One of the most popular ‘how to’ videos released on Silverson Machines YouTube channel is on the manufacture of mayonnaise – the video currently has over 80,000 views!
Whether you are making a traditional mayonnaise, a low-fat recipe or a vegan alternative, producing mayonnaise is challenging. The mixing equipment used for the manufacturing process has a significant impact on the quality of the finished product. The challenge comes from needing a mixer that can complete several mixing processes. For example, mayonnaise is an oil-in-water emulsion, so the mixer must be able to form a stable emulsion, but it must also be able to maintain movement in the vessel during oil addition when the viscosity begins to increase. Oil addition must be controlled because if it is added too quickly this can cause the emulsion to break. In low-fat formulations where gums and thickeners such as starches are added to enhance mouthfeel, the mixer needs to incorporate and hydrate these ingredients without forming agglomerates. These tasks are beyond the capabilities of conventional mixing equipment such as agitators or stirrers.
The Silverson Mayonnaise plant can carry out the entire mayonnaise manufacturing process. This includes preparation of premixes, hydration of thickening and stabilising agents and preparation of the final oil-in-water emulsion.
Water is recirculated from the vessel through the system by the In-Line mixer, specially designed to handle high viscosity products without the need for additional pumps. The egg (either powder or liquid) is added to the vessel and is rapidly wetted out and dispersed into the high velocity liquid stream. Recirculation continues as the remaining aqueous phase ingredients are dispersed and hydrated. The Mayonnaise plant uses a separate hopper for oil addition and when the oil feed valve is opened, oil is drawn down from this hopper into the aqueous phase at a controlled rate. The aqueous and oil phase ingredients pass directly into the workhead of the In-Line mixer, where they are subjected to intense high shear. This finely disperses the oil into the aqueous phase, immediately forming an emulsion. The vinegar (and/or lemon juice) is added with the last of the oil. Recirculation of the product continues to ensure a uniform consistency as the viscosity rises. After a short recirculation period the process is completed and the finished product can be discharged.
The Mayonnaise Plant is ideal for batches of up to 100 kilos and allows users to practically eliminate operator error, offering greater batch-to-batch consistency. In addition to this unit, Silverson offers mixers for both full scale production and laboratory and pilot models for batches of up to 12 litres. Thanks to the Silverson rotor/stator mixer design, comparable results can be achieved across the product range, making scale-up a relatively straightforward process.
As well as Mayonnaise, Silverson High Shear mixers can also be used for the production of other sauces and dressings including Ketchups, Hummus, Salad Dressings and Mustards. If you’d like to find out more about any of the above applications, or watch the ‘How to’ videos, please visit: www.silverson.co.uk
