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e r s t enbe rgSc t i rode r

A N SPX BRAND

Fine Food

p p l ic a t i o n Sh e e t

atch productionof may onn aise and ketchup

M a yon na ise a nd ke tc h u p a re use d f o r man y p u rp oses,

e .g. for sand w ich es, salads, F re n ch fr ies or as i n g redien tsfo r o the r foo d pr od u c ts. SPX Flow T echnology o fle rs

sup e rio r G erst enb e rg S c h ro der pr ocessing eq u ipm en t

fo r b o th co nt in u ous a nd batch p ro du c tion o f m ayonnaise

an d k e tchu p . S P X F lo w T ech n o logy su p p lies G e rs tenberg

S c h rode r e mu lsi fy ing s ys te m s u n d er th e n a m es E RS , w hic h

is a co n tinuou s sys te m , a n d EBS , w h ic h i s a ba tch sy s tem.

Only th e EBS wi ll b e d esc rib ed in t his a ppl icatio n s h ee t.

M ay o n n a ise is a n oil-in-wa te r e m u ls io n . T he i n g redi e nt s u sed

in m ayonnaise can b e div ided in to seve ral p h ases, e.g. :

An oil p hase only containing oil .

An egg phase only containi n g egg substances (whole

egg , egg yolk o r m ixture).

A v in ega r ph ase whi c h can co ntai n v in egar, sp ices ando the r flavou rs. T he v in e g a r ph ase can a lso act as a

pr ese rv a tive a g ai n s t m ic ro b ia l sp oil age . A p H at 3 .5 - 4 is

des irab le fo r th e fin a l m a yonna ise .

A w a te r p h ase wh ich ca n c on ta in w a ter, c o ld - o r w a rr n-

s w el ling st a rch, s ta b ilise r, f la v o ur s a nd p rese rv a tives. The

lat te r in co mb in a tio n wi th lo w p H resul ts i n a lo n g shelf

life .

T o o b tain the mos t s table mayon n a ise it is desirable to have

small homogeneous o il dro p lets. The d rop let s ize should

b e b etween 2 a nd 8 u rn. T his is o bt ai n e d b y mechanical

treat m e n t w ith a h igh shea r m ixe r.

A higher oi l conten t and a finer distribution o f the oi l dr oplets

res u lt in a h ig he r viscosity o f the mayon n aise re g a rd less o f

p roduc tio n m e th od , i.e . con tin u ou s o r b a tc h .

Ke tch up in g redien ts can be d iv ide d in to seve ral p hases, e.g.:

T omato pas te.

A vinegar p hase w h ich ca n co nt a in vinega r, s p ices, sugar

and other fl a vours. T h e vinega r p hase can a lso act as a

preservative agai n s t m ic ro b ial s p oilage. A pH a t 3 .5 - 4is desirable , because the preservat ives are mo re eff icient

when the pH < 4 e.g. resulti n g in lo ng er she lf life.

W ater p hase w hic h ca n c ont ai n wa ter , s tar ch,

pr e s e rvatives and flavours .

T o ob tai n a s ta b le ke tchup inten si ve m ec hani c a l tr e a tm e n t

is esse n tial reg ard le ss of p roduct ion met hod, i .e . co nt inu o u s

o r batch.

Ba tch produc tion

P rior to the batch p rod u cti on all in g redients are m eas ur ed.

T he he a rt 0 1 the E B S line is a mixing tank to which the

ingredien ls are a d ded from below and in a cer tain o rd e r.

F or mayonnaise the wa ter p hase co u ld b e a d ded fi rs t, oiten

consist ing of w a te r , s ta b ilise r and s pi ces . In case of lo w

fa t m ayo nnai se wit h ho t s we lling star c h the wat e r p h as e is

h ea te d up a nd subseque n tly c ool e d d o wn . Th e egg is a dd e d

a n d the ble n d is ci rcu la ted by th e h ig h sh ea r mi xe r mou n te d

al the bo tt om o f th e ta nk w h ile th e oi l is s low ly add ed unt il

the desi red amo u n t of oi l and visc o si ty is o b ta in e d. F in ally

the vinegar is a d d ed in or d e r t o a dju s t th e p H a nd th e

produ c t is ready for filling . F o r higher capac ities per hour it

is recommended to use cold swelling s tarch due to shor ter

production time per b a tch.

F or k e tchup the w a te r p h ase coul d be added firs t, oiten

cons is ting of e. g. sal t, s u ga r a nd s tab ilise r. Th en th e vinega r

p hase isadde d and th e bl e nd is c irc u la ted by th e s pec ia l hi g h

s h ea r m ixer mou n ted a t the bot tom of th e ta nk for s u perior

mixing while the to m a to p as te is s low ly add e d . Aft e r m ixin g

the produ c t is hea ted u p l o r a ce rtai n t ime . T he tem p e ra tu re

prof ile depends on the used ing redients. In ard e r to avoid a

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hi gh num b er o f hea t r esis tan t mic ro organ isms in t he p roduc t,

it is reco mm e nd a b le to h ea t th e p roduc t up to 1 0 0 C for

about 8 minu tes. Th e final v iscosi ty of the product depends

on th e reci p e a nd t he h ea t trea tm en t.

Fig . 1: EBS pr in cipie process

The EBS can be incorpo ra ted in any n ew o r exis tin g p rod u c t

l ine and the cont rol panel can be del ivered as a manua lly

contro lled o r as an au tomatic a lly con trolled pa n el .

vacuurn fun c tion in th e pr ocess ta n k e n su re s no ai r in th e

final product .

The EBS processing sys te m ensures a s ta b le e mul s ion a nd

a short p roduc tio n tim e . T he equip m e n t is s uit a b le for b oth

hot and cold processi ng. T he h ot p rocess is re q ui re d whe n

using wa rm-swell ing sta rch for the produc tion o f a l o w fat

mayonnaise.

T he EBS p rod u ction of fe rs l o w was te a n d qu ick c h a ng eover

from one rec ipe to ano th e r d ue to m in im al pr o d uc t vol um e i n

th e EBS as we ll as sh ort cl ea n ing time.

Water c ::::> --OC:===:Jl

Steam

Condensate

Water/s tarch phas e preparat ion

Fi g . 2 : An exampl e o f a mayonnai se proces s wi th seperat e water/ starc h ph a s e preparation

Other advantages of the S

H y g ie n ic a nd r o b us t des ign:

M ee ts the requi remen ts fo r the fo o d i n dus try a n d occupies

minimu m floo r space

Vac uu rn p rod u c tio n :

N o ai r in the final p rod u cl

H ig h shea r m ixe r:

Sh or t p rod u ction time

X FlowTechnoloqywww.qs a s .comwww. s pxit. co rn

Ind irect thermal t rea tm en t:

For the heating p rocess w h en hot swelling s ta rch is use d

for p roduc tion of low fa l mayo n naise

E asy lo o p erate :

Ea s y opera tion o f the p la nt with th e cont rol p a n el

Co s t s aving:

Minimal pr od u c t was te compared wi th continuo u s

produc tion

D e6; i tt: