Production of mayonnaise in a batch process

Mayonnaise is a multi-component system, the complexity of which is due not only to a wide range of components, but also to the fact that the main components (oil and water) are insoluble in each other. It is practically impossible to obtain a homogeneous (close to homogeneous) and stable system of components insoluble in each other, even with intensive stirring (emulsification), as well as homogenization. This can be achieved only under certain conditions of preparation and adherence to a strict sequence of technological operations, ensuring the directed interaction of all components.

Schematically, the production of mayonnaise consists of the following technological stages:

Preparation of individual components of the recipe composition;

Preparation of the paste (emulsifying and structuring base);

Preparation of "coarse" emulsion;

Preparation of a finely dispersed emulsion (homogenization);

The introduction of flavoring and aromatic additives, which was not possible in the previous stages.

Preparation of bulk components

Bulk components: powdered milk, granulated sugar, egg powder, mustard powder, salt are sieved on vibrating screens with magnets for capturing ferro-impurities, with a mesh cross section of 1-3 mm. The absence of lumps in dry components increases their moisture content and dispersion during swelling, surfactant properties and emulsifying ability.

Preparation of vinegar-saline solution

A clear saline solution from a salt solvent is fed into a container for preparing an acetic-salt solution, in which it is diluted with water to 13-15% concentration for mayonnaises with a high fat content and up to 9-10% concentration for low-calorie mayonnaises. There, by a vacuum pump, 80% acetic acid is supplied in the amount prescribed by the recipe. Concentration acetic acid the solution should be no more than 7-9% for high-calorie mayonnaise and no more than 5-6% for mayonnaise with a reduced oil content.

In the absence of a salt solvent, it is allowed to supply dry salt to a container for an acetic-salt solution, equipped with a stirrer with a rotational speed of 60-80 rpm, stirring the acetic-salt solution until the salt is completely dissolved.

Making flavored vinegar

80% acetic acid gives the mayonnaise an undesirable specific pungent aftertaste (despite the fact that the acidity of the mayonnaise is within the required range). Flavored vinegar is used to improve the taste of mayonnaise.

Flavored vinegar is obtained by infusing acetic acid with various spices ( Bay leaf, allspice, black pepper). The ground spices are placed in a linen bag, which is dipped into a vessel with a previously prepared solution of acetic acid of the required strength, then the entire contents are heated to 80-90 ° C, after which, without removing the spices, the vinegar solution is cooled and then the bag with spices is removed.

Cooking mustard

In order to avoid the appearance of an excessively bitter taste in mayonnaise, mustard powder is preliminarily prepared as follows. 24 hours before the production of mayonnaise, the required amount of mustard powder is placed in an enamel or stainless steel tank. The mustard powder is poured with water at 80-100 ° C in a ratio of 1: 2, stirred well until a uniform consistency and the top layer of mustard is smoothed. A layer of water with a temperature of 100 ° C and a height of 4-6 cm is carefully poured onto a flat surface of mustard. The tank is tightly closed with a lid and left alone for a day. Then the top layer of water is drained, and the mustard mass is ready for use-

Making mayonnaise paste

One of the conditions for obtaining stable emulsions is the correct preparation of emulsifiers, that is, obtaining them in the form of a homogeneous colloidal solution with maximum dispersion, which ensures the effectiveness of the emulsifying action.

The main emulsifiers providing the required stability of the emulsion are egg powder and milk powder.

Preparation of mayonnaise paste consists of the process of dissolving dry components and mixing them until homogeneous.

Dissolve dry components in two mixers: dry milk with mustard powder is dissolved in one mixer (if the mustard powder has not been previously steamed), and in the other, egg powder. It is possible to dissolve milk powder, mustard and egg powder in one mixer, although this is undesirable, since their processing temperatures are different. When making pasta in one mixer, the performance of the batch mayonnaise line decreases as the time for making the pasta increases.

Cooking mayonnaise paste in two mixers

If the mustard powder is not previously prepared in a separate container, the process of dissolving the components begins with steaming the mustard. Water 90-10 (° C) is poured into one of the small mixers and mustard powder is poured. The ratio of mustard powder to water is 1: (2-2.5), respectively. Then the mixer is turned on and stirred until a homogeneous mass is obtained. Then water is fed into the mustard mass 35-40 ° C, milk powder, baking soda, granulated sugar. The ratio of milk powder and water for high-calorie mayonnaises is 1: 3, for mayonnaises with ponies, the fat content is 1: 4. After loading, turn on the stirrer and put it into the mixer jacket steam For better dissolution of the components and their subsequent pasteurization, the temperature of the mixture is brought to 90-95 ° C and kept at this temperature for 10 -25 minutes, after which the mixture is cooled to 40-45 ° C.

In the case of preliminary steaming of the mustard powder, the hot chichngya mass is fed into the mixer along with the rest of the dry components before pasteurization (the amount of water introduced with the tanned mustard is taken into account).

In the second small mixer, egg powder and boDu 40-45 ° C are fed in a ratio of 1: (1.4-2) for high-calorie mayonnaise and a ratio of 1: (2.5-2.8) for mayonnaise with a reduced fat content. The stirrer is turned on, steam is supplied to the jacket, the temperature of the mixture is brought to 60-65 ° C and kept at this temperature for 20-25 minutes. To increase the dispersion of the solution, periodically include the emulsifier "for return" in the mixer. After 20-25 minutes, the solution is cooled to 30-40 ° C.

Prepared solutions of egg powder and milk powder with other components are mixed in any of the small mixtures: n - gels by pumping the solution.

Cooking mayonnaise paste in one mixer

If the mustard powder is not previously prepared in a separate container, then the process of dissolving the components begins with steaming the mustard.

Hot zoda 90-100 ° C and mustard powder in the ratio (2-2.5): 1, respectively, are fed into the mixer for preparing the pasta. Everything is thoroughly mixed until a homogeneous mass is obtained. Water 35-40 ° C and dry milk are fed into the mustard steamed in this way in a ratio of 3: 1 for high-calorie mayonnaise and 4: 1 for mayonnaise with a low fat content, sodium bicarbonate, granulated sugar and corn phosphate starch (when preparing salad The whole mixture with thorough mixing is kept at a temperature of 90-95 ° C for 20-25 minutes.

After dissolving and pasteurizing, the mixture is cooled to 40-45 e "Siv mixer serves water and egg powder in the ratio (1.4-2): 1 for high-fat mayonnaise and (2.5-2.8):] d, n mayonnaise with reduced Then the temperature of the mixture is brought to 60-65 ° C and the mixture is kept at this temperature with thorough mixing for 20-25 minutes. To increase the dispersion of individual components of the paste, the solution is periodically (5 minutes) passed through the emulsifier "for return" to the mixer ...

The mayonnaise paste prepared in this way is cooled to 30-40CC and transferred to a large mixer to prepare a coarse mayonnaise emulsion.

Since the effectiveness of the emulsifying and stabilizing action of the components that make up the paste (mustard powder, egg powder, milk powder) depends on their working readiness, you should pay attention to the fact that the mustard is thoroughly ground and does not contain non-swollen particles of lumps. The same applies to milk and egg powder. When mixing them, careful mutual picnpej - division must be achieved. This is achieved by mixing them in a mixer with a steam-water jacket equipped with an intensive dispersion agitator.

The readiness of the paste is determined visually by a sample taken during the mixing process. A sample of the paste taken on a wooden plate should be completely homogeneous, without visible lumps, and evenly drain off the plate. The mixing time is determined by the readiness of the paste and, in turn, depends on the readiness of the individual components for mixing.

If the solubility of egg powder or yolk and milk powder is insufficient, the dissolution time should be lengthened. In addition, the amount of soda can be varied to improve the solubility of milk powder. The low pH of the paste can lead to coagulation of the casein, which then leads to the stratification of the mayonnaise. When using egg powder with a high dispersion and swelling capacity, a mayonnaise with a high viscosity is obtained. It is recommended to use such a powder in a mixture with the usual one in a 1: 1 ratio.

The concentration of dry matter in mayonnaise paste for high-fat mayonnaise should be at least 37-38%, and for mayonnaise with a lower fat content - at least 32-34%.

