🏭 1. Introduction
The commercial mayonnaise production line is a fully integrated, food-grade solution engineered for the mass production of emulsified sauces like mayonnaise, salad dressing, and other viscous condiments. It combines precise ingredient dosing, high-shear mixing, vacuum emulsification, and aseptic filling, ensuring product consistency, microbiological safety, and long shelf life.
This system is widely used by:
Large-scale food processing factories
Sauce brand manufacturers
Ready-to-eat meal factories
Central kitchens and condiment OEMs
🍳 2. Process Flow Overview (Flowchart)
Raw Material Dosing → Water & Oil Phase Preparation → Vacuum Emulsification & Homogenization → Deaeration → Pasteurization (optional) → Cooling → Filling & Packaging → CIP Cleaning
Each step is automated and monitored via PLC-HMI control systems for optimal repeatability and hygiene.
⚙️ 3. Core Equipment & Specifications
| Equipment | Function | Key Specifications |
|---|---|---|
| Oil Tank | Stores edible oil; preheats if needed | SUS304/SUS316L, 200–3000L |
| Water Phase Tank | Prepares egg, vinegar, stabilizers | Agitated, heated |
| Vacuum Emulsifying Mixer | High-shear mixing under vacuum | 100–5000L, -0.09MPa, CIP-ready |
| High-pressure Homogenizer | Improves product texture | Pressure: 20–30MPa |
| Pasteurizer (Optional) | Inactivates bacteria to extend shelf life | Tubular or plate-type; 65–85°C |
| Cooling Unit | Lowers product temp to <20°C | Plate exchanger + chiller |
| Filling Machine | Volumetric or servo-driven | 500–10,000 jars/hr |
| CIP System | Fully automatic internal cleaning | Acid, alkali, hot water cycle |
| PLC Control System | Full process automation | Recipe control, real-time display |
📊 4. Production Capacity Options
| Model | Mixing Tank Volume | Output Capacity | Filling Speed (500g jars) |
|---|---|---|---|
| MPL-300 | 300L | 300 kg/h | 600–800 jars/h |
| MPL-1000 | 1000L | 1000 kg/h | 2000 jars/h |
| MPL-3000 | 3000L | 3000 kg/h | 6000 jars/h |
| MPL-5000 | 5000L | 5000+ kg/h | 10,000+ jars/h |
We also offer customized capacity options up to 10,000 kg/h for high-throughput factory needs.
🧭 5. Suggested Plant Layout (Simplified)
[Water Tank] [Oil Tank] ↓ ↓ [Emulsifying Mixing System] ↓ [Vacuum Homogenizer] ← [CIP Unit] ↓ [Pasteurization] → [Cooling] ↓ [Filling & Capping Line] ↓ [Labeling & Packaging]
👉 Full 2D/3D factory layout planning is provided, including:
Material flow zoning
Utility connection maps (steam, air, water, power)
Operator access paths
🧰 6. Customization Options
| Module | Custom Features |
|---|---|
| Mixing System | Batch or inline; vacuum or pressurized |
| Tank Material | SUS304 / SUS316L / food-grade PTFE |
| Heating Method | Electric, steam, thermal oil |
| Homogenizer | Optional 2nd-stage homogenization |
| Sterilization | Inline pasteurization or UV sterilizer |
| Packaging Format | Jar, pouch, sachet, squeeze bottle, bag-in-box |
| Control Interface | Siemens/HMI, remote monitoring, SCADA integration |
✅ 7. Advantages
High emulsifying stability: Prevents separation and oiling-off
Vacuum deaeration: Removes air bubbles, improving appearance and shelf life
CIP auto-cleaning: Minimizes downtime and meets HACCP/GMP standards
Customizable filling options: Compatible with glass, PET, and laminated packaging
Energy-efficient design: Low power consumption per kg of product
📦 8. Final Product Applications
Classic mayonnaise
Vegan or egg-free mayo
Spicy, herb-infused, or garlic mayo
Salad dressing and sandwich spreads
Export-grade condiments in jars, pouches, or sachets
📩 9. Value-Added Services
🛠️ On-site installation and commissioning
📚 SOP training for operators
🌍 Export-ready documentation (CE, ISO, UL available)
🔧 Lifetime spare parts support
Interested in a turnkey mayonnaise production solution tailored to your factory layout and target output?
➡️ Contact us for a personalized proposal, 2D/3D layout drawings, and a live equipment demo.
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