Equipment for the production of mayonnaise has specific requirements. Since the finished product does not pass completely heat treatment, the equipment on which it is manufactured (from the stage of preparation of raw materials to the process of packaging a 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 processing of internal surfaces up to 0.1 microns);
• have an automatic car wash unit.

Equipping the 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, to 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 recording 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 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 efficiently only with full automation.

In the production of mayonnaise with the main devices technological line are homogenizers (or dispersants), which must ensure the creation of homogeneous fine emulsions with a given particle size. The main working elements are high-speed mixers, high-pressure homogenizers, colloidal mills, rotor-stator systems, homogenizing devices, which are combined with evacuation of the product in a hermetically sealed apparatus and pumping the product "for return" at high speed, which allows achieving 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, multi-option, 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 the attachment of 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 go along 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 is also produced for small batches of experimental products in laboratories - 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 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, there is also a supply of live steam and inert gases 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 confitures, 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 obtaining dispersed and homogenized food products... For the production of mayonnaise emulsions, we offer DISHO (DISperses and HOmogenizes) plants 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 install 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 enterprises Catering, dairy and fat-and-oil 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.

Installation for preparation of mayonnaise firm "FLIGHT" is equipped with a homogenizer of the original design of Bulgarian production 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.

The 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, FlytM - 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 filling equipment is used, depending on the container used, the choice of which, in turn, is dictated by the specifics. technological process, 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. Traditional two-hundred-gram glass "mayonnaise" jars and glass jars with a "twist-off" lid are widely used. Mayonnaise is packed 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 aluminum foil lid 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.

The food industry has always been considered a fairly promising area for making a profit. But in order to start multiplying income by producing and selling finished products, it is important to choose a product that, regardless of the season, is in demand by the consumer. Here, without any doubt, we will include mayonnaise. It is the production of mayonnaise, according to many experts, today is one of the most promising industries. Having spent not so much money, you can organize your own stable business in the field of food production.

Our business valuation:

Initial investments - from 2,000,000 rubles.

Market saturation is medium.

The complexity of starting a business is 7/10.

Mayonnaise is a creamy mass prepared on the basis of plant and animal raw materials. This product is loved by consumers for its taste and is widely used for filling hot and cold dishes.
Despite the seeming complexity, it is not difficult to open a mini mayonnaise production plant in Russia. The main difficulties that will await every entrepreneur are associated with documenting the workshop and bringing it into proper form - sewerage and ventilation, preparation of warehouses, maintaining optimal storage conditions for raw materials and finished products. Let's not forget that it is a food enterprise that is planned, and therefore, here we will have to work on studying the regulatory documentation.

So, what does an entrepreneur have to foresee when setting up his own mayonnaise business?

Mayonnaise making technology and raw materials used

Technological scheme for the manufacture of mayonnaise

The raw materials used to obtain the finished product are generally available in any region of our country. But in order to minimize costs, it is better to conclude a contract for the wholesale supply of all the necessary components. And here it is worth choosing those suppliers who are located as close to the workshop as possible. What ingredients do you need to buy?

• Vegetable oil (soybean, sunflower, corn, olive).
• Milk (whole, dry),
• Sugar.
• Salt.
• Vinegar.
• Soda.
• Supplements.

The list of raw materials may vary, since each plant uses its own unique recipe, which is kept in the strictest confidence. Therefore, if an entrepreneur does not know how mayonnaise is made, he definitely needs to hire (even before the plant is launched) an experienced technologist who would calculate the ratio of all components. Success in the market will largely depend on this, because the tastier the product, the more demand it will be.

In general, the technology for the production of mayonnaise can be described as follows:

• Preparation for processing of individual components of the recipe.
• Getting a mayonnaise paste, when all raw materials are mixed until homogeneous.
• Heat treatment of the resulting paste at a temperature of 53-55 ° C.
• Cooling mayonnaise to a temperature of 15-20 ° C.
• Homogenization of the finished mayonnaise until a perfectly balanced mass is obtained.
• Packing and packaging of the product.

