The history of mayonnaise.

Mayonnaise production line.

Mayonnaise production.

The history of mayonnaise.

The birthplace of mayonnaise? How did mayonnaise come about? Who invented mayonnaise?
There is an island of Menorca in the Mediterranean Sea. Its capital is an ancient town called Mahon (Mayon). In the 18th century, incessant wars were fought among European rulers over this fertile place. In connection with those events, the history of mayonnaise sauce began.
In the 18th century, 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 the royal musketeer, Rene Descartes, essentially participated). After some time, the city was captured by the British. Just like his ancestors, Richelieu intended to hold out even if he starved to death.

Island of Menorca.

Naturally, the food supply in the captured city remained tight - there were only olive oil and turkey eggs. Can I make a lot with 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 best they could, experimented, invented, but there were too few available products.

When the French garrison and Richelieu himself could no longer look at all kinds of scrambled eggs and omelettes, the cook, who showed unusual soldierly ingenuity, found perhaps the most excellent solution, which will forever glorify him. Unfortunately, this decision did not preserve his name, since in a difficult struggle he simply forgot to name the sauce after his name).

This clever cook diligently began to grind several 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 becomes very tasty with this additive!

Richelieu and all his soldiers were completely delighted. In 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 the production of mayonnaise is now one of the most profitable.
It is also important that the equipment used in the production of mayonnaise is quite simple to use, 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 period of time, which is equal to 1 - 2 months.

Mayonnaise production technology.

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

Raw materials.
To obtain a mayonnaise product, in our country we mainly use sunflower oil; abroad we use soybean, corn, peanut, as well as cottonseed, olive and sesame oils.

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

In our country, egg powder is used as the basis for the emulsifying component. The egg yolk forms the basis of this emulsion and affects its durability, thickness, 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, lipovitellin and free proteins, phosphitin, livetin.

The following types of egg products are used: egg powder, granulated egg product, and dried egg yolk. In mayonnaise, the content of egg products ranges from 2 to 6% depending on the recipe.

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

Recently, proteins of plant origin, often soy, have been used more often. In our country, the use of edible soy protein, edible soy base, and edible soy concentrate is permitted.

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

In the production of mayonnaise from natural stabilizers, starch and modified starch remain the most widely used. In our country, we use phosphate corn starch grade B. Thanks to the esterification of starch with phosphates, we have obtained a food thickener, 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 we use maltin, which is produced from potato starch due to partial enzymatic hydrolysis with the following temperature treatment of the hydrolyzate. Maltin is an easily digestible carbohydrate that dissolves when heated to 75-80C.

After it has cooled, a gel of varying consistency is formed depending on the concentration.

In Germany, when making sauces, “coolie” is used - this is a thickener obtained from starch and flour of Guar grains.

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

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

Currently, xanthan, which is a biopolysaccharide, is used abroad to regulate most salad dressings.

Relatively intelligible polysaccharides are gums and mucilages, which are 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 are either one or more uronic acids.
Mustard powder is a flavor additive, and the proteins contained in this powder provide emulsification and structure 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 during storage, preservatives, mainly benzoic salts and sorbic acids, are introduced into their structure.

Mayonnaise is prepared in two ways: batch and continuous.

Manufacturing by batch technology includes the following steps:
- preparation of individual elements of the structure;
- preparing mayonnaise paste - dissolving the dry elements and mixing them until homogeneous. Dissolve the dry elements in two mixing devices: in the first - milk powder with mustard powder, and in the second - egg powder. The first is delivered with water at a temperature of 90-100 °C, a mixture of mustard and dry milk.
- exposure at a temperature of 90-95 °C for about 20-25 minutes with subsequent cooling to 40-45 °C. The egg powder composition 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 dry substances for high-calorie mayonnaise should be at least 37-38%, and for the rest - 32-34%;
- preparation of coarse mayonnaise sauce is carried out in large mixers, which are equipped with metal mechanisms with low speed. Add paste, vegetable oil, a solution of salt and vinegar or other acids to a large mixer; homogenization of liquid in piston homogenizers with a certain pressure to avoid separation of the prepared liquid.

