History of mayonnaise.

Mayonnaise production line.

Mayonnaise production.

History of mayonnaise.

Home of mayonnaise? How did mayonnaise come about? Who Invented Mayonnaise?
In the Mediterranean there is the island of Menorca. Its capital is an ancient town called Mahon (Mayon). In the 18th century, incessant wars were fought over this fertile place among European rulers. In connection with those events, the history of mayonnaise sauce began.
In the 18th century, in 1757, the city of Mahon was captured by the French under the leadership of the Duke de Richelieu (the same relative of Duke Armand Jean du Plessis Richelieu, who lived from 1585 to 1642. In The Three Musketeers, he besieged the fallen Huguenot fortress of La- Rochelle, in the siege of which, in fact, the royal musketeer Rene Descartes participated). After a while, the city was captured by the British. Like his ancestors, Richelieu was going to hold on even under the condition of starvation.

Menorca island.

Naturally, food in the captured city remained tense - there were only olive oil and turkey eggs. Is it possible to cook a lot from this set? The garrison cooks themselves were tired of such a poor “menu” and during the capture of the city they tried to diversify the menu as much as they could, experimented, invented, but there were too few products available.

When the French garrison and Richelieu himself were no longer able to look at all kinds of scrambled eggs and omelettes, the cook, who showed unusual soldier's ingenuity, found perhaps the most beautiful solution that glorified him forever. Unfortunately, this decision did not save his name, as in a hard struggle he simply forgot to name the sauce of his name).

This quick-witted cook diligently began to grind a few egg yolks with salt and sugar, then gradually poured in small portions and constantly stirred until completely homogeneous, then mixed with olive oil, added a little lemon juice to this mixture and thoroughly mixed it all again. (This is a classic recipe for regular mayonnaise.)

After all, even the most ordinary soldier's bread with this additive becomes very tasty!

Richelieu and all his soldiers were delighted. Under such conditions, victory over the enemies was guaranteed! This is how this delicious sauce appeared, later named after the captured city - "maon sauce" or "mayonnaise".

The new seasoning achieved worldwide fame, which was called "Provencal sauce from Mahon", or in French - "mayonnaise". And to this day, a common and more industrially produced sauce is mayonnaise. In our country, the annual consumption of mayonnaise is about three kilograms per person, and this figure is constantly increasing every year. In addition, the business plan for making mayonnaise is now one of the most profitable.
It is also important that in the manufacture of mayonnaise fairly easy-to-use equipment is used, and the method of preparing sauces is quite simple. All these factors make it possible to regulate the manufacturing process of products in a short time, which is equal to 1 - 2 months.

Mayonnaise production technology.

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

Raw material.
To obtain a mayonnaise product, sunflower oil is mainly used in our country, soybean, corn, peanut, as well as cottonseed, olive and sesame oils are used abroad.

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

In our country, egg powder is used as the basis of the emulsifying component. The yolk of the egg forms the basis of this emulsion and affects its endurance, density, color, as well as the taste of the finished product.

The emulsifying effect of egg yolk or powder is determined by lecithin, as well as other phospholipids, membrane-forming lipoproteins: lipovitellin, lipovitellinin and free proteins, phosphitin, livetin.

Apply such varieties of egg products as egg powder, egg granular product, dry egg yolk. In mayonnaise, the content of egg products ranges from 2 to 6%, depending on the recipe.

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

Recently, vegetable proteins are more often used, more often soy. In our country, the use of edible soy protein, edible soy base, edible soy concentrate is allowed.

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

In the manufacture of mayonnaise from natural stabilizers, starch and modified starch remain the most widely used. Phosphate grade B corn starch is used in our country. Thanks to the esterification of starch with phosphates, a food thickener was obtained, the characteristic feature of which is the ability to dissolve in water or milk at room temperature.

In order to obtain low-calorie mayonnaise in our country, maltin is used, which is produced from potato starch due to partial enzymatic hydrolysis with the following thermal treatment of the hydrolyzate. Maltin is an easily digestible carbohydrate that dissolves when heated to 75-80C.

After it has cooled, a gel of different consistency is formed, depending on what concentration.

In Germany, in the manufacture of sauces, "coolie" is used - this is a thickener that is obtained from starch and flour of guar grains.

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

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

At the moment, abroad, xanthan, which is a biopolysaccharide, is used to regulate most salad dressings.

Relatively intelligible polysaccharides are gums and mucus, widely used in the manufacture of emulsion products. The more famous ones are gum arabic and gum tragacanth. According to the chemical structure, gums are classified as heteropolysaccharides, which consist of a certain amount of monosaccharides, among which there is either one or more uronic acids.
Mustard powder is a flavor additive, and the proteins contained in this powder equip emulsification and structural formation.

Water, salt, sugar, mustard powder, dill essential oil, ground black pepper, cumin, extracts of spicy and aromatic materials are added to mayonnaise. If sweet mayonnaise is produced, then flavoring extracts are added to it according to the technical description.
In order to increase the strength of low-calorie emulsion products to the development of unpleasant microbiological processes while saving, preservatives are introduced into their structure, mainly benzoic salt and sorbic acid.

Mayonnaise is prepared in two ways: batch and continuous.

Manufacturing by periodic technology includes the following steps:
- preparation of individual elements of the structure;
- preparation of mayonnaise paste - dissolving dry elements and mixing them to a homogeneous position. The dry elements are dissolved in two mixing devices: in the first - milk powder with mustard powder, and in the second - egg powder. Water with a temperature of 90-100 ° C, a mixture of mustard with powdered milk are delivered to the first.
- exposure at a temperature of 90-95 °C for about 20-25 minutes with subsequent cooling to 40-45 °C. The composition of the egg powder is heated to 60-65 °C, held for 20-25 minutes for pasteurization, and then cooled to 30-40 °C. Next, the compositions from these two mixing devices are combined. The density of solids for high-calorie mayonnaise should be at least 37-38%, and for the rest - 32-34%;
- preparation of a coarse composition of mayonnaise sauce - is carried out in large mixers, which are equipped with metal mechanisms with a low speed. Pasta, vegetable oil, a solution of salt and vinegar or other acids are added to a large mixer; homogenization of liquid in piston homogenizers with a certain pressure to avoid stratification of the prepared liquid.

