mayonnaise technology. What equipment is needed for the production of mayonnaise? Mayonnaise continuous production lines

Batch production of mayonnaise

Mayonnaise is a multicomponent 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 from components insoluble in each other even with intensive mixing (emulsification), as well as homogenization. This can only be achieved under certain conditions of preparation and adherence to a strict sequence of technological operations that ensure the directed interaction of all components.

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

Preparation of individual components of the prescription composition;

Paste preparation (emulsifying and structuring base);

Preparation of a "rough" emulsion;

Preparation of a finely dispersed emulsion (homogenization);

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

Preparation of bulk components

Bulk components: milk powder, granulated sugar, egg powder, mustard powder, salt are sieved on vibrating screens with magnets for trapping ferroimpurities, with a cell cross section of 1-3 mm. The absence of lumps in dry components increases their moisture capacity and dispersion during swelling, surface-active properties and emulsifying ability.

Preparing the vinegar solution

The clear brine from the brine is fed into a vessel for preparing the acetic brine, in which it is diluted with water to 13-15% concentration for high-fat mayonnaises and to 9-10% concentration for low-calorie mayonnaises. 80% acetic acid is supplied there with a vacuum pump in the amount specified in the recipe. The concentration of acetic acid in the solution should be no more than 7-9% for high-calorie mayonnaises and no more than 5-6% for mayonnaises 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 rotation speed of 60-80 rpm, stirring the acetic salt solution until the salt is completely dissolved.

Making Flavored Vinegar

80% acetic acid gives mayonnaise an undesirable specific sour taste (despite the fact that the acidity of mayonnaise lies 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 lowered into a vessel with a pre-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.

mustard preparation

To avoid the appearance of an excessively bitter taste in mayonnaise, mustard powder is pre-prepared as follows. 24 hours before the production of mayonnaise, the required amount of mustard powder is placed in an enameled or stainless steel tank. Mustard powder is poured with water at 80-100 ° C in a ratio of 1: 2, mixed well until a homogeneous consistency and the top layer of mustard is smoothed. A layer of water with a temperature of 100 ° C is carefully poured onto a flat surface of mustard, 4-6 cm high. 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 -

Mayonnaise preparation

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 that provide the necessary stability of the emulsion are egg powder and milk powder.

The preparation of mayonnaise paste consists of the process of dissolving the dry ingredients and mixing them until a homogeneous state.

The dry ingredients are dissolved in two mixers: milk powder with mustard powder is dissolved in one mixer (if the mustard powder was not steamed beforehand), and egg powder is dissolved in the other. It is possible to dissolve milk powder, mustard and egg powder in one mixer, although this is undesirable, since they have different temperature regimes for processing. When preparing pasta in one mixer, the productivity of the batch mayonnaise line decreases, as the time for preparing the pasta increases.

Preparation of mayonnaise paste in two mixers

If the mustard powder is not pre-prepared in a separate container, then the process of dissolving the components begins with 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 mixed until a homogeneous mass is obtained. Next, water is fed into the mustard mass 35-40 ° C, powdered milk, baking soda, granulated sugar.The ratio of powdered milk and water for high-calorie mayonnaise is 1: 3, for mayonnaise with low fat content - 1: 4. After loading, turn on the mixer and let 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 maintained at this temperature for 10-25 minutes, after which the mixture is cooled to 40-45 ° C.

In the case of pre-parking mustard mustard powder - mustard - mass is fed into the mixer along with the rest of the dry ingredients before pasteurization (the amount of water added with tanned mustard is taken into account).

The second small mixer is fed with egg powder and 40-45°C bodu in a ratio of 1: (1.4-2) for high-calorie mayonnaises and in a ratio of 1: (2.5-2.8) for low-fat mayonnaises. The stirrer is turned on, steam is added 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 min 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 mixes: n - gels by pumping the solution.

Preparation of mayonnaise paste in one mixer

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

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

After dissolution and pasteurization, the mixture is cooled o 40-45e "Civ the mixer is supplied with 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. .

