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PDE – IAssignment on mayonnaise
Presented ByMastan Vali K16FT1D7821
Under the Guidance ofMr. S Sashikanth
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 regulations 4 4 4
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 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
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
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
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 %
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
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
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
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
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
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
Proposed Plant LayoutTotal Plant Area = 88 M2 =0.021 acre Scale 1 M = 2CM
Storage Tank
Homogenizer Filler
THANK YOU
