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Mayonnaise homogenization Equipment

Homogenization is the process of reducing particle size in mixtures to improve the consistency, uniformity, and stability of the product. The choice of a homogenizer depends on the nature of the product, desired particle size, the physical state of the ingredients, and pressure requirements during the process. Homogenization is widely used in the biotech industry for cell lysis and in the pharmaceutical industry for the emulsification of creams and ointments; it also finds applications in the cosmetics and food industries for improving the consistency and uniformity of various products.

Homogenization

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 

Equipment operating under the rotor/stator principal is often employed when more traditional methods of stirring cannot achieve desired results. High performance continuous dispersing equipment is needed to achieve desirable results for almost any mixing process in circumstances where other machines fail.
<h2>Rotor/stator mixing in a robust and simple package that is easy to clean</h2>
The IKA ULTRA-TURRAX UTL 2000 is inline high-performance single-stage dispersing machine used for the production of emulsions and suspensions. The UTL 2000 uses the rotor/stator principle and is best suited for continuous applications that cannot be accomplished using conventional stirring methods.

During the full continuous process the components to be mixed are fed into the machine at an appropriate rate through various inlet connections. These components are then thoroughly mixed, dispersed or homogenized within the machine and discharged from the machine through the outlet. Thus, all particles or droplets are treated producing a narrow particle or droplet size distribution with minimal concentration/quality variations. Additionally, the UTL 2000 creates a pumping action which can be used for transfer purposes at low to moderate viscosities with a maximum of about 20 m (ca. 2 bar).

The machines are designed for easy and reliable scale-up and sizes are available with throughput from 50 to 125.000 liters per hour.

Dispersing machine for emulsions and suspensions

For products of medium viscosity and relatively consistent particle size such as honey, cremes, and some plastics, a simple, low cost mixing machine is useful to ensure even dispersion.  The most efficient production plants take advantage of such equipment in continuous production processes to minimize required floor space and serve double-duty as mixing and pumping/transfer equipment.
<h2>A basic effective mixing machine with transport pump capabilities and low cost</h2>
The lower-priced ULTRA-TURRAX UTL 1000 machines from IKA are particularly multifunctional and are used for the mixing, dispersing (emulsifying/suspending) and homogenizing of solid and liquid substances up to viscosities of several thousand mPa·s, such as honey, plastic masses and crèmes. The mixing components are fed into the machine at the inlet connection. The materials are mixed, homogenized and then discharged from the machine via the outlet connection. The economic dispersing machine does not have automatic suction, but does have a conveyor height of up to 20 meters.  Units are available with flow rates from 4.800 to 125.000 liters per hour.

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Economic dispersing machine for emulsions and suspensions

When processes call for homogenized emulsions with extremely fine particle sizes the traditional toothed ring dispensers are not always sufficient.  For extremely high levels of disintegration required to produce true micro-emulsions, extreme pressure cycling is more successfully used.
<h2>Homogenization with pressure shock to achieve extremely small particle sizes</h2>
The HPH High Pressure Homogenizer from IKA uses one or more piston pumps to apply pressure up to 2000 bar to the liquid medium to be homogenized.  The fluid is then fed through a homogenizing valve which very quickly reduces the pressure to the atmosphere.  This abrupt change in pressure in the moving fluid causes cavitation, a high degree of turbulent flow, and internal shearing forces in the fluid all of which serve to break up and distribute larger particles forming a very fine emulsion.  The pressure applied on the uphill side of the homogenizing valve is infinitely adjustable as is the flow rate through the valve, so the process can be easily adapted to achieve a wide range of outcomes and to accommodate fluids with different flow characteristics.  All parts that contact the product flow are stainless steel and autoclavable and the entire unit is designed for robustness and long service life.

High-pressure homogenizer

When producing liquid and viscous products such as mayonnaise, sauces, dressings and ketchup it’s vital to achieve thorough emulsification and homogenization to ensure product quality. Traditional homogenizing solutions can be slow and difficult to clean, increasing downtime between batches. A modern vacuum-based system offers the flexibility to produce a wide range of products quickly, with exceptional quality and short cycle time.


<h2>Vacuum processing plant for emulsions, suspensions and gels</h2>
The MultiVacH from Enoop is a state-of-the-art processing plant for the production of high-quality sauces, mayonnaise, <a href="https://making.com/ketchup/">ketchup</a> and other liquid and viscous products.

Designed to be completely flexible, MultiVacH can be used whenever liquids or powders need to be thoroughly mixed and offers both cooling and heating to suit all production methods.

Ingredients are circulated via vacuum pump to a high-shear mixing element, then recirculated. This allows for extremely fast processing, as the circulation of product provides additional macro-mixing.

Downtime associated with batch or product changes is reduced to an absolute minimum thanks to fully pumped emptying via the recirculation line. In addition, rotating clean-in-place nozzles speeds up cleaning, allowing the MultiVacH to be used in multi-recipe environments.

Heating and cooling are via a double-jacket system, with direct steam injection available for high-temperature recipes.

Control is via a Siemens PLC with 12” touchscreen display, allowing observation and control of all parameters. Production can be manual, semi-automatic or fully automatic to your requirements.

Vacuum based homogenizer

From food to pharma, homogenization is an essential step in the production process that provides uniformity to the product by improving its physical properties. If not homogenized, the fluid product might degenerate over time, leading to the formation of sediments and phase separation. This will lead to the loss of desirable product properties like uniformity, viscosity, consistency and reduced shelf life. 
<h2>Reducing product particle size using cavitation provides fluid stability</h2>
High Pressure Industrial Homogenizer from HOMMAK facilitates permanent homogenization of heterogeneous fluid products like milk, fruit juices, creams, ointments and more. The homogenization effect is achieved by reducing the product particle size through cavitation, shear force, impact velocity and turbulence effect under pressure, thereby preventing phase separation in the product.

The homogenizer consists of two main elements – the compression block and the homogenization unit. As the name suggests, the compression block compresses the ingredients under high pressure. The homogenization unit micronizes the decomposed particles to the specified size per the product.

The equipment's design and manufacturing considerations like capacity, pressure, material selection and valve design are tailored to its specific industrial application.

Pilot plant homogeniser

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

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

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

In the production of food and beverage products, maintaining a consistent texture and particle size is crucial. Challenges arise with products containing pieces, requiring gentle handling to prevent damage or maintaining specific solid-liquid ratios.
<h2>Homogenizes and pumps products with pieces</h2>
The TP22 from Bertoli (Interpump Group) is an industrial homogenizer designed to handle products containing pieces up to 60mm. With a power capacity of 9.2 kW and maximum pressure of 16 bar, it achieves a throughput of up to 12000 liters per hour. This equipment operates with two pistons (2xØ120) and ensures constant solid-liquid ratios, making it ideal for applications in the food and beverage sector. It features an automatic greasing system that consumes 2 kg/1500h of NSF H1 grease, contributing to lower maintenance costs. The TP22 requires a minimum feeding air pressure of 7 bar with air consumption at 42 Nm³/h. Its extended maintenance program ensures long-term reliability and efficiency in operation.

Industrial homogenizer for food and beverage applications

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

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

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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