The uninterrupted production of mayonnaise products on a self-acting line using votator-type heat exchangers consists of the following actions: prescription dosing of all elements in the preparatory group; mixing the elements and forming the mayonnaise composition in an interval of 15 minutes, deaerating 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.
. Container for collecting vegetable oil.
. Intermediate container - collecting 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 product to packaging. Filling machine - product packaging.

The structure of demand for mayonnaise is changeable: Russian citizens more often reject cheap varieties and give preference to expensive and better quality ones. Secondly, the campaign is having an impact in combating excessive consumption of foods that contain cholesterol, causing customers to try to balance their diet. Mayonnaise quietly drives sour cream out of the consumption basket. Also, most mayonnaise manufacturers are inclined to diversify and introduce sauces into their range.

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

In the Russian Federation, about 38 organizations are engaged in the mayonnaise business. Five large industries - Unilever, NMZhK, Solnechnye Produkty, Essen Production AG, Efko - their share accounts for 62.7% of the market in value terms and 63.8% in physical terms.

In this article:

The production of mayonnaise and ketchup is rightfully considered 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 products, which differ from the standards of mass production. This trend can serve a budding entrepreneur well.

On average, the population consumes about 3.5 kilograms of pasty 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. Deciding on the organizational form of business

To operate 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 warehouses, food warehouses and supermarkets, which often prefer to cooperate with a reliable company.

To prepare periodic reporting, it will be more economical 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 releasing the first batch of pasty products, it is recommended to study state standards:

• GOST R 53590-2009 Mayonnaise and mayonnaise sauces. General technical conditions.
• GOST R 52141-2003 Ketchups. General technical conditions.
• 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. To complete it, it is necessary to decide on the regulatory document according to which the paste products will be produced.

Regulatory documents can be the above-mentioned GOSTs or personally developed specifications (technical conditions).

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 the yolks, only the whites, or both are taken. Eggs must be pasteurized to kill salmonella and other bacteria. Eggs are delivered to large enterprises in metal tanks in liquid form.

Using 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 they arrive at the mini-plant. The pump also pumps oil into storage tanks. Next, additional ingredients are weighed - spices that need to 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, the raw eggs are poured into a large refrigerated tank. Thus, in the production workshop there are 3 containers: with pasta, eggs and soybean oil. Next, in a certain ratio (according to the company’s recipe), all components are sent to a mixing vat.

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

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

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

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

Ketchup production technology

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

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

A sugar-salt solution is placed in it.

Digester

The mixture is thoroughly mixed in a giant cauldron. Steam is supplied between the internal and external walls of the unit, which prevents the mass from burning. The stirrers constantly rotate and make the ketchup homogeneous, i.e. homogenization of the mixture occurs.

Digester structure

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 ketchup.

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

The containers can be manufactured in a neighboring workshop. The basis is PVC granules, which many plastic products are made of. Next, 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 pressed 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 ketchup bottle weighs only 42 grams; it comes to bottling directly from the conveyor, barely cooling down.

In this case, ketchup is bottled using hot technology, when the temperature of the finished product should not be less than 80 degrees. In this case, the appearance and proliferation of bacteria in the sauce is prevented. Next, the bottles are equipped with caps, labels and packaged in boxes.

Technology for producing mustard from seeds

The starting ingredients 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.

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

Mustard seed is added last. A huge rotary mixer mixes all the components for about an hour at a speed that helps break up 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). During the grinding process, the mixture is heated to 60 degrees, as a result of which it turns into bright yellow mustard with a creamy consistency. Before bottling, the finished product is checked for uniformity.

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

Let's organize a mini-factory - a list of mandatory steps

The preliminary stage of releasing the first batch of the finished product is:

• choosing a room that meets sanitary and hygienic requirements;
• acquisition of a technological line;
• search for an experienced technologist.

The equipment procurement stage is inextricably linked with the planned production volume. Almost all technological 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 forward-thinking entrepreneur are the cost of the production line and the degree of automation of the technological process.