Coarse emulsion of mayonnaise

A coarse emulsion (preliminary emulsification) is prepared in large mixers equipped with throwing devices with a low rotation frequency (preferably frame-type mixers), or with a drive with a variable speed. Under all conditions, the agitators must ensure uniform mixing in all layers of the mixer, without stagnant zones.

The paste prepared in small mixers is transferred to a large mixer. After pumping the mayonnaise paste into a large mixer, vegetable oil (20-25 ° C) is fed into the pogo with continuous stirring in the amount required by the recipe. In the first 7-10 minutes, oil is supplied slowly (4-6 l / min), then more quickly (10-12 l / min). It is allowed to start the oil supply 3-7 minutes before the end of pumping all the mayonnaise paste into a large mixer. To ensure even distribution, oil is fed into the mixer through a special sprayer (shower), which is a perforated coil.

At the end of draining all the oil, a previously prepared solution of salt and vinegar is fed into the mixer at a rate of 6-8 l / min from a tank specially designed for this purpose. Then soluble spices are introduced (spices insoluble in the emulsion, flavoring and aromatic additives must be set after homogenization of the emulsion). After feeding a solution of salt and vinegar, stirring is continued for 1-7 minutes.

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 production of a reactive type of emulsions, and at a certain stage of emulsification, to phase reversal.

The coarse emulsion obtained in the mixer must correspond to the established type of oil-in-water emulsion, be sufficiently strong and not delaminate before passing through the homogenizer. Visually, such an emulsion has a homogeneous appearance and does not delaminate in a sample taken with slight stirring.

Homogenizing mayonnaise emulsion

The final stage of obtaining a commercial mayonnaise is homogenization, carried out using piston homogenizers. Homogenization of the mayonnaise emulsion must be carried out with strict adherence to the recommended pressure below. The value of the pressure on the homogenizer is set by adjusting the gap in the homogenizing head.

When feeding the emulsion into the homogenizer, the optimum pressure is set to ensure that the desired consistency of mayonnaise is obtained. The mayonnaise is fed back into the large mixer after the homogenizer until the desired pressure is reached. For high-fat mayonnaise, the optimal pressure is within 0.90-1.1 MPa (9-11 kgf / cm2), for low-fat mayonnaise 15.0-17.5 MPa (150-175 kgf / cm2), for Lyubitelsky mayonnaise 2.5-3.0 MPa, for salad dressings 12.5-13.0 MPa (125-130 kgf / cm2). "

In a large mixer, the emulsion should be slightly mixed, since intensive mixing can lead to destruction (delamination) of the emulsion or phase inversion, prolonged sludge (without mixing) can also lead to delamination.

After establishing the required pressure, the finished mayonnaise from the homogenizer is sent to the container for the finished mayonnaise.

Deviation from the optimal pressure for a specific concentration of the emulsion leads to destruction: in case of excess pressure, adsorption films are destroyed, leading to coalescence of the oil and water phases; if the pressure is too low, fine dispersion is not achieved and, therefore, the possibility of obtaining a finely dispersed and stable emulsion is excluded.

When operating piston homogenizers, it is necessary to exclude the possibility of air leaks and its presence under the valves, which disrupts the operation of the valves and, consequently, the operation of the homogenizer as a whole.

Cooking mayonnaise with spices and flavors

When making mayonnaise with spices and flavors, tomato paste, Southern sauce or red sweet pepper puree are introduced into a large mixer before serving the uxuy and salt solution. If the tomato paste is very thick, it can be diluted with a solution of vinegar and salt. Spices (in their natural form) are added to mayonnaise in ground form after sifting on a sieve with a mesh size of 0.1 cm in containers for ready-made mayonnaise equipped with stirrers, then stirring is continued until they are evenly distributed over the entire mass of the product.

Carbonic extracts of spices are added manually simultaneously with an acetic-salt solution in the form of oil solutions prepared in a ratio of 1: 50 or 1: 100.

Powdered components sifted on vibrating screens are fed into the appropriate hoppers: egg powder - into the 1st, mustard powder - into the 2nd, milk powder - into the 3rd, granulated sugar - into the 4th.

Baking soda is fed directly into the mixer 9. Hot water is supplied from the water tank 17 to the mixer 9, then mustard powder is loaded from the hopper 2 through the scale 7 into the mixer. After the mustard powder is brewed into the mixer 9, warm water is supplied from the water tank 17, milk powder is loaded from the hopper 3 through the scales, and granulated sugar from the hopper 4.

The whole mass is thoroughly mixed, heated to 90-95 ° C and kept at this temperature until the milk powder is completely dissolved. Dry egg powder is loaded into the mixer 8 from the hopper 1 through the scales, and then water is supplied from the tank 17 at a temperature of 40-45 ° C.

The mass in the mixer 9 is cooled to 40-45 ° C and a solution of egg powder is fed there from the mixer 8 by the pump-emulsifier 5 and thoroughly mixed until a homogeneous mayonnaise paste is formed. The prepared paste is cooled to 30-40 ° C and pumped by a pump-emulsifier 5 into a large mixer 10, where vegetable oil is fed from the tank 14 through the tank 28 installed on the balance 13.

From the salt solvent 15, a saturated salt solution enters the tank 18, where it is diluted to the required concentration, and the prescription amount of 80% acetic acid is also fed here. After entering vegetable oil add the prepared vinegar-saline solution.

For more complete dispersion, the mayonnaise emulsion from the large mixer 10 is passed through the homogenizer 11 into the tank 12 for the finished mayonnaise. From the tanks 12, the finished mayonnaise is fed for packaging into dry clean cans through an automatic filler 21, a seaming machine 22 and a labeling machine 23. The mayonnaise should be packaged immediately after it has been produced, since contact with air oxygen impairs the taste and preservation of mayonnaise.

Small mixer (see fig. 43) for preparation of mayonnaise paste - stainless steel apparatus, has a stirrer and a jacket for steam and water. The apparatus is closed by a lid with a hatch.

Technical specifications

TOC \ o "1-3" \ h \ z Capacity, m3 ................................... ..................................... 1,5

Mixer rotation frequency, rpm. ... 70-80

Number of mixers, pcs. ..... 2

Agitator type ................................................ ......... Ramiaia

The large mixer for preparing the mayonnaise emulsion is similar in design to the small mixer.

Mixer technical characteristics

Capacity, m3 ............................................... ......................... 2.0

Agitator type ................................................ ... Frame

Number of mixers, pcs .............................................. .......... 2

Mixer rotation frequency, rpm. ... 60-80

Electric motor power, kW ... 3

Dimensions, mm:,

Length................................................. ........... 2000

Width................................................. .......................... 1000

Height................................................. .......... 1000

An emulsifier pump (see fig. 44) is used to disperse the components of the mayonnaise paste and feed them into a large mixer.

Technical characteristics of the emulsifier pump

Productivity, kg / h ....................................... 1000-3000

Emulsion feed height, m ​​5

Electric motor power, kW. ... ... 1.5-2

Rotation frequency, rpm .... 1450 Dimensions, mm:

Length................................................. ............ 554

Width................................................. ............................ 280

Height................................................. ............................ 300

The homogenizer (fig. 75) is used to obtain a finely dispersed mayonnaise emulsion. According to the principle of operation of the homogenizer

E mixers; 10 - large mixer; 16 - trap; 17 - water tank;

■ acetic acid

21 - automatic filler; 22 - ordered acetic acid; 27-tel -: wx and disinfectant solutions;

(f Legend denoted

Styliye oil; a

Electric motor power A063-6, kW

Rotation frequency, rpm .......................................

Plunger diameter, mm ............................................

// - homogenizer; 12 - containers for ready-made mayonnaise; 13 - scales for oil; 14- containers for oil; / 5 - saline solution; 16 - trap - "17 - tank for volts 18 tank for vinegar-saline solution; 19 - scales for vinegar-salt solution; 20 - boiler for preparing warm water, 2 / - automatic-filling machine - ordering automatic machine; 23 - labeling machine; 24 - a stacking machine; 25 - a can-washing machine; a container with concentrated acetic acid "V-flow-

Weights for weighing the vinegar-salt solution; 30 - a tank for the preparation of washing and disinfecting solutions -

Technical characteristics of the homogenizer

Productivity, l / h .........................................

