What a mayonnaise processing plant does
A mayonnaise processing plant emulsifies the oil and water-based components of mayonnaise into a smooth, stable product. In Wahal's plants a high-speed rotor/stator mechanism creates a strong shearing action for this. It improves the texture and stability of the mayonnaise and disperses flavors uniformly.
Speed and shear levels can be adjusted to suit different recipes and ingredients, including plant-based mayonnaise. The mixers are easy to clean and maintain and are built for large-scale production.
For the background on oil-in-water and water-in-oil emulsions, see emulsification. For a process-level view of mayonnaise mixing, see the mayonnaise process page.
Mayonnaise manufacturing plant: the vacuum homogenization unit
The core of the plant is a vacuum homogenization unit: a customized integrated solution for mixing, cutting, homogenizing and emulsification. It works in a hermetically sealed environment, and solids are drawn into the liquid stream under vacuum while mixing.
| Component | What it does |
|---|---|
| Vacuum homogenization | Sealed vessel gives a smooth texture and removes air pockets. Helps take solid ingredients into the process, lowers the boiling point of the product, saves energy and shortens process time. |
| Four-stage homogenizer | Mixing and emulsification, with fine droplets of the emulsion. |
| Contra-rotary agitator | Perforated blades and scrapers blend the ingredients in the main vessel. |
| Direct steam injection (DSI) | Efficient heating of the product. |
| Bucket lifts | Automatic feeding of solids, vegetables and other ingredients directly into the main vessel. |
| Automatic dosing unit | Controlled dosage of oil, solids, liquids and other ingredients. |
| PLC/SCADA control panel with HMI | Recipe storage, with actuated valves, load cells for weight indication and flow control for recipe formulation. |
The vacuum emulsification plant page lists further options for this type of unit: a triple jacket with insulation for heating and cooling, CIP models with residue discharge valves, adjustable shear rate for shear-sensitive products, a dosing trolley with lift and tilt conveyor, and recirculation and discharge functions.
For inline rotor-stator machines with one, two or four stages, see our inline homogenizer.
Mayonnaise machines: other Wahal equipment for emulsions and sauces
Wahal's mayonnaise mixer machines are rotor-stator high shear mixers and homogenizers. Depending on the recipe and the fineness you need, other Wahal machines can sit alongside the vacuum unit. Each one has its own page.
| Machine | Where it fits |
|---|---|
| High shear homogenizer mixers | Rotor-stator homogenizers in inline, batch and bottom-mounted designs. Used for sauces, dressings and mayonnaise, among other food products. |
| Inline homogenizer | Installed in the pipeline; self-pumping in most cases. Single, two or four rotor-stator stages, 15 to 200,000 litres per hour. Used for emulsions, sauces and dispersions in food, dairy and beverage. |
| Colloid mill | Shears the product between a high-speed rotor and a fixed stator. Used for sauces, dressings and mayonnaise, for a smooth texture and uniform consistency. |
| High-pressure homogenizer | Pump homogenizer for the nano range. Works best when fed a uniform, fine premix, which a high shear homogenizer produces. |
| Shear pump | Pumps and shears in one inline unit; handles high-viscosity lines. |
Why a mayonnaise production line runs under vacuum
- Smooth texture. Vacuum homogenization removes air pockets from the final product.
- Less oxidation. Vacuum processing removes air bubbles, which limits oxidation and gives a smoother, better-looking product.
- Stable emulsion. Combining vacuum and high shear improves the stability of emulsions and helps prevent phase separation over time.
- Less energy and time. Vacuum lowers the boiling point of the product, which saves energy and shortens process time.
Wahal names mayonnaise production as a typical use for a vacuum mixing system. See vacuum mixing vs vacuum cooking for when each system fits.
What the plant makes
- Mayonnaise, including plant-based and garlic mayonnaise
- Sauces and dips
- Syrups, spreads and dressings
- Flavored emulsions
Making tomato ketchup? See our tomato ketchup plant, which covers the reception, washing, sorting, pulping, cooking and filling sections. For sauce lines in general, see the vacuum sauce production line.
Test your recipe before you buy
You can run a trial of your own product on a Wahal machine in our fully equipped laboratory and see exactly what results you get, and how fast. If you need longer, our rental program lets you keep a machine, pre-configured to your requirements, for as long as you need. See trials and rentals.
Frequently asked questions
What is a mayonnaise processing plant?
A mayonnaise processing plant, also called a mayonnaise manufacturing plant or production plant, emulsifies the oil and water-based components of mayonnaise into a smooth, stable product. Wahal's plant is built around a vacuum homogenization unit with a four-stage homogenizer, a contra-rotary agitator, direct steam injection, an automatic dosing unit and PLC/SCADA control.
What machine is used to make mayonnaise?
Wahal makes mayonnaise with rotor-stator high shear mixers and homogenizers, which emulsify the oil and water phases. In the plant they work as a vacuum homogenization unit. Inline and batch high shear homogenizers and a colloid mill are also used for sauces, dressings and mayonnaise.
How is mayonnaise made in a factory?
In a Wahal plant the automatic dosing unit meters oil, solids and liquids, and bucket lifts can feed solids and other ingredients into the main vessel. In the sealed vessel a contra-rotary agitator blends the batch, and the four-stage homogenizer emulsifies the oil and water phases into fine droplets under vacuum. Direct steam injection heats the product, and the PLC/SCADA panel stores the recipe. For a process-level view, see the mayonnaise process page.
Can the plant make plant-based, garlic or flavored mayonnaise?
Yes. Wahal high shear mixers are used for plant-based mayonnaise production, and the same plant serves garlic mayonnaise, sauces and dips, syrups, spreads and dressings, and flavored emulsions. Speed and shear can be adjusted to suit different recipes and ingredients.
Why is mayonnaise made under vacuum?
Vacuum homogenization removes air pockets and gives a smooth texture. It also limits oxidation, improves emulsion stability and lowers the boiling point of the product, which saves energy and process time.
What capacity can a mayonnaise plant have?
Wahal's vacuum mixing systems range from 100 litres for pilot and R&D use to 20,000 litres for industrial plants, with PLC/HMI recipe control and CIP/SIP cleaning options. Tell us your daily output and we will work from that. See vacuum mixing vs vacuum cooking.
What does a mayonnaise manufacturing plant cost?
The cost depends on your product, recipe and daily output, so no single price applies. Tell us those three, or run a trial on a Wahal machine before you decide.
Can I test my mayonnaise recipe before buying?
Yes. You can run a trial on your own product in our fully equipped laboratory, and a rental program lets you keep a machine pre-configured to your requirements.
