Mayonnaise recipe in production. Mayonnaise production: a profitable food business

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

There are two versions of the invention of 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 prominent people of that time.

According to one of them, it 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 city was besieged by the British. The French had practically no food left except for eggs and olive oil. Omelettes and scrambled eggs were prepared from these products. You yourself understand that such a “variety” can bother not only an aristocrat accustomed to delicacies. And therefore, Richelieu, by all means available to the duke, showed his displeasure to the cook. The resourceful cook ground the egg yolks with salt and sugar, added oil and spices to the resulting mixture, and beat it all thoroughly.

According to another version, the invention of mayonnaise is associated with the name of the commander Louis of Crillon, the first Duke of Magona. In 1782, being in the Spanish service, the duke won 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 dishes were served with a sauce made from products for which the island was famous. Brought to Europe, this sauce was called Mahon, in French - mayonnaise, and became a classic dressing for cold appetizers.

But real noble mayonnaise cannot be compared with what is sold in the store. In order for you to have a starting point in taste, you can make your own mayonnaise. 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 should not be rancid)

egg yolk (carefully separated from 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 presence of spices. Therefore, we recommend adding to taste: red pepper, tarragon, garlic, curry, mustard, lemon zest. All ingredients must be at room temperature. Beat the yolk with a mixer (the higher the speed, the better) with salt and sugar. With continuous beating, slowly pour in the diluted lemon juice, then in small portions the oil (pour the next portion after the previous one is completely mixed), at the end add the spices.

To date, mayonnaise has become one of the most common industrially produced sauces in the world, as it is suitable for almost any dish, and in some, such as Olivier, mimosa, herring under a "fur coat", we simply cannot replace it. The word mayonnaise from the name of a certain sauce has become a generic name for a whole range of products.

In Russia, the definition of mayonnaise is very broad, although our beloved classic "Provencal" - an example of "Russian traditions" - in countries such as Germany and the UK could not be called "mayonnaise" at all due to its low fat content. In the legislation of these states, 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 sauce at 49-20%. The content of egg yolk is also limited, which is approximately equivalent to its content in the classic Russian "Provencal". 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 mayonnaises are divided into high-calorie with a fat mass fraction of more than 55%, medium-calorie with a fat mass fraction of 55-40% and low-calorie - less than 40%.

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

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

In cases where the manufacturer wants to use a familiar name, the authors "sew on the third ear", i.e. they add some epithet to the name and get a phrase like “Light Provence”, which frees them from following the recipes stipulated by GOST and gives the widest field for experimentation.

But it is not all that bad. In place of confusion and falsification, many worthy brands of mayonnaise come again, with a new original taste worthy of the traditional "Provencal". There are more mayonnaises with flavors, fat content and composition that allow 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 mayonnaise names often do not mean anything, and, under the same name, you can find a variety of products.

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 - only they can provide a traditional taste, their pale likeness - flavorings. Stabilizing (stabilizer and starch) and preservative additives - no harm, as well as health benefits, although there is a lot of debate about this. For medium and low-calorie mayonnaise, they are indispensable, and if they are not indicated on the label, most likely the manufacturer is misleading you.

The production date 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, as well as excessive heating of mayonnaise, destroys its structure. At temperatures above the optimum, the shelf life is drastically reduced. Buy only at 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 approximately 240 g!

Plant for the production of mayonnaise and mayonnaise creams

Specialists in the food industry have developed about 40 recipes and names of mayonnaise, and only a few of them are known to the wide mass of buyers, 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 produce various types of mayonnaise, creams, sauces and seasonings, which by their nature are emulsions of fat in water. The plant produces mayonnaises and creams according to batch technology.

The technological sequence contains the following cycles:

water heating;
mustard steaming;
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 mayonnaise is heated in a water heater tank. Mustard in the form of a paste is placed on pallets and steamed in a steaming tank. Loose components of mayonnaise (powdered milk, 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 down to 45 °C, vegetable refined deodorized oil is fed into the mixer through the appropriate 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 mayonnaise a sharp taste and aroma, prevents the development of bacterial flora (providing the required pH of the medium). Then homogenization (creation of a homogeneous mixture) of the mayonnaise emulsion is performed.

Homogenization of fat-containing mixtures is necessary for the crushing of fat globules, while their settling during storage is reduced (mayonnaise does not delaminate). In the homogenizer, liquid is passed at high speed through a narrow gap. At the same time, due to a sharp pressure drop at the edge of the homogenizer slot, 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 can be 10 ... 15 kg / sq. cm, and for low-fat (salad seasonings) - 120 ... 130 kg / sq. cm. The mayonnaise machine can be equipped with both a 30 atm pressure homogenizer and a 100 atm pressure homogenizer.

