the mustard plant, pepper and turmeric, salt, water and white vinegar. The crushed ingredients are poured into a mixing tank with water and vinegar.

The approximate proportions for making yellow mustard are as follows: 60% water, 20% vinegar, 15% seeds and 5% spices.

The mustard seed is added last. A huge rotary mixer mixes all components for about an hour at a speed that breaks the beans (up to 265 km / h).

Rotary mixer

The contents are poured into a stainless steel mill.

Inside the unit there are 2 artificial stones that grind the grains (millstones). In the process of grinding, the mixture is heated to 60 degrees, as a result of which it turns into a bright yellow mustard of a creamy consistency. Before filling into bottles, check the finished product for homogeneity.

If the particles are larger than a quarter of a millimeter, then specialists adjust the millstones to a finer grinding program.

We organize a mini-plant - a list of mandatory stages

The preliminary stage for the release of the first batch of the finished product are:

• selection of a room that meets sanitary and hygienic requirements;
• purchase of a technological line;
• search for an experienced technologist.

The stage of purchasing equipment is inextricably linked with the planned volume of production. Almost all technological lines have a similar configuration. The difference lies in the design of the homogenizer - an apparatus that is responsible for crushing into microscopic droplets. The main factors that influence the choice of a forward-thinking entrepreneur are the cost of the technological line and the degree of automation of the technological process.

You also need to decide on the packaging method. For mayonnaise, tubes (plastic disposable bags) or plastic containers are the most preferred options.

Equipment for this type of packaging is cheap. In the case of filling in glass jars, the finished product will have a maximum shelf life, and the production process will be laborious.

Thus, the first method of packing pasty products (mayonnaise, ketchup and mustard) is most preferable, since it will be possible to achieve minimum storage and transportation costs.

We acquire a technological line for the production of pasty products, which consists of the following units:

• long-term pasteurization baths with stirrers; (photo bath)
• boiler;
• homogenizer; (photo homogenizer)
• vacuum installation; (photo vacuum installations)
• pump for transfer;
• storage tanks for raw materials and finished products; (photo storage tanks)
• dispenser and packaging unit. (photo packing machine)

The cost of the technological line is 3,000,000 rubles.

It is planned that the products of the mini-plant will be in the middle price segment. Production of mayonnaise, ketchup and mustard is planned.

Economic feasibility of the production process

For the functioning of a mini-plant for the production of pasty products, 9 people will be enough:

• director - 13,000 rubles;
• chief technologist - 12,000 rubles;
• laboratory assistant - 11,000 rubles;
• manager for purchasing raw materials and sales of finished products - 9,000 rubles;
• 5 employees to service the line (5,000 rubles each) - 25,000 rubles.

The total monthly payroll is 70,000 rubles.

The monthly fixed costs will be divided into the following sections:

• Payroll - 70,000 rubles;
• utility costs - 7,000 rubles;
• rent of an industrial building - 10,000 rubles;
• transportation costs - 5,000 rubles;
• packing container - 4,000 rubles.

Total: 96,000 rubles.

Mayonnaise production business plan

Let's determine the cost of 1 kilogram of mayonnaise (2 cans of 500 grams). The initial ingredients for the production of the finished product are:

• vegetable oil - 25% (30 rubles per 1 liter) - 7.5 rubles;
• eggs (egg powder) - 20% (30 rubles for 10 pieces) - 6 rubles;
• water, sugar and salt - 46% (20 rubles per 1 kg) - 9.20 rubles;
• acetic acid - 3% (35 rubles per 1 liter) - 1.05 rubles;
• spices 6% - (80 rubles per 1 kg) - 4.80 rubles.

Total: 28.55 rubles.

The planned daily production of mayonnaise is 70 kg (140 plastic jars or 350 tubes). Thus, the monthly output, taking into account 22 working days, will be equal to 1540 kg (3080 packages of the finished product in plastic containers or 7700 pieces of the finished product in tubes).

Total cost = Monthly production x Cost of 1 kg of mayonnaise = 1540 kg x 28.55 rubles. = 43,967.00 rubles.

Gross income = Monthly output x Retail cost of 1 kg of mayonnaise = 1540 kg x 150 rubles. = 231,000 rubles.