Uninterrupted production of mayonnaise products on a self-acting line using votator-type heat exchangers consists in the following actions: prescription dosing of all elements in the preparatory group; mixing of the elements and formation of the mayonnaise composition in the interval of 15 minutes, deaeration of the mayonnaise composition; thermal processing in the first cylinders of the votator with a temperature of about 53-55°C; cooling the composition in the second cylinder of the votator to a temperature of about 15-20°C; homogenization of the mayonnaise composition in a homogenizer; packaging and sealing of cans; product packaging.

Mayonnaise production line.
. Capacity - picking up vegetable oil.
. Intermediate capacity - collection of vegetable oil before merging.
. Hydrodynamic device - fusion, grinding, temperature processing.
. Pump - supply of vegetable oil.
. Intermediate container - designed to preserve the product before packaging.
Screw pump - designed to supply the product to the packaging. Packing machine - product packaging.

The structure of demand for mayonnaise is changeable: Russian citizens more often reject cheap varieties and prefer expensive and better quality ones. Secondly, the results of the campaign in the fight against excessive consumption of foods that contain cholesterol, which is why clients try to balance their diet, have an impact. Mayonnaise imperceptibly drives sour cream out of the consumption basket. Also, most mayonnaise manufacturers tend to diversify and introduce sauces into the range.

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

In the Russian Federation, about 38 organizations are engaged in the mayonnaise business. The five large industries - Unilever, NMGK, Solnechnye Produkty, Essen Production AG, Efko - account for 62.7% of the market in value terms and 63.8% in real terms.

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

There are two versions of the invention of mayonnaise sauce. Both of them are associated with the city of Mahon, the capital of the island of Minorca, only they refer to different historical events and prominent people of that time.

According to one of them, it was in 1757. The Duke de Richelieu, commander of the French garrison, conquered the city of Mahon, the capital of the Spanish island of Minorca, and then the city was besieged by the British. The French had practically no food left except for eggs and olive oil. Omelettes and scrambled eggs were prepared from these products. You yourself understand that such a “variety” can bother not only an aristocrat accustomed to delicacies. And therefore, Richelieu, by all means available to the duke, showed his displeasure to the cook. The resourceful cook ground the egg yolks with salt and sugar, added oil and spices to the resulting mixture, and beat it all thoroughly.

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

But real noble mayonnaise cannot be compared with what is sold in the store. In order for you to have a starting point in taste, you can make your own mayonnaise. History has not conveyed to us the exact recipe, so we offer a generalized one from various sources:

olive oil - 150 ml (note: the oil should not be rancid)

egg yolk (carefully separated from protein) - 1 pc.

sugar - 1.5 teaspoons

salt - 1/3 teaspoon

lemon juice (freshly squeezed) - 1/2 tablespoon, diluted with 2 tablespoons of water

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

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

In Russia, the definition of mayonnaise is very broad, although our beloved classic "Provencal" - an example of "Russian traditions" - in countries such as Germany and the UK could not be called "mayonnaise" at all due to its low fat content. In the legislation of these states, there are strict requirements aimed at ensuring that the consumer is not misled by the name. Depending on the fat content, the sauce can be called mayonnaise at 80% fat, salad mayonnaise at 70-50% and dressing sauce at 49-20%. The content of egg yolk is also limited, which is approximately equivalent to its content in the classic Russian "Provencal". Real mayonnaises are expensive and high in calories, so their consumption, even in developed countries, does not exceed 5%. The main share falls on salad mayonnaise - about 50%. We have a different classification and mayonnaises are divided into high-calorie with a mass fraction of fat more than 55%, medium-calorie with a mass fraction of fat 55-40% and low-calorie - less than 40%.

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

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

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

But it is not all that bad. In place of confusion and falsification, many worthy brands of mayonnaise come again, with a new original taste worthy of the traditional "Provencal". There are more mayonnaises with flavors, fat content and composition that allow the buyer to optimally balance his diet.

Be sure to read the label and pay attention to the manufacturer first. A reputable company is a guarantee of quality, and the names of mayonnaise often do not mean anything, and, under the same name, you can find a very different product.

Pay attention to the composition of the products included in it. According to GOST, products are recorded in descending order of mass fraction. Eggs and milk - only they can provide a traditional taste, their pale likeness - flavorings. Stabilizing (stabilizer and starch) and preservative additives - no harm, as well as health benefits, although there is a lot of debate about this. For medium and low-calorie mayonnaise, they are indispensable, and if they are not indicated on the label, most likely the manufacturer is misleading you.

The production date is very important for domestic (imported sterilized) mayonnaises, since an unsterilized natural product cannot be stored for a long time.

Storage conditions at the point of sale - mayonnaise should be stored at a temperature of 3 to 7°C. Freezing, as well as excessive heating of mayonnaise, destroys its structure. At temperatures above the optimum, the shelf life is drastically reduced. Buy only at trusted retail outlets, because if you were sold mayonnaise from a refrigerated display case, this does not mean that it was stored in the back room in the refrigerator.

Flavors, spices, dyes - the choice of taste, the essence does not change.

Weight in grams and milliliters is not the same thing. 250 ml is approximately 240 g!

Plant for the production of mayonnaise and mayonnaise creams

Specialists in the food industry have developed about 40 recipes and names of mayonnaise, and only a few of them are known to the wide mass of buyers, mainly produced earlier by state-owned fat factories. For entrepreneurs who want to diversify this market segment, our lines for the production of mayonnaise and mayonnaise creams are intended. On them it is possible to produce various types of mayonnaise, creams, sauces and seasonings, which by their nature are emulsions of fat in water. The plant produces mayonnaises and creams according to batch technology.