Normal working pressure, MPa. Maximum allowable pressure, MPa Electric motor power A063-6, kW

Rotation frequency, rpm .......................................

Crankshaft rotation speed, rpm

Number of plungers, pcs .....................................

Plunger diameter, mm ............................................

Dimensions, mm:

Length................................................. ............ 700

Width................................................. ......... 1100

Height................................................. .......... 1100

Net weight, kg .............................................. ........ 720

Automatic filler is used for packaging mayonnaise in cans. Filling is done by volume.

The KNO-2 filler is a continuous vertical rotary machine. Structurally, the filler consists of the following units: a frame, a drive, a filling head, a mechanism for guiding cans and a conveyor. The filler performs the following operations: receiving cans from the conveyor line;

Supply and installation of cans under the bypass valves; filling cylinders with product; filling cans with a product;

Transfer of filled cans to the conveyor line for seaming. All units of the machine are mounted on the bed.

Filler specifications

Productivity, cans / min. ... ... 60-80

Number of filling cylinders, pcs. 6

Filling regulation limit, ml. ... 180-500

Dosage accuracy,% .............................................. ........... 2

The KZD seaming machine is designed for rolling up the lids of 200 ml mayonnaise cans. When using replacement parts supplied by the factory on a special order, the machine can be adjusted for seaming cans with a capacity of 350 and 500 ml. By design, the machine is a three-spindle rotary single-tower seamer of continuous operation.

Performance, baikn / mip. ... ... 60-80

Electric motor power, kW ... 2.3

The labeling machine is designed for sticking labels on cans with mayonnaise. This is a carousel car. The machine is adapted for installation in the line of the filling and filling unit. The machine consists of the following main units: a bed and a drive, a carousel with a work table, loading and unloading mechanisms, a glue bath with a spreading roller, feed mechanisms, stickers and stamping of labels, a carriage with a cassette for labels. The machine is driven by an individual electric motor through a V-belt transmission.

Technical characteristics of the device

Productivity, cans / min, up to. 60

Electric motor power, kW. ... one

The machine for washing glass jars (fig. 76) of the AMA-1 brand is a brushless, chain-powered, automatic washing machine. The machine consists of a body,

/ - loading table; 2 - pushing bar; 3 - the first tank with an alkaline solution; 4 - the second tank with an alkaline solution; 5 - zone of injection with an alkaline solution; 6-zone for sprinkling with warm water; 7 - zone for sprinkling with cold water; 8- pushers; 9- inclined plane

Zuyuyu car frame, tubs and casing. Chains run inside the machine with special can carriers attached to them.

This technology is a reflection of the general concept of mayonnaise production. 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 additives.

1. Preparation of dry components.
Bulk components - milk powder, sugar, egg powder, salt - are sieved and dosed by weight in accordance with the recipe into measuring containers.

2. Steaming mustard.
24 hours before the start of the production of mayonnaise, the required amount of mustard powder is placed in a stainless steel container and filled with water at a temperature of 80-100 gr. C in a ratio of 1: 2. The mixture is well stirred until a homogeneous consistency with smoothing of the top layer. On the flat surface of the mixture, water is carefully layered with a temperature of 100 g. With a height of 4-6 cm. The container is tightly closed with a lid and left alone for a day. Front
the use of the top layer of water is carefully removed.

3. Preparation of egg emulsion.
In a food container, egg powder is dispersed in warm water at a temperature of 40-50 degrees C in a 1: 1 ratio. Then hot water with a temperature of 60-75 ° C is added to the resulting mass until the ratio of egg powder and water is 1: 5. The composition is thoroughly mixed until a homogeneous mass is obtained.

4. Preparation of coarse mayonnaise emulsion.
Dry components are manually poured from measuring containers filled in accordance with the recipe into a tank-type mixer and filled with pre-prepared water with a temperature of at least 30-40 ° C. The mixture is thoroughly mixed and heated to a temperature of 80-85 ° C (pasteurization stage) by supplying water at a temperature of 95-100 ° C to the mixer jacket. Temperature control is carried out by the device. Pasteurization time 30 min. At the stage of mixing the pasteurizing solution, granulated sugar is manually added. At the end of psterization, the mass is mixed and cooled to a temperature of 50 ° С-55 ° С. Then the ready-made amount of the solution of egg powder and ready-made mustard is introduced. The temperature of the mixture is again brought to 60-65 ° C and kept there for 25-30 minutes, then the mixture is again cooled to a temperature of 30 ° C.

5. Preparation of a thin mayonnaise emulsion.
Vegetable oil is added to the resulting coarse mayonnaise emulsion with further stirring. After receiving the entire dose of oil and obtaining a homogeneous emulsion, an acetic-salt solution is introduced and the mixture is stirred for another 15-20 minutes. The resulting mixture is passed through a disperser. To improve the quality and properties of the product, it is advisable to pass the mayonnaise emulsion through a plunger-type homogenizer. The finished mixture is sent to a storage container.

6. Packing
Packing of mayonnaise is carried out in various consumer containers (glass jar, plastic bag, plastic bottle, Dou-pack, etc.)

Product characteristics of raw materials and semi-finished products. Mayonnaise is one of the promising food products. It is used as a seasoning for a variety of culinary dishes to enhance their nutritional value and enrich their taste, which helps to stimulate the appetite and improve digestion.

In contrast to margarine, mayonnaise is an oil-water emulsion, where the dispersion medium is water and the dispersed phase is oil.

The raw materials for the production of mayonnaise are vegetable refined deodorized oils, milk powder, egg powder, sugar, salt, mustard and other food and flavoring additives.

In the manufacture of mayonnaise, mainly liquid sunflower oil is used, less often soybean and light cottonseed oil. Ingestion of even a small amount of salomas is unacceptable, since the ability of salomas to crystallize leads to the destruction of the mayonnaise emulsion.

Powdered milk and egg powder, plant phospholipids are used as emulsifiers. Powdered milk is used simultaneously as a structurant, milk proteins are capable of swelling in the presence of moisture, and this helps water retention and provides a structuring effect on all the components that make up mayonnaise.

Mustard powder is a flavoring agent, and the proteins it contains also provide emulsification and structure formation.

Salt gives flavor to the product and has a preservative effect; baking soda maintains a certain pH, thereby improving the swelling of milk proteins.

Sugar is a flavoring agent, acetic acid performs the same function and, in addition, increases the bactericidal properties of mayonnaise. Phosphate corn starch (an ester of starch and phosphoric acid) is used as a structurant and stabilizer for low-concentration mayonnaise.

Water in the production of mayonnaise is necessary for dissolving salt and sugar, for dissolving and swelling milk proteins and other recipe components.

Liquid vegetable oils, milk powder, sand sugar and table salt are subject to the same requirements as in the production of margarine products. Egg powder is used in powder form, it should not have any foreign smell and taste. Mustard powder should be dry, have a pungent allyl oil scent and not darken. Mustard paste should not feel musty and not characteristic of fresh mustard bitterness, delight.

Features of production and consumption finished products. Mayonnaise, depending on the calorie content, is divided into three types: high-calorie with a mass fraction of fat over 55%, medium-calorie, containing 40 ... 55% fat, and low-calorie - less than 40% fat. According to their purpose and composition, mayonnaises are divided into table, with spices, with flavoring and gelling additives, dietary and for baby food.

Table mayonnaise has a delicate sour taste, good viscosity and consistency. Spiced mayonnaises have taste properties mayonnaise "Provencal", but enriched with the taste and smell of spices. These types of mayonnaise can be used as a seasoning for salads, vegetables, fish and meat dishes.

Mayonnaise with flavors and gelling additives are available spicy and sweet. These mayonnaises have the sweet taste of their respective essences. They contain phosphate starch as a gelling agent and are intended for seasoning fruit salads... They are also used for baby food and as sandwich products.

Diet mayonnaises are characterized by delicate taste... This mayonnaise is used in baby and diet food.