The financial indicators of the mini-plant for the first month of operation of the enterprise will be presented in the following form:

• gross income - 231,000 rubles;
• cost price - 43,967 rubles;
• gross profit - 187,033 rubles;
• monthly fixed costs - 96,000 rubles / 3 types of product = 32,000 rubles;
• profit net of tax (15%) - 131,778 rubles.
• return on sales - 57%.

Ketchup production business plan

Let's calculate the cost of 1 kilogram of ketchup (2 cans of 500 grams). The initial ingredients for the production of the finished product are:

• concentrated tomato paste 28% (100 rubles / kg) - 28 rubles;
• sugar 10% (30 rubles / kg) - 3 rubles;
• water 42% - 0 rubles;
• dried vegetables 9% (100 rubles / kg) - 9 rubles;
• spices - 4% (120 rubles / kg) - 4.80 rubles;
• salt - 7% (10 rubles / kg) - 0.70 rubles.

Total: 45.50 rubles.

The monthly output of the finished product will be 1650 kg or 5500 packages of 300 grams.

Total cost = Monthly production x Cost of 1 kg of ketchup = 1650 kg x 45.50 rubles. = 75,075.00 rubles.

Gross income = Monthly output x Retail value of 1 kg of ketchup = 1650 kg x 130 rubles. = 214,500 rubles.

The mini-plant will complete the first month of work on the sale of ketchup with the following financial indicators:

• gross income - 214,500 rubles;
• cost price - 75,075 rubles;
• gross profit - 139,425 rubles;
• profit net of tax (15%) - 123,539 rubles;
• return on sales - 57%.

Mustard business plan

Let's calculate the cost of 1 kilogram of mustard.

For its production, the following ingredients are required:

• water 60% - 0 rubles.
• mustard plant seeds 15% (90 rubles / kg) - 13.50 rubles;
• pepper 2% (150 rubles / kg) - 3 rubles;
• turmeric 2% (125 rubles / kg) - 2.50 rubles;
• salt 1% (10 rubles / kg) - 0.10 rubles;
• white vinegar 20%. (160 rubles / liter) - 32 rubles.

Total: 51.10 rubles.

The monthly output of the finished product will be 500 kg or 2500 cans of 200 grams.

Total cost = Monthly production x Cost of 1 kg of mustard = 500 kg x 51.10 rubles. = 25 550 rubles.

Gross income = Monthly output x Retail value of 1 kg of mustard = 500 kg x 150 rubles. = 75,000 rubles.

Subject to 100% sale of finished products, the mini-plant will complete the first month of operation with the following indicators:

• gross income - 75,000 rubles;
• cost price - 25,550 rubles;
• gross profit - 49,450 rubles;
• monthly fixed costs - 32,000 rubles;
• profit net of tax (15%) - 14,832 rubles.
• return on sales - 19%.

Thus, the production of mayonnaise, ketchup and mustard is an economically viable business. The total net profit is 271,935 rubles, and the average return on sales is 45%. Financial investments will be fully paid off in 1.5 years.

Sales of pasty products

The main force of the sales manager should be directed to the conclusion of contracts with wholesalers, grocery stores and supermarkets. At first, in order to stimulate strategic partners, it is advisable to use several simple techniques:

• provision of a discount on each additional box of goods that was purchased for a certain period of time; - to each intermediary for a free product (for example, 10 packs), subject to the purchase of a certain number of boxes;
• discount on products subject to self-pickup;
• monetary rewards for dealers (sellers) for their efforts to promote pasty products.

To increase product recognition, the manufacturer can make souvenirs with the company's logo (pens, calendars, notepads, etc.) and give them to the public free of charge. It will also be advisable to hold an action to sell packaging at a discounted price. Stimulation of short-term sales growth is possible in case of sale at a lower cost of 2-3 related products (mayonnaise, ketchup and mustard).

During the first months of operation of the mini-factory, investments in advertising will not differ in impressive sizes. This is especially true of plans to work exclusively for your region, as well as cooperation with small wholesalers and directly with supermarkets. In this case, the taste of the manufactured products will work for themselves. However, in the case of an increase in the assortment, it will be necessary to correctly promote the product. Bright packaging, a creative slogan, participation in international competitions and winning prizes will contribute to an increase in consumer demand.

The production of mayonnaise has not yet been fully studied, since there are many technologies for preparing a mixture as a basis for a future product. Everything goes back to ancient times, when unusual ways of creating this "delicacy" were used to add spice and originality to food.