The technological sequence contains the following cycles:

water heating;
mustard steaming;
loading water, bulk components and oil into the mixer;
mixing of components;
loading acid solution;
homogenization of the emulsion and delivery of finished products to the tank.

Manufacturing technology:

the water used as a component of mayonnaise is heated in a water heater tank. Mustard in the form of a paste is placed on pallets and steamed in a steaming tank. Loose components of mayonnaise (powdered milk, salt, sugar, etc.) are sieved in the presence of lumps.

Heated water is supplied to the mixer-pasteurizer by means of a pump. Then, according to the recipe, bulk components and steamed mustard are loaded. The mixture is stirred for 30-35 minutes. In this case, the mixture is pasteurized at a temperature of 78-80 °C.

After the mixture has cooled down to 45 °C, vegetable refined deodorized oil is fed into the mixer through the appropriate pressure hose. After mixing the components for 15-20 minutes, a coarse mayonnaise emulsion is formed.

At the next stage, a 9% solution of acetic (or other) acid is introduced into the mixer. Vinegar gives mayonnaise a sharp taste and aroma, prevents the development of bacterial flora (providing the required pH of the medium). Then homogenization (creation of a homogeneous mixture) of the mayonnaise emulsion is performed.

Homogenization of fat-containing mixtures is necessary for the crushing of fat globules, while their settling during storage is reduced (mayonnaise does not delaminate). In the homogenizer, liquid is passed at high speed through a narrow gap. At the same time, due to a sharp pressure drop at the edge of the homogenizer slot, fat particles are crushed and evenly distributed in the emulsion.

Different types of mayonnaise in fat content require different pressures when homogenizing the mixture. For high-fat mayonnaise, the optimal pressure can be 10 ... 15 kg / sq. cm, and for low-fat (salad seasonings) - 120 ... 130 kg / sq. cm. The mayonnaise machine can be equipped with both a 30 atm pressure homogenizer and a 100 atm pressure homogenizer.

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

Part of the equipment:

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

Mayonnaise recipes

Mayonnaise is a creamy, multi-component, highly dispersed emulsion of refined and deodorized vegetable oil in an aqueous medium, into which egg powder, milk powder, mustard, salt, sugar, vinegar, as well as a number of flavoring, aromatic and gelling additives and spices are first introduced.

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

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

1. High-calorie with an oil content of more than 55%.
2. Medium-calorie with oil content in the range of 40% - 55%
3. Low-calorie with oil content less than 40%.

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

By the nature of the contained spices and additives, the following mayonnaises are distinguished:

Mayonnaise with tomato. Contains 30% tomato paste, which gives the mayonnaise a distinct tomato flavor. The presence of at least 45% vegetable oil and other spices makes tomato mayonnaise a valuable seasoning for all kinds of vegetable, fish and meat dishes.

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

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

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

Mayonnaise fortified. Contains 35% vegetable oil, enriched with vitamins C and B. It has a pleasant aroma and slightly sour taste. Contains corn oil, rich in vitamin E, which has healing anti-sclerotic properties. Recommended for seasoning meat, fish and vegetable dishes.

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

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

table 2

Characteristics of the feedstock

Vegetable oil . For the production of mayonnaises, the following vegetable oils are used: sunflower oil GOST 1129; soybean oil GOST 7825; corn oil GOST 8808; peanut butter GOST 7981; cottonseed oil GOST 1128; cottonseed salad oil TU 10-04-02-60-89; olive oil TU 10-04-11/13-87. The following vegetable oils are used for the production of mayonnaise: sunflower oil GOST 1129; soybean oil GOST 7825; corn oil GOST 8808; peanut butter GOST 7981; cottonseed oil GOST 1128; cottonseed salad oil TU 10-04-02-60-89; olive oil TU 10-04-11/13-87.

All vegetable oils must be fully refined, including deodorized, and meet the standards for deodorized oils. For the production of mayonnaise, any of the listed oils must be processed no later than 1 month from the date of its refining.

Egg powder. GOST 2858. The product is light yellow in color, uniform throughout the mass, should be easily sieved through a sieve of 0.7 - 1.0 mm, should not have an extraneous taste and smell. In the presence of lumps, the latter should be easily crushed.

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

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

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

The following types of dairy products are allowed:

• dry skimmed cow's milk GOST 4495;
• dry cream GOST 1349, premium;
• dry milk product “SMP” TU 49-934-82;
• whey protein concentrate TU 49 939-82 or TU 49 979-85;
• dry buttermilk TU 49 247-74.

It is also allowed to use other dairy products in accordance with regulatory and technical documents and in accordance with the technical description for a particular variety of mayonnaise, permitted by the state sanitary and epidemiological supervision authorities for the manufacture of food products.

Granulated sugar. GOST 21. Loose, dry to the touch, without foreign tastes and odors, color is white with a sheen. Should be completely soluble in water. The sugar solution should be clear.

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

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

Vinegar. The following types of vinegar are allowed:

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

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

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

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

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

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

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

Flavoring and stabilizing additives.

• dill essential oil TU 10.04.13.68-88. Solution with a mass fraction of 20% in deodorized vegetable oil;
• ground black pepper OST 18-279-76;
• cumin OST 18-37-71;
• orange essence OST 18-103-84;
• phosphate corn starch grade B TU 18 RSFSR 279-79;
• carboxymethyl potato starch TU 10 BSSR 111-86.

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

Table 3

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

Technological process of production.

The technological process provides for the creation of optimal conditions that make it possible to obtain a homogeneous (close to homogeneous) and stable system from components that are practically insoluble in each other (oil - water). Factors such as the concentration of dry components, oil feed rate, conditions for swelling and pasteurization of dry components, and the intensity of mechanical action are also taken into account.

The production of mayonnaise consists of the following technological operations:

1. Paste preparation (emulsifying and structuring base);
2. Preparing a coarse emulsion.
3. Preparation of a fine emulsion (homogenization).
4. Transportation of finished products to the warehouse.