The main trends in the expansion of the assortment and the development of new formulations of mayonnaise are the reduction of calories by reducing the content of fats and sugar, increasing the biological value by completely or partially replacing traditional components with natural biologically and physiologically active substances.

Stages of the technological process. The production of mayonnaise can be divided into the following stages and operations:

- preparation of dry and liquid components;

- dosing of components and preparation of phases;

- dosing phases;

- temperature treatment of phases;

- preliminary emulsification;

- getting ready-made mayonnaise;

- packing of mayonnaise;

- packing in boxes;

- transportation to the warehouse and storage of finished products.

Characteristics of equipment complexes. The mayonnaise production line begins with a set of equipment for the preparation of dry and liquid components, including containers and pumps. Further along the technological process, complexes for the preparation and dosing of phases are provided, containing counters, heat exchangers, containers, pumps and homogenizers.

The next complex is designed for temperature treatment and pre-emulsification, which includes heat exchangers, metering pumps and emulsifiers.

The leading one is a set of equipment for obtaining finished mayonnaise, which contains containers and dosing pumps.

The final complex includes equipment for packing mayonnaise and placing it in boxes.

The machine-hardware diagram of the technological line for the production of mayonnaise is shown in Fig. 3.15.

The device and principle of operation of the line. On the line, mayonnaise is produced as follows. In the container 7 refined deodorized vegetable oil arrives. Sifted dry components (egg powder, skimmed milk powder, mustard powder, granulated sugar, salt, baking soda) are weighed on the scales in accordance with the distribution of the recipe set in phases and sent to containers 6 and 7 for cooking phases 2 and 4 .

Phase 1 - vegetable oil heated in a plate heat exchanger up to 20 ± 2 ° С. Phase 2 - suspension of egg powder in vegetable oil - egg powder is mixed with vegetable oil supplied through the volume counter at a temperature of 65 ± 2 ° C. Phase 3 - 10% acetic acid solution, which is prepared by mixing 80% acetic acid and water. Phase 4 - vegetable oil, skimmed milk powder, mustard powder and soda - all components are mixed at 20 ± 5 ° C and stirrer speed 0.83 s -1. After the formation of a homogeneous suspension, water, granulated sugar and salt are fed.

For cooking phase 2 from the container 1 pump 4 through the volume counter 5 and heat exchanger 3 fed into the container 6 vegetable oil with a temperature of (65 ± 2) ° С and egg powder is loaded, the phase is mixed and pasteurized 2 ... Next phase 2 enters the distribution tank 14, from which the metering pump 11 is sent for cooling to (15 ± 5) ° С into the cooling cylinder of the combinator-heat exchanger 8 and further into the combinator-emulsifier (homogenizer) 15.

Rice. 3.15. Machine-hardware diagram of the mayonnaise production line

In the container 7 for cooking phase 4 from the container 1 pump 4 through the volume counter 5 vegetable oil is pumped and pre-weighed skimmed milk powder, mustard powder and soda are supplied. Then water is supplied through the volume counter 5 and the rest of the dry components (granulated sugar and salt) are introduced. After stirring, the phase 4 goes to the distribution tank 9, from where by the metering pump 11 - for pasteurization into the heating cylinder of the combinator-heat exchanger 8. Pasteurization is carried out at (82 ± 2) ° С with holding at this temperature for 6 minutes. Then, in the second cooling cylinder of the combinator-heat exchanger 8 phase 4 cools down to (15 ± 5) ° С.

The pressure at the outlet of the cooling cylinders should be 0.15 ... 0.20 MPa. From the combinator-heat exchanger phase 4 goes to the combinator-emulsifier 15.

Phase 3 - 10% acetic acid solution - prepared in a tank 2 .

Vegetable oil (phase 1 ) via a plate heat exchanger 12 and distribution capacity 13 metering pump 11 fed to the combinator-emulsifier 15 ... The pre-emulsion formed in it is sent to a rotary homogenizer 16, where it is mixed with a 10% solution of acetic acid (phase 3 ) supplied by the metering pump 11 from the container 10. Mayonnaise emulsion is processed in a rotary homogenizer 16 by punching through the gap between the stator and the rotor (from 0.1 to 1.5 mm) at a rotor shaft speed of 13.3 ... 15.0 s -1.

Ready-made mayonnaise after homogenizer 16 enters the container 17 , whence by a screw pump 18 fed into the dispenser of the filling machine 19, which pours mayonnaise into PVC cups with a capacity of 250 g. From the filling machine, the cups with mayonnaise are sent to the machine 20 for packing in corrugated cardboard boxes. The machine places 4 cups on top in 3 rows and 3 layers (36 pcs.) In each box. Banded boxes are sent to the warehouse, where the finished product is stored until dispatch to the consumer at a temperature of 0 ... 18 ° C and a relative humidity of no more than 76%.

The production of mayonnaise is one of the most common sauces in the industry, produced on a global scale. To create it, you need a lot of ingredients and special equipment. Mayonnaise is widely used in the food web. It is gradually replacing traditional sour cream and is a versatile dressing in home cooking.

The range of these products is diverse. The main differences between the brands are: the composition of the sauce, its quality, the name of the manufacturer and the cost. In the pursuit of leadership and turnover, in order to generate more profit, many companies have resorted to substitutes for natural raw materials or reduced the required dosage of ingredients when creating mayonnaise. Because of this, the production line of this product does not always meet the required quality standards.

What should be the mayonnaise mass, the history of its creation and the production process, will be discussed later.

There is no information in history about who invented mayonnaise. It is known that the first mention falls on the XVII century and there are disagreements in dating and events, however, the historical homeland of the sauce (in both cases) is the island of Minorca, the city of Mahon.

According to the first version, one of the chefs, in times of famine, during the siege of the capital city (in 1757) under the leadership of the Duke de Richelieu, came up with a mixture of the available products. The sauce consisted of turkey egg yolk, olive oil and spices. The liquid consistency, combined with bread, has become an elegant delicacy for the soldiers. The sauce got its name in honor of the besieged capital - "Maonsky", later - "Mayonnaise".

The second version says about a large feast in the capital of Mahon (1782), where the Spanish army, led by the commander Louis Crillons, celebrated their victory over the British. Experimental sauce dishes were served at the feast. The dressing was made from ingredients popular on the island at the time. The sauce brought to European countries was called "Maonian", which means "mayonnaise" in French.

Mayonnaise appeared over 200 years ago

Organization of mayonnaise production

Registration of individual entrepreneurship in this industry is carried out in stages:

1. Determination of the form of management.
2. Selection of partners.
3. Registration with the tax office.
4. Familiarization with regulations.
5. Trial batch release.
6. Image creation.

You need to start your mayonnaise business with registration. It is recommended to register a small plant as an LLC. This form of ownership will allow attracting more investments in the future.

Wholesale depots, food warehouses, shops and supermarkets will be an ideal solution in the partnership issue.

Registration. It is carried out according to the general taxation system, at the output of which, you need to receive a package of documents from OKVED. Of the entire list of papers, you only need a special code: 15.87 - a certificate of production at the enterprise of various kinds of spices and seasonings.

Before releasing the first batch of a pasty mixture, it is recommended to study the main forms of GOST.

After that, a small amount of products is sent for inspection to the Sanitary and Epidemiological Service, which examines the mayonnaise for compliance with state regulations. A successful outcome - obtaining a certificate for the mass sale of goods. It is also necessary to come up with a logo for the company, under which the products will be delivered to the store shelves.

Technologies and recipes

The technology for the production of mayonnaise implies the creation of favorable conditions for obtaining a homogeneous and stable mass from incompatible components. This takes into account the influence of other factors on this process (for example, the concentration and pasteurization of dry elements) on which the high-quality production of goods depends. In this regard, the following sequence of preparation of mayonnaise is distinguished:

• dosage calculation;
• making egg paste, then mustard;
• adding vegetable oil;
• preparation of vinegar solution;
• preparation of a coarse, finely dispersed emulsion;
• packing of goods;
• styling;
• transportation to the warehouse.

Making mayonnaise under industrial conditions with the addition of spices and fruit fillings allows you to create various varieties of this type of sauce. And from the percentage of vegetable oil, it is classified according to the degree of calorie content: high, medium and low. Based chemical composition and intended use: dining rooms, with spices, dietary.