Methods for obtaining a finished product may vary, but literally every process that takes place in its manufacture must be strictly controlled. After all, even the slightest deviations from the specified parameters can lead to poor-quality products.

Equipment for the production of mayonnaise

Mayonnaise Production Line

The next thing an entrepreneur has to do is buy equipment for the production of mayonnaise. The suppliers offer a wide choice of technical equipment. The differences in the line arrangement are insignificant, therefore, when choosing devices, it is better to focus on some other parameters:

• price,
• power,
• degree of process automation,
• packing method.

A standard vacuum mayonnaise production line consists of the following pieces of equipment:

• Intermediate and final containers for mixing raw materials and storing the finished product before packaging.
• Pasteurizer.
• Homogenizer.
• Filling machine.

At the same time, as the automation and equipment of the line vary, the market price of equipment for the production of mayonnaise also changes. For example, a line with a capacity of up to 1000 kg / day can be purchased for 700,000 rubles. But more powerful equipment (up to 2,500 kg / day) will cost an entrepreneur no less than 1,500,000 rubles.

In addition to spending on basic equipment, the business plan should also include the cost of auxiliary units. In this case, chambers for storing certain types of raw materials and finished products will require large investments. This is at least another 200,000 rubles.

Sales options for the finished product

The shop for the production of mayonnaise will only start to make a profit when all the manufactured products are sold to customers. And it is precisely the search for interested consumers that will take up a lot of the entrepreneur's time at first.

There is little competition in this niche, but this does not make it easier to find buyers. Large hypermarket chains are reluctant to contact small businesses, and small wholesale sales will not generate large incomes.

It is important to offer customers a wide range of products. And the point here is not even the recipe of the mayonnaise itself, but in the container in which it will be packed. Plastic and glass jars, bags, disposable packaging - everything can be used.

To attract customers, it must be not only thought out technology system production of mayonnaise, but also a clearly planned marketing campaign. This means that we will add to the start-up costs the services of a designer for the development of attractive packaging. As for advertising, small and medium-sized businesses are unlikely to spend money on large-scale advertising campaigns, since the attention of buyers here is riveted on the products of large brands - there is no point in competing with them so far. At first, we focus on the quality of the finished product.

How profitable is the mayonnaise making business?

It has already been proven in practice that the production of mayonnaise can bring consistently high profits. And if you find the required start-up capital for organizing a business, then the workshop will be able to recoup all costs in a short time. And the investments, even by minimal estimates, will be impressive - at least 2,000,000 rubles. And the main items of expenditure will fall on the commissioning of the purchased line, preparation for the operation of the premises and the development of packaging design.

Investments will be slightly higher if the plant provides its own vehicle fleet for the delivery of finished products to customers.

The mayonnaise production line purchased for the available amount will produce no more than 1000 kg of the finished product per day. At the same time, the wholesale price for budget brand mayonnaise fluctuates around 50 rubles / kg. And knowing the average output volumes, you can determine the monthly sales revenue - it will be at least 900,000 rubles. Taking into account variable expenses (rent, transport, taxes, communications, salary for employees), the net profit will be ≈100,000 rubles.

Lots of people like sauces topped off with food. The inclusion of this ingredient in the recipe can significantly improve the taste of cooked food. For this reason, sauces are very popular. The most popular of these is mayonnaise.

It is worth noting that the production of this product, beloved by Russians, is quite profitable. It is possible to organize such a business with a small initial financial investment by purchasing easy-to-use technological equipment.

Production methods

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

There are hot and cold ways production of mayonnaise. The second variant of the technological process is currently used extremely rarely. The fact is that it is impossible to achieve a high quality of the product with cold production.

As for the hot technology, simultaneously with the homogenization of the ingredients, the entire mixture is heated to a certain temperature. At the same time, the taste of the product is more pronounced. That is why the equipment for the production of mayonnaise is currently mostly equipped with heating elements.

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

Application of bulk components

The technology for the production of mayonnaise at its first stage implies the process of dosing and preparation of the ingredients specified in the recipe. Bulk components such as mustard and egg powder, salt and granulated sugar, and powdered milk, are sieved on special vibrating screens. These devices have cells, the size of which does not exceed 3 mm.

