MAYONNAISE

Mayonnaise is a condiment sauce obtained by emulsifying edible vegetable oil(s) in an

aqueous phase consisting of vinegar, the oil-in-water emulsion being produced by the hens'
egg yolk. Mayonnaise may also contain optional ingredients. The egg York contains lecithin,
a fat emulsifier that serves as a stabilizer between the two liquids. High quality mayonnaise
has a firm texture and a small droplet size.
Mayonnaise reaches a peak in texture and a minimum in droplet size during mixing. At
longer mixing times the quality decreases and the mayonnaise becomes over-sheared. When
the ingredients are cold and a high amount of egg yolk is used, mayonnaise with a high
quality can be made.
Mayonnaise with an increased oil content has a firmer texture but is also more sensitive to
over-shear. Full-fat mayonnaise contains around 65 to 80 %. The oil is dispersed in a water
phase to form an oil-in-water (O/W) emulsion. A low viscosity characterizes phase inversed
mayonnaise, or broken mayonnaise, which is close to the viscosity of oil resulting in a water-
in-oil (W/O) emulsion. Low or reduced-fat mayonnaise, on the other hand, is a growing
market, with continually reducing oil content while maintaining similar product taste and
texture. As the oil is present in levels of at least 30 to 60 % by weight in light or low-calorie
mayonnaise, substantial reformulation is necessary in order to produce a mayonnaise product
with less than 5 % by weight vegetable oil.
 ESSENTIAL COMPOSITION AND QUALITY CRITERIA

5.1 General requirements

Mayonnaise shall have the following characteristics;

5.1.1 The texture of the product shall be semisolid, uniform, smooth and free from lumps due to poor
manufacturing;

5.1.2 It shall be free from impurities and foreign materials, rancidity and any other foreign flavours;

5.1.3 It shall be free from animal fats and oils;

5.1.4 The taste of mayonnaise shall be characteristic of mayonnaise;

5.1.5 Bubbles of oil shall be small and uniform in size; and

5.1.6 Egg white content shall not be more than 20% and the egg yolk shall not be less than 6% in accordance

5.2 Raw materials

5.2.1 All ingredients shall be of sound quality and fit for human consumption and shall comply with the

requirements of the relevant standards.

5.2.2 Water used shall comply with the requirements laid down.

5.2.3 Eggs and egg products shall be from the poultry birds, unless otherwise specified.

5.2.4 Ingredients added to impart a characterizing flavour to the products shall be used in quantities

sufficient to influence significantly the organoleptic properties of the product.

5.2.5 Raw materials shall be stored, treated and handled under suitable conditions to maintain their chemical

and microbiological characteristics.

5.3 Essential ingredients

Mayonnaise shall consist of the following essential ingredients, which shall be of sound quality and fit for

human consumption:

a) Potable water

b) Acidifying agents such as lemon juice or vinegar

c) Edible vegetable oils

d) Egg white;

e) Pasteurised egg yolk; and

f) Food grade salt

5.4 Optional ingredients

Other ingredients which may be used include but are not limited to the following:

a) Sugar

b) Condiments, spices, herbs complying with relevant standards;

c) Mustard;

d) Dairy products complying with relevant standards.