How is mayonnaise made in production? There are several ways: cold process and semi-hot. The semi-hot method involves adding the main components to water boiled up to 95 degrees. The resulting mass is cooled to 65 degrees, and then mixed with an emulsifier and oil.

In the cold way, most often, high-calorie mayonnaise is produced by mixing all the components at room temperature. Medium and low-calorie mayonnaise with this method of production requires time and adherence to the exact proportions of adding dry matter.

There are several technologies for the production of mayonnaise

Requirements for the premises

The area of ​​the premises is chosen in such a way that the technological scheme of the future enterprise meets all the necessary safety and sanitary requirements. In addition, the enterprise should include the following halls: for equipment, storage of finished products and raw materials.

The security of the premises is as follows:

• insulation with fire-resistant structures;
• use of heat-resistant electrical equipment;
• efficient ventilation system;
• portable fire extinguishers;
• appropriate inscriptions (eg exit, no smoking).

Sanitary standards of the premises:

1. Creation of comfortable conditions for personnel and equipment: air conditioning system with maintenance of temperature, humidity and air purity;
2. Control of water hardness: installation of a system to increase the resource of steam production;
3. Premises or refrigeration units with a temperature of 0-18 degrees (air humidity no more than 75%) for storing finished products;
4. The use of packaging material with a polymer coating.

Raw materials

The composition of mayonnaise paste includes many different components, which, when mixed, determine its qualitative and quantitative composition. The list of ingredients is headed by:

• vegetable oils;
• emulsifiers;
• egg products;
• stabilizers;
• thickeners;
• food and flavoring additives.

As a fat base, you can use any type of oil, which must be refined and deodorized.

Emulsifiers are preferably used in various combinations in order to obtain highly stable emulsions at low consumption.

Eggs are used fresh and canned, whole or partially (yolk) raw. The thickeners are based on starches and their derivatives. The main sweetener of mayonnaise is sugar.

Equipment

Equipment for the production of mayonnaise has various schemes, taking into account which the structures are classified on the line:

1. Continuous plan (high performance).
2. Partially continuous designs (the process is carried out in different devices).

For enterprises, in the commercial field, a range of installations with different numerical indicators of productivity is presented. For example, for small businesses, there is a supply of batch lines available. And on an industrial scale, a continuous design is often used. It is important to note that periodic lines only work effectively with full autonomy.

Construction elements:

1. Boiler for heating water.
2. Mixer (sterilizer).
3. Pump.
4. Refueling tank.
5. Control Panel.
6. Mustard steaming trays.
7. Additional equipment (various accessories).
8. Mixer.

After the product is cooked, quality control is mandatory

Quality control of finished products

How mayonnaise is prepared in production can be learned from the results of clinical trials, where the finished substance is checked for organoleptic, microbiological, physical and chemical properties... At the conclusion of the inspection of each stage, the commission gives consent to the goods for the sale of goods or, conversely, does not let it pass.

The organoleptic assessment is made up of:

1. The consistency of the sauce.
2. Taste indicators, smell.
3. Colour.

A certain brand of goods is compared by the above components with the technical description of the product specified by the manufacturer. The consistency should resemble a thick sour cream type product with single air bubbles, white or yellow colors, uniform in all respects, in which obvious particles of spices may be present.

Physicochemical assessment is carried out according to the standards, which comply with the mass fraction of fat, moisture, egg products; acidity and stability of the emulsion. Microbiological indicators must comply with the permissible levels of sanitary rules and regulations.

Financial calculations

The business plan for the production of mayonnaise comes down to drawing up the material balance of the technical process, the purpose of which is to determine:

• consumption rates of raw materials per 1 ton of finished products;
• composition;
• the amount of waste material.

Comment. When calculating, one should take into account possible losses. They can be chemical, for example, water evaporation, and not related to this process (for example, shortage during weighing or sampling).

The calculation of project financing is carried out according to the following scheme:

1. An estimate of the total value of the enterprise is given.
2. Own funds that can be invested are calculated.
3. The amount that needs to be borrowed is calculated (not enough for the full implementation of production).
4. Credit and its volume.
5. Interest rate accounting.
6. Depositing a collateral for a certain amount is a loan security.

A competently drawn up business plan and correctly made financial calculations will contribute to obtaining a stable income

After the financial calculation, you need to make an assessment of the economic efficiency of the project:

• the estimated payback period of production;
• taking into account the accepted discount rate;
• the payback period of this rate;
• net worth;
• internal rate of return;
• its investment index;
• breakeven of the project;
• loan repayment period;
• minimum debt repayment ratio (loan).

Manufacturing costs. This includes installing and equipping the premises with the necessary equipment, hiring workers, purchasing raw materials, advertising, transport and export of finished products.

Mayonnaise production has a steady upward trend due to its primitive composition. Its popularity among the population is growing every year, and the turnover market along with it. The product range has many differences that make each brand mayonnaise sauce special in taste. The consistency is used as a seasoning for enhancing dishes or when preparing food products.

The constituents of mayonnaise make it possible to include ingredients that increase the biological value of the finished product: energy, physiological, food. As a result, the use of sauce has a beneficial effect on the human body. The introduction of new elements in the composition of the sauce, improves and modifies its properties.

An effective role in the sales market is played by incoming product quality control, which filters out defective goods. To avoid such a situation, when opening your own business, you must comply with all legal regulations and recommendations. These include the leased area, its arrangement, the purchase of equipment and the production process.

Conclusion

Correct business conduct is the key to the company's success, which depends on the leader and his subordinates. A favorable atmosphere leads production to prosperity and future expansion. This means that in the near future, the turnover and cash flow will increase, which will close the "debt hole" and bring the company to a positive level.

Mayonnaise is of the noblest origin. French cuisine is inextricably linked with the use of sauces, of which there are more than three thousand. Traditionally, sauces were named after the inventors or the locality and people to whom the French attributed these culinary traditions. This is how, for example, Tatar sauce (mayonnaise with cucumbers and capers), Russian sauce (mayonnaise with caviar) were invented. All famous sauces were created in the 17th-19th centuries. The authorship of many sauces belongs to representatives of the titled nobility. Such is the Bechamel sauce, the invention of which is attributed to the Marquis Louis de Bechamel, and the modest Soubise onion sauce to the Princess de Soubise.

There are two versions of the invention of the "Mayonnaise" sauce. Both of them are associated with the city of Mahon, the capital of the island of Minorca, only they refer to different historical events and outstanding people of that time.

According to one of them, the case was in 1757. The Duke de Richelieu, commander of the French garrison, conquered the city of Mahon, the capital of the Spanish island of Minorca, and then the British besieged the city. The French have practically no food left, except eggs and olive oil. Omelets and scrambled eggs were made from these products. You yourself understand that such a "variety" can get bored not only by an aristocrat who is accustomed to delicacies. And therefore Richelieu, by all means available to the duke, showed his displeasure to the cook. The resourceful chef rubbed the egg yolks with salt and sugar, added oil and spices to the mixture, and beat it all thoroughly.

According to another version, the invention of mayonnaise is associated with the name of the commander Louis of Crillons, the first Duke of Magon. In 1782, while in the Spanish service, the duke conquered the capital of the island of Minorca, the city of Mahon, from the British. After the battle, a feast was held, where for the first time food was served with a sauce made from the products for which the island was famous. Brought to Europe, this sauce was called Mahon, in French - mayonnaise, and became a classic dressing for cold snacks.

But the real noble mayonnaise cannot be compared with what is sold in the store. In order for you to have a reference point in your taste, you can prepare mayonnaise yourself. History has not conveyed to us the exact recipe, so we offer a generalized one from various sources:

olive oil - 150 ml (note: the oil must not be rancid)

egg yolk (carefully separated from the protein) - 1 pc

sugar - 1.5 teaspoons

salt - 1/3 teaspoon

lemon juice(freshly squeezed) -1/2 tablespoon, diluted with 2 tablespoons of water

Any noble sauce requires the mandatory presence of spices. Therefore, we recommend adding to taste: red pepper, tarragon, garlic, curry, mustard, lemon zest. All ingredients should be at room temperature. Beat the yolk with a mixer (the higher the speed, the better) with salt and sugar. With continuous whisking, slowly pour in the diluted lemon juice, then in small portions the oil (pour the next portion after completely stirring the previous one), add spices at the end.