Preparation of a 10% solution of acetic acid.

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

Pre-ground spices are placed in a linen bag, which is placed in a container with acetic acid. Then the entire contents are brought to a temperature of 80ºС, after which, without removing the bag, they are cooled. Next, the spices are removed.

Preparation and dosing of bulk components.

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

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

Mayonnaise preparation.

Mayonnaise paste is prepared alternately in two mixers as follows: In the first mixer, water is added, then milk powder, mustard powder, salt, granulated sugar and soda. Water is set in quantity, based on ensuring the ratio to mustard powder as 2.5 to 1, and to dry milk as 3 to 1 (for high-calorie mayonnaise). The dry components are loaded with the mixer running, then heating is turned on (through the water “jacket” of the mixer) and the temperature of the mixture is brought to 90-95ºС for better dissolution and pasteurization of the components. At this temperature, the milk-mustard paste is kept for 15–20 minutes, then cooled (with running cold water through the “jacket” of the mixer) to a temperature of 30–40 ° C, after which water and egg powder are fed into the milk-mustard paste in a ratio of 1.4–2 0 to 1 for high-calorie mayonnaise and 2.2 - 2.8 to 1 for medium and low-calorie mayonnaise. Loading is carried out with the mixer running; then turn on the heating again and bring the temperature of the paste to 60-65ºС, at which it is kept for 15-20 minutes, after which the paste is cooled to a temperature of 25-30ºС, after which the paste is pumped into the second mixer. The readiness of the paste in the first mixer is determined visually by the sample taken during the mixing process. The sample taken on a wooden plate must be completely homogeneous, without visible lumps and flow evenly from the plate.

Preparation of a "coarse" emulsion.

In the second mixer (P3-OZU-0.35), a “coarse” mayonnaise emulsion is prepared, for which it is necessary to ensure uniform mixing in all layers of the mixer, without stagnant zones.

After pumping the mayonnaise paste from the first mixer to the second, the calculated portion of vegetable oil with a temperature of 20-25ºС is fed into the latter with constant stirring. In the first 7 - 10 minutes, the oil is fed slowly at a rate of 10 - 12 liters per minute, then more quickly (25 l / min). It is allowed to start the oil supply 3-7 minutes before the end of pumping all the mayonnaise paste from the first mixer to the second one. The deodorized oil is fed into the mixer by a B3-OPA-2 rotary pump (if it is stored in tanks), or loaded manually (if it enters production and is stored in canisters).

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

After applying a 10% solution of acetic acid, stirring is continued for 5 - 7 minutes. The sequence of adding vegetable oil and a 10% solution of acetic acid to the mayonnaise paste must be strictly observed. This is due to the fact that a one-time or non-sequential input of them can lead to separation of the emulsion.

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

Homogenization of the “coarse” mayonnaise emulsion.

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

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

It is recommended that the homogenization process be carried out in parallel with the process of mixing the components in the second mixer. It is allowed to carry out the homogenization process also during the preparation of mayonnaise paste in the first mixer, in parallel with the pasteurization process of the components (also in circulation mode), not excluding the homogenization of mayonnaise in the second mixer.

Packing and packaging of the finished product.

Ready mayonnaise, after the homogenization process, from the second mixer P3-OZU-0.35 is sent for packing in polypropylene cups, glass jars, or plastic bags.

The food industry has always been considered a fairly promising area for profit. But in order to start multiplying incomes by producing and selling finished products, it is important to choose a product that, regardless of the season, is in demand among the consumer. Here, without any doubt, we include mayonnaise. It is the production of mayonnaise, according to many experts, that today is one of the most promising industries. Having spent not so much money, you can organize your own stable business in the field of food production.

Our business valuation:

Starting investments - from 2,000,000 rubles.

Market saturation is average.

The complexity of starting a business is 7/10.

Mayonnaise is a creamy mass prepared on the basis of vegetable and animal raw materials. This product is loved by consumers for its palatability and is widely used to season hot and cold dishes.
Despite the apparent complexity, it is not difficult to open a mini mayonnaise plant in Russia. The main difficulties that will await every entrepreneur are related to the documentation of the workshop and bringing it into proper form - sewerage and ventilation, preparation of warehouses, maintaining optimal storage conditions for raw materials and the finished product. Let's not forget that it is a food enterprise that is planned, and therefore, here we will have to work on studying the regulatory documentation.

So, what should an entrepreneur organize his own mayonnaise production business?

Mayonnaise manufacturing technology and raw materials used

Technological scheme for the manufacture of mayonnaise

The raw materials used to obtain the finished product are publicly available in any region of our country. But in order to minimize costs, it is better to conclude contracts for the wholesale supply of all necessary components. And here it is worth choosing those suppliers that are located as close as possible to the workshop. What ingredients are to be purchased?

• Vegetable oil (soybean, sunflower, corn, olive).
• Milk (whole, dry),
• Sugar.
• Salt.
• Vinegar.
• Soda.
• Additives.

The list of raw materials may vary, since each specific plant uses its own unique recipe, which is kept in the strictest confidence. And therefore, if an entrepreneur does not know how mayonnaise is made, he definitely needs to hire (even before the launch of the plant) an experienced technologist who would calculate the ratio of all components. Success in the market will largely depend on this, because the tastier the product, the more demand it will have.

In general, the mayonnaise production technology can be described as follows:

• Preparation for processing of individual components of the recipe.
• Obtaining mayonnaise paste, when all raw materials are mixed to a homogeneous state.
• Heat treatment of the resulting paste at a temperature of 53-55 °C.
• Cooling mayonnaise to a temperature of 15-20 °C.
• Homogenization of finished mayonnaise until a perfectly balanced mass is obtained.
• Packing and packaging of the product.

The methods of obtaining the finished product may vary, but literally every process that takes place during its manufacture must be strictly controlled. After all, even the slightest deviation from the specified parameters can lead to low-quality products.

Mayonnaise production equipment

Mayonnaise production line

The next thing an entrepreneur has to do is to buy equipment for the production of mayonnaise. Suppliers offer a wide choice of technical equipment. The differences in the arrangement of lines are insignificant, therefore, when choosing devices, it is better to focus on some other parameters:

• price,
• power,
• degree of process automation,
• packing method.

A standard vacuum mayonnaise production line consists of the following pieces of equipment:

• Intermediate and final containers for mixing raw materials and storing the finished product before packaging.
• Pasteurizer.
• Homogenizer.
• Packing machine.

At the same time, as the automation and equipment of the line vary, the market price of equipment for the production of mayonnaise also changes. For example, a line with a capacity of up to 1000 kg / day can be purchased for 700,000 rubles. But more powerful equipment (up to 2500 kg / day) will cost the entrepreneur no less than 1,500,000 rubles.

In the business plan, in addition to spending on the main equipment, it is also worth including the cost of auxiliary units. In this case, chambers for storing certain types of raw materials and finished products will require large investments. This is at least another 200,000 rubles.

Sales options for the finished product

The mayonnaise production shop will only start to make a profit when all manufactured products are sold to customers. And just the search for interested consumers will take a lot of time from the entrepreneur at first.

The competition in this niche is low, but this does not make it any easier to find buyers. Large hypermarket chains are reluctant to contact small businesses, and small wholesale sales will not generate large revenues.

It is important to offer customers a wide range of products. And the point here is not even in the recipe of the mayonnaise itself, but in the container in which it will be packaged. Plastic and glass jars, bags, disposable packaging - everything can be used.

To attract customers, not only the technological scheme for the production of mayonnaise should be thought out, but also the marketing campaign should be clearly planned. This means that we will add the services of a designer to the development of attractive packaging to the start-up costs. As for advertising, it is hardly worth spending money on large-scale advertising campaigns for small and medium-sized businesses, since the attention of buyers here is riveted to the products of large brands - it makes no sense to compete with them yet. At first we make the main bet on the quality of the finished product.

How profitable is the mayonnaise business?

It has already been proven in practice that the manufacture of mayonnaise can bring consistently high profits. And if you find the required start-up capital for organizing a business, then the workshop will be able to recoup all costs in a short time. And investments, even according to minimal estimates, will be impressive - at least 2,000,000 rubles. And the main items of expenditure will fall on the commissioning of the purchased line, the preparation for operation of the premises and the development of packaging design.

Investments will be somewhat higher if the plant provides for its own fleet of vehicles for the delivery of finished products to customers.

The line for the production of mayonnaise purchased for the available amount will produce no more than 1000 kg of the finished product per day. At the same time, the wholesale price for mayonnaise of a budget brand fluctuates around 50 rubles/kg. And knowing the average production volumes, you can determine the monthly sales revenue - it will be at least 900,000 rubles. Taking into account variable expenses (rent, transport, taxes, communications, salaries for employees), the net profit will be ≈100,000 rubles.

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

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

Technology and equipment for the production of mayonnaise

The technological process for the production of mayonnaise provides for the creation of optimal conditions that make it possible to obtain a homogeneous (close to homogeneous) and stable system from components that are practically insoluble in each other (for example, water and oil). Taking into account such factors as the concentration of dry components, the conditions of swelling and pasteurization of dry components, the rate of oil supply, the intensity of mechanical action.

Mayonnaise production consists of the following technological stages:

1. Dosing of components
2. Cooking egg paste
3. Preparation of mustard-milk paste
4. Vegetable oil supply
5. Preparation of vinegar-salt solution
6. Making a coarse emulsion
7. Preparing a fine emulsion
8. Packaging of ready-made mayonnaise
9. Stacking ready-made mayonnaise in a shipping container
10. Transportation of finished products to the warehouse

Dosing of components - VDP-500 The production of mayonnaise begins with the preparation and dosing prescription components. Bulk components: egg powder, skimmed milk powder, mustard powder, sugar, salt, soda enter the workshop in bags, stacked 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 performed using a flowmeter.

Preparation of egg paste - VDP-500 and VGA-1000 Mayonnaise production starts from making egg paste. To do this, water and egg powder are supplied to the VDP-500 (in accordance with the recipe). Mixing with 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. There are several benefits to using a vacuum to make mayonnaise, some of which are: The introduction of sunflower oil into the product in a thin stream through the circulation channel connecting the disperser and the reactor, which reduces the preparation time of the product and ensures the production of a stable emulsion. The absence of air inclusions in the finished product, which increases the taste and shelf life. Before pumping, a visual sample is taken from the egg paste to determine the readiness. The sample taken on a wooden plate must be completely homogeneous, without lumps, and flow evenly from the plate. The egg paste is cooled to 20-30°C in the main mixer during preparation and cooling of the mustard-milk paste by heat exchange with the ambient air.

Preparation of mustard-milk paste - VDP-500

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

Supply of vegetable oil to the main mixer - VGA-1000

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

Preparation of acetic-salt solution - VDP-500

The preparation of an acetic-salt solution consists of two stages:

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

VDP-500 prepares 10% 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).

Further, in VDP-500 with a 10% acetic solution, is added saline solution. The resulting acetic-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 mustard-milk paste as an example). The supply of acetic-salt solution can be started simultaneously with the introduction of the last portions of vegetable oil.

Preparation of a homogeneous emulsion - VGA-1000

A coarse emulsion is prepared in the VGA-1000, equipped with a mixing device with a low rotational speed (frame type mixer). The mixer must provide uniform mixing in all layers of the mixer without stagnant zones.

The sequence of adding oil and acetic-salt solution to the paste must be strictly observed. This is due to the fact that a one-time or high-speed input of them can lead to the production of an emulsion of the reverse type, 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 delaminate before it circulates through the rotary pulsation apparatus. Visually, such an emulsion has a uniform appearance and does not delaminate in the selected sample with weak stirring.