 Scope of HACCP Plan
Hazard Analysis Critical Control Point, or HACCP, is a system, which gives
us a proactive common-sense approach to the safety management of our
food products. The HACCP system was launched publicly in 1971, and is
designed to identify and control hazards that may occur anywhere in a food
processing operation. The purpose of this food safety program is to identify
and control, prevent and eliminate food safety hazards. From the intake of
product to the arrival of the finished product at the customers, taking into
account all possible Microbiological, Chemical or Physical hazards which
could occur during this process. The HACCP Team will ensure that all
working practices adhere to all current food safety legislation. The HACCP
team have determined to address the potential of Microbiological, Chemical
and Physical contamination through the process of Intake, Handling,
Storage, Quality Control and Distribution of product from intake to delivery
of the product to the customers. The benefits of the HACCP system are as
follows: -
➢ A Preventative System
➢ A Systematic Approach
➢ Helps demonstrate ‘Due Diligence’ Internationally accepted
➢ Strengthens Quality Management Systems
➢ Facilitates regulatory inspection/external audits
➢ Demonstrates Management commitment
 Formation of food safety team
A food safety team will be formed. This will consist of a food safety team leader and food
safety member [i.e., representatives of all key departments (like production, QC laboratory,
purchase, raw material and packaging material stores, maintenance, finished goods stores,
Research and development etc.) in that food industry]. Here the consultant has to keep in
mind that he should conduct specific training of the food safety team (if required in local
language) in coordination with the food safety team leader. The entire team as a unit should
have sufficient knowledge and experience of organization's products, processes, equipment
and associated food safety hazards. The competence of the team members varies from
organization to organization and region to region. Though now many new and sophisticated
food industries are setting up their plants in various regions of India and the personnel
working therein are technically competent. The food safety team leader should be a well-
qualified person having sufficient experience in that organization or that type of industry. He
should have good communication and motivation skills. He should be knowledgeable in food
safety principles and practices. He should have good management skills like planning,
coordinating, controlling etc. He should ensure that the food safety team has relevant
expertise with identification of possible hazards. Processing steps and sequence followed by
that organization. If required he should recommend top management to hire the services of
external consultant to participate and guide the food safety team’s working. Records should
be maintained to demonstrate that the food safety team has required multi-disciplinary
knowledge and experience. This is called as competence assessment, education, training, and
skills. This exercise is to be done and records of the results of the exercise as well as the
actions taken thereon (to ensure achievement of required competence by one and all in the
organization) is to be maintained not only for the members of the food safety team but for all
operating and management team members of the organization e.g., right from those who are
responsible for selection of suppliers through incoming inspection and production personnel
(many of them may be contract workers, if the food processing organization is seasonal in
characteristic) to those who load the finished goods in vehicles like containers (for export
may be).
Typical Minimum Qualifications Criteria for Food Safety Team Leader and Members
in Mayonnaise Processing Organization

Role in the Food Safety Required Minimum Required Minimum Expertise Required Minimum
Team Qualifications Experience

Food safety team leader B. Tech (Food) 1. Working experience of food 10 years
processing

2. Good Knowledge of food safety

and microbiological concepts

3. Good communication and

managerial skills

Food safety team member, B. Tech (Food) / B.Sc. 1. Working experience of processing 6 years
production (Chem)
2. Good Knowledge of food safety
and microbiological concepts

3. Knowledge of operation of
machines

Food safety team member, B.Sc. (Microbiologist) 1. Good Knowledge of 5 years

QA Microbiology

2. Knowledge of food processing

industry

3. Knowledge of chemical,
Microbiological analysis and
methods

4. Good Knowledge of food safety

concept

Food safety team member, D.E.E / D.M.E./ D.I.E 1. Working experience of processing 5 years
maintenance
2. Good knowledge of Machinery
operation maintenance, cleaning
used in food processing industry

3. Knowledge of Calibration
Techniques

4. Basic Knowledge of food safety

Food safety team member, B.Sc. (Food) 1. Good knowledge of raw material 5 to 6 years
raw material handling and management

2. Basic Knowledge of food safety

3. Good Worker management skills

 End Product Characteristics

Product Name Mayonnaise

Oil, emulsifier (egg yolk prescribed in some

countries), vinegar (as pH regulator and as
Raw Materials and flavor), spices, flavors (sugar, salt,
Ingredients Used mustard…) and stabilizers (thickeners for
mayonnaise with <70% oil only).

Specific Product Colour, Flavour, Taste

Specifications (as per product specifications)

General Product Refer to Product Specifications

Specification
(Appearance, etc.)

Preservation Method Aseptic pouches are shelf-stable, requiring

no refrigeration or preservatives.