The mayonnaise paste prepared in this way is cooled to 30-40 CC 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, attention should be paid to ensure that the mustard is thoroughly ground and does not contain unswollen particles of lumps. The same applies to milk and egg powder. Pzh their mixing should be achieved careful mutual picnpej - division. This is achieved by mixing them in a mixer with a steam jacket equipped with an intensive dispersion mixer.

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

In case of insufficient solubility of egg powder or yolk and milk powder, the dissolution time should be extended. In addition, to improve the solubility of milk powder, you can vary the amount of soda. The low pH of the paste can cause the casein to coagulate, which then causes the mayonnaise to separate. When using egg powder with high dispersion and swellability, mayonnaise with increased viscosity is obtained. It is recommended to use this powder in a mixture with the usual one in a ratio of 1:1.

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

Preparing a coarse mayonnaise emulsion

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

The paste prepared in the small mixers is transferred to the large mixer. After pumping the mayonnaise paste into a large mixer, vegetable oil (20-25 ° C) is fed into it with continuous stirring in the amount required by the recipe. In the first 7-10 minutes, the oil is fed slowly (4-6 l/min), then more rapidly (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 uniform distribution, the oil is fed into the mixer through a special atomizer (shower), which is a perforated coil.

After 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 added (spices that are insoluble in the emulsion, flavoring and aromatic additives should be added after the emulsion has been homogenized). After supplying 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 their one-time or high-speed introduction can lead to the production of a double-type 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 strong enough and not delaminate before passing through the homogenizer. Visually, such an emulsion has a uniform appearance and does not delaminate in the selected sample with weak stirring.

Mayonnaise emulsion homogenization

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

When the emulsion is fed into the homogenizer, the optimum pressure is set to ensure that the mayonnaise of the required consistency is obtained. Until the desired pressure is established, the mayonnaise after the homogenizer returns to the large mixer. For high-fat mayonnaises, the optimal pressure lies in the range of 0.90-1.1 MPa (9-11 kgf / cm2), for low-fat mayonnaises 15.0-17.5 MPa (150-175 kgf / cm2), for mayonnaise "Amateur" 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 the destruction (separation) of the emulsion or phase reversal, long settling (without mixing) can also lead to segregation.

After establishing the desired pressure, the finished mayonnaise from the homogenizer is sent to a container for ready-made mayonnaise.

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

During the operation of piston homogenizers, it is necessary to exclude the possibility of air leakage 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 flavorings

In the manufacture of mayonnaises with spices and flavorings, tomato paste, Southern sauce or red sweet pepper puree are introduced into a large mixer before supplying a solution of vinegar and salt. If the tomato paste is very thick, it can be thinned with a solution of vinegar and salt. Spices (in their natural form) are added to mayonnaise in ground form after sieving on a sieve with a mesh size of 0.1 cm into containers for ready-made mayonnaise equipped with mixers, then stirring is continued until they are evenly distributed throughout the 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 sieves 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 9 mixer. From the 17 water tank, hot water enters the 9 mixer, then mustard powder is loaded from the 2 hopper through the 7 scales into the mixer. After the mustard powder has been brewed, warm water is supplied to the mixer 9 from the water tank 17, milk powder is loaded from the hopper 3 through the scales, and granulated sugar is loaded from the hopper 4.

The whole mass is thoroughly mixed, heated to 90-95 ° C and maintained at this temperature until the powdered milk 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 supplied from the mixer 8 with an emulsifier pump 5 and thoroughly mixed until a homogeneous mayonnaise paste is formed. The prepared paste is cooled to 30-40 ° C and pumped with an emulsifier pump 5 into a large mixer 10, where vegetable oil is supplied from the container 14 through the tank 28, mounted on the scales 13.

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

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

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

Technical specifications

TOC \o "1-3" \h \z Capacity, m3 .............................. ............................... 1.5

Agitator speed, rpm . 70-80

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

Agitator type .................................................. .........Ramiaya

A large mixer designed for preparing mayonnaise emulsion is similar in design to a small mixer.

