PDE – I

Assignment on mayonnaise

Under the Guidance of Presented By

Mr. S Sashikanth Mastan Vali K
16FT1D7821
 Introduction
• Mayonnaise is a thick sauce made by emulsification of
oil, egg yolk along with vinegar. It can be added with salt,
mustard or herbs to enhance the flavour.
• It is also known as mother sauce or kitchen sauce.
• Mayonnaise was invented in 1756 by the French chef of
the Duc de Richelieu.
• It is served as sauce with vegetables, meat, poultry and
fish, or as a salad dressing.
• It is also used as dip sauce for fried food like French fries,
nuggets etc.
• Commercial egg-free alternatives are available for vegans
and others who avoid animal products.
• Commercial mayonnaise, which will last up to 6
months in the refrigerator, at least 65 % oil by
weight (except reduced-fat).
• The standard of identity also requires that all
commercial "real mayonnaise" use only egg as an
emulsifier.
• Reduced fat mayonnaise, which isn't considered
real mayonnaise, usually contains modified food
starch, cellulose gel and other thickeners and
emulsifiers
 Site Selection
Factors Hyderabad Kakinada Vijayawada

Energy availability 4 3 3
Raw Material
Availability
5 3 3

Man Power 4 4 4

Transportation 5 4 3

Supplies 5 4 4
Taxes and
4 4 4
regulations

Infrastructure 5 4 4

Total Points 32 26 25
 Raw Material Availability
• Vegetable Oil:
Sarda Agro Oils Ltd, R.R. Dist, Hyderabad.
http://www.sardaoils.com/products.html
• Whole Egg Liquid:
Eggway International Asia Pvt Ltd, Hyderabad
• Mustard Powder:
Hyderabad Food Products Pvt Ltd, Hyderabad.
http://www.suryamasale.com/musturd.html
 Manufacturing Process
• Mayonnaise production can be executed in
batches or in-line with a necessary production
rate.
Batch Process:
• The production in batch is adequate for low
output production below 1000kg/h.
In-line Process or Continuous Process:
• The continuous process is suitable for production
higher than 1000kg/h.
 Selection of Process
Continuous Process:
• There are 4 tanks with necessary portions of
various ingredients
1. Vegetable oil
2. Water with Previously dissolved sugar
3. Vinegar with previously dissolved salt and lemon juice
powder
4. Whole Egg liquid
5. Mustard Powder Bags
6. Lemon Juice powder Bags
 Advantages
• Constant and automated recipe control of dosing
accuracy with possibility of easy modification of
product appearance by adjustment of processing
parameters during actual production.
• Constant and reproducible quality level of the
final products in terms of composition, viscosity
and structure.
• No air incorporation during the continuous
production, thus oil oxidation is prevented.
 Process Flow Sheet
Addition of Whole Egg to Pre Emulsion Tank

Addition of Water with Sugar to the Pre Emulsion Tank

Addition of Oil to the Mix

Add. of Vinegar with Salt & Lemon Juice

Add. Of Mustard

Emulsion Tank

Homogenization

Mayonnaise

Empty Jars Filling into Jars

 Ingredient Formulation
Full Fat (80 % Oil) Formula Low Fat Formula

Vegetable Oil 75 % Vegetable Oil 50 %

Whole Egg 10 % Whole Egg 4%

Vinegar 4% Other Thickeners 4%

Sugar 1%

Salt 1% Vinegar 3%

Spices (e.g. Mustard 0.5 % Sugar 1.5 %

Powder)
Salt 0.7 %
Water 8%
Spices 1.5 %
Lemon Juice 0.5 %

Water 35.3 %
 Product Specifications
Nutritional Information
• Particle Size: 1-5µm
Typical Values For 100g
Energy 725 Kcal
• Shelf Life: At 15 – 20°C
Fat 80 g Six months from date of
Saturated Fat 6.9 g manufacturing.
Carbohydrate 8.8 g • Filling Material: PET Jars
Protein 1.9 g
• Filling SKU: 500g
Salt 1.2 g
Fibre 0.7 g • Allergen: Contains Egg
Sodium 0.5 g and Mustard
 Material Balance (5000 kg)
500 Kg Addition of Whole Egg to Pre Emulsion Tank

