为您的蛋黄酱生产定制解决方案

Why choose ProXES for mayonnaise processing?

• High Quality - Gentle processing for optimum texture and taste
• Efficiency - Reduced production times and high throughput, shelf life up to 21 days
• Flexibility - Adaptable to different recipes and production volumes
• Sustainability - Energy-efficient processes and reduced operating costs

How Is Mayonnaise Made in Factories?

In factories, mayonnaise is produced as a stable oil-in-water emulsion on dedicated processing lines. During industrial production, the oil phase is dispersed into tiny droplets between 2 and 10 microns in size - with the majority ideally around 3 to 4 microns. To create these droplets, significant mechanical energy is required, typically applied through high-shear mixing in a rotor-stator system. Without that shear force, the oil droplets would simply recombine over time and the product would separate.

To keep the emulsion stable, an emulsifier is needed. The emulsifier has both an oily and an aqueous side: the oily part penetrates the oil droplet, while the aqueous side faces the surrounding water phase. This is what keeps the emulsion stable and gives mayonnaise its characteristic high viscosity.

The emulsifier in classic mayonnaise is mainly lecithin, sourced from egg yolk. Full-fat mayonnaise contains 8–10% egg yolk, 79–80% oil, plus vinegar, sugar, salt, and mustard - and no further binding agents. Because of this, full-fat mayonnaise is fully dependent on the stability of the emulsion. In medium and low-fat variants, the water phase is instead bound by starch and/or gums (e.g. xanthan gum), which take over part of the egg yolk's role.

How Mayonnaise Is Produced - Step by Step

Industrial mayonnaise production in a modern processing plant follows these core steps:

• Ingredient preparation: weighing and dosing of water, vinegar, egg yolk (or plant-based lecithin), mustard, salt, sugar, and stabilizers
• Pre-mixing of the aqueous phase: dissolving water-soluble ingredients into a homogeneous base
• Oil dosing: the critical step. Oil is added at controlled rates of up to 3 kg/s, directly influencing batch time and emulsion quality
• High-shear emulsification: the oil phase is broken down into 2–10 micron droplets using a rotor-stator homogenizer
• Homogenization & fine-tuning: droplet size is refined and the emulsion is stabilized
• Cooling (if hot process): rapid cooling preserves texture and extends shelf life
• Filling & packaging: transfer to filling lines for jars, tubes, pouches, or bulk containers

For low-fat mayonnaise, an additional step is required: starch or hydrocolloid preparation, typically handled by a dedicated module like CuliFlex, which gently cooks and incorporates starches into the mix.

Watch how industrial mayonnaise is made on a ProXES processing line, from ingredient dosing and high-shear emulsification to the finished, stable oil-in-water emulsion.

蛋黄酱生产线：热与冷

有了 ProXES，您就可以完全灵活地根据自己的确切要求来生产蛋黄酱--无论是采用热生产方法还是冷生产方法。我们拥有最先进的设备，包括 ProxxD 和 Combitherm，无论选择哪种方法，都能确保最佳效果。我们将共同优化您的工艺，以满足您的特定需求，无论是符合法规要求还是市场偏好。

Key Challenges in Mayonnaise Production

Running an industrial mayonnaise processing plant means balancing speed, consistency, and flexibility – all at once. Time pressure, strict quality requirements, and the need to adapt to market trends create significant challenges for manufacturers. The main issues our customers face:

• Time pressure and throughput: growing demand forces manufacturers to shorten batch times without losing quality. A high oil dosing rate (up to 3 kg/s) is one of the most effective levers to increase throughput and energy efficiency per batch
• Emulsion stability: inconsistent droplet size leads to phase separation, oil release, and shortened shelf life. Precise control of shear and homogenization is essential
• Air incorporation: trapped air causes oxidation, off-flavors, and reduced shelf life. Vacuum processing (e.g. via Vacutherm) prevents this and ensures a homogenous emulsion with consistent density
• Recipe flexibility: consumer trends (vegan, low-fat, clean-label, allergen-free) demand systems that handle both traditional and modern formulations without retooling
• Hot vs. cold processing: different markets and regulations favor different methods. Equipment must support both seamlessly
• Scaling from R&D to production: a recipe that works in the lab has to survive the jump to 6,000 kg/h without losing its character
• Energy consumption: modern systems like the ProxxD reduce specific energy input to around 5 kWh/ton, a key factor for both cost and sustainability targets

Every line can be extended with modular technology, so your mayonnaise plant grows with your product portfolio - whether that means adding vegan variants, low-fat SKUs, or entirely new emulsified sauces.

蛋黄酱变化多端？没问题！

蛋黄酱是全球家庭和餐饮服务业的主食，随着人们对植物性选择、低脂替代品和方便食品的需求不断增加。有了 ProXES 加工系统，无论是小批量还是大批量生产，您都可以有效地提高生产能力。

灵活性和适应性
利用 CuliFlex 等模块化扩展技术，您可以显著扩大产品范围。我们的系统既适用于传统蛋黄酱，也适用于现代替代品，如素食或低脂品种，以及调味品和酱料。这种灵活性使您能够快速适应市场变化，而无需额外投资。

凭借我们深厚的行业专业知识和尖端技术，您可以将创新理念转化为商业上成功的产品，同时快速响应消费趋势和市场需求。

用于大批量生产的高性能蛋黄酱生产线

对于大规模的工业蛋黄酱生产，ProXES 可提供完整的定制解决方案，以满足大批量生产企业的独特需求。我们的系统将高效率与卓越的产品质量结合在一起，确保您能够在不降低标准的情况下始终如一地达到生产目标。通过整合 ProxxD 等先进技术，我们提供无缝、节能的操作，旨在提高生产率的同时降低成本。无论您是要扩大产品范围，还是要扩展现有业务，ProXES 都能为工业食品生产设定新标准，帮助您在不断变化的市场中保持竞争力。