The resulting coarse emulsion to be converted into ready-made mayonnaise must pass homogenization process, which is carried out using a rotary-pulsation apparatus, the principle of its operation is described in the passport.

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

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

mayonnaise packaging

Mayonnaise is fed from the container for finished products for packaging. Packing is carried out on any intended for this packing machine.

Packing should be done immediately after production, as contact with atmospheric oxygen worsens the taste and preservation of mayonnaise.

Packing packaged mayonnaise in a transport container

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 in a warehouse at a temperature of 0 to +18°C until dispatch to the consumer.

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 - "Salad"

Mayonnaise "Mustard"

(mass fraction of fat not less than 37%)

low calorie mayonnaise(using stabilizers Keltrol and Manukol (Great Britain))

(mass fraction of fat not less than 37%)

Mayonnaises with a mass fraction of fat of at least 47%

The mayonnaise production equipment offered by our company is convenient to operate 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 performance. The price of equipment for the production of mayonnaise is always negotiable due to the unpredictability of costs.

Mayonnaise has been and remains a popular Russian product. Mayonnaise production is profitable, requires small investments and simple technological equipment. They say that one Moscow company started production using the Vyatka washing machine as equipment. Three years later, six conveyor lines produced several tens of tons of finished products per day.

According to the most rough estimates, only in Moscow there are about a hundred "mayonnaise" enterprises, both medium-sized and very small, between which there is quite tough competition. All equipment for the production of mayonnaise is almost identical to each other and differs only in some minor details. There is equipment from Western manufacturers on the market, but it is several times more expensive than domestic equipment (for example, you will have to pay about $ 150 thousand for German equipment). A similar installation by the Moscow company Prospekt costs only about $ 7 thousand. produce ketchup, toothpaste, shampoo, etc.

Mayonnaise - what to eat it with

Mayonnaise is a creamy, finely dispersed oil-in-water emulsion made from refined deodorized oils with the addition of emulsifiers and flavors. The finished product must comply with OST 10-77-87 “Mayonnaise. Specifications". Mayonnaise must be absolutely homogeneous in structure and consistency.

Mayonnaise is obtained by mixing various components and subsequent homogenization, in which vegetable oil particles dissolve in water particles, splitting up to 5 microns (this is impossible with conventional mixing).

The shelf life of mayonnaise is only 1 month, but with the use of special emulsifier additives, it can be increased up to 2 months.

Now almost any equipment sold allows you to get high-quality mayonnaise, but here it is important to find the exact ratio: mayonnaise must be of high quality, and at the same time cheap - just then it will be in high demand.

The main ingredient of mayonnaise is refined and deodorized vegetable oil. It accounts for the main cost of the product.

In Russia, thick mayonnaise with a fat content of 67% is in greatest demand (the traditionally popular Provencal is one of these).

Pasteurization

Now the main demand falls on complexes of medium and high productivity - from 6 to 14 tons per day. Many entrepreneurs prefer not to take risks and buy equipment of small capacity - from 2 to 5 tons. Then, by purchasing new tanks, you can significantly increase the capacity.

One of the main conditions when choosing equipment is the availability of a pasteurizer for egg powder and milk powder, since pasteurization is simply necessary for all products of animal origin. It occurs at a temperature of 60 ° C for egg powder and 85-9 CGS for milk at. different modes to therefore separately from each other (in turn in the same bath).

Technology

There are two technologies for the production of mayonnaise: hot and cold. Cold is now used extremely rarely, because it produces a product of insufficient quality. With hot technology, simultaneously with homogenization, the entire mixture is also heated to a certain temperature. With hot technology, mayonnaise has a more pronounced taste, and now almost all “mayonnaise” equipment is equipped with heating elements. If your company has a source of steam (it is much more economical than electricity), it makes sense to order the installation of a special spiral that heats the tank from steam.

The production of mayonnaise begins with the preparation and dosing of prescription components. The required amount of water is also dosed into the main mixing tank.

This is followed by the preparation of mustard-milk paste. To do this, water, milk powder, mustard powder, granulated sugar and soda are mixed in one tank (mixer). After loading the ingredients, the mixture mixing system is turned on. Next, the resulting mixture is pasteurized (at 80 C") and then pumped into the main homogenizer tank.

If there is an additional tank, egg paste is prepared: for this, water and egg powder are mixed, heating the mixture to 65 ° C. Then the already cooled paste is pumped into the main mixer-homogenizer.

By the same principle, a solution of acetic acid is prepared in a small mixer according to the recipe. Then a saline solution is added to the resulting acetic solution and it is also thoroughly mixed, entering the main homogenizer tank.

Then the initial "rough" emulsion is prepared - for this, the resulting mixture is mixed. Visually, this emulsion should have a uniform appearance and not delaminate with weak stirring.

But this is not yet ready-made mayonnaise. A coarse emulsion must go through a homogenization process, which is carried out by repeatedly pumping the mixture through a device of the same name. As a result, ready-made mayonnaise is obtained.

Then a sample is taken from the batch: it must be completely homogeneous, without visible bundles, lumps, and have a viscosity characteristic of mayonnaise, as well as color, taste and smell.

Then the mayonnaise must be pumped into a special container for finished products, freeing the main tank for a new cycle.

Equipment

The Prospect enterprise itself makes equipment for the production of mayonnaise of various capacities, which determines its cost (in turn, the productivity depends on the volume of tanks). Only three people are required to operate the kit. For example, the LPU-M31-150 model with a minimum productivity of 6600 kg of products per day costs about 180 thousand rubles, the LPU-M32-300 (with a capacity of 8800 kg / day) costs 215 thousand rubles, and the line with a capacity of 15200 kg / day costs more than 260 thousand rubles. One of the main advantages of such equipment is that, in addition to mayonnaise, it can produce all other pasty products: mustard, yogurt, ketchup and various sauces (with minimal modification).

One of the new activities of Prospekt is the preparation and opening of a full turnkey complex for the production of mayonnaise (and not only): from a business plan and renovation of the premises to certification of finished products.