Technical characteristics of the mixer

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

Agitator type .................................................. .. . frame

Number of agitators, pcs ............................................... .......... 2

Agitator rotation frequency, rpm. . 60-80

Electric motor power, kW... 3

Dimensions, mm: ,

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

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

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

The 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

Speed, 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;

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

(f Conditional designation

vegetable oil; a

Electric motor power А063-6, kW

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

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

//-- homogenizer; 12 - containers for ready-made mayonnaise; 13 - scales for oil; 14- containers for oil; /5 - salt solution; 16 - trap - "17 - tank for volts; 18 tank for vinegar-salt solution; 19 - scales for vinegar-salt solution; 20 - boiler for preparing warm water; - laying machine; 25 - bank washing machine; container with concentrated acetic acid "V -leak-

Weights for weighing the acetic 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 Motor power A063-6, kW

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

Frequency of rotation of a cranked shaft, rpm

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

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

Dimensions, mm:

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

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

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

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

The automatic filler is used to pack mayonnaise into jars. Filling is done by volume.

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

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

Removal of filled cans to the conveyor line for seaming. All components of the machine are mounted on the frame.

Technical characteristics of the filler

Productivity, banks/min. . . 60-80

Number of filling cylinders, pcs. 6

Filling control limit, ml. . 180-500

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

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

Productivity, baikn/mip. . . 60-80

Electric motor power, kW ... 2.3

The labeling machine is designed for sticking labels on mayonnaise jars. This is a carousel machine. The automatic machine is adapted for installation in the line filling and filling unit. The machine consists of the following main units: a frame and a drive, a carousel with a working table, loading and unloading mechanisms, a glue bath with a spreading roller, feed mechanisms, labeling and stamping labels, a carriage with a label cassette. The drive of the machine is carried out from an individual electric motor through a V-belt transmission.

Technical characteristics of the device

Productivity, banks/min., up to. 60

Electric motor power, kW. . one

The glass jar washing machine (fig. 76) of the AMA-1 brand is a brushless chain washing machine that works automatically. The machine consists of a body

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

Zuemogo carcass, bathtubs and casing. Inside the machine are chains with special can carriers attached to them.

In this article:

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

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

Organizational nuances of the food business

1. Decide on the organizational form of management

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

For the preparation of periodic reporting, it would be more cost-effective to use the services of an outsourcing company.

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

2. We study regulations

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

• GOST R 53590-2009 Mayonnaises and mayonnaise sauces. General specifications.
• GOST R 52141-2003 Ketchups. General specifications.
• GOST 9159-71 Mustard seeds.

3. Product certification

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

The above-mentioned GOSTs or personally developed specifications (technical specifications) can act as regulatory documents.

Mayonnaise production technology

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

With the help of a pump, the eggs are pumped through a hose into a cooling receiving tank.

The second main ingredient is soybean oil. All tanks or other containers that come from the supplier must be hermetically sealed and not opened until arrival at the mini-factory. The pump also pumps oil to storage tanks. Next comes the weighing of additional ingredients - spices, which must be added according to the company's secret recipe.

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

Meanwhile, raw eggs are poured into a large refrigerated tank. Thus, 3 containers are placed in the production workshop: with pasta, eggs and soybean oil. Further, in a certain ratio (according to the company's recipe), all components are sent to a mixing tank.

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

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

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

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

Ketchup production technology

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

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

A sugar-salt solution is placed in it.

digester

In a giant cauldron, the mixture is thoroughly mixed. Steam is supplied between the inner and outer walls of the unit, which does not allow the mass to burn. The agitators are constantly spinning and make the ketchup homogeneous, i.e. mixture is homogenized.

The device of the digester

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

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

Containers can be made in a nearby workshop. PVC granules are taken as a basis, which many plastic products consist of. Next, a dye is added - so the container will acquire a noticeable red color.

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

Hot red "sausages" are crimped on both sides by the walls of the molds.

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

It is noteworthy that a standard bottle for ketchup weighs only 42 grams, it goes straight from the conveyor to bottling, barely cooling down.

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

Technology for the production of mustard from seeds

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

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

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

rotary mixer

The contents are poured into a stainless steel mill.

