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Mayonnaise cooling Equipment

Industrial cooling equipment varies according to the consistency and temperature conversion demands the material you are handling, but the process typically involves heat exchange treatment as your products are conveyed through a cooling chamber equipped with extraction fans or circulating water. Temperature control is a crucial aspect of your commercial production and cooling systems are applied to a range of industries.

Cooling

Mayonnaise is created by blending oil with eggs, and then flavoring with vinegar, mustard, herbs, and spices. The eggs are a natural emulsifier that creates a uniform mixture. Ingredients are pumped into mayonnaise manufacturing equipment. First, a dynamic mixer maintains the desired level of emulsification of the mixture, which then moves on to packaging and bottling once reaching a satisfactory consistency.

Mayonnaise 

<span style="font-weight: 400;">The production of creams, sauces, ragouts, ready-to-bake, and similar products require combinations of mixing, heating and cooling, necessitating several pieces of equipment. By combining temperature treatments and mixing processes in one machine, cost can be reduced and efficiency increased, all while maintaining excellent product quality.</span>


<h2>Combined mixing and thermal treatment system for a wide range of products</h2>
<span style="font-weight: 400;">Tonelli has used it’s well-known industry experience to bring together cutting-edge mixing and thermal treatment processes in one unit - the Tonelli CombiTherMix.</span>

<span style="font-weight: 400;">The CombiTherMix features a centrifugal homogenizer that offers 3 different types of rotating impeller, allowing you to achieve the optimal results for your product.</span>

<span style="font-weight: 400;">Integral scrapers and interchangeable mixing tools make this a fully flexible machine able to handle recipes from delicate sauces to hearty ragouts, or robust pâtés.</span>

<span style="font-weight: 400;">The CombiTherMix features a host of cooking options including saturated steam, food-grade steam injection, and hard vacuum treatments. For cooling and freezing it has the facility to use pumped iced water or liquid nitrogen. All are available in the same single unit, saving you money over having multiple production equipment.</span>

<span style="font-weight: 400;">Featuring an aseptic discharge valve for hygiene, the CombiTherMix is constructed of stainless steel for easy cleaning and hygienic practice. </span>

Temperature-treatment mixer for bakery &amp; gastronomy

To make smooth batches of mayonnaise or ketchup you need to use process equipment for stirring, heating, and cooling the emulsions. This can be a time- and space-consuming process and each technology comes with a different set of challenges from efficiency to cleaning.


<h2>Mixes, cuts, emulsifies, heats, cools, and deaerates your mixture</h2>
<span data-contrast="auto">The Stephan Vacutherm by ProXES is an adaptable and expandable all-in-one emulsion processing system. The system combines cutting, mixing, heating, cooling, and deaerating to ensure a compact and streamlined production of both hot and cold batches. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">With a double-jacket vessel and a rotor-stator homogenizer the Stephan Microcut, the equipment guarantees stable emulsions while emulsifying and homogenizing even chunky products. With the aid of the vacuum system and corresponding hoppers, extensive dosing options for solid, semi-solid, and liquid ingredients are possible.</span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">Fast and gentle heating is achieved by direct steam injection and can reach the maximum working temperature of 95C, or optionally 110C. It is also possible to use the double jacket for indirect heat cooking or cooling. The power of the equipment ranges from 1600 to 3600 l/h. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">What is more, the Vacutherm operates under an inclined working position of 70 degrees</span><span data-contrast="auto"> </span><span data-contrast="auto">without any residue buildup, thanks to the scrapers that follow the contour. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

All-in-one system for making emulsions

When producing high-viscosity products like ketchup, mayonnaise, or peanut butter, achieving uniform heat transfer can be challenging. Traditional heat exchangers often struggle with these conditions, leading to inconsistent product quality and increased maintenance requirements.
<h2>Heat and cool high-viscosity products efficiently</h2>
The Contherm® Scraped Surface Heat Exchanger from Alfa Laval is designed for continuous and semi-continuous processing of a wide range of viscosities. Its unique single-wall design ensures efficient heat transfer and reliable mechanical performance even with viscosities greater than 50,000 cP. The system can handle particles up to 36 mm, making it versatile for various applications including food, chemicals, pharmaceuticals, and personal care products. Horizontal and vertical installation options offer flexibility to meet space constraints. Additionally, the vertical configuration includes a hydraulic system for quick and safe inspections, reducing service costs.