Today mayonnaise has become one of the most widespread industrially produced sauces in the world, as it suits almost any dish, and in some, such as olivier, mimosa, herring under the "fur coat", it is simply not replaceable. The word mayonnaise from the name of a certain sauce has become a specific name for a whole range of products.

In Russia, the definition of mayonnaise is very wide, although our favorite classic "Provencal" is an example of "Russian traditions" - in countries such as Germany and Great Britain they could not even be called "mayonnaise" because of their low fat content. In the legislation of these countries, there are strict requirements aimed at ensuring that the consumer is not misled by the name. Depending on the fat content, the sauce can be called mayonnaise at 80% fat, salad mayonnaise at 70-50% and dressing at 49-20%. Also, the content of egg yolk is limited, which is approximately equivalent to its content in the classic Russian "Provence". Real mayonnaises are expensive and high in calories, so their consumption, even in developed countries, does not exceed 5%. The main share falls on salad mayonnaise - about 50%. We have a different classification and mayonnaise is divided into high-calorie with a mass fraction of fat over 55%, medium-calorie with a mass fraction of fat 55-40% and low-calorie - less than 40%.

The domestic consumer liked mayonnaise, they quickly got used to it, and certain consumption traditions developed. It successfully replaces the traditional sour cream and is currently the main universal sauce used in cooking.

Currently, a huge number of mayonnaises are presented on the windows of stores, of very different composition and quality, so that it became difficult for a non-specialist to figure out what he was actually buying. In connection with a decrease in payment demand, manufacturers, in pursuit of profit, began to switch to the production of mayonnaise with a low oil content, with previously unconventional thickening additives, and a decrease in the proportion of flavoring components - eggs, milk, sugar. All this led to a change in taste beyond recognition and discrediting of traditional names such as "Provencal", "Egg", since the product sold under these brands often only remotely resembles their taste and has little in common with the classic recipe.

In those cases when the manufacturer wants to use the familiar name, the authors "sew on the third ear", i.e. add any epithet to the name and get a phrase like "Provencal light", which frees them from adhering to the recipes stipulated by GOST and gives the broadest field for experimentation.

But it is not all that bad. Instead of confusion and falsification, many worthy brands of mayonnaise come again, with a new original taste worthy of the traditional "Provencal". More mayonnaise appears with flavors, fat content and composition, allowing the buyer to optimally balance his diet.

Be sure to read the label and pay attention to the manufacturer first. A reputable company is a guarantee of quality, and the names of mayonnaise often do not mean anything, and under the same name, you can find a very different product.

Pay attention to the composition of the products included in it. According to GOST, products are recorded in descending order of mass fraction. Eggs and milk - traditional taste only they can provide, their pale likeness is flavors. Stabilizing (stabilizer and starch) and preservative additives - no harm, as well as health benefits, although there is much debate about this. For medium and low-calorie mayonnaises, you cannot do without them, and if they are not indicated on the label, most likely the manufacturer is misleading you.

The date of production is very important for domestic (imported sterilized) mayonnaises, since an unsterilized natural product cannot be stored for a long time.

Storage conditions at the point of sale - mayonnaise should be stored at a temperature of 3 to 7 ° C. Freezing, like overheating mayonnaise, destroys its structure. Above the optimum temperature, the shelf life is sharply reduced. Buy only in trusted retail outlets, because if you were sold mayonnaise from a refrigerated display case, this does not mean that it was stored in the back room in the refrigerator.

Flavors, spices, dyes - the choice of taste, the essence does not change.

Weight in grams and milliliters is not the same thing. 250 ml is about 240 g!

Installation for the production of mayonnaise and mayonnaise creams

Food industry experts have developed about 40 recipes and names of mayonnaise, and a wide mass of buyers knows only a few of them, mainly produced earlier by state-owned fat factories. For entrepreneurs who want to diversify this market segment, our lines for the production of mayonnaise and mayonnaise creams are intended. It is possible to use them to make various types of mayonnaise, creams, sauces and spices, which by their nature are fat-in-water emulsions. The plant produces mayonnaise and creams using batch technology.

The technological sequence contains the following cycles:

water heating;
steaming mustard;
loading water, bulk components and oil into the mixer;
mixing of components;
loading acid solution;
homogenization of the emulsion and delivery of finished products to the tank.

Manufacturing technology:

the water used as a component of the mayonnaise is heated in the hot water tank. Mustard in the form of a paste is placed on pallets and steamed in a steaming tank. Loose components of mayonnaise (milk powder, salt, sugar, etc.) are sieved in the presence of lumps.

Heated water is supplied to the mixer-pasteurizer by means of a pump. Then, according to the recipe, bulk components and steamed mustard are loaded. The mixture is stirred for 30-35 minutes. In this case, the mixture is pasteurized at a temperature of 78-80 ° C.

After the mixture has cooled to 45 ° C, refined deodorized vegetable oil is fed into the mixer through a suitable pressure hose. After mixing the components for 15-20 minutes, a coarse mayonnaise emulsion is formed.

At the next stage, a 9% solution of acetic (or other) acid is introduced into the mixer. Vinegar gives the mayonnaise a sharp taste and aroma, prevents the development of bacterial flora (providing the required pH of the medium). Then homogenization (creating a homogeneous mixture) of the mayonnaise emulsion is performed.

Homogenization of fat-containing mixtures is necessary for crushing the fat globules, thus reducing their settling during storage (mayonnaise does not stratify). In the homogenizer, liquid is forced through a narrow slit at high speed. At the same time, due to the sharp pressure drop at the edge of the homogenizer slot, the fat particles are crushed and evenly distributed in the emulsion.

Different types of mayonnaise in fat content require different pressures when homogenizing the mixture. For high-fat mayonnaise, the optimal pressure may be 10 ... 15 kg / cm 2, and for low-fat (salad dressings) - 120 ... 130 kg / cm 2. The mayonnaise plant can be equipped with both a homogenizer with a pressure of 30 atm and a homogenizer with a pressure of 100 atm.

The finished product is pumped into the filling device tank or storage tank.

Part of the equipment:

Water heater tank
Mixer-pasteurizer
Homogenizer pump
Steamer tank
Control post
Mustard steaming trays
A set of additional equipment and accessories
Stirrer type frame
Mixer rotation speed, rpm 45
Pasteurization temperature, ° С 50 ... 95

Mayonnaise recipes

Mayonnaise is a creamy, multicomponent, highly dispersed emulsion of refined and deodorized vegetable oil in an aqueous medium, into which egg powder, milk powder, mustard, salt, sugar, vinegar, as well as a number of flavoring, aromatic and gelling additives and spices are preliminarily introduced.

In addition to the production of Provencal mayonnaise, this equipment can be used to produce different varieties mayonnaise with the addition of spices and fruit fillers: with horseradish, red pepper, coriander, tomato paste, lemon essence, various kinds fruit juices etc.

Mayonnaise is classified into three groups for its vegetable oil content:

1. High-calorie with an oil content of more than 55%.
2. Medium-calorie with oil content in the range of 40% - 55%
3. Low-calorie with less than 40% oil.

Typical representatives of the first group of mayonnaise with a high oil content are mayonnaise: "Provencal", "Milk" and "Diabetic" (see table. 1.)