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

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

We organize a mini-factory - a list of mandatory steps

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

• selection of premises that meet sanitary and hygienic requirements;
• acquisition of a technological line;
• search for an experienced technologist.

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

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

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

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

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

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

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

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

Economic feasibility of the production process

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

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

Total monthly payroll - 70,000 rubles.

Monthly fixed costs will consist of the following sections:

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

Total: 96,000 rubles.

mayonnaise business plan

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

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

Total: 28.55 rubles.

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

Full cost \u003d Monthly output x Cost of 1 kg of mayonnaise \u003d 1540 kg x 28.55 rubles. = 43,967.00 rubles.

Gross income \u003d Monthly output x Retail value of 1 kg of mayonnaise \u003d 1540 kg x 150 rubles. = 231,000 rubles.

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

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

Ketchup production business plan

Calculate the cost of 1 kilogram of ketchup (2 jars of 500 grams). The initial ingredients for the production of the finished product are:

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

Total: 45.50 rubles.

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

Full cost \u003d Monthly output x Cost of 1 kg of ketchup \u003d 1650 kg x 45.50 rubles. = 75,075.00 rubles.

Gross income \u003d Monthly output x Retail value of 1 kg of ketchup \u003d 1650 kg x 130 rubles. = 214,500 rubles.

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

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

Mustard production business plan

Calculate the cost of 1 kilogram of mustard.

The following ingredients are required for its production:

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

Total: 51.10 rubles.

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

Full cost = Monthly output x Cost of 1 kg of mustard = 500 kg x 51.10 rubles. = 25,550 rubles.

Gross income \u003d Monthly output x Retail value of 1 kg of mustard \u003d 500 kg x 150 rubles. = 75,000 rubles.

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

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

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

Sales of pasty products

The main forces of the sales manager must be directed to the conclusion of contracts with wholesalers, grocery stores and supermarkets. At first, in order to stimulate strategic partners, it is advisable to use a few simple tricks:

• providing a discount from each additional box of goods that was purchased for a certain period of time; - to each intermediary for a free product (for example, 10 pieces of packages), subject to the purchase of a certain number of boxes;
• discount on products subject to self-delivery;
• cash incentives for dealers (sellers) for their efforts to promote pasty products.

To increase the recognition of products, the manufacturer can make souvenirs with the company logo (pens, calendars, notepads, etc.) and hand them over to the public for free. It would also be advisable to hold a campaign to sell packaging at a discounted price. Stimulation of short-term growth in sales is possible in the case of sale at a reduced cost of 2-3 related products (mayonnaise, ketchup and mustard).

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

History of mayonnaise.

Mayonnaise production line.

Mayonnaise production.

History of mayonnaise.

Home of mayonnaise? How did mayonnaise come about? Who Invented Mayonnaise?
In the Mediterranean there is the island of Menorca. Its capital is an ancient town called Mahon (Mayon). In the 18th century, incessant wars were fought over this fertile place among European rulers. In connection with those events, the history of mayonnaise sauce began.
In the 18th century, in 1757, the city of Mahon was captured by the French under the leadership of the Duke de Richelieu (the same relative of Duke Armand Jean du Plessis Richelieu, who lived from 1585 to 1642. In The Three Musketeers, he besieged the fallen Huguenot fortress of La- Rochelle, in the siege of which, in fact, the royal musketeer Rene Descartes participated). After a while, the city was captured by the British. Like his ancestors, Richelieu was going to hold on even under the condition of starvation.

Menorca island.

Naturally, food in the captured city remained tense - there were only olive oil and turkey eggs. Is it possible to cook a lot from this set? The garrison cooks themselves were tired of such a poor “menu” and during the capture of the city they tried to diversify the menu as much as they could, experimented, invented, but there were too few products available.

When the French garrison and Richelieu himself were no longer able to look at all kinds of scrambled eggs and omelettes, the cook, who showed unusual soldier's ingenuity, found perhaps the most beautiful solution that glorified him forever. Unfortunately, this decision did not save his name, as in a hard struggle he simply forgot to name the sauce of his name).