Scraped surface heat exchanger for viscous products

In the production of sauces, dressings, and emulsions, achieving a homogeneous product is crucial. Traditional mixing methods often fall short, resulting in a mixture with air bubbles and lumps. This complicates consistency and quality control.
<h2>Achieve lump-free high viscosity mixes quickly</h2>
The ProcessMaster by Daniatech is specifically developed for mixing products with medium to high viscosities. Utilizing a vacuum system, it draws powder below the liquid level to instantly wet the powder, eliminating air incorporation and ensuring a homogeneous dispersion in seconds. The mixer features a high-shear mechanism combined with a scraper agitator that generates a controlled vortex in the tank. The unit comes equipped with an insulated jacket, allowing for rapid heating and cooling using steam or ice water. For faster heating, direct steam valves can be added. This results in a stable, lump-free product with an optimized energy-efficient mixing process, reducing maintenance costs. The ProcessMaster is ideal for producing sauces, mayonnaise, dressings, gels, creams, and emulsions. It ensures homogenization down to 3µ and handles viscosities up to 50,000 cP.

High-shear mixer for high viscosity products

Emulsions enhance foods with a creamy mouthfeel and richer flavors. But the immiscible nature of oil-and-water mixtures makes it challenging to maintain consistency in textures and taste across batches.


<h2>Versatile, powerful, and reliable</h2>
The ProxxD® high-shear emulsifier from ProXES guarantees reproducibility batch after batch. The built-in proprietary automation system hands full control over the shear energy input and other critical parameters.

Droplet distribution impacts emulsion stability and the sensory profile of the final product. FrymaKoruma specializes in droplet size control and is the world market leader in emulsion-based food processing systems.  Its technology solution disperses fine droplets with precision to create superior-quality foods and extend their shelf-life.

The ProxxD® is a highly versatile system that is easily adaptable to match your exact processing needs. Besides emulsification, the ProxxD® performs a range of food processing functions, including dosing &amp; weighing, mixing, and vacuum deaerating.

The integrated unit has been redesigned with a small footprint but large capacities, reaching up to 5,000 kg/hour depending on the product recipe.

Batch processing system for emulsions and suspensions

ProXES specializes in liquid and semi-liquid foods, cosmetics, and pharmaceuticals process machines and lines. ProXES partners from co-creating first ideas,developping tailor-made concepts, go to market and scaling production.

If you are looking for ideas on how to make mayonnaise production better, look no further!



<a href="https://www.proxes.com/de/">ProXES</a> is hosting a webinar called <a href="https://go.proxes.com/en/webinar-mayonnaise-real-to-light">"Mayonnaise: Real to Light"</a> on the 6th of March, where you can learn about the advancements in both cold and hot processing. The webinar introduces how the ProxxD® can help you make the production of your mayo even better.

Webinar: master mayo-making

Food

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

Sauces bring personality to a dish. From a spicy, dense Zhoug to a tangy, runny Suero, sauces add an extra dimension of flavor, texture, and mouthfeel. But developing recipes into industrial products with long shelf lives and consistent tastes is a complex process. Specialized sauce making equipment prepares and combines the ingredients into delicious, high-quality foods. The result is a sauce ready to elevate meals.

Sauce

Texture and consistency are critical to foods with delicate compositions like dressings and fruit juices. But the base ingredients do not always mix into a homogenous recipe, especially in the case of emulsions such as mayonnaise.


<h3>Disperse the components uniformly into the mix</h3>
The Standard Production Plant (SPP) from IKA is a high-shear mixer for fine foods and beverages, including ketchup, plant-based cheese, and hummus. The system incorporates a two-stage unit that blends the ingredients and, secondly, disperses them homogeneously across the medium.

A rotor-stator solution achieves dispersion with a narrow particle size distribution, ensuring stable emulsions and suspensions with the longest possible shelf-life. Meanwhile, the dispersing chamber produces a vacuum to maintain a constant flow rate regardless of viscosity level.

The SPP is available in batch volumes from 25 to 4,000 liters and is equipped with spray nozzles for quick and easy clean-in-place without additional pumps.

Homogenization and emulsifying system for fine foods

Built upon its world-leading laboratory equipment, IKA Process is a game changing manufacturer of dispersing machines, homogenizers, stirrers, jet flow agitators, and kneading machines.

Moliere famously said that slow-growing trees bear the best fruit. Clearly, the 17th-century playwright never ran a mayonnaise production facility.

In food manufacturing, once the recipe is developed and reproducible, every minute lost is an extra cost.

“<em>Time is money</em>,” reminds us Rolf Schmidt, “<em>But time efficiency means the highest quantity at the highest quality.</em>”


<h2>Superior dispersal starts with the droplets</h2>
As a food processing expert at <a href="https://www.linkedin.com/company/ika-works">IKA Process Equipment</a>, Rolf isn’t simply throwing around platitudes. The processing equipment firm existing for more than 110 years, has developed a unique dispersing machine for uniformly dispersing the oil phase in the aqueous phase at high speed.

