Mayonnaise Manufacturing & Production

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CreWin Mayonnaise Manufacturing & Production

The mayonnaise production process is essentially a non-Newtonian fluid handling process highly sensitive to shear rates and temperature fluctuations. As an oil-in-water (O/W) emulsion system typically containing up to 80% oil, the core challenge in manufacturing mayonnaise lies in precisely controlling the Phase Inversion point under extremely high oil-phase ratios.

Mayonnaise can be a beneficial addition to your diet when enjoyed in moderation. First, due to its Vitamin E content, it can play a supportive role in maintaining long-term cardiovascular health. Furthermore, because mayonnaise contains healthy fats, it acts as an effective carrier for fat-soluble nutrients (such as Vitamins A, D, E, and K), helping your body absorb these essential vitamins more efficiently from other foods like fresh vegetables.

Additionally, mayonnaise made with high-quality vegetable oils provides unsaturated fats, which are helpful in managing healthy cholesterol levels. It is also a source of essential nutrients, including Vitamin K, Vitamin E, and vital minerals such as potassium and selenium, contributing to a well-rounded intake of micronutrients.

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To meet the rigorous standards of the mayonnaise industry, the CreWin mayonnaise processing equipment and mixer utilizes advanced rheological control logic to ensure consistent quality from R&D pilot testing to large-scale production. Whether it is a classic high-oil formula pursuing the ultimate creamy mouthfeel or a low-fat recipe relying on thickeners for sensory compensation, CreWin achieves a stable and uniform microstructure.

Formula

Ingredient of Mayonnaise

Maintaining the ideal balance of ingredients is essential for both flavor and long-term shelf-life. In the mayonnaise industry, the aqueous phase typically features a precise nutrient profile, including 9–11% salt and 7–10% sugar alongside an edible oil content of over 50%. While this rich composition provides the desired mouthfeel, it also requires strict environmental control to ensure product integrity.

The most critical factor in manufacturing mayonnaise safely is managing the acidity levels. By maintaining a consistent pH range between 3.6 and 4.0, the formulation creates a naturally stable environment that effectively inhibits unwanted microbial activity. During mayonnaise production, achieving this precision is vital. CreWin’s advanced mixing tank ensures that acidulants and salts are distributed with absolute uniformity, guaranteeing that every batch meets the highest safety and quality standards required for global distribution.

Ingredient	78% Oil Formula	Low Fat Formula	Viscosity	Purpose
Vegetable	78%	50%	0.0398 Pa·s	Emulsion & body
Oil	/	/	/	/
Egg Yolk	7.9%	4.7%	~23,000 cps	Primary emulsifier
Thickeners	/	4%	Varies	Viscosity & stability
Vinegar	3.8%	3%	12-15 cps	pH regulator & flavor
Sugar	1.2%	1.5%	6.22 cp	Flavor & nutritive
Salt	1.1%	0.7%	/	Flavor enhancer
Spices (Mustard)	0.5%	1.5%	70,000 cps	Flavor & stabilization
Water	7.5%	36%	1 cp	Continuous phase

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Process

Production Process

Preparation of the Aqueous Phase

The egg (liquid/powder) and vinegar are dispersed into water to activate the emulsifiers and build a stable aqueous base,mixing of starch,water for 15-20min.
Hydration of Stabilizers

Remaining water-phase ingredients are added via high-velocity circulation, ensuring stabilizers are fully hydrated and lump-free
Efficient
Mixing

As oil is rapidly introduced, intense shear force binds the phases, instantly creating the signature thick, creamy mayonnaise texture.

The rest of the oil, vinegar, and seasonings are integrated under continuous mixing to achieve a perfectly uniform flavor and viscosity.Blend all the mixture for 15-20min.
Temperature Control

We support both Cold Process (<5°C) for freshness and Hot Process (70°C) for enhanced shelf life and safety.When manufacturing mayonnaise via this route, the egg yolk undergoes a specialized pasteurization process—typically between 65°C and 75°C. This thermal treatment is carefully calibrated to ensure microbial safety while preserving vital natural emulsifiers like lecithin.

Process

Production Process

Preparation of the Aqueous Phase

The egg (liquid/powder) and vinegar are dispersed into water to activate the emulsifiers and build a stable aqueous base,mixing of starch,water for 15-20min.