This quick-witted cook diligently began to grind a few egg yolks with salt and sugar, then gradually poured in small portions and constantly stirred until completely homogeneous, then mixed with olive oil, added a little lemon juice to this mixture and thoroughly mixed it all again. (This is a classic recipe for regular mayonnaise.)

After all, even the most ordinary soldier's bread with this additive becomes very tasty!

Richelieu and all his soldiers were delighted. Under such conditions, victory over the enemies was guaranteed! This is how this delicious sauce appeared, later named after the captured city - "maon sauce" or "mayonnaise".

The new seasoning achieved worldwide fame, which was called "Provencal sauce from Mahon", or in French - "mayonnaise". And to this day, a common and more industrially produced sauce is mayonnaise. In our country, the annual consumption of mayonnaise is about three kilograms per person, and this figure is constantly increasing every year. In addition, the business plan for making mayonnaise is now one of the most profitable.
It is also important that in the manufacture of mayonnaise fairly easy-to-use equipment is used, and the method of preparing sauces is quite simple. All these factors make it possible to regulate the manufacturing process of products in a short time, which is equal to 1 - 2 months.

Mayonnaise production technology.

Mayonnaise is a creamy mass, which is made from refined and deodorized vegetable oils, adding protein and various flavoring components and spices. This product is prepared for human consumption, mainly for cold dishes as a condiment.

Raw material.
To obtain a mayonnaise product, sunflower oil is mainly used in our country, soybean, corn, peanut, as well as cottonseed, olive and sesame oils are used abroad.

In the manufacture of mayonnaise, various combinations of emulsifiers are often used. This makes it possible to obtain a highly stable composition with a lower consumption of emulsifiers.

In our country, egg powder is used as the basis of the emulsifying component. The yolk of the egg forms the basis of this emulsion and affects its endurance, density, color, as well as the taste of the finished product.

The emulsifying effect of egg yolk or powder is determined by lecithin, as well as other phospholipids, membrane-forming lipoproteins: lipovitellin, lipovitellinin and free proteins, phosphitin, livetin.

Apply such varieties of egg products as egg powder, egg granular product, dry egg yolk. In mayonnaise, the content of egg products ranges from 2 to 6%, depending on the recipe.

Traditionally used in the production of mayonnaise are emulsifiers such as skimmed milk, dry milk product SMP, whey protein concentrate, dry buttermilk.

Recently, vegetable proteins are more often used, more often soy. In our country, the use of edible soy protein, edible soy base, edible soy concentrate is allowed.

The main problem is the regulation of the emulsion. In the manufacture of mayonnaise, hydrocolloids are used, the regulating effect of which is determined by the formation of a three-dimensional network structure with an increase in viscosity. Also, hydrocolloids interact with emulsifiers. By chemical nature, hydrocolloids are the same polysaccharides.

In the manufacture of mayonnaise from natural stabilizers, starch and modified starch remain the most widely used. Phosphate grade B corn starch is used in our country. Thanks to the esterification of starch with phosphates, a food thickener was obtained, the characteristic feature of which is the ability to dissolve in water or milk at room temperature.

In order to obtain low-calorie mayonnaise in our country, maltin is used, which is produced from potato starch due to partial enzymatic hydrolysis with the following thermal treatment of the hydrolyzate. Maltin is an easily digestible carbohydrate that dissolves when heated to 75-80C.

After it has cooled, a gel of different consistency is formed, depending on what concentration.

In Germany, in the manufacture of sauces, "coolie" is used - this is a thickener that is obtained from starch and flour of guar grains.

Thanks to the acid hydrolysis method, starch solutions are extracted, which differ in low viscosity. In the production of potato starch with monochloroacetic acid, carboxymethyl starch is extracted, which has a high regulatory effect in combination with milk powder and egg powder.

The most promising mayonnaise thickener and regulator is sodium alginate, which is derived from alginic acids. Alginic acid is found in brown algae and is excreted by certain types of bacteria. The salt of alginic acid dissolves in cold water to form a viscous solution. Alginates are of interest for therapeutic and prophylactic feeding, due to the fact that it contributes to the removal of heavy metal ions and radioactive isotopes from our body.