“<em>We have put our very long experience in dispersing techniques into our dispersing machine DBI</em>,” says Rolf as he explains the technology of the Standard Production Plant (SPP) series. Conventional machines add the oil to the water and then often need to further homogenize the mixture, whereas the IKA machine allows to shorten this process.

The IKA technique comminutes oil materials directly when distributing them into the circulating water. The heart of the system is the rotor-stator. As the oil phase travels through the high-shear mechanism, it breaks down into uniform fine droplets.

Mayonnaise is around 80% oil, whereas making mayonnaise on an industrial scale starts with a 100% water phase and introduces oil droplets at high intensity until they reach the accurate recipe ratio. Directly dispersing the oil in the mixture shortens the processing time and increases the dispersal efficiency.
<h2>Process 500 liters of mayo in 5 minutes</h2>
Rolf points out that it’s not only the way of downsizing drops that make the technique faster: “<em>Our solution actively pumps the oil into the dispersing machine, injecting it with a higher speed than in common systems.</em>”

The unique design of the dispersing machine facilitates the efficient dispersal of the droplets. It allows to integrate the oil faster and more efficiently than in common systems. In Rolf’s customer experience, this often decreases the processing time by more than half. In fact, the SPP 500 system can produce 500L of mayonnaise in just 5 minutes.

With new varieties launched every year, the mayo market has been evolving rapidly since the original recipes of 18th-century France. That was long after Moliere’s time, but had he tried the condiment, he would have discarded his own advice and advocated instead for faster production.

Make a batch of mayo before you can finish a bag of fries

Large-volume producers of single-serve packs, such as sugar sticks, instant coffee, and instant soup, continuously pack different product sizes into cartons. Intelligent and flexible infeed systems are needed to ensure your products integrate smoothly into the carton line at higher speeds.


<h2>Pack stick packs or flow packs into cartons continuously</h2>
The VENTO Cartoner from Mpac is a carton packaging system with a smart infeed system suitable for single-serve products such as condiments or coffee and milk powders. The unit is made of hygienic stainless steel materials. It has an open design for easy visibility of product flow and quick access to the components in case of maintenance and cleaning.

The entire system is servo-driven and coupled directly to its components for minimum maintenance and long operating life. It is designed to operate 24/7, allowing maximum production yield, and is equipped with an advanced intelligent machine interface that provides information on machine status, maintenance, and changeover controls based on product application. The processes include carton erecting, loading, transportation, and closing. Changeover for different carton sizes and types can be done quickly and automatically.

High-speed Cartoner For Single-Serve Products

Basically, to make milk powder, you need to remove the water content from the liquid milk and turn it into powder. How to do it? After pasteurizing and homogenizing the milk, milk’s water content is removed through filtration, evaporation, and drying. You have then to cool and sieve it before filling the containers. Here's how you get milk powder.

Milk powder

Sugar is the fuel that drives photosynthesis in plants. The leafy organisms constantly convert water and carbon dioxide into glucose. But it takes manufacturers specialized sugar processing technology to extract the sweet crystals from them. Today, most sugar products are derived either from sugarcane or sugar beet.

Sugar

Ketchup processing begins with tons of tomato paste that is mixed and heated together with sugar, vinegar, and spices in a cooking kettle. After cooking, any remaining fibers and particles are filtered out. Once it reaches the right viscosity, your tomato ketchup production process is finished and ready for packaging and transport.

Ketchup

White, black and brown seeds from the mustard plant are the key constituents of this colorful and classic condiment. The various mustard production technology includes a mixer that mixes the mustard seeds with a handful of other ingredients and a mill that finely grinds the seeds to impart their characteristic flavor.

Mustard

Mpac Group is an industry leader in packaging automation, cartoning, and case-packing technologies.

Its complexity begins with the term itself, which has no clear and precise definition in the industry. As Jan Verweijen and Frank Jeurissen from the Mpac Group explain, the big question is always: is it a sachet or a stick pack?

“What is what” is defined by the way it is sealed, not by its width or length. A stick pack is a product with three seals, one of which is in the middle, lengthwise. Instead, a sachet is a four-sided sealed product with no seal in the middle.

First introduced in Japan in the 70s to pack sugar, these single-use sticks are now used to pack everything you can think of. But what impact does your product have on the cartoning process?


<h2>The first step is to find the right balance.</h2>
Stick packs are first filled vertically; this means that all the product is on the bottom.