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

Equipment for this type of packaging is inexpensive. 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 packaging 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 technological line for the production of pasty products, which consists of the following units:

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

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

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

Economic feasibility of the production process

To operate 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 procurement of raw materials and sales of finished products - 9,000 rubles;
• 5 workers to service the line (5,000 rubles each) - 25,000 rubles.

Total monthly payroll is 70,000 rubles.

Monthly fixed costs will consist of the following sections:

• Payroll – 70,000 rubles;
• utility costs - 7,000 rubles;
• rental of an industrial building – 10,000 rubles;
• transportation costs – 5,000 rubles;
• packaging containers – 4,000 rubles.

Total: 96,000 rubles.

Business plan for mayonnaise production

Let's determine the cost of 1 kilogram of mayonnaise (2 jars of 500 grams each). The starting 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 production volume of mayonnaise is 70 kg (140 plastic jars or 350 tubes). Thus, monthly production, 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).

Total cost = Monthly production x Cost of 1 kg of mayonnaise = 1540 kg x 28.55 rubles. = 43,967.00 rubles.

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

The financial performance indicators of the mini-plant for the first month of 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 minus taxation (15%) – 131,778 rubles.
• return on sales - 57%.

Ketchup production business plan

Let's calculate the cost of 1 kilogram of ketchup (2 jars of 500 grams each). The starting ingredients for the production of the finished product are:

• concentrated tomato paste 28% (100 rub./kg) – 28 rubles;
• sugar 10% (30 rub./kg) – 3 rubles;
• water 42% – 0 rubles;
• dried vegetables 9% (100 rub./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.

Total cost = Monthly production x Cost of 1 kg of ketchup = 1650 kg x 45.50 rubles. = 75,075.00 rubles.

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

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

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

Mustard production business plan

Let's 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 rub./kg) – 3 rubles;
• turmeric 2% (125 rub./kg) – 2.50 rubles;
• salt 1% (10 rub./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 each.

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

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

Subject to 100% sales of finished products, the mini-plant will complete the first month of operation 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 minus 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 concluding contracts with wholesalers, grocery stores and supermarkets. At first, in order to stimulate strategic partners, it is advisable to use several simple techniques:

• providing a discount for each additional box of goods that was purchased over a certain period of time; - each intermediary for a free product (for example, 10 pieces of packaging), subject to the purchase of a certain number of boxes;
• discount on products subject to pickup;
• monetary incentives for dealers (sellers) for their efforts to promote paste products.

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

During the first months of operation of the mini-factory, investments in advertising will not be impressive. This is especially true for plans to work exclusively in 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, if the assortment increases, it will be necessary to properly promote the product. Bright packaging, a creative slogan, participation in international competitions and winning prizes will help increase demand from consumers.

We manufacture equipment for the production of mayonnaise using hot and cold methods, both on the basis of UG-UGM and on the basis of conventional vacuum homogenizing devices such as VGA and VGA-GD.

Technological lines for the production of mayonnaise and equipment from our production are widely used in food production enterprises and workshops; they can be used in oil and fat, canning and dairy industries.

Technology and equipment for mayonnaise production

The technological process for the production of mayonnaise involves 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 (for example, water and oil). Taking into account factors such as the concentration of dry components, conditions for swelling and pasteurization of dry components, oil supply rate, and the intensity of mechanical impact.

The production of mayonnaise consists of the following technological stages:

1. Dosing of components
2. Making egg paste
3. Preparation of mustard-milk paste
4. Vegetable oil supply
5. Preparation of vinegar-salt solution
6. Preparation of coarse emulsion
7. Preparation of fine emulsion
8. Packaging of ready-made mayonnaise
9. Packing finished mayonnaise into transport containers
10. Transportation to the warehouse of finished products

Dosing of components - VDP-500 Mayonnaise production begins with preparation and dosing of prescription components. Bulk components: egg powder, skimmed milk powder, mustard powder, sugar, salt, soda are supplied to the workshop in bags, placed on pallets and unpacked as necessary. Dosing of dry components is carried out on platform technological scales. Vegetable deodorized oil enters the container provided for it, the volume of oil is determined using a measuring ruler. Dosing the required amount of water into the small mixer further VDP-500, is carried out using a flow meter.