The history of the production of mayonnaise and sauces

Food historians have proposed four possible theories for the origin of mayonnaise. The most popular story dates back to June 28, 1756, when the French captured Port Mayon on the Spanish island of Menorca. In preparation for the Victory Day, the Duke's chef was forced to replace the olive oil with cream in a sauce. Unexpectedly pleased with the result, the chef christened 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 shuffle. Another food expert, Prosper Montagnier, argued that the origin lies in the old French word "moyeu", which means egg yolk.

Still others insist that the creamy sauce was in-house developed by the city of Bayonne in southwestern France. Thus, what was originally called "mayonnaise" was later modified to be mayonnaise.

Regardless of its origin, mayonnaise was rapidly gaining popularity, so it should come as no surprise that it has appeared throughout European cuisine. In the early 1900s, a German immigrant named Richard Hellmann discovered a delicacy in New York City. The salads that his wife made with were especially popular. When customers started asking if they could buy the mayonnaise itself, Hellmans decided to wholesale it 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 success with her 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 Company in 1933 and presented at the World's Fair in Chicago. Ultimately, the product became known as the Kraft Miracle Whip Salad Dressing.

Mayonnaise production technology - features of each culture

To create mayonnaise, you only need 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 mixing two liquids, in this case vinegar and oil, causes one of them to form small droplets that disperse 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 a set of cavities with rotating impellers. The controlled pumping action causes the cavities to fill and empty. The impellers move the mixed fluid from one cavity to another.

The result is a single consistency, which is so important for this type of product. Next, the various components are added, which is a way of diversifying the base mix.

Adding ingredients:

1. The pre-measured ingredients are fed into the lines through openings in the side of the pumps or from the pressure sleeves.
2. The mayonnaise is transported through a 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. Moreover, they are not vacuum sealed.

This kind of mayonnaise is used by almost 80% of businesses 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 bulkiness of the oil, and to improve mouthfeel and ensure a stable emulsion.

Spices and other natural seasonings can be added with the exception of turmeric and saffron. They gave the mayonnaise a yellow tint, which the consumers did not like, so the technological line for the production of mayonnaise with them did not last long.

They also use vinegar, which is distilled from distilled alcohol, lemon or lime juice (diluted with water). Soybean oil is the most common ingredient used to make mayonnaise.

Large-scale production is usually carried out using a specially designed plant. 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, food service 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. In the first stage of production, the egg, which can be used in liquid or powder form, is dispersed in water. It acts as an emulsifier.
2. The residual 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 will immediately pick it up. 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, but they serve vital functions. The mixing equipment must be able to disperse and humidify them properly with a relatively low volume of liquid. If the egg and other emulsifiers are not properly dispersed and hydrated, the emulsion can break during the oil addition step.

Hydration of stabilizers and thickeners is one of the most difficult 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 can burst if not added correctly to the continuous phase. It is very difficult to control when the process is done manually.

The droplets of the oil phase should be reduced to a minimum size to maximize the surface area of ​​the oil in the continuous production of mayonnaise to ensure a stable emulsion consistency. It is impossible to get it without special equipment.

Aeration should be minimized or eliminated to maximize product shelf life.

Equipment for making mayonnaise

To achieve the desired result, you need to select 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 quickly wetted and dispersed in the high liquid velocity stream.
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 go directly to the working head of the mixer, where they are intensively mixed. 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. Recirculation of the product continues to provide a uniform consistency as the viscosity increases. After a short period, the process ends and the finished product is discharged.

The method is ideal for small batches for immediate use. Aeration is minimized, the system practically eliminates operator error. The profitability of the raw materials is maximized as the thickeners are fully hydrated and the other ingredients are properly dispersed. Mass production of mayonnaise proceeds in a slightly different way. The process is suitable for making more than 1000 kg of products per hour:

1. The metering pumps simultaneously add different ingredients to the tank in the required proportions.
2. The mixture is pumped through a built-in mixer, and mayonnaise is obtained only through one compartment, moreover, all ready at once, and then pumped into a buffer tank and prepared for packaging.

Equipment for the production of mayonnaise in mass quantities should be installed in accordance with accepted quality standards so that later the products can 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. Samples of mayonnaise are taken and tasted during the manufacturing process.

Variety of mayonnaise-based sauces

There are many varieties of mayonnaise, including light and fat-free. This healthy condiment can be part of a well-balanced diet to suit 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 the main source of our daily vitamin E intake.