Primary Packaging Glass jars topped with metal lids, pouches

Secondary Packaging Bag-in-box packaging is ideal for delivering

bulk amounts of mayonnaise for fast-paced
institutional environments

Shelf Life One year from the Manufacturing Date

Labelling Instructions Name of the product, Batch Code, Drum

Number, Net wt., Gross wt., Date of
Manufacture, Date of Expiry, FPO No.,
Exporter’s Address and other as per
Customers requirement

Applicable Legislation(s) FPO, Weights and Measures Act and PFA.

Applicable legislation of the importing
country

Potential Mishandling of the Product Rough handling, rolling of drums Keeping

in downright position Storage at High
temperature Storage under Direct sunlight
Use of leaky and puff bags
 Product Identification, Intended Use and Process

Standards of Identification

Mayonnaise

When classifying a food product by name it must contain a standard set of ingredients put
forward by the Food and Drug Administration. There can be substitutes for certain ingredients
with others but these must be on the list that is provided by the FDA. Each of these ingredients
is required to be written on the label, for all consumers to view. This is how the nomenclature
for each food product is given (http://www.accessdata.fda.gov).
Mayonnaise is an emulsified semisolid food that is made with vegetable oils. This is not limited
to just vegetable oil however; sunflower oil, Soya oil, and rapeseed oil may also be used in
making mayonnaise. No mineral oil may be used in the preparation of mayonnaise.
One or both of the following acidifying ingredients must also be used in the preparation of
mayonnaise. These acidifying ingredients are any vinegar or any vinegar diluted with water to
acidity, of no less than 2.5% by weight, calculated as acetic acid, or any type of vinegar or diluted
vinegar that is combined with an extra acidifying ingredient that is listed in the following
section. Salt and nutritive carbohydrate sweeteners are two of these ingredients. Any spice or
natural flavouring may also be used as long as it does not change the color of the mayonnaise to
a colour, which is given by egg yolks. Saffron and turmeric may not be added to
mayonnaise. Monosodium glutamate and Sequestrant(s) may also be used in the preparation of
mayonnaise. These Sequestrants can be one of the following; calcium disodium EDTA (calcium
disodium ethylenediamine- tetraacetate) and/or disodium EDTA (disodium
ethylenediaminetetraacetate). Other Sequestrants may also be used. Sequestrants are used to
preserve the colour and the flavour of the mayonnaise. Other acidifying ingredients are citric
and/or malic acid. These ingredients may be added in an amount that is no greater than 25% of
the weight of the acids of the vinegar or diluted vinegar. This must be calculated as acetic
acid. The last acidifying ingredient that may be added is the crystallization inhibitor. These can
include lecithin, polyglycerol esters of fatty acids, and oxystearin. Other crystallization
inhibitors may also be used. When talking about vinegars in this paragraph any mixture of two
more vinegars can also be considered vinegar (http://www.accessdata.fda.gov).
The next ingredients that may be added are lemon juice and/or lime juice. These can be added
in a type of mixture, which can be diluted with water to an acidity, of no less than 2.5% by
weight. This acidity must be calculated as that of citric acid. The final ingredient that must be
added before it can be officially called mayonnaise is the egg yolk-containing ingredient. The
following type of egg yolks may be added to the mixture: frozen, dried, and liquid. The following
types of whole eggs may also be added: liquid, frozen, and dried.
Also, any of the previous egg containing ingredients can also be mixed with liquid and or frozen
egg whites. This final addition of eggs will give the name of this mixture as mayonnaise
(http://www.accessdata.fda.gov).
PHYSICAL NATURE/ORGANOLEPTIC PROPERTIES:
A thick white mayonnaise.
INGREDIENTS (IN DESCENDING ORDER):
Vegetable Oil, Water, Spirit Vinegar, Sugar, Salt, Dried Egg Yolk, Stabiliser (Xanthan Gum),
Modified Maize
Starch, Mustard Flour, Preservative (Potassium Sorbate), Lemon Juice Concentrate, Colour
(Paprika Extract).
ALLERGY ADVICE: Contains Egg and Mustard.
QUALITY PARAMETERS:
Analytical Acid (%): 0.6 – 0.8
Salt (%): 1.0 – 1.5
Viscosity (spTD/5rpm): 10 - 30
pH: <3.6
Physical Organoleptic: Appearance and taste typical of
Mayonnaise, comparable to standard sample.
METAL DETECTION:
Metal Detector Sensitivity: 4.0mm Fe, 5.0mm Non-Fe, 8.0mm Stainless Steel,
Checked on an hourly basis.