In addition, they are equipped with special magnets that trap ferro-impurities. Lumps are removed during the preparation of dry ingredients. This allows you to increase the moisture content and dispersion of the products during swelling. Also, dry components increase surface-active and emulsifying characteristics.

Making vinegar

The mayonnaise production line makes it possible to make the next component of the popular sauce. This is flavored vinegar. This ingredient allows you to avoid the undesirable specific pungent taste of the finished product. Flavored counterpart acetic acid prepared by insisting.

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

Acetic salt solution

Equipment for the production of mayonnaise includes units that prepare another component of everyone's favorite sauce. It is an acetic-salt solution. For this, a special container is used. A saline solution is fed into it, which is dissolved with water.

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

Mustard production

The prepared mayonnaise should not have an excessive bitter taste. That is why the mustard powder included in the recipe must be previously placed in an enameled or stainless steel tank. The dry ingredient is diluted with water, the temperature of which should be at least eighty degrees. After a day, the liquid is poured off, getting ready-made mustard.

List of required equipment

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

The container in which the vegetable oil is collected;

An intermediate tank where the oil is collected before mixing;

Hydrodynamic machine, where the mixture is ground and heat treated;

A pump supplying the line with vegetable oil;

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

A screw pump feeding mayonnaise for packaging;

A filling machine that puts the product directly into a container.

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

The work of the machine takes place without human intervention. It is much more efficient. However, it should be borne in mind that the cost of an automatic machine, as a rule, is three to four times more expensive than a semiautomatic device.

Mayonnaise has been and remains a popular Russian product. The production of mayonnaise is profitable, requires little investment and simple processing equipment. They say that a Moscow company started production using a Vyatka washing machine as equipment. Three years later, six conveyor lines produced several tens of tons of finished products per day.

According to the most rough estimates, in Moscow alone there are about a hundred "mayonnaise" enterprises, both medium and very small, between which there is a rather tough competition. All equipment for the production of mayonnaise is almost identical to each other and differs only in some insignificant details. There is equipment from Western manufacturers on the market, but it is several times more expensive than domestic equipment (for example, for a German one you will have to pay about $ 150 thousand). A similar installation by the Moscow company "Prospekt" costs only about $ 7 thousand. With a simple reconfiguration and the use of other ingredients, it is capable produce ketchup, toothpaste, shampoo, etc.

Mayonnaise - what is it eaten with

Mayonnaise is a creamy fine dispersion oil-in-water emulsion made from refined deodorized oils with the addition of emulsifiers and flavorings. The finished product must comply with OST 10-77-87 “Mayonnaise. Technical conditions ". Mayonnaise should be absolutely uniform in structure and consistency.

Mayonnaise is obtained by mixing various components and subsequent homogenization, in which the particles vegetable oil dissolve in water particles, splitting down to 5 microns (this is not possible with normal mixing).

The shelf life of mayonnaise is only 1 month, but with the use of special additives-emulsifiers, it can be increased to 2 months.

Now, almost any equipment sold allows you to get high-quality mayonnaise, but here it is important to find the exact ratio: mayonnaise must be of high quality, and at the same time cheap - then it will be in high demand.

The main ingredient in mayonnaise is refined and deodorized vegetable oil. It is he who accounts for the main cost of the product.

In Russia, the greatest demand is for thick mayonnaise with a fat content of 67% (this includes the traditionally popular Provencal).

Pasteurization

Now the main demand is for complexes of medium and high productivity - from 6 to 14 tons per day. Many entrepreneurs prefer not to take risks and buy equipment of small capacity - from 2 to 5 tons. Then, by purchasing new tanks, you can significantly increase the capacity.

One of the main conditions when choosing equipment is the presence of a pasteurizer for egg powder and milk powder, since pasteurization is simply necessary for all products of animal origin. It occurs at a temperature of 60 ° С for egg powder and 85-9СГС for milk at. different modes to, therefore, separately from each other (in turn in the same bath).