The Dialog Plus trading company also offers a complete mini-factory for the production of mayonnaise with a capacity of 3 tons / day, occupying an area of ​​only 30 m 2 and costing about 127 thousand rubles, and a complex with a capacity per ton more, which can be placed on an area of ​​60 m 2 - more than 200 thousand rubles.

Also, the Tveragroprodmash company sells complexes for the production of mayonnaise for 222 thousand rubles. 50% advance payment, but only one small capacity - 3 tons per day.

The Belarusian company Vaem offers quite expensive complexes worth $25,000, and the same company supplies both stabilizers and preservatives.

An unconventional module is offered by the Krasnoarmeisky Research Institute of Mechanization: it is designed for the preparation of low-calorie mayonnaise based on whey. Its productivity is 250 kg / hour, and the cost is very high - 600-700 thousand rubles! (Produced only on prepaid orders.) However, it is possible to partially replace expensive vegetable oil with whey, which reduces the cost of finished products by 1.5 times.

The Akmalko company also sells universal plants for the production of mayonnaise and various pasty products (ketchup, mustard, jams) of its own production using German components with a capacity of $ 57 thousand. Its feature is the ability to produce mayonnaise with a long shelf life (up to 6 months) without the addition of preservatives , due to the presence of a device for flow-through pasteurization of the finished mixture and the next immediately sealed and hot (at a temperature of 95 ° C) packaging.

Packaging is the key to success

In order to sell the resulting product and ensure stable demand for it, it must be packaged with high quality and beautifully - after all, it is by the packaging that buyers usually judge the product.

In total, the three most common types of packaging are used for pasty products: these are plastic bags, glass jars and plastic cups. Of course, the use of bags will have a minimal impact on the cost of finished products, then plastic cups follow in terms of costs, and the most expensive packaging is glass jars with a twist-off lid. The choice of packaging also largely depends on the positioning of your product - for example, if you represent it in the highest price category and rely on wealthy buyers (for sale in expensive supermarkets), then it makes sense to prefer twist-off glass jars, which are the most convenient (their after opening, it can be reused several times, covering the remains of the product and ensuring the longest shelf life). Many provincial entrepreneurs, according to representatives of companies selling packaging equipment, prefer ordinary cans with roll-top lids - these lids are almost three times cheaper than "twist-off".

More packaging equipment is divided into automatic and semi-automatic. The latter means that you will have to assign a special worker to install each individual cup, then seal and remove it. The machine works practically without human intervention, which is much more productive. As a rule, automatic machines are 3-4 times more expensive than semi-automatic ones.

True, not all types of packaging have inexpensive semi-automatic machines. For example, many manufacturers traditionally pack mayonnaise in packages of 150-250 g, but only expensive machines are produced for packages. Semi-automatic bag filling and sealing machines are available only for milk, but they are not suitable for mayonnaise. The fact is that they are able to solder only ordinary polyethylene, and it has the peculiarity of passing fat. For mayonnaise, a special laminated polypropylene film (lavsan-polypropylene) is used.

For example, the Dialog-plus company offers a milk filling machine AO-111 with a capacity of 22-25 bags per minute, occupying an area of ​​2 m 2. The automatic machine performs the following operations: bactericidal treatment of the film, forming bags from the film, applying the date on the film, filling the bags with the product, stacking the bags in boxes in a given quantity and removing already filled boxes. And all this will cost you 148 thousand rubles, plus you will have to pay another 3.5 thousand rubles for an additional nozzle for mayonnaise.

A vertical filling machine AV 50F (Zh) manufactured by the Moscow company Flight M with a dosing range of 0.1 to 1.0 liters and a capacity of up to 35 packs per minute will cost $ 9,000.

In the same company, you can also purchase a Chinese automatic machine of the DXDL-50 series for filling and packaging products with a capacity of 40-60 packages per minute, however, the maximum capacity of one package is only up to 150 ml. In it, an electronic counter will display the number of packages produced, and a photoelectric sensor will control the uniformity of the tape feed and the identity of the sealed packages. The price of such a unit is almost $ 11 thousand. Recently, imported mayonnaise has appeared on sale in “standing” packages, which are more convenient for consumers than simple ones.

The BESTROM company offers automatic packaging machines for pasty and liquid products weighing from 50 g to 50 kg with a capacity of up to 100 bags per minute, costing from $ 65 to 85 thousand, assembled from American components. Moreover, they are able to form bags in the form of a pillow or with a flat bottom, and are also equipped with any type of weight and volume dispensers.

Of course, imported equipment is much more expensive than domestic, but also much more reliable. True, in the event of a breakdown, the repair of an imported unit will cost much more than a domestic one. For example, a device for dispensing and sealing cups from the American company PHOENIX costs from $23,000 (40 doses per minute) to $180,000 (250 doses).

If your output is small or financial possibilities do not yet allow, then you can purchase a semi-automatic device for packing mayonnaise into plastic cups. True, for this you will need two units: one for filling and dosing, and the other directly for capping. Between them is a worker.

For example, a semi-automatic dispenser for viscous products of the UD-2 brand produced by Prombiofit costs 25 thousand rubles. In it, doses are dispensed automatically once every 6 seconds through two channels at once (i.e., two cups are filled at the same time), and the container is set to the filling position and manually removed by the operator, which, of course, is quite laborious. The product enters the unit through flexible hoses by suction from a stainless steel supply tank. The unit is supplied with dosing cylinders of one of the following sizes: 50, 120, 250 and 500 ml, and it is possible to smoothly adjust the dose volume in the range from 20 to 100% of the volume of the dosing cylinder.

An interesting development was carried out at the Prospekt company, replacing the inner ball traditional for a filling tap with another system (the former has a significant drawback - periodic freezing due to the ingress of harder particles).