PACKAGING MATERIAL
Pouches & Glass Bottles
The flow chart has been designed so that each step has been allocated a number. All steps that
are repeated throughout the process have been allocated the same number to save repetition in
the risk analysis table. The method used to establish CCP’s within this HACCP plan has been
based on the significance of each hazard as determined by the risk analysis table. Hazards
which can be controlled, Prevented or eliminated by the application of Per- Requisite
Programme are not included in the HACCP table.
Therefore, these hazards have been identified in the risk analysis and have not been carried
forward to the HACCP table as CCP’s. All other hazards not controlled by PRP and defined
as highly significant within the Risk Analysis Table have been carried over to the HACCP
table as a CCP. These hazards are all monitored and a record of that activity maintained.
Hazards defined as less than significant within the Risk Analysis Table are not carried over to
the HACCP Table and may not be monitored or a record maintained.

TOTAL RISK = LIKELIHOOD x SEVERITY

Likelihood
1 = Improbable event - once every five years
2 = Remote possibility - once every year
3 = Occasional event - once per month
4 = Probable event - once per week
5 = Frequent event -once per day
Severity
1 = Negligible - no impact or not detectable
2 = Marginal - only internal company target
levels affected
3 = Significant - Impact on critical limits
4 = Major - Impact on customer (may not be
the public)
5 = Critical - public health risk / public
product recall
 PROCESS FLOW DIAGRAM

Recieving of all the raw Addition of

materials like Egg, Oil , whole egg in Addition of
Hold all the raw
Spieces , Sugar pre-emulsion Water & Sugar
material in
tank in Pre-
different tanks
emulsion tank
CCP - 1

Mixing at third
operational Addition of Oil
Addition of Mixing
speed continues slowly to the Mix in
Vinegar , Salt , Continues at
in the mixer a way that the final
Lemon Juice Second
(Pre-emulsion product should have
(Spices if Operational
tank) 65-85% fat content
required) Speed
by wt.
CCP - 2

Homogenisation
Mayonnaise Filling into Jars
CCP 3
Process Step / List of Hazard and Likely Severity Is this a critical Raw
all the raw material Source occurrence Material (Yes /No)
used in plant (High/
Medium/Low)
Liquid, pasteurized B – Salmonella Low – Med Medium Yes
egg C – Allergen High High Yes
P- None Negligible None No

Sugar B – None Negligible N No

C- Pesticides Medium N Yes
P- Large Lump, Medium-High M Yes
metal, glass

Vinegar B- None Negligible N No

C- None Negligible N No
P- None Negligible N No

Salt B- None Negligible N No

C- None Negligible N No
P- Large Lump, Medium - High M Yes
metal, glass
Oil B- None Negligible N No
C-None Negligible N No
P-None Negligible N No
Glass Jars B- None Negligible N No
C- None Negligible N No
P- Pieces/Shards Medium - High M Yes
List every Critical Does this raw material Is this hazard(s) Is this hazard Can a viable product
Ingredient identified in or process step CONTROLLED to the ELIMINATED still be produced if the
the Raw Material INTRODUCE or best of the plant's (reduced to an process step listed in
Hazard Analysis. INTENSIFY a ability by Support acceptable level) at this Column 4 fails? If
List every process step, potential food safety Programs? If YES, list or a later process step? YES, this step must be
from Receiving to hazard? If YES all of the Support if NO, write "none" considered a CCP
Shipping, shown on the identify hazard(s). (Be Programs that will and continue to the identify the CCP
simplified Process Flow as specific as possible control the introduction next hazard or process number. If NO, this is
Diagram. Go to when listing the hazard or intensification of the step If YES, identify not a CCP enter No
Column 2 and its source.) If no hazard(s) identified in the last process step Go to the next hazard
Note: If this is a last hazard is identified, Column 2 If NO, write where it will be or process step
process step identified write "none" "none." eliminated.
in Column 4, list the Go to column 3. None
hazard eliminated in Go to column 4. If you are at that
Column 2 process step, proceed to
Column 5, if not, go to
the next hazard or
process step. (Note: If
no control or
elimination is identified
in Column 3 or 4 and
these are necessary for
food safety, you must
stop, modify the step,
process, product, or
Support Programs.)
Liquid Pasteurized B- Salmonella Supplier Control Pasteurizer CCP1
Eggs Program
C- Allergen Supplier Control No
Program
P- None None None
B- Bacteria Supplier Control
Bulk Receiving & C- Allergen Program for all the
Storage P-Metals, bones, glass, Hazards
sticks