Technology

There are two technologies for the production of mayonnaise: hot and cold. Cold water is now used extremely rarely, since it produces a product of insufficient quality. With hot technology, simultaneously with homogenization, the entire mixture is also heated to a certain temperature. With hot technology, mayonnaise has a more pronounced taste, and now almost all "mayonnaise" equipment is equipped with heating elements. If you have a steam source at your enterprise (it is much more economical than electricity), it makes sense to order the installation of a special spiral that heats the tank from steam.

The production of mayonnaise begins with the preparation and dosing of the recipe components. The required amount of water is also dosed into the main mixing tank.

This is followed by the preparation of mustard-milk paste. To do this, water, milk powder, mustard powder, granulated sugar and soda are mixed in one tank (mixer). After loading the ingredients, the mixture stirring system is turned on. Next, the resulting mixture is pasteurized (at 80 C ") and then pumped into the main homogenizer tank.

If there is an additional tank, egg paste is prepared: for this, water and egg powder are mixed, heating the mixture to 65 ° C. Then the already cooled paste is pumped into the main mixer-homogenizer.

By the same principle, a solution of acetic acid is prepared in a small mixer according to the recipe. Then a saline solution is added to the resulting vinegar solution and is also thoroughly mixed, entering the main homogenizer tank.

Then the initial "rough" emulsion is prepared - for this, the resulting mixture is mixed. Visually, this emulsion should have a uniform appearance and not delaminate with slight stirring.

But this is not yet ready-made mayonnaise. The coarse emulsion must go through the homogenization process, which is carried out by repeatedly pumping the mixture through the device of the same name. As a result, a ready-made mayonnaise is obtained.

Then a sample is taken from the batch: it must be completely homogeneous, without visible stratification, lumps, and have a viscosity characteristic of mayonnaise, as well as color, taste and smell.

Then the mayonnaise must be pumped into a special container for finished products, freeing the main tank for a new cycle.

Equipment

The enterprise "Prospect" itself makes equipment for the production of mayonnaise of various capacities, which determines its cost (in turn, the performance depends on the volume of the tanks). Only three people are required to service the kit. For example, the LPU-M31-150 model with a minimum capacity of 6,600 kg of products per day costs about 180 thousand rubles, LPU-M32-300 (with a capacity of 8,800 kg / day) - 215 thousand rubles, and a line with a capacity of 15,200 kg / day costs more than 260 thousand rubles. One of the main advantages of such equipment is that in addition to mayonnaise, it can produce all other pasty products: mustard, yogurt, ketchup and various sauces (with minimal revision).

One of the new directions of Prospect's activity is the preparation and opening of a full complex of mayonnaise production (and not only) on a turnkey basis: from a business plan and renovation of premises to certification of finished products.

The Dialog Plus trading company also offers a complete mini-plant for the production of mayonnaise with a capacity of 3 tons / day, occupying an area of ​​only 30 m 2, and costing about 127 thousand rubles, and a complex with a capacity of one ton more, which can m 2 - more than 200 thousand rubles.

Also, the company "Tveragroprodmash" sells complexes for the production of mayonnaise for 222 thousand rubles. 50% prepayment, but only one small capacity - 3 tons per day.

The Belarusian company Vaem offers quite expensive complexes worth $ 25,000, and the same company supplies both stabilizers and preservatives.

An unconventional module is offered by the Krasnoarmeisk Research Institute of Mechanization: it is designed for the preparation of low-calorie mayonnaise based on whey. Its productivity is 250 kg / hour, and its cost is very high - 600-700 thousand rubles! (Produced only to order on a prepaid basis.) True, it is possible to partially replace expensive vegetable oil with whey, which reduces the cost of finished products by 1.5 times.

The Akmalko company also sells universal installations for the production of mayonnaise and all kinds of pasty products (ketchup, mustard, jams) of its own production using German components with a capacity of $ 57 thousand. Its feature is the ability to produce mayonnaise long-term storage(up to 6 months) without adding preservatives, due to the presence of a device for flow pasteurization of the finished mixture and the next immediately sealed and hot (at a temperature of 95 ° C) packaging.

Packaging is the key to success

In order to sell the resulting product and provide it with a steady demand, it must be packaged in a high-quality and beautiful way - after all, it is by the packaging that buyers usually judge the product.

In total, the three most common types of packaging are used for pasty products: these are plastic bags, glass jars and plastic cups. Of course, the use of sachets will have a minimal effect on the cost of the finished product, followed by plastic cups, and the most expensive packaging is glass jars with a twist-off lid. The choice of packaging also largely depends on the positioning of your product - for example, if you present it in the highest price category and rely on wealthy customers (for sale in expensive supermarkets), then it makes sense to prefer the "twist-off" glass jars, which are the most convenient (their can be used several times after opening, covering product residues and ensuring the longest shelf life). Many provincial entrepreneurs, according to representatives of companies selling equipment for packaging, prefer regular cans with roll-up lids - these lids are almost three times cheaper than twist-off.

Packaging equipment is also divided into automatic and semi-automatic. The latter means that you have to assign a dedicated worker to install each individual cup, then seal and remove it. The machine, on the other hand, works practically without human intervention, which is much more productive. As a rule, automatic machines are 3-4 times more expensive than semi-automatic machines.

However, not all types of packaging have inexpensive semiautomatic devices. For example, many manufacturers traditionally pack mayonnaise in packages of 150-250 g, but only expensive machines are produced for packages. Semi-automatic bag filling and sealing machines are available only for milk, but they are not suitable for mayonnaise. The fact is that they are capable of soldering only ordinary polyethylene, and it has the peculiarity of allowing fat to pass through. For mayonnaise, a special laminated polypropylene film (lavsan-polypropylene) is used.

For example, the Dialog Plus company offers a milk-filling machine AO-111 with a capacity of 22-25 bags per minute, occupying an area of ​​2 m 2. The machine performs the following operations: bactericidal processing of the film, forming bags from the film, applying the date on the film, filling the bags with the product, placing the bags in boxes in a given quantity and removing the already filled boxes. And all this will cost you 148 thousand rubles, plus you will have to pay an additional 3.5 thousand rubles for an additional attachment for mayonnaise.

A vertical filling machine AV 50F (Zh) manufactured by the Moscow company "Flight M" with a dosage range from 0.1 to 1.0 liters and a capacity of up to 35 packs per minute will cost $ 9 thousand.

In the same company, you can also purchase a Chinese automatic machine of the DXDL-50 series for filling and packaging products with a capacity of 40-60 packages per minute, however, with a maximum capacity of one package of only up to 150 ml. In it, an electronic counter will display the number of packages produced, and a photoelectric sensor will control the uniformity of the ribbon supply and the identity of the sealed bags. The price of such a unit is almost $ 11 thousand. Recently, imported mayonnaise in "standing" packages appeared on sale, which are more convenient for consumers than simple ones.

The BESTROM company offers machines for packing pasty and liquid products weighing from 50 g to 50 kg with a capacity of up to 100 bags per minute, costing from $ 65 to 85 thousand, assembled from American components. Moreover, they are capable of forming bags in the form of a pillow or with a flat bottom, and are also equipped with any type of weight and volumetric dispensers.

Of course, imported equipment is much more expensive than domestic equipment, but it is also much more reliable. True, in the event of a breakdown, the repair of an imported unit will cost much more than a domestic one. For example, a device for dosing and sealing cups of the American company PHOENIX costs from $ 23 thousand (40 doses per minute) to $ 180 thousand (250 doses).

If your volume of production is small or your financial capabilities do not yet allow, then you can purchase a semiautomatic device for packing mayonnaise into plastic cups. True, for this you need two units: one for filling and dosing, and the other directly for capping. And between them is a worker.

For example, a semi-automatic dispenser for viscous products of the UD-2 brand produced by Prombiofit costs 25 thousand rubles. In it, doses are dispensed automatically once every 6 seconds through two channels at once (i.e. two cups are filled at the same time), and the container is set to the filling position and removed by the operator manually, which, of course, is quite laborious. The product enters the unit through flexible hoses by suction from a stainless steel supply tank. The unit is supplied with dosing cylinders of one of the following standard sizes: 50, 120, 250 and 500 ml, and it is possible to smoothly adjust the dose volume in the range from 20 to 100% of the dosing cylinder volume.

An interesting development was carried out in the Prospekt company, replacing the internal ball, traditional for the filling tap, with another system (the former has a significant drawback - periodic freezing due to the ingress of more solid particles).

Then the cups must be installed in a special machine for airtight welding with aluminum foil lids. For example, a USS-2 unit with a maximum capacity of up to 600 units / hour costs about 20 thousand rubles. In the process of operation, the already filled cup is installed by the operator into the cell of the welding stand, covered with a foil lid, is brought to the welding position by turning the transport rotor and is hermetically welded. Moreover, the installation can be equipped with a device for applying the date of packaging to the container.

Novgorod Machine Building Plant offers a similar, but more advanced, semi-automatic device, model POLUR-250, for cups of two standard sizes: 75 and 95 mm in diameter. In it, the timer sets the heating time for the aluminum foil when sealing, and the thermostat maintains the set temperature. Equipment manufactured by the Israeli company PACK LINE Ltd. much more expensive than domestic. For example, a semi-automatic machine for manual capping of plastic cups ROV-IS costs from $ 1.8 to $ 3.5 thousand, and a fully automatic machine - from $ 15 thousand.

But, of course, the most productive are still automatic machines, besides they will save on wages for the employee: for this operation he simply will not be required. For example, the Ryazan plant "Elf-4M" offers an IPKS-051 automatic machine with a capacity of 1100 cups per hour and filling doses of 200 and 250 g. This unit costs almost $ 7 thousand.

The Ukrainian OJSC "Complex" also offers a filling and sealing machine of the MK-OFS model. It is possible to install one or two additional dispensers designed to add other components to the main product, including those with soft fillers, which can give new taste qualities to the main product. Also, the device allows, due to the presence of a special mechanism, to install a transparent polymer lid on a sealed cup.

The Belarusian company VAEM, which produces equipment jointly and from components of the Polish company POLTRAK, enjoys a well-deserved reputation in the market. For example, a PA-2000 automatic machine for packing semi-liquid products into plastic cups with a capacity from 1600 to 2000 packs / hour, with a dosage from O to 500 ml and a cost of $ 14.6 thousand.

Seamer for glass jars with a capacity of 15 cans / min. UZSB-RE models can be purchased for 28 thousand rubles, a semiautomatic vacuum packaging machine using the "twist-off" system with a capacity of 500 cans / hour costs about 22_ thousand. rub. (and, for example, a semiautomatic semiautomatic device from Prodmashservice with a capacity of 800 cans / hour can be purchased for $ 3500).

American company PJI Inc. in Russia offers a device for induction sealing of the necks of cans with metal foil. This kind

packaging retains the freshness and aroma of products and allows you to significantly extend its shelf life by preventing the ingress of oxygen and moisture into the package. In addition, sealing with foil eliminates the leakage of products under the lid, even with external pressure on the can. To perform this operation, a lid is screwed onto the neck of the can using a conventional capping machine. In this case, the covers must have a special insert with a foil layer. After sealing, the cans, moving along the conveyor, pass under the induction head. The electromagnetic field heats up the foil, and it is welded to the edge of the neck. The cost of such a manual device is about $ 7 thousand, and an automatic machine is $ 18.5 thousand.

Recently, the Moscow-based company Prombiofit, known for its development of lines for filling and packaging liquid and pasty products, has created and released a trial batch of vacuum capping machines. The installation turned out to be light, compact and can be freely placed on a regular table. The vacuum chamber allows, using easily replaceable inserts, to seal the most varied can sizes: with a diameter of 50 to 110 mm and a height of 70 to 170 cm.The operator, sitting at the table, manually sets the can filled with product into the vacuum chamber and covers it with a lid. Then, with the help of sequential rotation of the vertical and horizontal levers of the installation and pressing the pedal of the air compressor, the working cavity of the chamber is evacuated and the can is sealed at the same time. The degree of vacuum in the can is controlled during the sealing process using a vacuum gauge. Then the operator takes out the finished can from the chamber and installs the next one - the whole cycle of one operation takes no more than 6-7 seconds. The productivity of this machine is about 500 cans / hour, and it costs 10 times cheaper than a similar unit made in Germany. The plant produced by "Prombiofit" is designed to work "in tandem" with a 1.5 kW compressor and with an outlet air pressure of 2 to 5.5 atm. A UU-5 semi-automatic vacuum capping device for cans with a twist-off screw cap costs 28.8 thousand rubles without a compressor and from 34.8 thousand rubles. with compressor. In addition to this device, you can purchase a counter of sealed cans for 4.5 thousand rubles.