400 Kg + 50 Kg Addition of Water with Sugar to the Pre

Emulsion Tank

3750 Kg Addition of Oil to the Mix

200 + 50 + 25 Kg Addition of Vinegar with Salt, Lemon Juice

25 Kg Addition of Mustard

Emulsion Tank 5000 Kg

2 % Loss Homogenizer 4900 Kg

Mayonnaise

2 % Loss Filling into Jars 4802 Kg (9604 Jars)

 Process Scheduling
Minimum Early
Latest Finish
Operation Residence Time Start (ES) TMRT min Capacity Kg/Hr
(LF) min
(MRT) min min

Addition of Whole Egg

2 0 73 407 73.7

Addition of Water +
4 2 69 409 66
Sugar Mix

Addition of Oil 5 6 64 410 548.8

Addition of Vinegar +
2 11 62 407 40.55
Salt + Lemon Juice

Addition of Mustard 2 13 60 407 3.7

Homogenization 30 15 30 435 689.6

Filling
30 45 0 435 1324.6 Jars/hr
 GANTT Chart
Filling 45 435 0

Homogenization 15 435 30

Add. Mustard 13 407 60

Early Start
Add. Of Vinegar + Salt + Lemon Juice 11 407 62
TMRT
Latest Finish
Addition of Oil 6 410 64

Add. Of Water + Sugar Mix 2 409 69

Addition of Whole Egg 0 407 73

0 100 200 300 400 500 600

 List of Equipment
Required Capacity
S. No Process Required Qty

Liquid Egg Storage Tank with

1 1 600 Kg
agitator

2 Water Storage tank with agitator 1 550 Kg

3 Oil Storage Tank with agitator 1 4500 Kg

4 Vinegar Storage Tank with agitator 1 350 Kg

5 Homogenizer 1 700 – 750 Kg/Hr

6 Filler 1 1350 Jars/hr

 Specifications
Material of Manufacturer / Manufacturer
Equipment Name Dimensions Capacity
Construction Supplier Link
Shree Bhagawathi
http://storagetank
2300mm Machtech (Ind)
Oil Storage tank SS 304 & 316 5000 Lit india.com/mixing-
(H)×1420mm (D) Pvt Ltd ,
vessel.html
Ahmedabad
Shree Bhagawathi
http://storagetank
1470mm(H) Machtech (Ind)
Egg Storage Tank SS 304 & 316 1000 Lit india.com/mixing-
×970mm(D) Pvt Ltd ,
vessel.html
Ahmedabad
Shree Bhagawathi
http://storagetank
1470mm(H) Machtech (Ind)
Water Storage Tank SS 304 & 316 1000 Lit india.com/mixing-
×970mm(D) Pvt Ltd ,
vessel.html
Ahmedabad
Shree Bhagawathi
http://storagetank
Vinegar Storage SS 304 & 316 1370mm(H) Machtech (Ind)
500 Lit india.com/mixing-
Tank ×700mm(D) Pvt Ltd ,
vessel.html
Ahmedabad
http://www.steph
2000mm(L)×2000 Stephan Food
an-
Inline Homogenizer SS 304 & 316 mm(W)×2300mm( 1500 – 3000 L/H Processing
machinery.com/in
H) Machinery, Pune
dex.php?id=53

1800mm http://www.blenz
Blenzor India Pvt
Filler SS 304 & 316 (L)×1800mm 20-25 Jars / Min or.com/Rotary-
Ltd, Mumbai
 Proposed Plant Layout
Total Plant Area = 88 M2 =0.021 acre Scale 1 M = 2CM
 Storage Tank

Homogenizer Filler
THANK YOU