Mixer B- Bacteria GMP’s Personnel CCP 2

Practice
C-Cleaner, Sanitizer Chemical Control None
Policy
P- Lump, Glass, Metal GMP -Personnel Metal
practices, Glass Policy Detector/Glass X
ray Unit
Homogenization B- Bacteria GMP’s Personnel CCP 3
Practice
C- Cleaner, Sanitizer Chemical Control
Policy
P – Lump GMP -Personnel Metal Detector
practices, Glass Policy
Cooling B- None
C- None
P-None
Glass Storage B-None Glass X-ray Unit
C-None
P- None
 PRP (Pre-requisite programme)

PRPs are to be implemented to assist in controlling likelihood of occurrence of hazards and

their levels in product and product processing environment as well as contamination of product
and possible cross contamination between products. Clause 7.2.3 says that Codex alimentarius
commission recommended international code of practice general principles of food hygiene
(CAC/RCP 1- 1969, Rev 4-2003) to be followed for PRP. It contains PRPs (as required by clause
7.2.3) divided into eight categories.

PRP Category PRP aspects

Primary production 1. Environmental Hygiene.
2. Hygienic production of food sources.
3. Handling, storage and transport.
4. Cleaning, maintenance and personnel
hygiene at primary production
Establishment design and Facilities 1. Location
2. Premises and rooms
3. Equipment
4. Facilities
Control of Operation 1. Control of food hazards
2. Key aspects of hygiene control systems
3. Incoming material requirements
4. Packaging
5. Water
6. Management and supervision
7. Documentation and records
8.Recall procedures
Establishment Maintenance and Sanitation 1. Maintenance and cleaning
2.Cleaning programme
3. Pest control systems
4. Waste management
5. Monitoring effectiveness
Establishment Personal Hygiene 1. Health status
2. Illness and injuries
3. Personal cleanliness
4.Personal behaviour
5.Visitors
Transportation 1.General
2.Requirements
3.Use and maintenance
Product Information and Consumer 1. Lot identification
Awareness 2.Product information
3. Labeling
4.Consumer education
Training 1. Awareness and responsibilities
2. Training programme
3. Instruction and supervision 4. Refresher
training
 Verification of food safety management system
Verification plan should be prepared defining verification aspect, method, frequency and
responsibilities for verification. Verification records should be maintained. Following is a sample
verification plan. All columns are not filled fully. The student may take it up as an exercise to
complete the plan.

Verification plan

Aspect 1. Frequency Method

2. Responsibility
Product Description 1. Yearly
2. Food safety team
Reviewing the adequacy
Flow Diagram 1.Yearly or event driven
basis like changes in
infrastructure, installation of
new machines
Reviewing the adequacy
customer complaints,
changes in statutory and
regulatory requirements.
Verifying whether the flow
diagram is in congruence
with the ground reality

2. Food safety team

Hazard Analysis Worksheet
Assessment and
categorization of control
measures
OPRP plan
CCP plan
Plant layout
Organization chart
Applicable legislation and
regulations
All SOPs and format
Traceability test
Internal Audit
Pest control schedule/
checklist
Result of external audit
Emergency situation
PRP documents
OPRP records
CCP records
Training records
Calibration records
Validation records
Customer complaints
Specifications for raw
materials, final products,
packaging materials
 Traceability system
Identification of product lots and their relationship with batches of raw material, processing
and delivery record should be maintained. Traceability system should identify incoming
material from immediate suppliers and initial distribution route of the end product.