Preparation of egg paste - VDP-500 and VGA-1000 Mayonnaise production begins with preparing egg paste. To do this, water and egg powder are supplied to the VDP-500 (in accordance with the recipe). Mixing using a homogenizer-dispersant lasts no more than 2-3 minutes. Then the mixture is heated to a temperature of 60-65°C, kept for 15-20 minutes at a given temperature and pumped into the main mixer further VGA-1000. VGA-1000 is a vacuum homogenizing apparatus. Using a vacuum in the preparation of mayonnaise has several advantages, here are some of them: Introduction of sunflower oil into the product in a thin stream through a circulation channel connecting the dispersant and the reactor, which reduces the preparation time of the product and ensures the production of a stable emulsion. There are no air inclusions in the finished product, which increases taste and shelf life. Before pumping, a visual test is taken from the egg paste to determine readiness. The sample taken on a wooden plate must be completely homogeneous, without lumps, and flow evenly from the plate. Cooling of egg paste to 20-30°C occurs in the main mixer during the preparation and cooling of mustard-milk paste by heat exchange with ambient air.

Preparation of mustard-milk paste - VDP-500

After pumping the egg paste from the VDP-500, it begins to preparing mustard milk paste. To do this, water, milk powder, mustard powder, granulated sugar and soda are supplied to the VDP-500 (mass fraction of components according to the recipe). Water is supplied in the amount recommended in the recipe. The loading and restoration of dry components is carried out in a stream by introducing them through a funnel installed into the circulation channel connecting the VDP-500 and a homogenizer - a rotary-pulsation type dispersant. Then the mixture is heated to a temperature of 80-85°C, kept for 15-20 minutes at the given temperature and cooled to 25-30°C (according to the passport for the small mixer). Next, turn off the mixing system and pump the cooled mustard-milk paste into VGA-1000, according to a scheme similar to egg paste. Before pumping, a visual test for readiness is also taken from the mustard-milk paste.

Supplying vegetable oil to the main mixer - VGA-1000

The next step in preparing mayonnaise is vegetable oil supply into the main mixer. This process is carried out from a provided container using a centrifugal pump or by gravity through a solenoid valve with the vacuum turned on. It is also possible to supply vegetable oil from a small mixer using the above method. The amount of oil supplied to the main mixer must correspond to the recipe. To ensure uniform distribution, the oil is fed in a thin stream into the circulation pipeline, mixing directly in the flow with the mass previously prepared in the VGA.

Preparation of vinegar-salt solution - VDP-500

The preparation of a vinegar-salt solution consists of two stages:

In a specially designed container, prepare a saline solution as follows. The amount of water specified in the recipe at a temperature of 15-16°C is poured into the container, and the recipe amount of table salt is added there. The solution is thoroughly mixed with a wooden spatula and allowed to settle (to allow impurities to settle). If the solution has settled, it can be used without filtration, carefully draining it from the sediment. Before use, the cloudy solution is filtered through two layers of gauze.

10% is prepared in VDP-500 acetic acid solution. To do this, water is supplied to the VDP-500 in the amount necessary to dilute a solution of 80% acetic acid to a 10% solution (mass fraction of the solution in accordance with the recipe).

Next, in VDP-500 with a 10% vinegar solution, add saline solution. The resulting vinegar-salt solution is mixed for 5-10 minutes using a mixing system and fed into the VGA (the pumping process is described in detail using the example of mustard-milk paste). The supply of vinegar-salt solution can be started simultaneously with the introduction of the last portions of vegetable oil.

Preparation of homogeneous emulsion - VGA-1000

In VGA-1000, equipped with a mixing device with a low rotation speed (frame-type mixer), a coarse emulsion is prepared. The mixer should ensure uniform mixing in all layers of the mixer without stagnant zones.