Finished products are pumped into the filling device tank or into the storage tank by means of a pump.

Part of the equipment:

Tank water heater
Mixer-pasteurizer
Pump with homogenizers
Steamer tank
Control post
Trays for steaming mustard
A set of additional equipment and accessories
Agitator type frame
Agitator rotation speed, rpm 45
Pasteurization temperature, °С 50...95

Mayonnaise recipes

Mayonnaise is a creamy, multi-component, 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 first introduced.

In addition to the production of mayonnaise "Provencal", on this equipment, it is possible to produce various varieties of mayonnaise with the addition of spices and fruit fillers: with horseradish, red pepper, coriander, tomato paste, lemon essence, various kinds of fruit juices, etc.

Mayonnaise is classified according to the content of vegetable oil into three groups:

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 oil content less than 40%.

Characteristic representatives of the first group of mayonnaises with a high oil content are mayonnaises: “Provencal”, “Milk” and “Diabetic” (see Table 1.)

By the nature of the contained spices and additives, 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.

Mayonnaise with horseradish. Contains 18% peeled and chopped horseradish and at least 52% vegetable oil. It has a spicier taste than other types of mayonnaise and is a special seasoning for aspic and other cold fish and meat dishes.

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

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

Mayonnaise fortified. 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 healing anti-sclerotic properties. Recommended for seasoning meat, fish and vegetable dishes.

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

The recipes of the listed mayonnaises are shown in Table 2.

table 2

Characteristics of the feedstock

Vegetable oil . For the production of mayonnaises, the following vegetable oils are used: sunflower oil GOST 1129; soybean oil GOST 7825; corn oil GOST 8808; peanut butter 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 butter 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 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. The product is light yellow in color, uniform throughout the mass, should be easily sieved through a sieve of 0.7 - 1.0 mm, should not have an extraneous taste and smell. In the presence of lumps, the latter should be easily crushed.

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

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

Dry milk. GOST 4495. Fine dry powder with a creamy tint, having the taste of pasteurized milk. The presence of easily crumbling lumps is allowed.

The following types of dairy products are allowed:

• dry skimmed cow's milk 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 also allowed to use other dairy products in accordance with regulatory and technical documents and in accordance with the technical description for a particular variety 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, color is white with a sheen. Should be completely soluble in water. The sugar solution should be clear.

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

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

Vinegar. The following types of vinegar are allowed:

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

Vinegar should be clear without sediment. Slight yellow staining is allowed. The taste should be sour, strong and clean, characteristic of vinegar. Warmth is not allowed. Allowed for use in the production of mayonnaise and other acetic acids permitted by the state sanitary and epidemiological supervision for the manufacture of food products.

Tomato paste. Homogeneous, without particles of skin or seeds, orange-red in color. Dry matter not less than 30%. The taste is characteristic of a tomato, without bitterness or foreign aftertaste.

Horseradish. Freshly ground, should not contain individual pieces. Should not have foreign mechanical impurities. Before grinding, horseradish roots should be clean with as few recesses as possible, in which sand or earth may remain during cleaning. Before grinding, horseradish is steamed for 3-5 minutes to destroy the peroxidase enzyme.

Acid citric food food. GOST 908, grades "Extra" and higher. Colorless or slightly yellowish crystals. Weak solutions have a pleasant sour taste.

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

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

Flavoring and stabilizing additives.

• dill essential oil TU 10.04.13.68-88. 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;
• phosphate corn starch grade B TU 18 RSFSR 279-79;
• carboxymethyl potato starch TU 10 BSSR 111-86.

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

Table 3

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

Technological process of production.

The technological process provides for the creation of optimal conditions that make it possible to obtain a homogeneous (close to homogeneous) and stable system from components that are practically insoluble in each other (oil - water). Factors such as the concentration of dry components, oil feed 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. Paste preparation (emulsifying and structuring base);
2. Preparing a coarse emulsion.
3. Preparation of a fine emulsion (homogenization).
4. Transportation of finished products to the warehouse.

Preparation of a 10% solution of acetic acid.

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

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 80ºС, after which, without removing the bag, they are cooled. Next, the spices are removed.

Preparation and dosing of bulk components.

The main bulk components: egg powder, skimmed milk powder, mustard powder, sugar, salt. As needed, sift through a sieve. Screening is necessary not only from a sanitary point of view, but also from a technological one, since the absence of lumps ensures stable emulsions. So, the more dispersed the mustard powder, the higher its moisture capacity and emulsifying properties, the better the consistency of mayonnaise and the higher its resistance.

Further, the components are hung and enter the loading area in the R3-OZU-0.35 mixers. It is obvious that mixers P3-RAM-0.35 are supposed to have two units for their sequential use. Bulk components are loaded manually.