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Hydration of Stabilizers and Functional Ingredients

Remaining water-phase ingredients are added via high-velocity circulation, ensuring stabilizers are fully hydrated and lump-free.

High-Shear Emulsification and Oil Incorporation

As oil is rapidly introduced, intense shear force binds the phases, instantly creating the signature thick, creamy mayonnaise texture.

Final Blending and Texture Development

The rest of the oil, vinegar, and seasonings are integrated under continuous mixing to achieve a perfectly uniform flavor and viscosity.Blend all the mixture for 15-20min.

Cold and Hot Processing Options for Product Safety

We support both Cold Process (<5°C) for freshness and Hot Process (70°C) for enhanced shelf life and safety.When manufacturing mayonnaise via this route, the egg yolk undergoes a specialized pasteurization process—typically between 65°C and 75°C. This thermal treatment is carefully calibrated to ensure microbial safety while preserving vital natural emulsifiers like lecithin.

Problem

Problems with Using Traditional Mixers

Continuous phase ingredients constitute only a small proportion of the total formulation but perform vital functions. Standard mixers often struggle to disperse and hydrate these properly in relatively low liquid volumes.
Stabilizers and thickeners are highly prone to clumping, forming "fish-eyes" or lumps that standard mixers simply cannot break down. This leads to extended hydration times and wasted material.
Due to the high proportion of oil, a weak emulsion usually stems from poor dispersion or inconsistent dosing—a common failure in manual or conventional processes.

Long-term stability depends on reducing oil droplets to the smallest possible micron size to maximize the surface area of oil within the continuous phase.
The timing and ratio of vinegar (and/or lemon juice) addition are critical for both taste and the physical stability of the mixture.
Air trapped during mixing can lead to oxidation,product discoloration,and degraded freshness

Solution

Crewin Solution

Drawing on deep expertise in fluid mechanics, our mayonnaise emulsification mixer, CreWin, provides a turnkey solution integrating high-speed powder dispersion, intelligent quantitative emulsification, vacuum degassing, and zero-waste discharge. This system is specifically engineered to produce a high-viscosity oil-in-water emulsion with exceptional stability.

Phase 1

The process begins with the seamless integration of a high-shear In-Line mixer and a vessel recirculation system. This setup creates a continuous and controlled flow environment, laying the foundation for a uniform emulsion.
Phase 2

Utilizing a high-velocity liquid stream, the system ensures that egg components are instantly wetted and dispersed. Recirculation continues until the ingredients achieve total hydration, ensuring a smooth, agglomeration-free base.
Phase 3

The system offers flexible feeding options: ingredients can be added directly into the vessel, dosed quantitatively, or induced via a specialized powder feed hopper tailored to batch size and ingredient characteristics. Continuous circulation ensures a consistent, clumping-free mixture.
Phase 4

During the final stages of oil addition, the aqueous and oil phases can be introduced under vacuum. This critical step facilitates the formation of a dense microstructure while effectively preventing aeration, ensuring a superior, air-free product finish.
Phase 5

As viscosity rises, a multi-dimensional scraper system continuously directs material toward the center flow, ensuring total uniformity throughout the batch. For post-production, integrated CIP (Clean-in-Place) spray balls allow for an automated and high-standard cleaning process.

Advantages

Crewin Strategic Advantages

Maximizing Yield

Full hydration of thickeners and active ingredients. Scalable solutions for both R&D and mass production,ensuring that your formulation maintains consistent quality as you scale up.
Superior Reaction Rates

High energy input achieves dispersion quality unattainable by traditional methods.
High-Viscosity Capability

Easily processes heavy emulsions; compatible with auxiliary pumps or secondary In-Line shear stages.

Sanitary & Stable emulsion

Our closed-loop vacuum system effectively prevents oxidation and ensures an air-free product finish. Precision scrapers work continuously to minimize material waste and improve heat transfer, keeping the mayonnaise production environment hygienic and efficient.
Extreme Flexibilityfor Modern Markets

Easily adaptable to diverse recipes, from premium sauces to vegan/low-fat alternatives.
Unmatched Cost-Efficiency

Achieve the stability of a turnkey Mayonnaise industrial plant without excessive capital expenditure.

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