The order of adding oil and vinegar-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 formation of a reverse emulsion, and at a certain stage of emulsification to phase reversal.

The coarse emulsion obtained in the main mixer must correspond to the established type of oil-in-water emulsion, be strong enough and not separate before it circulates through the rotary pulsation apparatus. Visually, such an emulsion has a homogeneous appearance and does not separate in the selected sample with weak stirring.

The resulting rough emulsion must pass homogenization process, which is carried out using a rotary pulsation apparatus; the principle of its operation is outlined in the passport.

The homogenization process is carried out until a homogeneous emulsion is obtained. A single pass of coarse emulsion is possible. At the end of homogenization, the rotary pulsation apparatus is turned off.

After homogenization, samples are taken from the batch of finished mayonnaise. The sample taken on a wooden plate must be completely homogeneous, without lumps or visible separations, flow evenly from the plate and have a viscosity characteristic of mayonnaise, as well as color, taste and smell.

Mayonnaise packaging

From the finished product container, mayonnaise is served for packaging. Packing is carried out on any intended for this purpose filling machine.

Packing should be done immediately after production, since contact with air oxygen impairs the taste and safety of mayonnaise.

Packaging of packaged mayonnaise in transport containers

Finished products are placed in corrugated cardboard boxes in accordance with GOST 13516-86 No. 52-1, which are placed on pallets and transported to the finished product warehouse.

Finished goods warehouse. Finished products must be stored until dispatch to the consumer in a warehouse at a temperature from 0 to +18°C.

Recipes for mayonnaise

High calorie mayonnaise - "Provencal"

High calorie mayonnaise - "Lactic"

(mass fraction of fat not less than 67%)

Mayonnaise "Egg"

(mass fraction of fat not less than 57.5%)

Medium-calorie mayonnaise "Amateur"

(mass fraction of fat not less than 47%)

Low-calorie mayonnaise - "Saladny""

Mayonnaise "Mustard"

(mass fraction of fat not less than 37%)

Low-calorie mayonnaise(using stabilizers Keltrol and Manukol (UK))

(mass fraction of fat not less than 37%)

Mayonnaise with a fat mass fraction of at least 47%

The equipment for the production of mayonnaise offered by our company is easy to use and reliable. Along with ready-made production lines, we can offer individual systems and modules.

You can buy equipment for the production of mayonnaise according to pre-agreed options, dimensions and productivity. The price of equipment for the production of mayonnaise is always negotiable due to the unpredictability of costs.

The production of mayonnaise has not yet been fully studied, since there are many technologies for preparing the mixture as a base for the future product. Everything goes back to ancient times, when extraordinary ways of creating this “delicacy” were used to make food piquant and unusual.

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 Minorca. 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 christened the final sauce “mayonnaise” in honor of the place of victory.

Carame, a 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 stir. Another food expert, Prosper Montagnier, argued that the origin lay in the old French word "moyeu", which means egg yolk.

Still others insist that the cream sauce was the city of Bayonne's own creation in southwestern France. Thus, what was originally called "mayonnaise" was later modified to mayonnaise.

Regardless of its origins, mayonnaise quickly gained popularity, so it is not surprising that it appeared throughout European cuisine. In the early 1900s, a German immigrant named Richard Hellmann opened the delicacy in New York City. The salads his wife made were especially popular. When customers began asking if they could buy the mayonnaise itself, Hellmans decided to produce it in bulk and sell it by weight in small wooden jars to measure the oil.

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

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

Mayonnaise production technology - features of each crop

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

Creating an emulsion:

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

The result is a uniform consistency, which is so important for this type of product. Next, various components are added, which is a way to diversify the base mixture.

Adding ingredients:

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

This 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 creating 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 bulking effect of oil, and to improve mouthfeel and provide 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 its composition did not last long.

