1. Ingredient Storage and Handling:

   • Ingredient Silos or Storage Tanks:

     • Store bulk quantities of ingredients such as oil, egg yolks, vinegar, and other additives.
     • Ingredients are pumped from these storage tanks to the mixing and emulsification process.

2. Weighing and Measurement:

   • Ingredient Weighing Systems:

     • Ensure accurate measurements of each ingredient based on the recipe.
     • Automated systems may be used for precise weighing.

3. Pre-Mixing and Blending:

   • Pre-Mixing Tanks:

     • Combine specific quantities of oil, egg yolks, and other liquid ingredients in pre-mixing tanks.
     • Preliminary blending helps prepare the ingredients for the emulsification process.

4. High-Speed Disperser:

   • Emulsification Stage:

     • Use a high-speed disperser to break down the oil phase and disperse it into fine droplets.
     • Achieve a stable emulsion by combining the oil phase with water-based ingredients.

5. Inline Homogenizer:

   • Fine Emulsification:

     • Pass the emulsified mixture through an inline homogenizer for further refinement of particle size and improved stability.
     • Creates a smooth and consistent texture in the mayonnaise.

6. Vacuum Deaeration (Optional):

   • Deaeration Equipment:

     • Remove air bubbles from the mayonnaise to enhance its stability and prevent separation.
     • Vacuum deaeration is an optional step.

7. Cooling:

   • Jacketed Cooling Tanks:

     •  Cool the mayonnaise to the desired temperature using jacketed cooling tanks.
     • Controlled cooling helps set the emulsion and improve the viscosity.

8. Seasoning and Flavor Addition:

   • Seasoning Tanks:

     • Introduce seasonings, herbs, spices, and other flavorings to the mayonnaise.
     • Ensure thorough mixing for uniform flavor distribution.

9. Quality Control and Adjustments:

   • Quality Testing Stations:

     • Conduct quality checks for taste, texture, and appearance.
     • Make any necessary adjustments to meet quality standards.

10. Packaging:

    • Packaging Machines:

      • Fill the mayonnaise into containers, jars, or other packaging formats.
      • Automated filling and packaging equipment may be used for efficiency.

11. Cleaning-In-Place (CIP) System:

    • Equipment Cleaning:

      • Implement a CIP system for thorough cleaning of the production equipment, ensuring hygiene and preventing cross-contamination.

12. Storage and Distribution:

    • Finished Goods Warehouse:

      • Store packaged mayonnaise in a dedicated warehouse before distribution.
      • Mayonnaise may be distributed to retailers, supermarkets, or other outlets.

Additional Considerations:

• Automation and Control Systems:

  • Modern mayonnaise preparation plants often incorporate automated control systems for precision and efficiency.

• Hygiene and Sanitation:

  • Adherence to strict hygiene and sanitation standards is critical to ensure the safety and quality of the mayonnaise.

• Batch or Continuous Production:

  • Mayonnaise production can be organized as batch processes or continuous processes, depending on the production scale and facility design.

A well-designed mayonnaise preparation plant integrates various stages and equipment to produce mayonnaise efficiently, meeting quality standards and ensuring a consistent product for consumers.