Name raw materials	Mass fraction of components by formulation options,%
Rust oil refines. deodorizer	65,40	65,40	64,90	64,70	65,60	65,65	64,20	65,00	65,80	65,80	65,70	65,70	65,40	65,70	65,70	65,90
Egg powder Egg yolk (dry)	5,00	5,00	5,00	5,00	4,30	4,30	5,00	5,00	4,00	4,00	4,00	4,00	4,50	4,00	4,00	3,50
Powdered milk fat-free	1,60	2,00							1,70	2,10	2,00	2,40	1,60	2,00	2,40
Powdered milk whole			2,25	2,82
Dry cream					2,30	2,70	2,80									2,40
Concentrate whey protein (KSB)					2,30	2,70
Soy protein food													0,50
Mustard powder	0,75 -	0,25 -– 0,50	0,75	0,25 -– 0,50	0,75	0,25 -– 0,50	0,75	0,25 -– 0,75	0,75	0,25 - - 0,50	0,75	0,25 - - 0,50	0,75	0,75	0,25 - - 0,50	0,50 - - 0,75
Sodium bicarbonate	0,05	0,05	0,03	0,03	0,03	0,05	0,03	0,05	0,05	0,05	0,05	0,05	0,05	0,05	0,05	0,05
Sugar (sand)	1,50	1,50	1,50	1,50	1,50	1,50	1,50	1,50	1,60	1,60	1,50	1,50	1,50	1,50	1,50	1,50
Salt cookery	1,00 -– 1,30	1,10 -– 1,30	1,00 -– 1,30	1,10 -– 1,30	1,00 -– 1,30	1,10 -– 1,30	1,10 -– 1,30	1,10 -– 1,30	1,10 - - 1,30	1,10 - - 1,30	1,00 - - 1,30	1,10 - - 1,30	1,10 - - 1,30	1,00 - - 1,30	1,10 - - 1,30	1,10 - - 1,30
Acetic acid (80%)	0,55 - – 0,75	0,55 - – 0,75	0,55 - – 0,75	0,55 -– 0,75	0,55 -– 0,75	0,55 -– 0,75	0,55 - – 0,75	0,55 -– 0,75	0,60 - - 0,75	0,60 - - 0,75	0,55 - - 0,75	0,55 - - 0,75	0,55 - - 0,75	0,55 - - 0,75	0,55 - - 0,75	0,55 - - 0,75
Alginate sodium														0,05 - - 0,10	0,05 - - 0,10	0,05 - - 0,10
Starch potato carboxymethyl									0,20	0,20
Sodium- carboxymethyl- cellulose											0,10	0,10
Water	24,15- - 23,65	24,15- - 23,50	24,00 - - 23,50	24,03 - - 23,38	23,95 - - 23,45	23,90 - - 23,25	24,05 - - 23,65	24,23 - - 23,35	24,20 - - 23,85	24,30 - - 23,70	24,35 - - 23,70	24,35 - - 23,70	24,05 - - 23,65	24,40 - - 23,85	24,40 - - 23,70	24,45 - - 23,75

By the nature of the spices and additives contained, the following mayonnaises are distinguished:

Mayonnaise with tomato. Contains 30% tomato paste, which gives the mayonnaise a distinct tomato flavor. The presence of at least 45% vegetable oil and other spices makes tomato mayonnaise a valuable seasoning for all kinds of vegetable, fish and meat dishes.

Horseradish mayonnaise. Contains 18% refined and crushed horseradish and at least 52% vegetable oil. Has a sharper taste than other types of mayonnaise and is a special seasoning for aspic and other cold fish and meat dishes.

Mayonnaise "Yuzhny". Contains 13% Yuzhny sauce and at least 56% vegetable oil. Retains the taste of Provencal mayonnaise, enriched with spices in the Yuzhny sauce. Mayonnaise "Yuzhny" can be recommended for all vegetable, fish and meat dishes.

Salad mayonnaise. Contains 35% vegetable oil, has an oily, slightly pungent, slightly sour taste. Recommended for vegetables, fish and meat salads and vinaigrettes. It can also be used as a seasoning for fish and meat dishes.

Fortified mayonnaise. Contains 35% vegetable oil, enriched with vitamins C and B. It has a pleasant aroma and slightly sour taste. Contains corn oil, rich in vitamin E, with therapeutic anti-sclerotic properties. Recommended for seasoning meat, fish and vegetable dishes.

Lemon mayonnaise. Contains 35% vegetable oil. Availability in mayonnaise citric acid and lemon essential oil gives him the taste of lemon. It can be recommended as a seasoning for vegetable and meat dishes, fruit salads and in baby food.

The recipes for the listed mayonnaise are shown in Table 2.

table 2

Raw materials and supplies	Mayonnaise variety
	With tomato	With horseradish	"Yuzhny"	Salad	Mustard	Vitaminiz	Citric
Deodorized oil
Egg powder
Skimmed milk powder
Sugar (sand)
Edible table salt
Mustard powder
Acetic acid (80%)
Drinking soda
Tomato paste
Chopped horseradish
Southern sauce
Vitamin C
Vitamin B
Lemon acid
Lemon essence (4 cr.)
Water

Raw material characteristics

Vegetable oil ... The following vegetable oils are used for the production of mayonnaise: sunflower oil GOST 1129; soybean oil GOST 7825; corn oil GOST 8808; peanut oil GOST 7981; cottonseed oil GOST 1128; cottonseed salad oil TU 10-04-02-60-89; olive oil TU 10-04-11 / 13-87 .. The following vegetable oils are used for the production of mayonnaise: sunflower oil GOST 1129; soybean oil GOST 7825; corn oil GOST 8808; peanut oil GOST 7981; cottonseed oil GOST 1128; cottonseed salad oil TU 10-04-02-60-89; olive oil TU 10-04-11 / 13-87.

All vegetable oils must be fully refined, including deodorized, and meet the requirements of the standards for deodorized oils. For the production of mayonnaise, any of the listed oils must be processed no later than 1 month from the date of its refining.

Egg powder. GOST 2858. Product of light yellow color, homogeneous throughout the mass, must be easily sifted through a sieve 0.7 - 1.0 mm, must not have foreign taste and odor. If there are lumps, the latter should be easily crushed.

Instead of egg powder, the following can also be used in the production of mayonnaise:

• dry egg product, granulated TU 10.16 Ukrainian SSR 15-87;
• dry egg yolk OST 49-181-81;

Powdered milk. GOST 4495. Fine dry powder with a cream shade, which tastes like pasteurized milk. The presence of easily crumbling lumps is allowed.

The following types of dairy products are allowed:

• skimmed dry cow's milk spray GOST 4495;
• dry cream GOST 1349, premium;
• dry milk product "SMP" TU 49-934-82;
• whey, protein concentrate TU 49 939-82 or TU 49 979-85;
• dry buttermilk TU 49 247-74.

It is allowed to use other dairy products in accordance with regulatory and technical documents and in accordance with the technical description for a specific grade of mayonnaise, permitted by the state sanitary and epidemiological supervision authorities for the manufacture of food products.

Granulated sugar. GOST 21. Loose, dry to the touch, without foreign tastes and odors, white color with shine. Must completely dissolve in water. The sugar solution should be clear.

Table salt. GOST 13830, grade “Extra”. Pure white, odorless and free of pollution. Salt solution (5%) should not have any foreign taste. Sodium chloride content - 99.7%, water-insoluble components - no more than 0.03%, moisture - no more than 0.1%.

Mustard powder. OST 18-308-77, first grade. Intensely yellow in color, dry to the touch, bitter taste. When rubbed in water, it should have a pungent smell of allyl oil. The size of the powder particles should be no more than 0.3 mm.

Vinegar. The following types of vinegar are allowed:

• acetic acid GOST 61;
• acetic acid wood chemical food GOST 6968, premium;
• acetic acid GOST 6-09-4191-76;
• purified synthetic acetic acid, food grade TU 13-0279907-2-90;
• natural alcoholic vinegar OST Lithuanian SSR 422-79;
• apple cider vinegar TU 10-04-03-02-86.

The vinegar should be clear with no sediment. Light yellow coloration is allowed. The taste should be sour, strong and clean, typical of vinegar. Astringency is not allowed. Allowed for use in the production of mayonnaise and other acetic acids approved by the state sanitary and epidemiological supervision for the manufacture of food products.

Tomato paste. Homogeneous, without skin particles or seeds, orange-red color. Dry matter not less than 30%. Taste characteristic of tomato, without bitterness or off-flavor.

Horseradish. Freshly chopped, should not contain individual pieces. Should not have any foreign mechanical contamination. Before grinding, the roots of horseradish should be clean with as few depressions as possible, in which sand or earth can remain during cleaning. Before crushing, horseradish is steamed for 3-5 minutes to destroy the peroxidase enzyme.

