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Integrated Hygienic Production Line for High-Stability Mayonnaise & Emulsified Dressings
LENO TANK provides a complete, high-shear equipment solution for the industrial-scale manufacturing of mayonnaise, salad dressings, and other oil-in-water emulsions. Our systems are engineered to achieve the critical fine droplet size and uniform dispersion required for exceptional product stability, luxurious texture, extended shelf life, and consistent batch-to-batch quality.
Core Production Stages & LENO TANK Equipment Integration:
| Production Stage | Critical Process Requirement | Recommended LENO TANK Equipment | Key Value & Advantage |
|---|---|---|---|
| 1. Ingredient Preparation & Metering | Precise weighing and pre-mixing of aqueous phase (vinegar, egg yolk, mustard, lemon juice) and oil phase. Temperature control is crucial. | Jacketed Mixing & Preparation Tanks, Powder Induction Systems | Jacketed tanks provide precise temperature control for ingredient hydration and holding. Powder Induction Pumps enable dust-free, accurate incorporation of stabilizers and dry spices. |
| 2. Pre-Mixing & Coarse Emulsification | Initial combination of phases to form a coarse, unstable emulsion before final homogenization. | High-Shear Mixers (Ultra-Turrax type) | High-speed rotor-stator mixers provide intensive, inline shear to break down the oil phase into small droplets and uniformly disperse egg yolk and mustard, which act as natural emulsifiers. |
| 3. High-Pressure Homogenization & Finishing | Applying extreme mechanical energy to create a fine, stable, sub-micron emulsion. This is the most critical step for texture and shelf life. | High Pressure Homogenizers | Forces the pre-mix through a narrow valve at pressures from 300 to 600+ bar. This creates intense shear, cavitation, and impact, reducing oil droplet size dramatically. This results in a thicker, creamier texture, enhanced flavor release, and prevents phase separation for months. |
| 4. Deaeration & Cooling | Removing entrained air from the viscous product to prevent oxidation and density variation, and cooling to packing temperature. | Vacuum Deaerators, Scraped-Surface Heat Exchangers | Vacuum Deaerators remove air bubbles efficiently, preventing rancidity and ensuring accurate fill weight. Scraped-Surface Heat Exchangers provide rapid, controlled cooling of the viscous mayonnaise without damaging its structure. |
| 5. Storage & Transfer | Gently holding the finished product before filling, maintaining homogeneity without applying destructive shear. | Sanitary Storage Tanks with Slow-Speed Agitators | Tanks with large-diameter, slow-speed anchors or paddle agitators keep the product uniform without breaking down the delicate emulsion. |
| 6. Filling & Packaging | Hygienically transferring the viscous product to filling machines for jars, pouches, or tubes. | Sanitary Lobe or Piston Pumps, Mobile CIP Systems | Positive Displacement Pumps offer gentle, pressure-stable transfer. Mobile CIP Carts ensure rapid and validated cleaning of all product lines and fillers, essential for preventing microbial contamination in egg-based products. |
Why Choose LENO TANK’s Mayonnaise Production Solution?
Guaranteed Emulsion Stability: Our High Pressure Homogenizers are not optional but core to the process. They engineer the physical stability of your product, enabling reductions in stabilizers and ensuring a premium, clean-label texture that resists syneresis (water separation).
Precision & Repeatability: From PLC-controlled ingredient dosing to precise pressure control in homogenization, every parameter is recorded and repeatable. This guarantees identical taste, texture, and viscosity for every batch, from pilot to full scale.
Hygiene Designed for Sensitive Products: All product contact surfaces are AISI 316L Stainless Steel with electropolished finishes. The system supports full CIP (Clean-in-Place) and COP (Clean-Out-of-Place) protocols, which are critical for products containing eggs and other sensitive ingredients.
Scalable from R&D to High-Output: We offer a seamless scale-up path. Optimize your recipe and critical homogenization pressure on a lab-scale homogenizer, then confidently scale to a continuous production line with identical shear and energy input per volume.