Mayonnaise preparation.

Mayonnaise paste is prepared alternately in two mixers as follows: In the first mixer, water is added, then milk powder, mustard powder, salt, granulated sugar and soda. Water is set in quantity, based on ensuring the ratio to mustard powder as 2.5 to 1, and to dry milk as 3 to 1 (for high-calorie mayonnaise). The dry components are loaded with the mixer running, then heating is turned on (through the water “jacket” of the mixer) and the temperature of the mixture is brought to 90-95ºС 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. Loading is carried out with the mixer running; then turn on the heating again and bring the temperature of the paste to 60-65ºС, at which it is kept for 15-20 minutes, after which the paste is cooled to a temperature of 25-30ºС, after which the paste is pumped into the second mixer. The readiness of the paste in the first mixer is determined visually by the sample taken during the mixing process. The sample taken on a wooden plate must be completely homogeneous, without visible lumps and flow evenly from the plate.

Preparation of a "coarse" emulsion.

In the second mixer (P3-OZU-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 20-25ºС is fed into the latter with constant stirring. In the first 7 - 10 minutes, the oil is fed slowly at a rate of 10 - 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 pumping all the mayonnaise paste from the first mixer to the second one. The deodorized oil is fed into the mixer by a B3-OPA-2 rotary pump (if it is stored in tanks), or loaded manually (if it enters production and is stored in canisters).

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

After applying 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 input of them can lead to separation of the emulsion.

The “coarse emulsion” obtained in the second mixer must correspond to the established type of “oil in water” emulsion, be strong enough and not delaminate before passing it through the homogenizer. Visually, such an emulsion has a uniform appearance and does not delaminate in the selected sample with weak stirring.

Homogenization of the “coarse” mayonnaise emulsion.

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

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

It is recommended that the homogenization process be carried out in parallel with the process of mixing the components in the second mixer. It is allowed to carry out the homogenization process also during the preparation of 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.

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

Mayonnaise is one of the most common food products and one of the most popular consumer goods. Its consumption in Russia reaches 3 kg per person per year, and this figure is constantly growing. Mayonnaise production is considered one of the most profitable. In addition, it is distinguished by simple technology, which allows you to set up the production process in a short period of 1 - 2 months.

To establish your own production of mayonnaise, you need: firstly, a room that meets sanitary and hygienic requirements, secondly, equipment, and thirdly, an experienced technologist.

Before purchasing equipment, it is necessary to determine the volume of production. And only after that proceed to the selection of a set of equipment. The compositions of the kits are very similar, the differences lie in the design of the homogenizer - units that crush the mass of oil into microscopic drops. However, these differences are not fundamental. The main factors influencing the choice are the price of equipment and the degree of automation of the technological process.

The choice of packaging equipment depends directly on the packaging method that will be used in production. The easiest way is packing in plastic containers, the shelf life when using this type of packaging is minimal. But the equipment used for this type of packaging is the least expensive of all types. Packing in glass jars is the most hygienic and gives maximum shelf life. The equipment is also relatively inexpensive. However, this is the most time-consuming way of packaging. The most expensive equipment is used to pack mayonnaise in plastic disposable bags, this is the least labor-intensive way. In addition, in this case, the cost of storage and transportation of the product is minimal.

The table shows important technical indicators of kits based on IPKS-056 miniplant

The raw materials needed for the production of mayonnaise include: vegetable oil (sunflower, soybean, corn, cottonseed), egg powder, whole cow's milk dry and skimmed milk, corn and potato starch, granulated sugar, salt, acetic acid, drinking soda, water. The taste of the finished product will largely depend on the quality of the raw materials, as well as on the recipe. Recipes are developed by technologists, branded recipes are trade secrets. Therefore, the quality of the product, and hence its success in the market, largely depends on the qualification of the technologist.

Below is a table of the cost of the main components of raw materials (without VAT, as of September 1999 in the Moscow region) (note site: prices can be substituted for the current ones - the main principle of calculations)

The mayonnaise production process consists of four main steps:
. Preparation of prescription components
Mayonnaise preparation
Preparation of mayonnaise emulsion
Packing, packaging, labeling

Mustard preparation.

24 hours before the start of mayonnaise production, the required amount of mustard powder is placed in an enameled or stainless steel bowl and poured with water at a temperature of 80-100 ° C in a ratio of 1: 2. The mixture is well mixed until a homogeneous consistency with smoothing the top layer. Water with a temperature of 100 ° C, 4-6 cm high, is carefully poured onto a flat surface of the mixture. The container is tightly closed with a lid and left alone for a day. Before use, the top layer of water is carefully drained.

Preparation of egg powder solution.