At the moment, abroad, xanthan, which is a biopolysaccharide, is used to regulate most salad dressings.

Relatively intelligible polysaccharides are gums and mucus, widely used in the manufacture of emulsion products. The more famous ones are gum arabic and gum tragacanth. According to the chemical structure, gums are classified as heteropolysaccharides, which consist of a certain amount of monosaccharides, among which there is either one or more uronic acids.
Mustard powder is a flavor additive, and the proteins contained in this powder equip emulsification and structural formation.

Water, salt, sugar, mustard powder, dill essential oil, ground black pepper, cumin, extracts of spicy and aromatic materials are added to mayonnaise. If sweet mayonnaise is produced, then flavoring extracts are added to it according to the technical description.
In order to increase the strength of low-calorie emulsion products to the development of unpleasant microbiological processes while saving, preservatives are introduced into their structure, mainly benzoic salt and sorbic acid.

Mayonnaise is prepared in two ways: batch and continuous.

Manufacturing by periodic technology includes the following steps:
- preparation of individual elements of the structure;
- preparation of mayonnaise paste - dissolving dry elements and mixing them to a homogeneous position. The dry elements are dissolved in two mixing devices: in the first - milk powder with mustard powder, and in the second - egg powder. Water with a temperature of 90-100 ° C, a mixture of mustard with powdered milk are delivered to the first.
- exposure at a temperature of 90-95 °C for about 20-25 minutes with subsequent cooling to 40-45 °C. The composition of the egg powder is heated to 60-65 °C, held for 20-25 minutes for pasteurization, and then cooled to 30-40 °C. Next, the compositions from these two mixing devices are combined. The density of solids for high-calorie mayonnaise should be at least 37-38%, and for the rest - 32-34%;
- preparation of a coarse composition of mayonnaise sauce - is carried out in large mixers, which are equipped with metal mechanisms with a low speed. Pasta, vegetable oil, a solution of salt and vinegar or other acids are added to a large mixer; homogenization of liquid in piston homogenizers with a certain pressure to avoid stratification of the prepared liquid.

Uninterrupted production of mayonnaise products on a self-acting line using votator-type heat exchangers consists in the following actions: prescription dosing of all elements in the preparatory group; mixing of the elements and formation of the mayonnaise composition in the interval of 15 minutes, deaeration of the mayonnaise composition; thermal processing in the first cylinders of the votator with a temperature of about 53-55°C; cooling the composition in the second cylinder of the votator to a temperature of about 15-20°C; homogenization of the mayonnaise composition in a homogenizer; packaging and sealing of cans; product packaging.

Mayonnaise production line.
. Capacity - picking up vegetable oil.
. Intermediate capacity - collection of vegetable oil before merging.
. Hydrodynamic device - fusion, grinding, temperature processing.
. Pump - supply of vegetable oil.
. Intermediate container - designed to preserve the product before packaging.
Screw pump - designed to supply the product to the packaging. Packing machine - product packaging.

The structure of demand for mayonnaise is changeable: Russian citizens more often reject cheap varieties and prefer expensive and better quality varieties. Secondly, the results of the campaign in the fight against excessive consumption of foods that contain cholesterol, which is why clients try to balance their diet, have an impact. Mayonnaise imperceptibly drives sour cream out of the consumption basket. Also, most mayonnaise manufacturers tend to diversify and introduce sauces into the range.

Our manufacturers account for the largest volume of the mayonnaise sauce market - 92% in volume and 90% in value, and this ratio remains constant.

In the Russian Federation, about 38 organizations are engaged in the mayonnaise business. The five large industries - Unilever, NMGK, Solnechnye Produkty, Essen Production AG, Efko - account for 62.7% of the market in value terms and 63.8% in real terms.

The production of mayonnaise has not yet been fully studied, since there are many technologies for preparing the mixture as the basis for a future product. Everything has been going on since ancient times, when extraordinary methods were used to create this "delicacy" to add spice and unusualness to food.