Commercial mayonnaise is also one of the safest foods around. Salad dressings contain pasteurized eggs that have been heat-treated to kill harmful bacteria and ensure product safety, so you can be sure of it. Tatar, spicy, mustard sauces are created on the basis of mayonnaise. Since the production of mayonnaise involves the application of basic principles, they can be supplemented. To diversify the taste, and not the consistency or proportions, you can use seasonings.

Russian factories - how are they different?

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

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

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

Hollandaise mayonnaise-based sauce recipe

You will need a blender to mix the food.

1. Add double the yolks (to cover the blender blades).
2. Add 2 tsp. salt.
3. Melt butter in a small saucepan over medium heat. Once it starts to separate and is still bubbling, pour a little into the blender with the motor running.
4. Add a little more oil, the emulsion should "give out" a change in the sound when the blender motor is running.
5. Continue to pour in butter slowly without adding any milk solids.
6. Season to taste with lemon juice, salt and pepper.

Some mayonnaise companies have incorporated this recipe into the base of some sauces. You can diversify them with the help of spices and a combination of ingredients in the ratio of proportions.

Tartar recipe

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 food until a uniform consistency is formed. 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 labels and brands, using cheap recipes and available raw materials. Thanks to such factors, many businessmen can obtain goods and create their own sales business. If we talk about setting up production, then we should start with small batches, because for continuous sales of 1000 kg, you need to find sales points. Egg-free mayonnaise is gaining popularity - vegetarians and people who cannot stand this product will be the main consumers.

Equipment for the production of mayonnaise has specific requirements. Since the finished product does not undergo complete heat treatment, the equipment on which it is manufactured (from the stage of preparing raw materials to the process of packaging the prepackaged product) must be bacteriologically clean.

For 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 internal surface treatment up to 0.1 microns);
• have an automatic car wash unit.

Equipping equipment for the production of mayonnaise with a deaeration unit is of no small importance, which makes it possible to increase the shelf life of the product and avoid oxidative deterioration.

In modern requirements for technological equipment, great importance is attached to the complete 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, control and automatic registration of the entire course of the product production process are linked into the technological chain.

It is desirable that the equipment is cleaned and disinfected with solutions in a closed cycle (without the need to dismantle the equipment) - CIP (Cleaning In Place). To do this, the following requirements must be met:

• valves should 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 materials from which the equipment is made.

Equipment types

Depending on the various production schemes, the equipment for the release of mayonnaise is divided into high-performance lines of continuous or semi-continuous action, in which various stages of the process are carried out in different devices arranged in series, and small batch-type units for carrying out all operations in one container, the productivity of which varies in wide limits (from 30 to 6000 l / h).

Continuous Mayonnaise Production Lines

Lines for continuous and semi-continuous production of mayonnaise have their own advantages and disadvantages. The 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.

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.

Automated high-performance lines "Johnson" (up to 1 t / h), lines of firms "Gilder Corp.", "Cherry Barrell", "Holsum Food Co", "Stork SalatOMatic", "Schroeder" operate on continuous and semi-continuous technologies.

The technological scheme for the production of mayonnaise and salad dressings on the Johnson line is shown in Figure 1.

1 - hopper for egg powder; 2 - hopper for dry components; 3 - oil container; 4, 13 - containers for water and vinegar; 5 - deaerator; 6, 15, 23 - pumps; 7, 10 - metering pumps; 8, 9 - Votators; 11 - votator supply tank; 12 - starch bin; 14 - tank for preparation of starch suspension; 16 - finished product tank; 17 - filling machine; 18 - seamer; 19 - homogenizer; 20 - feed tank of the homogenizer; 21 - tank for sanitary scrap; 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 batch lines are compactness, cost-effectiveness, and a wide range of productivity. However, it should be said that periodic lines work effectively only with full automation.

In the production of mayonnaise, the main devices of the technological line are homogenizers (or dispersants), which must ensure the creation of homogeneous fine emulsions with a given particle size. High-speed mixers, high-pressure homogenizers, colloidal mills, rotor-stator systems, homogenizing devices are used as the main working elements, which are combined with evacuation of the product in a hermetically sealed apparatus and pumping the product "for return" at a high speed, which makes it possible to achieve the desired degree of dispersion finished product.

We will present equipment for the production of mayonnaise of some leading German companies.