They also use vinegar, which is distilled from distilled alcohol, and 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 plant. This process is often semi-automated and under vacuum. Research and development uses experimental small-scale production, typical of the "ready-to-eat" market: sandwich makers, food service companies and other small companies. For them, mayonnaise needs to 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. It acts as an emulsifier.
2. The remaining continuous phase ingredients are then added and mixed until dispersed and hydrated.
3. The oil is added so quickly that the continuous mixing phase immediately raises it. This leads to a sharp increase in the viscosity of the product during the formation of the emulsion.

Problem:

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

Hydration of stabilizers and thickeners is one of the most difficult mixing operations. The ingredients may need to be stirred for a long time to ensure complete hydration.

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 oil surface area in the continuous mayonnaise production step to ensure a stable emulsion consistency. This cannot be achieved without special equipment.

Aeration should be minimized or eliminated to ensure maximum product shelf life.

Equipment for making mayonnaise

To achieve the desired result, you need to select the optimal equipment for creating mayonnaise. The devices operate on 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 is quickly wetted and dispersed in the high velocity liquid stream.
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 the oil flows from the hopper into the aqueous 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 uniform consistency as viscosity increases. After a short period, the process is completed and the finished product is discharged.

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 occurs somewhat differently. The process is suitable for producing more than 1000 kg of products per hour:

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

Equipment for the production of mayonnaise in mass quantities should be installed in accordance with accepted quality standards, so that the products can then pass inspections and testing.

Quality control of finished products

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

A variety of mayonnaise-based sauces

There are many varieties of mayonnaise, including light and low-fat. This health-promoting seasoning can be part of a well-balanced diet to suit any dietary requirement. Mayonnaise is made from pure oils such as soybean and canola. They are a natural source of alpha-linolenic acid, an essential omega-3 fatty acid. In addition to providing important 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 the product is safe, so you can trust it. Tatar, spicy, and mustard sauces are created on the basis of mayonnaise. Since the production of mayonnaise involves the use of basic principles, they can be supplemented. You can diversify the taste, not the consistency or proportions, with the help of seasonings.

Russian factories - how are they different?

The production of mayonnaise in Russia is somewhat different from foreign ones due to technology and equipment. Thus, many technologists use basic recipes, creating only “shades” of compositions in terms of fat content and acidity.

To replace the fat from egg yolks, modified food starches are added. To ensure that low-fat mayonnaise retains the creamy texture and body of real mayonnaise, starches from corn or agar product (seaweed extraction) are used. In Moscow, mayonnaise production is carried out by top-level technologists. However, the recipe is standard and has not changed for years. The Togrus trademark does not change traditions and age-old quality standards.

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

Mayonnaise-based 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 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 produce a change in sound when the blender motor operates.
5. Continue adding the oil slowly without adding milk solids.
6. Season to taste with lemon juice, salt and pepper.

Some mayonnaise production companies have incorporated this recipe into the base of some sauces. You can diversify them using spices and a combination of ingredients in proportions.

Tartar recipe

There are recipes for “Tartare” based on mayonnaise. It’s easy to do, 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 production business is quite a profitable business. The basis for such enrichment was created by Africans: they produce the sauce in simple jars without inscriptions or brands, using a cheap recipe and available 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, you need to find sales points. Egg-free mayonnaise is gaining popularity - vegetarians and people who cannot tolerate this product will be the main consumers.

The product will be packaged in plastic containers (buckets) of various capacities: from 500 ml - for retail; up to 5 liters – for catering establishments (cafes, canteens, kitchens). The market niche for mayonnaise is a regional and affordable product in the “economy” category.

Assessment of business prospects

The fairly high popularity of mayonnaise and a large number of consumers are the reasons why the mayonnaise market in Russia is one of the largest in the world. Thus, according to UkrAgroConsult estimates, the volume of mayonnaise consumption in Russia last year exceeded 750 thousand tons. And the market itself has more than doubled over the past 10 years. The potential audience can be divided into two groups - retail clients (B2C sector) and corporate clients (B2B sector). The lion's share of product sales (up to 95%) will go to the direct end consumers of mayonnaise - Russians who buy it at various retail outlets.

