Lecture Notes on Mayonnaise Production

Quality and Catastrophic Phase Inversion

Overview

• Institution: Department of Food Technology, Engineering and Nutrition at Lund University
• Authors: Ebba Widerström & Rebecca Öhman
• Year: 2017
• Supervisors: Fredrik Innings, Dragana Arlov, and Björn Bergenståhl
• Examiner: Marilyn Rayner

Abstract

• Importance of high quality and avoiding phase inversion in industrial mayonnaise production.
• Use of high shear mixer and immersion blender to test different conditions.
• Variables tested: stirring speed, temperature, egg content/type, oil content.
• Findings:
  • Cold ingredients and high egg yolk content improve quality.
  • Increased oil content makes mayonnaise firmer but more susceptible to over-shear.
  • Phase inversion risks: prolonged mixing, rapid oil addition.
  • Egg yolk powder requires low oil flow rate.

Introduction to Mayonnaise

• Mayonnaise: an oil-in-water (O/W) emulsion with egg yolk as an emulsifier.
• Full-fat mayonnaise contains 75-80% oil.
• Risk of phase inversion to water-in-oil (W/O) emulsion if not properly managed.

Objective

• Investigate parameters affecting emulsion formation and breakage.
• Focus on rotor tip speed, oil flow rate, emulsifier type, ingredient temperature, and oil content.

Background

Basics of Mayonnaise

• Ideal mayonnaise characterized by firm texture and small droplet size.
• Industrial mixing involves premixing, coarse emulsion, and emulsification steps.

Ingredients

• Oil: Contributes to stability, viscosity, and flavor.
• Egg: Emulsifier properties primarily from egg yolk.
• Vinegar: Lowers pH, enhances flavor and preservation.
• Salt and Sugar: Flavor and stability, counteracts vinegar flavor.
• Mustard: Flavor and color enhancement.

Emulsions

• Structure: Oil droplets in continuous water phase.
• Droplet size affects emulsion stability.
• Stability challenged by creaming, flocculation, and coalescence.

Methodology

Mayonnaise Production

• Use of high shear mixer and immersion blender.
• Recipes with varying percentages of egg yolk and oil content.

Analysis

• Texture measured by force to compress (Stevens value).
• Droplet size measured using laser diffraction.

Results and Discussion

Mayonnaise Quality

• Emulsification Speed: Faster speeds decrease production time but increase sensitivity to over-shear.
• Temperature: Cold ingredients stabilize texture without affecting droplet size.
• Recipe Variations:
  • Decreased egg yolk reduces emulsifier quantity, affecting texture and droplet size.
  • Egg yolk powder provides higher texture but increases sensitivity to over-shear.
  • Whole egg results in low-quality mayonnaise.
• Increased Oil Content:
  • Higher oil content improves firmness but raises phase inversion risk.

Phase Inversion

• Catastrophic Phase Inversion: Caused by high oil content and fast oil addition.
• Emulsification Phase Inversion: Occurs with over-shearing.
• Coarse Emulsion Phase Inversion: Results from improper mixing or excessive oil.

Conclusion

• Achievement of high-quality mayonnaise involves balancing various production parameters.
• Over-shearing and phase inversion are major risks in industrial production.
• Recommendations include controlled oil addition and cold ingredient usage.

Recommendations

• Use cold ingredients and high egg yolk content for best quality.
• Carefully manage oil addition rate to prevent phase inversion.
• Consider recipe modifications based on desired texture and stability.