The history of the production of mayonnaise and sauces

Food historians offer four possible theories for the origin of mayonnaise. The most popular story dates from June 28, 1756, when the French captured Port Mayon on the Spanish island of Menorca. In preparation for the victory celebration, the duke's chef was forced to replace the olive oil with cream in the sauce. Unexpectedly pleased with the result, the chef dubbed the final sauce "mayonnaise" in honor of the place of victory.

Carame, French writer and author of Cuisinier Parisien: Trarte des Entries Froids, believed that the word was derived from the French verb "manier", which means to mix. Another food expert, Prosper Montagnier, has argued that the origin lies in the old French word "moyeu", which means egg yolk.

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

Regardless of its origin, mayonnaise quickly gained popularity, so its appearance in all European cuisine is not surprising. In the early 1900s, a German immigrant named Richard Hellmann discovered the delicacy in New York. The salads his wife made with were especially popular. When customers started asking if they could buy the mayonnaise itself, Hellmans decided to make it in bulk and sell it by weight in small wooden oil-measuring jars.

Eventually the Hellmans began sorting their mayonnaise into glass jars. In 1913 they built their first mayonnaise factory. California company Best Foods Inc. also enjoyed the success of its version of mayonnaise. In 1932, she acquired the Hellman brand and continued to produce both versions of the sauce.

The production of which was focused on the manufacture of salad dressings, was developed by the National Dairy Products Company in 1933 and presented at the World's Fair in Chicago. The product eventually became known as the Kraft Miracle Whip Salad Dressing.

Mayonnaise production technology - features of each culture

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

Creating an emulsion:

1. To maintain the correct degree of emulsification, a continuous mixing system is used. An emulsion (technically known as a colloid) occurs when mixing two liquids, in this case vinegar and oil, causes one of them to form small droplets that disperse throughout the other liquid.
2. The mixture of vinegar and oil is continuously moved through a series of pumps that mix the ingredients. These devices have a cavity or set of cavities with rotating impellers. The adjustable pumping action causes the cavities to fill and empty. The impellers move the mixed fluid from one cavity to another.

It turns out a single consistency, which is so important for this type of product. Next comes the addition of various components, which is a way to diversify the base mixture.

Adding Ingredients:

1. The pre-measured ingredients are fed into the pipelines through holes in the sides of the pumps or from the pressure bushings.
2. Mayonnaise moves through the pumping system to the bottling station. Pre-sterilized jars move along a conveyor belt and pre-measured quantities of mayonnaise are placed in them. They are sealed with metal screw clamps. However, they are not vacuum sealed.

Such mayonnaise is used by almost 80% of enterprises and factories. The standard scheme did not change for a long time until varieties of sauces with additives appeared.

Raw materials for making sauces and mayonnaises

Mayonnaise is an oil-in-water emulsion that can contain up to 80% oil. Thickeners such as starches are used in low-fat products to replace the natural viscosity and bulk effect of oil, as well as to improve mouthfeel and ensure the formation of a stable emulsion.

You can add spices and other natural seasonings, with the exception of turmeric and saffron. They gave mayonnaise a yellow tint, which consumers did not like, so the mayonnaise production line with them in the composition did not last long.

Vinegar is also used, which is distilled off from distilled alcohol, lemon or lime juice (diluted with water). Soybean oil is the most common type of ingredient used in the production of mayonnaise.

Large-scale production is usually carried out using a specially designed installation. This process is often semi-automated and under vacuum. For research and development, pilot small-scale productions are used, typical of the “ready-to-eat” market: sandwich makers, food service companies and other small companies. For them, mayonnaise must be produced in a way that will increase their sales, but at the same time experiment with the components of the composition.

Some typical recipes would be:

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

Problem:

The "continuous phase ingredients" make up only a small fraction of the total composition, but they perform vital functions. The mixing equipment must be able to disperse and moisten them properly with a relatively low liquid volume. If egg and other emulsifiers are not properly dispersed and hydrated, the emulsion may break during the oil addition step.