In a food container, egg powder is dispersed in warm water at a temperature of 40-50 ° C in a ratio of 1: 1, then hot water at a temperature of 60-75 ° C is added to the mass until a ratio of egg powder and water is 1: 1.5. The composition is thoroughly mixed by hand until a homogeneous mass is obtained.

Preparation of acetic-salt solution.

In an aluminum tank, previously filled with the amount of salt corresponding to the recipe, 9% table vinegar according to the recipe is poured and diluted with water.

Mayonnaise preparation

Dry components from the filled volumetric containers are poured into the mixer-emulsifier and filled with boiled water with a temperature of at least 30-40 ° C. The mixture is pasteurized (heated to 80-85 ° C) with thorough mixing for 30 minutes. Sugar is added. At the end of pasteurization, the mass is mixed and cooled to a temperature of 50-55 o C. Then the prepared amount of egg powder and mustard is introduced. The mixture is heated again (up to 60-65 ° C) and kept at it for 25-30 minutes, and then cooled to 30 ° C.

Preparation of mayonnaise emulsion

Vegetable oil is introduced into the mayonnaise paste with further stirring. After receiving the entire dose of oil and obtaining a homogeneous emulsion, an acetic-salt solution is introduced and the mixture is still mixed for 15-20 minutes. At the last stage, the final homogenization of the resulting mixture is carried out using a homogenizer pump, after which the product is poured into flasks or containers of finished products for further packaging and packaging. As we said above, mayonnaise can be packaged in several ways. On small lines, polymer packaging and simple and efficient dosing (by volume) devices of the UD-2 type and installations for welding cups made of polystyrene with Al-foil USS-2 are most often used.

Approximate recipes for the preparation of mayonnaises "Salad", "Provencal"

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

The cost of production consists of the cost of raw materials, materials, fuel, energy, fixed assets, labor resources, as well as other costs for its production and sale.

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

Initial data:
work is carried out in 3 shifts (8 hours each);
the salary of each worker is 1500 rubles;
25 working days in a month;
sales of products - 100%.
Purchasing wholesale prices for raw materials and ingredients (without VAT, as of September 1999 in the Moscow region) (note site: prices can be substituted for the current ones - the main principle of calculations)
Main conclusions from the calculation results
1. The break-even point in time for all sets is the same and is about half a month (note openbusiness: ???). This is due to the same ratio of fixed and variable costs, taken in the calculations.
2. The performance of the equipment determines its payback period and the amount of net profit. The higher the productivity of the equipment, the higher the net profit and the shorter the payback period.
3. Profitability in these calculations is 10%. But its level depends on the prices for the sale of the final product - if prices significantly exceed the cost of the final product produced, then the planned profit will grow and, accordingly, the profitability of production will increase.

Based on materials from Equipnet.ru

Batch production of mayonnaise

Mayonnaise is a multi-component system, the complexity of which is due not only to a wide range of components, but also to the fact that the main components (oil and water) are insoluble in each other. It is practically impossible to obtain a homogeneous (close to homogeneous) and stable system 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 the 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 kept 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 pouring 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.

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

To prepare phase 2 from tank 1, pump 4 pumps 4 through volume counter 5 and heat exchanger 3 into tank 6 with vegetable oil at a temperature of (65 ± 2) ° C and egg powder is loaded, phase 2 is mixed and pasteurized. Next, phase 2 enters distribution tank 14 , from which the dosing pump 11 is sent for cooling to (15 ± 5) ° C into the cooling cylinder of the combinator-heat exchanger 8 and then to the combinator-emulsifier (homogenizer) 15.

In the tank 7 for the preparation of phase 4 from the tank 1, the pump 4 pumps vegetable oil through the volume counter 5 and pre-weighed skimmed milk powder, mustard powder and soda are fed. Then water is supplied through the volume counter 5 and the remaining dry components (granulated sugar and salt) are introduced. After mixing, phase 4 is sent to the distribution tank 9, from where the metering pump 11 is used for pasteurization into the heating cylinder of the combinator-heat exchanger 8. Pasteurization is carried out at (82 ± 2) ° C with holding at this temperature for 6 minutes. Then, in the second cooling cylinder of the combinator-heat exchanger 8, phase 4 is cooled to (15 ± 5) °C.

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

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

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

The finished mayonnaise after the homogenizer 16 enters the container 17, from where it is fed by a screw pump 18 to the dispenser of the filling machine 19, which pours the mayonnaise into PVC cups with a capacity of 250 g. The machine stacks 4 cups on top in 3 rows and 3 layers (36 pcs) in each crate. The wrapped boxes are sent to the warehouse, where the finished products are stored until sent to the consumer at a temperature of 0 ... 18 ° C and a relative humidity of no more than 76%.

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 with 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 followed by 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 ones. 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.