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PDE – I Assignment on mayonnaise Presented By Mastan Vali K 16FT1D7821 Under the Guidance of Mr. S Sashikanth

Mayonnaise Plant Design

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Page 1: Mayonnaise Plant Design

PDE – IAssignment on mayonnaise

Presented ByMastan Vali K16FT1D7821

Under the Guidance ofMr. S Sashikanth

Page 2: Mayonnaise Plant Design

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.

Page 3: Mayonnaise Plant Design

• 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

Page 4: Mayonnaise Plant Design

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 regulations 4 4 4

Infrastructure 5 4 4

Total Points 32 26 25

Page 5: Mayonnaise Plant Design

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

Page 6: Mayonnaise Plant Design

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.

Page 7: Mayonnaise Plant Design

Selection of ProcessContinuous Process:• There are 4 tanks with necessary portions of

various ingredients1. Vegetable oil2. Water with Previously dissolved sugar3. Vinegar with previously dissolved salt and lemon juice

powder4. Whole Egg liquid5. Mustard Powder Bags6. Lemon Juice powder Bags

Page 8: Mayonnaise Plant Design

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.

Page 9: Mayonnaise Plant Design

Process Flow Sheet

Filling into Jars

Mayonnaise

Homogenization

Emulsion Tank

Add. Of Mustard

Add. of Vinegar with Salt & Lemon Juice

Addition of Oil to the Mix

Addition of Water with Sugar to the Pre Emulsion Tank

Addition of Whole Egg to Pre Emulsion Tank

Empty Jars

Page 10: Mayonnaise Plant Design

Ingredient FormulationFull Fat (80 % Oil) Formula

Vegetable Oil 75 %

Whole Egg 10 %

Vinegar 4 %

Sugar 1 %

Salt 1 %

Spices (e.g. Mustard Powder)

0.5 %

Water 8 %

Lemon Juice 0.5 %

Low Fat Formula

Vegetable Oil 50 %

Whole Egg 4 %

Other Thickeners 4 %

Vinegar 3 %

Sugar 1.5 %

Salt 0.7 %

Spices 1.5 %

Water 35.3 %

Page 11: Mayonnaise Plant Design

Product SpecificationsNutritional Information

Typical Values For 100g

Energy 725 Kcal

Fat 80 g

Saturated Fat 6.9 g

Carbohydrate 8.8 g

Protein 1.9 g

Salt 1.2 g

Fibre 0.7 g

Sodium 0.5 g

• Particle Size: 1-5µm• Shelf Life: At 15 – 20°C

Six months from date of manufacturing.

• Filling Material: PET Jars• Filling SKU: 500g• Allergen: Contains Egg

and Mustard

Page 12: Mayonnaise Plant Design

Material Balance (5000 kg)

Filling into Jars

Mayonnaise

Homogenizer

Emulsion Tank

Addition of Mustard

Addition of Vinegar with Salt, Lemon Juice

Addition of Oil to the Mix

Addition of Water with Sugar to the Pre Emulsion Tank

Addition of Whole Egg to Pre Emulsion Tank500 Kg

400 Kg + 50 Kg

3750 Kg

200 + 50 + 25 Kg

2 % Loss 4900 Kg

4802 Kg (9604 Jars)2 % Loss

5000 Kg

25 Kg

Page 13: Mayonnaise Plant Design

Process SchedulingOperation

Minimum Residence Time

(MRT) min

Early Start (ES)

minLatest Finish

(LF) min TMRT min Capacity Kg/Hr

Addition of Whole Egg 2 0 73 407 73.7

Addition of Water + Sugar Mix 4 2 69 409 66

Addition of Oil 5 6 64 410 548.8

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

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

Page 14: Mayonnaise Plant Design

GANTT Chart

Addition of Whole Egg

Add. Of Water + Sugar Mix

Addition of Oil

Add. Of Vinegar + Salt + Lemon Juice

Add. Mustard

Homogenization

Filling

0 100 200 300 400 500 600

0

2

6

11

13

15

45

407

409

410

407

407

435

435

73

69

64

62

60

30

0

Early StartTMRTLatest Finish

Page 15: Mayonnaise Plant Design

List of EquipmentS. No Process Required Qty Required Capacity

1 Liquid Egg Storage Tank with agitator 1 600 Kg

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

Page 16: Mayonnaise Plant Design

SpecificationsEquipment Name Material of

Construction Dimensions Capacity Manufacturer / Supplier

Manufacturer Link

Oil Storage tank SS 304 & 316 2300mm (H)×1420mm (D) 5000 Lit

Shree Bhagawathi Machtech (Ind) Pvt Ltd , Ahmedabad

http://storagetankindia.com/mixing-vessel.html

Egg Storage Tank SS 304 & 316 1470mm(H) ×970mm(D) 1000 Lit

Shree Bhagawathi Machtech (Ind) Pvt Ltd , Ahmedabad

http://storagetankindia.com/mixing-vessel.html

Water Storage Tank SS 304 & 316 1470mm(H) ×970mm(D) 1000 Lit

Shree Bhagawathi Machtech (Ind) Pvt Ltd , Ahmedabad

http://storagetankindia.com/mixing-vessel.html

Vinegar Storage Tank

SS 304 & 316 1370mm(H) ×700mm(D) 500 Lit

Shree Bhagawathi Machtech (Ind) Pvt Ltd , Ahmedabad

http://storagetankindia.com/mixing-vessel.html

Inline Homogenizer SS 304 & 3162000mm(L)×2000mm(W)×2300mm(H)

1500 – 3000 L/HStephan Food Processing Machinery, Pune

http://www.stephan-machinery.com/index.php?id=53

Filler SS 304 & 3161800mm (L)×1800mm (W)×2100mm (H)

20-25 Jars / Min Blenzor India Pvt Ltd, Mumbai

http://www.blenzor.com/Rotary-Paste-Filler.html

Page 17: Mayonnaise Plant Design

Proposed Plant LayoutTotal Plant Area = 88 M2 =0.021 acre Scale 1 M = 2CM

Page 18: Mayonnaise Plant Design

Storage Tank

Homogenizer Filler

Page 19: Mayonnaise Plant Design

THANK YOU