The hydration of stabilizers and thickeners is one of the most complex mixing operations. It may be necessary to stir the ingredients for a long time to fully hydrate.

Due to the high proportion of oil in the recipe, the emulsion may break if it is not added to the continuous phase correctly. This is very difficult to control when the process is done manually.

The oil phase droplets must be reduced to a minimum size to maximize the surface area of ​​the oil in the continuous mayonnaise production step to ensure a stable emulsion consistency. This is impossible to obtain without special equipment.

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

Equipment for making mayonnaise

To achieve the desired result, you need to choose the optimal equipment for making mayonnaise. The devices work according to the following principle:

1. Water is recirculated from the vessel through the system using a specially designed In-Line Mixer. or liquid) is added to the vessel and rapidly wetted and dispersed in the high velocity liquid flow.
2. The remaining ingredients in the aqueous phase are then added to the vessel. Recirculation continues until the ingredients are completely dispersed and hydrated.
3. The oil supply valve opens and oil flows from the hopper into the water phase at a controlled rate. The ingredients of the water and oil phases enter directly into the working head of the mixer, where they are subjected to intensive mixing. This process finely distributes the oil in the aqueous phase, immediately forming an emulsion. Vinegar or lemon juice is added with the last portion of oil.
4. Recirculation of the product continues to provide a consistent consistency as the viscosity increases. After a short period, the process ends and the finished product is unloaded.

The method is ideal for small batches intended for immediate use. Aeration is minimized and the system virtually eliminates operator error. Raw material yield is maximized as thickeners are fully hydrated and other ingredients are properly dispersed. Mass production of mayonnaise is somewhat different. The process is suitable for making more than 1000 kg of products per hour:

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

Equipment for the production of mayonnaise in mass quantities should be installed according to accepted quality standards, so that the products can then be checked and tested.

Quality control of finished products

All raw materials are checked for freshness when they enter the processing plant. Stored materials are also checked periodically. Mayonnaise samples are taken and taste tested during the manufacturing process.

Variety of sauces based on mayonnaise

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

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

Russian factories - how do they differ?

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

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

Sometimes, according to recipes, salt is added to enhance the flavor. This amount is about 1/16 teaspoon of salt per tablespoon of mayonnaise. Preservatives such as calcium disodium salt are added to increase shelf life. But the production of mayonnaise in Noginsk was relatively recently formed, but the plant already has many awards for the honorary title of "worthy sample."

mayonnaise hollandaise sauce recipe

You will need a blender to mix the products.

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

Some mayonnaise enterprises have introduced such a recipe into the basis of some sauces. You can diversify them with the help of spices and a combination of ingredients in the ratio of proportions.

Recipe "Tartar"

There are recipes for "Tartar" based on mayonnaise. It is done simply, given that the base is already ready:

1. Mayonnaise - 300 g.
2. Sour cream - 200 g.
3. Pickled cucumber - 1 piece.

Mix the products until a uniform consistency is formed. Add garlic and herbs to taste. Sprinkle with lemon juice before serving.

Benefit

The mayonnaise business is a fairly lucrative business. Africans created the basis for such enrichment: they produce the sauce in simple jars without inscriptions and brands, using cheap recipes and affordable raw materials. Thanks to such factors, many businessmen can secure goods and create their own sales business. If we talk about setting up production, then we should start with small batches, because for continuous sales of 1000 kg, we need to find sales points. Egg-free mayonnaise is gaining popularity - vegetarians and people who cannot tolerate this product will be the main consumers.

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

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

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

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

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

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

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

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

Equipment types

Depending on the different production schemes, equipment for the production of mayonnaise is divided into high-performance continuous or semi-continuous lines, in which the 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 tank, the performance of which varies widely. limits (from 30 to 6000 l/h).

Mayonnaise continuous production lines

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

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

The disadvantages of continuous lines are:

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

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

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

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

Batch equipment

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

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

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

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

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

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

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

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

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

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

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 also have a disintegrator as the main working body.

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

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

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

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

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

Domestic equipment

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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