Then the cups must be installed in a special machine for hermetic welding with aluminum foil lids. For example, a USS-2 plant with a maximum capacity of up to 600 units per hour costs about 20,000 rubles. During operation, the already filled cup is installed by the operator in the cell of the welding stand, covered with a foil lid, brought to the brewing position by turning the transport rotor and hermetically sealed. Moreover, the installation can be additionally equipped with a device for applying the packing date to the container.

Novgorod Machine-Building Plant offers a similar but more advanced semi-automatic device POLUR-250 for cups of two sizes: 75 and 95 mm in diameter. In it, the timer sets the heating time for aluminum foil during sealing, and the thermostat maintains the set temperature. Equipment manufactured by the Israeli company PACK LINE Ltd. much more expensive than domestic. For example, a semi-automatic machine for manual capping of plastic cups POV-IS costs from $1.8 to $3.5 thousand, and fully automatic - from $15 thousand.

But, of course, automatic machines are still the most productive, and besides, they will save on the wages of the employee: he simply will not be required for this operation. For example, the Ryazan plant Elf-4M offers an IPKS-051 automatic machine with a capacity of 1100 cups per hour and with filling doses of 200 and 250 g. This unit costs almost $ 7 thousand.

The Ukrainian OJSC “Complex” also offers a filling and capping machine of the MK-OFS model. It is possible to install one or two additional dispensers in it, designed to add other components to the main product, including those with soft fillers, which can give new taste qualities to the main product. Also, the device allows, due to the presence of a special mechanism, to install a transparent polymer lid on a sealed cup.

The well-deserved popularity in the market is enjoyed by the Belarusian company VAEM, which produces equipment jointly and from the components of the Polish company POLTRAK. For example, the PA-2000 automatic machine for packing semi-liquid products into plastic cups, with a capacity of 1600 to 2000 packs per hour, with a dosage of 0 to 500 ml and a cost of $ 14.6 thousand.

Sealer for glass jars with a capacity of 15 jars / min. UZSB-RE models can be bought for 28,000 rubles; rub. (and, for example, a semi-automatic seaming machine at the Prodmashservice company with a capacity of 800 cans / hour can be purchased for $ 3,500.).

American company PJI Inc. in Russia offers a device for induction sealing of the necks of cans with metal foil. This kind

packaging preserves the freshness and aroma of products and allows you to significantly extend its shelf life by preventing the ingress of oxygen and moisture into the package. In addition, foil sealing eliminates the leakage of products under the lid even with external pressure on the jar. To perform this operation, a cap is screwed onto the neck of the jar using a conventional capping machine. In this case, the covers must have a special insert with a foil layer. After capping, the cans, moving along the conveyor, pass under the induction head. The electromagnetic field heats up the foil, and it is welded to the edge of the neck. The cost of such a manual device is about $ 7 thousand, and an automatic machine - $ 18.5 thousand.

Recently, the Moscow enterprise "Prombiofit", known for its development of lines for bottling and packaging of liquid and pasty products, has created and produced a trial batch of vacuum capping machines. The installation turned out to be light, compact and freely placed on a regular table. The vacuum chamber allows sealing jars of various sizes using easily replaceable liners: with a diameter of 50 to 110 mm and a height of 70 to 170 cm. The operator, sitting at the table, manually places the jar filled with the product into the vacuum chamber and covers it with a lid. Then, by successively turning the vertical and horizontal levers of the installation and pressing the pedal of the air compressor, the working cavity of the chamber is simultaneously evacuated and the can is sealed. The degree of rarefaction in the bank is controlled during the capping process using a vacuum gauge. Then the operator takes the finished can out of the chamber and installs the next one - the entire cycle of one operation takes no more than 6-7 seconds. The productivity of this machine is about 500 cans / hour, and it costs 10 times cheaper than a similar German-made unit. The installation produced by "Prombiofit" is designed to work "in pair" with a compressor with a capacity of 1.5 kW and with an air pressure at the outlet from 2 to 5.5 atm. A semi-automatic device for vacuum sealing cans with a twist-off type screw cap, model UU-5, already costs 28.8 thousand rubles without a compressor and from 34.8 thousand rubles. with compressor. In addition to this device, you can purchase a counter of sealed cans for 4.5 thousand rubles.

In such banks, products can be stored for up to 6 months without losing their taste and nutritional qualities, so you can not be afraid of a “delay” of products in the warehouse. Can packaging has another quality that positively affects consumer demand: the product is clearly visible to the buyer.

Also, the Bulgarian company INDEX-6 Ltd in Moscow offers a device for automatic capping and evacuation by steam of a wide range of factory-made glass jars with twist-off lids with a capacity of up to 12 thousand pieces per hour. For example, the IND-Close 14 model with a capacity of 1 thousand pieces. per hour costs $6,000, and 12,000 pieces per hour is already twice as expensive. The company also supplies the IND-Dose 42 volumetric dosing machine. It is designed in a modular way and can be supplied with two, three, four, five or six filling heads. Accordingly, the productivity of the unit increases almost proportionally.

Mayonnaise and other spreadable products can also be filled and packaged in pur-pack or tetra-rex laminated cardboard boxes. The KRU-2 semi-automatic machine requires two operators to operate and is capable of filling and sealing up to 400 bags per hour. Such a line costs almost 77.5 thousand rubles.

After the end of the packaging cycle, a label sticker and marking with the expiration date should be marked. For example, a semi-automatic labeling machine with a capacity of up to 1500 pieces per hour can be purchased for $ 47 thousand, and with a capacity of 600 pieces. / hour - for 30 thousand rubles.

And the last stage is the group packaging of glass jars or plastic cups. For this, thermoplastic machines are used. Many companies sell them, and they are relatively inexpensive: from 17 thousand rubles. (domestic, with a capacity of only 70 packs per hour) and up to several thousand dollars for Western analogues.

Of course, all packaging equipment is not included in the standard kits, and therefore you have to buy it separately or through the same company that sells equipment for the production of mayonnaise (which is the most optimal - after all, everything is too individual, depending on the productivity and products planned for release).

Dmitry TIKHOMIROV