Food grade citric acid. GOST 908, “Extra” and higher grades. Colorless or slightly yellowish crystals. Weak solutions have a pleasant sour taste.

Food soy protein. TU 10-04-02-31-88. The following types of protein products are allowed:

• food grade sodium alginate TU 15-544-83;
• soybean food base TU 10-04-02-37-88;
• food soy concentrate TU 10-04-02-22-87;
• food soy protein (PMP) TU 10-04-02-58-89.

Flavoring and stabilizing additives.

• dill essential oil TU 10.04.13.68-88. A solution with a mass fraction of 20% in deodorized vegetable oil;
• ground black pepper OST 18-279-76;
• cumin OST 18-37-71;
• orange essence OST 18-103-84;
• corn starch phosphate grade B TU 18 RSFSR 279-79;
• potato starch carboxymethyl TU 10 BSSR 111-86.

Drinking water. GOST 2874. Should not have bacterial contamination, suspended solids. It should be transparent, colorless, tasteless and odorless. Raw and pasteurized water is used for mayonnaise. Raw water is used if it has impeccable taste, color, odor and general hardness not higher than 2 mg-eq / l. Water used in the production of mayonnaise by organoleptic indicators must meet the requirements specified in table 3.

Table 3.

	The name of indicators	Norm	Test methods
	Smell at 20 ° C and when heated to 60 ° C, points, no more		GOST 33P-41
	Smack at 20 ° C, points, no more		GOST 33P-41
	Chromaticity on a platinum-cobalt scale, degrees, no more		GOST 33P-41
	Turbidity on a standard scale, mg / l, no more		GOST 33P-41

According to biological requirements, water must comply with the indicators and standards specified in table. 4. Table 4.

	The name of indicators	Norm	Test methods
	The total number of bacteria in 1 ml of undiluted water, no more		GOST 33P-41
	The number of bacteria of the E. coli group: Determined on a dense, elective medium, using the concentration of bacteria on membrane solutions in 1 liter of water (porridge index), no more When using liquid media for the accumulation of coli-titer, not less		GOST 33P-41 GOST 33P-41

Technological production process.

The technological process provides for the creation of optimal conditions that allow obtaining a homogeneous (close to homogeneous) and stable system of components that are practically insoluble in each other (oil - water). Factors such as the concentration of dry components, oil supply rate, conditions for swelling and pasteurization of dry components, and the intensity of mechanical action are also taken into account.

The production of mayonnaise consists of the following technological operations:

1. Preparation of the paste (emulsifying and structuring base);
2. Preparation of a coarse emulsion.
3. Preparation of a finely dispersed emulsion (homogenization).
4. Transportation of finished products to the warehouse.

Preparation of 10% acetic acid solution.

A 10% solution of acetic acid is prepared by dissolving the concentrated composition in the calculated amount of water. To catch drops and vapors of acetic acid, a trap is installed filled with a solution of soda ash. In the case of preparing mayonnaise with aromatic and flavoring additives, prepare the so-called. flavored vinegar by infusing various spices in a solution of acetic acid (bay leaves, black and allspice, nutmeg, cardamom, cinnamon, cloves, etc.).

Pre-ground spices are placed in a linen bag, which is placed in a container with acetic acid. Then the entire contents are brought to a temperature of 80 ° C, after which, without removing the bag, they are cooled. Then the spices are removed.

Preparation and dosing of bulk components.

The main bulk components: egg powder, dry skim milk, mustard powder, sugar, salt. Sifted through a sieve as needed. Sifting is necessary not only from a sanitary point of view, but also from a technological point of view, since the absence of lumps ensures the production of stable emulsions. So, the more dispersed the mustard powder, the higher its moisture capacity and emulsifying properties, the better the consistency of the mayonnaise and the higher its durability.

Then the components are hung up and fed to the loading area in the P3-RAM-0.35 mixers. Obviously, mixers R3-RAM-0.35 are supposed to have two units for their sequential use. Loading of bulk components is carried out manually.

Preparing the mayonnaise paste.

The mayonnaise paste is prepared alternately in two mixers as follows: In the first mixer, water is set, then milk powder, mustard powder, salt, granulated sugar and soda. Water is set in quantity, based on the provision of the ratio to mustard powder as 2.5 to 1, and to milk powder as 3 to 1 (for high-calorie mayonnaise). Loading of dry components is carried out when the mixer is running, then the heating is switched on (through the water jacket of the mixer) and the temperature of the mixture is brought to 90-95 ° C for better dissolution and pasteurization of the components. At this temperature, the milk-mustard paste is kept for 15-20 minutes, then cooled (with running cold water through the “jacket” of the mixer) to a temperature of 30-40 ° C, after which water and egg powder are fed into the milk-mustard paste in a ratio of 1.4 - 2 , 0 to 1 for high-calorie mayonnaise and 2.2 - 2.8 to 1 for medium- and low-calorie mayonnaise. The loading is carried out with the stirrer running; then the heating is switched on again and the temperature of the paste is brought to 60-65 ° C at which it is kept for 15 - 20 minutes, after which the paste is cooled to a temperature of 25-30 ° C, after which the paste is pumped into the second mixer. The readiness of the paste in the first mixer is determined visually by a sample taken during the mixing process. The sample taken on a wooden plate should be completely homogeneous, without visible lumps and should drain evenly from the plate.

Coarse emulsion preparation.

In the second mixer (P3-RAM-0.35), a “coarse” mayonnaise emulsion is prepared, for which it is necessary to ensure uniform mixing in all layers of the mixer, without stagnant zones.

After pumping the mayonnaise paste from the first mixer to the second, the calculated portion of vegetable oil with a temperature of 20-25 ° C is fed into the latter with constant stirring. In the first 7 to 10 minutes, oil is fed slowly at a rate of 10 to 12 liters per minute, then more quickly (25 l / min). It is allowed to start the oil supply 3 - 7 minutes before the end of the pumping of all mayonnaise paste from the first mixer to the second. Deodorized oil is fed to the mixer by a rotary pump B3-OPA-2 (if it is stored in tanks), or it is loaded manually (if it goes into production and is stored in canisters).

After adding vegetable oil, the prescription amount of 10% acetic acid solution is fed into the second mixer at a speed of 6 - 8 liters per minute. The supply of a 10% solution of acetic acid can be organized by gravity using a special measuring vessel with a scale. The supply of the acetic acid solution can be started simultaneously with the addition of the last portions of the vegetable oil.

After feeding a 10% solution of acetic acid, stirring is continued for 5-7 minutes. The sequence of adding vegetable oil and a 10% solution of acetic acid to the mayonnaise paste must be strictly observed. This is due to the fact that a one-time or non-sequential introduction of them can lead to stratification of the emulsion.

The coarse emulsion obtained in the second mixer must correspond to the established type of oil-in-water emulsion, be sufficiently strong and not delaminate before passing it through the homogenizer. Visually, such an emulsion has a homogeneous appearance and does not delaminate in a sample taken with slight stirring.

Homogenization of “coarse” mayonnaise emulsion.

An important stage in obtaining high-quality mayonnaise is the homogenization process carried out on a rotary-pulsation apparatus of the RPA type, which combines the principles of operation of a centrifugal pump, a dismembrator, a disintegrator and a colloid mill. By means of pulsating, shock and other hydrodynamic influences occurring in the RPA apparatus, the physical and mechanical properties of the mayonnaise emulsion change, which ensures that the mayonnaise of the required consistency is obtained.

The homogenization process is carried out in the mode of circulation of the mayonnaise emulsion according to the scheme: mixer - rotary-pulsating apparatus - mixer. The minimum circulation rate is 2 volumes / cycle.

It is recommended that the homogenization process be carried out in parallel with the mixing process of the components in the second mixer. It is allowed to carry out the homogenization process also when preparing mayonnaise paste in the first mixer, in parallel with the pasteurization process of the components (also in circulation mode), not excluding the homogenization of mayonnaise in the second mixer.

Packing and packaging of the finished product.

The finished mayonnaise, after the homogenization process, from the second mixer R3-OZU-0.35 is sent for packing in polypropylene cups, glass jars, or in plastic bags.