To start a new Mayonnaise manufacturing facility details for the entrepreneurs of Food processing sector

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

2. 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.

3. • 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

4. 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

5. 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

6. 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.

7. 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

8. 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.

9. 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

10. Ingredient Formulation
Full 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 %

11. Product Specifications
Nutritional 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

12. 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

13. Process Scheduling
Operation
Minimum
Residence Time
(MRT) min
Early
Start (ES)
min
Latest 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

14. GANTT Chart
0
2
6
11
13
15
45
407
409
410
407
407
435
435
73
69
64
62
60
30
0
0 100 200 300 400 500 600
Addition of Whole Egg
Add. Of Water + Sugar Mix
Addition of Oil
Add. Of Vinegar + Salt + Lemon Juice
Add. Mustard
Homogenization
Filling
Early Start
TMRT
Latest Finish

15. List of Equipment
S. 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

16. Specifications
Equipment 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://storagetank
india.com/mixing-
vessel.html
Egg Storage Tank SS 304 & 316
1470mm(H)
×970mm(D)
1000 Lit
Shree Bhagawathi
Machtech (Ind)
Pvt Ltd ,
Ahmedabad
http://storagetank
india.com/mixing-
vessel.html
Water Storage Tank SS 304 & 316
1470mm(H)
×970mm(D)
1000 Lit
Shree Bhagawathi
Machtech (Ind)
Pvt Ltd ,
Ahmedabad
http://storagetank
india.com/mixing-
vessel.html
Vinegar Storage
Tank
SS 304 & 316 1370mm(H)
×700mm(D)
500 Lit
Shree Bhagawathi
Machtech (Ind)
Pvt Ltd ,
Ahmedabad
http://storagetank
india.com/mixing-
vessel.html
Inline Homogenizer SS 304 & 316
2000mm(L)×2000
mm(W)×2300mm(
H)
1500 – 3000 L/H
Stephan Food
Processing
Machinery, Pune
http://www.steph
an-
machinery.com/in
dex.php?id=53
Filler SS 304 & 316
1800mm
(L)×1800mm 20-25 Jars / Min
Blenzor India Pvt
Ltd, Mumbai
http://www.blenz
or.com/Rotary-

17. Proposed Plant Layout
Total Plant Area = 88 M2 =0.021 acre Scale 1 M = 2CM

18. Storage Tank
Homogenizer Filler

19. THANK YOU