Key Equipment: Vacuum Emulsifier / (Jacketed) Mixing Tank
This document describes the process flow and equipment configuration of the mayonnaise (sauce) production line, focusing on the line layout built around the core emulsifying equipment — the Vacuum Emulsifier / (Jacketed) Mixing Tank.
Mayonnaise is a high-oil, oil-in-water emulsified sauce made from vegetable oil, egg yolk, vinegar/lemon juice, salt, sugar and spices through emulsification, homogenization and defoaming. Egg-yolk lecithin acts as the natural emulsifier. The core process is to disperse the oil into ultra-fine droplets and emulsify them stably, forming a fine, thick, non-separating emulsion system. The oil droplet size and emulsion stability directly determine the taste, texture and shelf stability of the mayonnaise, and are the key links of the whole production line.
By material flow, the mayonnaise (sauce) production line is divided into four functional zones — pretreatment, emulsification, post-treatment, and filling & packaging — organized around the core emulsifying equipment (Vacuum Emulsifier / (Jacketed) Mixing Tank):
| Functional Zone | Main Processes | Main Equipment | Function |
|---|---|---|---|
| Pretreatment zone | Raw material inspection, weighing & batching | Electronic scales, batching containers, egg liquid pasteurization equipment | Inspect and weigh raw materials such as vegetable oil, egg yolk liquid, vinegar and seasonings |
| Emulsification zone (core) | Egg-phase/water-phase preparation, oil-phase metering, emulsification, homogenization, defoaming | Vacuum Emulsifier / (Jacketed) Mixing Tank | Emulsify and homogenize the egg phase and oil phase in the jacketed mixing tank and vacuum-degas to make mayonnaise |
| Post-treatment zone | Intermediate inspection | Inspection equipment | Test semi-finished products on physicochemical and sensory indicators |
| Filling & packaging zone | Filling, packaging, finished product inspection | Filling machine, packaging machine, coding equipment | Metered filling, packaging and labeling; inspect finished products before warehousing |
Materials flow sequentially from the pretreatment zone into the emulsification zone, post-treatment zone and filling & packaging zone, forming a continuous, closed and traceable food production flow.
The typical process flow of mayonnaise (sauce) is: raw material inspection → weighing & batching → (egg-phase/water-phase preparation and oil-phase metering in parallel) → vacuum emulsification → intermediate inspection → filling → packaging → finished product inspection & warehousing. Each step is described as follows:
| No. | Process Step | Step Description | Key Control |
|---|---|---|---|
| 1 | Raw material inspection | Inspect raw materials such as vegetable oil, egg yolk liquid, vinegar, salt, sugar and spices; store them for later use after they pass | — |
| 2 | Weighing & batching | Accurately weigh each raw material according to the formula | Accurate proportioning |
| 3 | Egg-phase/water-phase preparation | Mix the egg yolk liquid, vinegar, salt, sugar and spices evenly | Accurate proportioning |
| 4 | Oil-phase metering | Meter the vegetable oil at the set ratio and have it ready | Oil-phase ratio ★ |
| 5 | Vacuum emulsification | Add the oil phase slowly in the vacuum emulsifier; emulsify at high speed, homogenize and vacuum-degas, producing a fine mayonnaise | Emulsification ★ (core) |
| 6 | Intermediate inspection | Test semi-finished products on fat content, viscosity, emulsion stability and other indicators; transfer to the next process after they pass | Pass/fail judgment |
| 7 | Filling | Quantitatively fill into packaging containers via the filling machine | Filling metering |
| 8 | Packaging | Sealing, labeling, coding, cartoning | Sealing integrity |
| 9 | Finished product inspection & warehousing | Inspect finished products against standards; warehouse them after they pass | Pass/fail judgment |
Note: The steps marked with ★ in the table (oil-phase ratio and vacuum emulsification) are key process control points, among which vacuum emulsification is the core control link of the whole production process.
The Vacuum Emulsifier / (Jacketed) Mixing Tank is the core equipment of the mayonnaise (sauce) production line. Its main body is a mixing tank with a heating/cooling jacket, integrated with a vacuum system, a high-speed homogenizing emulsifying head and a wall-scraping stirring device, combining emulsification, homogenization, defoaming and other functions in one unit, ensuring ultra-fine oil droplet dispersion and a stable emulsion.
| Item | Description |
|---|---|
| Function | Emulsifying the oil phase and egg phase, ultra-fine oil droplet dispersion, homogenization and vacuum defoaming — the key process that ensures mayonnaise emulsion stability |
| Main structure | Mixing tank with a heating/cooling jacket; steam or cooling water circulates in the jacket for temperature control |
| Stirring system | A central paddle works with a wall-scraping paddle to ensure thorough mixing of the high-viscosity sauce and prevent wall sticking |
| Homogenizing system | A high-speed homogenizing emulsifying head achieves ultra-fine oil droplets and uniform dispersion in the egg-yolk system |
| Vacuum system | The tank is evacuated to remove air entrained during emulsification, prevent separation and oil floating, and improve the fineness of the sauce |
| Temperature control | Heating and cooling through the jacket, combined with temperature sensors for precise emulsification temperature control |
| Advantages | Closed operation, good hygiene, high emulsifying efficiency, stable product quality, easy cleaning (CIP) |
In the production line, the Vacuum Emulsifier / (Jacketed) Mixing Tank receives materials from the egg-phase/water-phase preparation and oil-phase metering steps and completes emulsification under vacuum and high-speed homogenization, producing a fine and stable mayonnaise, which then passes through intermediate inspection into the subsequent filling and packaging processes.
Step 3 · Egg-phase/water-phase preparation
Mix the egg yolk liquid, vinegar, salt, sugar and spices evenly
Egg Phase Tank & Water Phase Tank |
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Step 5 · Vacuum emulsificationCore Equipment
Emulsifying the oil phase and egg phase, ultra-fine oil droplet dispersion, homogenization and vacuum defoaming — the key process that ensures mayonnaise emulsion stability
Vacuum Emulsifier Mixing Tank |
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Step 7 · Filling
Quantitatively fill into packaging containers via the filling machine
Four-Head Filling machine
Step 8 · Packaging
Sealing, labeling, coding, cartoning
Capping Machine |
Labeling Machine |
Inkjet Printer |
Supporting Equipment
Rotary Lobe Pump
The figure below shows the production process flow of mayonnaise (sauce). The core equipment highlighted in orange, the “Vacuum Emulsifier / (Jacketed) Mixing Tank”, sits at the vacuum emulsification step after egg-phase/water-phase preparation and oil-phase metering, and is the key equipment of the whole line.
Figure: Process flow of mayonnaise (sauce) (★ key equipment: Vacuum Emulsifier / (Jacketed) Mixing Tank; labeled in both Chinese and English)