Mandatory procedures

Following procedure should be documented: -

➢ Control of documents
➢ Control of records
➢ Handling of potentially unsafe product
➢ Procedure for correction
➢ Procedure for corrective action
➢ Withdrawal
➢ Internal audit

Validation of control measure combinations: -

It is to be ensured that standards, experience, research, experiments, competence of personnel

etc., validate the selected control measures and their combination with hazard control.
(Hazard elimination, prevention or reduction below the acceptance level)

Control of monitoring and measurement: -

Adequacy of monitoring and measuring methods as well as calibration of measuring

equipment should be done in a planned manner with national or international traceability.

Emergency preparedness: -

Emergency procedures should be established, implemented and maintained to manage

potential emergency situations and accidents that can impact food safety.

Regulatory bodies, suppliers, contractors, customers, consumers and others in the food chain should
be kept in communication loop with food safety related requirements.
Broad Category
Raw Material Supplier
Packaging Material Supplier
External testing Laboratories
Pest Controls
Machine and equipment
suppliers
Construction contractors
Transporter
External communication:-
Food Safety Aspect Who Communicates?
➢ Certificate of analysis Purchase manager
➢ Product specification
details
➢ Complaints regarding
raw material
➢ Products ingredient
details
➢ Regarding suppliers
approval certification
➢ Packaging material for
the raw materials
➢ Method of transportation
➢ Method of storage
➢ Certificate of analysis Purchase manager
➢ Product specification
details
➢ Nature of material and
Food grade certificate
➢ Complaints relating to
the packaging
➢ Mode of transportation
➢ Method of storage
➢ Scope of accreditation QC Manager
for the test to be done
➢ Test details (Report)
➢ MSDS (Material Safety QC Manager
Data Sheet) for the
pesticides used
➢ Pest control annual
maintenance Contract
➢ Procedure of spraying
➢ Effectiveness and safety
measures of spraying
➢ Concentration of sprays
used
➢ Investigation regarding
species of flies and
lifecycle studies
➢ Layout of pest control
activities
Maintenance manager
Management
Purchase manager
 DOCUMENTATION
What is a documented food safety management system?
This is a document which outlines all the food production you carry out in your business, it
highlights all the hazards associated with production, how you control those hazards, how
you monitor the control measures you have in place and what to do if things go wrong.

Why do I need a documented food safety management system?

You must have a documented food safety management system in place to show how you
manage food safety hazards in your business.
You must write these procedures down, update them as necessary and retain them so they can
be checked by our department during a food hygiene inspection.
You must also:

• keep them in place permanently.

• keep up-to-date documents and records relating to your procedures.
• review your procedures if you change what you produce or how you work.

Documentation Records: -

1. Audit records
2. Equipment records
3. Product records
4. Staff records
5. Cleaning schedule records
6. Hazard analysis plan
7. Record the inspection visit
 PACKAGING, SHELF LIFE AND STORAGE
CONDITION

How Long Is the Shelf Life of Mayonnaise?

The shelf life of Mayonnaise is 6-8 months unopened, and one month once you’ve broken the
seal on the bottle/ pouch. You have to refrigerate Mayonnaise once it's opened.

Apple cider vinegar is highly acidic. Because of this, it’s unlikely to be contaminated with
pathogens. But store it properly to extend the shelf life.

What about products made with Mayonnaise?

Mayonnaise colloquially referred to as "mayo” is a thick, cold, and creamy sauce or dressing
commonly used on sandwiches, hamburgers, composed salads, and French fries.

Packaging material:-

Glass and plastic bottles should be used for storing of mayonnaise