The main sales points for mayonnaise are now markets, pavilions, linear retail, as well as food supermarkets and hypermarkets. In this case, it is necessary to take into account regional trends: for example, if in the markets of Moscow, St. Petersburg and other large cities the demand for mayonnaise is gradually moving to the retail chain format, then in the regions markets or ordinary grocery stores dominate.

Separately, it should be said about possible niches for small and medium-sized mayonnaise producers. At the moment, the market in the “average” and “above average” price categories is firmly occupied by leading brands - TM “Makheev”, TM “Sloboda”, TM “Moscow Provencal” and TM “Ryaba”. These brands have strong marketing support and firmly hold their positions.

In this regard, there are not many free niches left for new manufacturers, but they still exist.

• Firstly, this is a regional niche for mayonnaise in the lower and budget categories. The main emphasis should be on promotion through non-chain retail - trade pavilions, markets, convenience stores, etc. outlets.
• Secondly, prospects for new manufacturers are opening up in fairly narrow and specific niches. In particular, these could be mayonnaises with some new and unusual flavors - since the traditional tastes “Provencal” and “olive” are firmly occupied by leading brands.
• Thirdly, additional prospects are opening up due to the B2B niche, which is formed by regional catering enterprises - canteens, cafes, as well as companies engaged in the production of custom salads and other dishes that include mayonnaise.

Production technology and necessary equipment

Mayonnaise is an “oil in water” emulsion made from refined deodorized oils, with the addition of emulsifiers, as well as various flavorings and spices. The technological process for preparing mayonnaise, the requirements for it and for the main starting components are regulated GOST 30004.1-93 "Mayonnaise. Technical conditions".

The following raw materials are used in production:

• sunflower, soybean, olive or corn oil;
• egg powder;
• powdered cow's milk (whole or skim);
• sugar, table salt, soda, mustard powder;
• acetic acid and water;

In order to obtain a final product with improved taste and consistency, it is allowed to add additives and stabilizers, the list of which is also determined by GOST.

General mayonnaise production process diagram consists of 10 stages, the first of which is the preparation and dosing of components. From which, in the second and third stages, egg and mustard-milk paste are made, respectively. The next steps are adding oil, and making, first, a vinegar-salt solution, then a coarse and, finally, a fine emulsion. In essence, this is ready-made mayonnaise, which is subsequently packaged in containers, placed on transport vehicles and sent to the finished product warehouse.

Equipment set

For small and medium-sized businesses, the Russian market offers a fairly large selection of equipment with appropriate productivity.

For example, the Russian company NPP Elf 4M offers the supply of affordable lines for portion production of mayonnaise for small businesses.

More productive equipment that meets the needs of medium-sized businesses is offered by the Russian manufacturer INOX.

In addition to the main production equipment, a business needs a cold storage room to store finished products. Considering that product shipments will be made 2 times a week, the chamber should provide storage for 3.5 days of production and have a volume of about 10 m3. A camera of this size from a Russian manufacturer costs about 118 thousand rubles.

Feasibility study of the project

The capital costs of starting a business are

• purchase of a line for the production of mayonnaise IPKS-0401 (capacity 1100 kg per day) - 621 thousand rubles;
• delivery, installation and launch of the production line - 100 thousand rubles;
• Purchase of a freezer - 118 thousand rubles.
• preparation and overhaul of production premises - 500 thousand rubles;
• creating a monthly supply of raw materials (butter, egg powder, milk, additives) and plastic containers - 500 thousand rubles.
• Registration of activities, coordination with the SES, other expenses - 200 thousand rubles.

Total investment for mayonnaise production: 2,039,000 rubles.

Calculation of revenue and profitability

The standard productivity of the line is 1100 kg of products per day.

Provided the site operates 250 days a year and reaches 50% of production capacity, 137.5 tons of mayonnaise will be produced per year.

The wholesale price of budget category mayonnaise (50% fat) in plastic packaging is around 50 rubles per 1 kg. Annual revenue from the sale of mayonnaise will be 6.85 million rubles, net profitability 20%, payback 18-24 months.