Before entering the stick packs into the cartons, you need to evenly divide the product over the left and the right side of the stick packs. This step is called equalization and it is done by horizontally shaking the product to redistribute the contents inside the sticks.

“<em>If the weight is not evenly distributed, all the stick packs will slide off toward one corner of the box leading to an unstable formation that can damage the sticks</em>.” Frank points out.

For mere mortals, powder is powder, but for the experts, coffee powder, for instance, has a different structure than cocoa powder.

“<em>Liquids do not need equalization as the fluids divide automatically.” </em>Jan explains.

In addition, the sticks must have a minimum size, usually around 80 or 90 millimeters, to be cartoned horizontally and the shorter the sticks, the more difficult to keep them stable.
<h2>On edge vs. random orientation - Which side do you stand on?</h2>
Premium single-use products, such as coffee or pharmaceuticals, are often packed with the brand name and description always facing the consumer.

“<em>When this is the case, we use a paddle conveyor that brings each stick pack on a single edge so that when pulled out of the box, the branded face is the first thing the consumer sees,</em>” says Jan.

Frank adds: “<em>In 90 percent of cases, manufacturers choose speed over where the stick pack is facing. With random orientation, you can easily speed up to 900 sticks per minute</em>”.

“<em>Our bomb bay system counts each stick individually and puts them together in the quantity the producer requires; then it drops the sticks into the bucket conveyor</em>.” continues Jan.

To prevent damage, the bomb bay system consists of multiple drop levels, and the sticks need to be always dropped at a limited height - no higher than 250 mm.

As every stick has two ends, cartoning single-serve packs may seem easy, but as Jan and Frank explained, the journey from equalization to orientation and bomb bay dropping is not exactly a piece of cake.

Unpacking the world of stick pack cartoning

Cosmetic

Pharmaceutical

With over one-third of the population consuming it daily in different forms, coffee is one of the most popular processed beverages worldwide. Not only serving as drinks, but coffee is also often regarded as a culture. Coffee manufacturing is a knowledge-intensive industry. Coffee beans from different regions will reveal different tastes, while the level of caffeine could also be different. When it comes to coffee bean processing, the range of roasts varies from light golden brown all the way to dark. The method of tasting coffee differs between countries, habits, and tools.

Coffee

According to a legend, Cleopatra soaked her sails in her perfume so that Mark Antony could smell her ships before they arrived. This is to say that, from soaps and shampoos to perfumes, conditioners and pomades, cosmetics have always been highly valued and used for their properties of aesthetic enhancement. Cosmetics are a broad class of topical agents applied for various purposes such as cleansing, protecting, beautifying, or otherwise altering your appearance. As a result, a wide array of processing equipment is used in the cosmetics industry.

Cosmetics

Eating is more than just nutrition, but we have found ways to increase the nourishing power of our foods. Nutraceuticals manufacturing, from vitamin C powder and probiotics to omega 3 oil, is a concentration of natural ingredients and health supplements that complement our diets. While dietary supplements are not quite haute cuisine, the process of extraction and purification is no less a blend of science and art.

Nutraceuticals

The building blocks of matter have driven the imagination of philosophers, scientists, and artists for millennia. But, for manufacturers, these elements have a more concrete existence as powders. Powder processing technology conditions these primary materials to create a vast range of products, from chemicals and foods to pharmaceuticals and ceramics.

Powder

<span style="font-weight: 400">Spice manufacturing is one of the world's oldest trading products. The word spice refers to any dried part of a plant other than the leaves and is used for seasoning and food coloring. Spices are made from dried barks, roots, berries, and twigs, while green leafy parts of plants are considered herbs. Well-known examples include cinnamon, chilies, star anise, ginger, garlic salt, turmeric, cumin, or pepper, as well as pre-mixed blends such as Masala, Five-Spice Powder, or Old Bay.</span>

Spices

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Mayonnaise cooling Equipment

Which mayonnaise cooling technology do you need?

Temperature-treatment mixer for bakery & gastronomy

All-in-one system for making emulsions

Scraped surface heat exchanger for viscous products

High-shear mixer for high viscosity products

There is currently no equipment listed with your specified properties, but we are sure we can help you. Try us!Contact us

Let's talk about your project!

Which mayonnaise cooling technology do you need?

Temperature-treatment mixer for bakery &amp; gastronomy

All-in-one system for making emulsions

Scraped surface heat exchanger for viscous products

High-shear mixer for high viscosity products

There is currently no equipment listed with your specified properties, but we are sure we can help you. Try us!Contact us

Let's talk about your project!

Temperature-treatment mixer for bakery & gastronomy