Industrial Mayonnaise Processing Plants & Production Lines

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.

Mayonnaise Production Lines: Hot vs. Cold

With ProXES, you have full flexibility to adapt your mayonnaise production to your exact requirements—whether through hot or cold production methods. Our state-of-the-art machines, including our ProxxD and Combitherm, ensure optimal results regardless of the chosen method. Together, we’ll optimize your processes to meet your specific needs, whether for regulatory compliance or market preferences.

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.

Different Mayonnaise Variations? No Problem!

Mayonnaise is a staple in households and foodservice globally, with increasing demand for plant-based options, low-fat alternatives, and convenience foods. With ProXES processing systems, you can efficiently expand your production capacity, whether you're producing small batches or large volumes. 

Flexibility and Adaptability
With modular extensions like the CuliFlex technology, you can significantly expand your product range. Our systems are designed for traditional mayonnaise as well as modern alternatives like vegan or low-fat varieties, along with dressings and sauces. This flexibility allows you to quickly adapt to market changes without the need for additional investment.

With our deep industry expertise and cutting-edge technology, you can turn your innovative ideas into commercially successful products, while responding rapidly to consumer trends and market demands.

High-Performance Mayonnaise Lines for Large Production Volumes

For large-scale industrial mayonnaise production, ProXES offers complete, customized solutions tailored to the unique demands of highvolume manufacturers. Our systems combine high efficiency with superior product quality, ensuring that you can consistently meet production targets without compromising on standards. By integrating advanced technologies like ProxxD, we provide seamless, energy-efficient operations designed to boost productivity while reducing costs. Whether you're expanding your product range or scaling up existing operations, ProXES sets new standards in industrial food production, helping you stay competitive in an evolving market.