In such jars, products can be stored for up to 6 months without losing their taste and nutritional qualities, so there is no need to be afraid of the "delay" of products in the warehouse. Canned packaging also has one more quality that has a positive effect on consumer demand: the product is clearly visible to the buyer.

Also, the Bulgarian company INDEX-6 Ltd in Moscow offers a device for automatic sealing and vacuuming by means of steam of a wide range of factory glass jars twist-off lids with a capacity of up to 12 thousand pieces per hour. For example, the IND-Close 14 model with a capacity of 1,000 units. an hour costs $ 6 thousand, and 12 thousand pieces / hour is already twice as expensive. The company also supplies the IND-Dose 42 volumetric dosing machine. It is modular in design and can be supplied with two, three, four, five or six filling heads. Accordingly, the productivity of the unit increases almost proportionally.

Mayonnaise and other pasty products can also be poured and packaged in pure-pack or tetra-rex laminated cardboard boxes. The semi-automatic installation KRU-2 requires two operators to operate, and it is capable of filling and welding up to 400 bags per hour. There is a similar line for almost 77.5 thousand rubles.

After the end of the packaging cycle, the label is attached and marked with the expiration date. For example, a semi-automatic labeling machine with a capacity of up to 1500 pcs / hour can be purchased for $ 47 thousand, and with a capacity of 600 pcs. / hour - for 30 thousand rubles.

And the last stage is the group packing of glass jars or plastic cups. For this, injection molding machines are used. They are sold by many firms, and they are relatively inexpensive: from 17 thousand rubles. (domestic, with a capacity of only 70 packs / hour) and up to several thousand dollars for Western counterparts.

Of course, all packaging equipment is not included in standard kits, and therefore you have to buy it separately or through the same company that sells equipment for the production of mayonnaise (which is most optimal - after all, everything is too individual, depends on the productivity and products planned for release).

Dmitry TIKHOMIROV

Mayonnaise is of the noblest origin. French cuisine indissolubly associated 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. famous sauces were created in the 17th-19th centuries. The authorship of many sauces belongs to representatives of the titled nobility. Such is the Béchamel sauce, the invention of which is attributed to the Marquis Louis de Béchamel, and the humble onion sauce"Soubise" to 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 no food but eggs and olive oil, practically not left. Omelets and scrambled eggs were made from these products. You yourself understand that such "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 Maonian, in French - mayonnaise, and became classic dressing for cold appetizers.

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 are divided into high-calorie with a mass fraction of fat more than 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 - the traditional taste can only be provided by them, their pale likeness is flavorings. 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. On them it is possible to make various types of mayonnaise, creams, sauces and seasonings, which by their nature are emulsions of fat in water. The plant produces mayonnaises 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 pungent 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
Stirrer 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 makes it possible to produce various varieties of mayonnaise with the addition of spices and fruit fillings: with horseradish, red pepper, coriander, tomato paste, lemon essence, various kinds of 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 chopped 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.

Yuzhny mayonnaise. 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 vegetable, fish and meat salads and vinaigrette. 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, which has medicinal 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. Can be recommended as a seasoning for vegetables 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, should be easily sifted through a sieve 0.7 - 1.0 mm, should 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 type 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 an impeccable taste, color, odor and total hardness not exceeding 2 mg-eq / l. The organoleptic characteristics of the water used in the production of mayonnaise 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 Escherichia 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 dry milk 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 pulsating, shock and other hydrodynamic effects occurring in the RPA apparatus, the physical and mechanical properties mayonnaise emulsion, which provides the desired consistency of mayonnaise.

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.