"A. Stefan & Sons GmbH & Co manufactures modern machines and plants for use in many areas of the food industry. For the production of mayonnaise, of interest are universal machines of the UMM / SK type, a universal vakuterm-mixer of the VM / MC type and a homogenizer “Stefan Microcut MCN 10/2”. These batch machines can operate both in manual and semi-automatic and automatic modes of process control according to a given program.

The unit "Stefan UMM / SK" has a rational design, suitable for integration into existing equipment, it is easy to maintain and wash, multivariate, allows you to obtain 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 for attaching a working tool - sharp knives or stirring blades. The set also includes a transport blade for removing particularly viscous materials from the walls and guiding them towards the center of the container. Thermal processes can take place simultaneously with mechanical processes in the machine: heating can be carried out either by direct steam supply or through a jacket. All processes can take place under vacuum conditions. A mini-version for small batches of experimental products in laboratories is also produced - UMM / SK 5.

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

The Stefan Vakuterm plant is designed for the production of sauces, mayonnaise, food emulsions, as well as pureed soups, various meat and fish products. The basis of the modular system of the vacuotherm (Figure 2) is a diagonally installed sealed working tank with an attached gear motor, on which a mixer with a scraper is fixed. The drive shaft is sealed from the side of the tank with a double-acting mechanical seal, which is steamed during sanitary measures. The circulation pump serves to feed the product evenly through the homogenizer and the recirculation system back into the working tank. At the end of the emulsification and homogenization cycle, additional components are added to the sauce and in the final stage, the process of homogeneous mixing takes place. The product can be circulated either through the homogenizer or bypassing it. The circulation pump is also an unloading pump.

1 - STEFAN vakuterm; 2 - loading opening DN 200; 3 - inspection 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 vakuterm systems are jacketed 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 way.

The vacuum system of the installation consists of a vacuum pump and a control unit operating in an automatically set mode. The main working element of the plant is the Stefan 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 homogenization and emulsification process.

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

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

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

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

Figure 3 - Processing
installation of MZM / VK "Delmix"

The product passes through the emulsifying head and through the recirculation pipe returns to the vessel 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 product dispersion. Installations "Delmix" are produced in 10 modifications, with a capacity from 7 to 3000 liters.

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

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

Domestic equipment

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

For example, a mini installation "MAIS" manufactured by SPKF "Stroyvest" (Dzerzhinsk, Nizhny Novgorod region) is designed for the production of food emulsions (mayonnaise, creams, pastes, jams, sauces, jams and other food mixtures of various recipes) at catering establishments, dairy and oil and fat factories, small and medium-sized businesses.

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

The plant can be equipped with a dispenser and an electric seaming machine with replaceable heads.

The "FLIGHT" company for the preparation of mayonnaise is equipped with an original Bulgarian-made homogenizer with a capacity of 1500 l / h. The plant productivity is up to 3000 kg / shift.

Shredders / mixers IS-160 and IS-80 are offered for the production of sauces and mayonnaise by the firm "KONSITA". The unit is equipped with a stirrer, a jacket, a vacuum chamber, a live steam injection manifold, as well as an automatic control.

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

In the installation for the production of MA-0.5 mayonnaise, offered by JSC Tveragroprodmash, with a capacity of 500 l / h, a colloidal mill of an original design is used as a homogenizer, 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-pulsating apparatus, are offered by AGRO-3 JSC. The equipment provides pasteurization of raw materials and finished mayonnaise. The cycle duration does not exceed 2.5-3 hours.

The installation for the production of mayonnaise, offered by the Ecomash enterprise, is designed for the preparation and packaging of various types of mayonnaise in polystyrene cups and glass jars. The kit includes a mixer, a rotary-pulsating apparatus, a pump, a set of locking equipment and a semiautomatic filling machine.

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

The packaging of mayonnaise in order to avoid deterioration in quality and reduce the shelf life is carried out immediately after production. For this, various packaging equipment is used, depending on the container used, the choice of which, in turn, is dictated by the peculiarities 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 two-hundred-gram glass "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" packaging, etc. The materials from which these types of containers are made have high chemical resistance to mayonnaise and its components, and hygienic indicators do not exceed the current sanitary standards.

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

Firm "Istok" offers automatic lines "Alta-4" for filling and sealing homogeneous viscous products in polystyrene cups with a lid made of aluminum foil with thermal varnish, 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, supplied by the "Flight-M" company.