Mayonnaise technology. What makes the equipment for the production of mayonnaise? Mass fraction of components by formulations,%

21.05.2020

Specific requirements are presented to machinery for the production of mayonnaise. Since the finished product does not pass full heat treatmentThe equipment on which it is manufactured (from the stage of preparation of raw materials to the packaging process of a packaged product) must be bacteriologically clean.

For this, in addition to compliance with the hygienic regime, the equipment must meet the following requirements:

be protected (sealing) from microflora from entering the external environment;
do not have congestion zones in which spontaneous reproduction of bacteria may occur;
easy to understand separate nodes for careful washing and disinfection;
manufactured from high quality materials (with permissible purity of the processing of internal surfaces up to 0.1 μm);
have a knot of an automatic washing.

An important meaning is equipped with the equipment for the production of mayonnaise by the deaeration unit, which makes it possible to increase product storage time, avoid oxidative damage.

In modern requirements for technological equipment, great importance is given to the full automation of production.

At the same time, weighing ingredients and raw materials are associated with the technological chain, the measurement of components in accordance with the recipe, mix them to the desired quality, control and automatic registering of the entire course of the product production process.

It is desirable that the cleaning and disinfection of the equipment is carried out by the closed cycle solutions (without the need to dismantle the equipment) - CIP (Cleaning in Place). For this, it is necessary to comply with the following requirements:

valves must prevent the contact of the detergent solution and products;
all surfaces in contact with the product must be available for detergent solution (in order to achieve full cleaning);
it is necessary to exclude the possibility of corrosion of materials from which the equipment is performed.

Types of equipment

Depending on the various production schemes, the equipment for the release of mayonnaise is divided into high-performance lines of continuous or semi-continuous action in which the various stages of the process are carried out in different deviceslocated sequentially, and small periodic aggregates for all operations in one container, the performance of which changes wide limits (from 30 to 6000 l / h).

Lines of continuous production of mayonnaise

The lines of the continuous and semi-continuous production of mayonnaise have their advantages and disadvantages. The benefits include:

high performance,
the possibility of full automation,
guarantee of constant product quality,
the possibility of easy replacement of outdated or defective modules.

The disadvantages of continuous lines are:

the need for large production areas;
significant material intensity;
high consumption of detergents;
increased product loss when conducting sanitary and hygienic measures.

According to continuous and semi-continuous technologies, automated high-performance lines "Joinson" are operating (up to 1 t / h), Lines of companies "Gilder Corp.", "Cherry Barrell", "Holsum Food Co", "Stork Salatomatic", "Schroeder".

The technological scheme for the production of mayonnaise and salad seasoning on the Johnson line is shown in Figure 1.

1 - bunker for egg powder; 2 - bunker for dry components; 3 - oil tank; 4, 13 - water and vinegar tanks; 5 - Deaeer; 6, 15, 23 - pumps; 7, 10 - dispense pumps; 8, 9 - woven; 11 - the spreading tank of the woven; 12 - bunker for starch; 14 - the cooking tank of the starch suspension; 16 - Buck finished products; 17 - the casting machine; 18 - Open machine; 19 - homogenizer; 20 - feeding tank of the homogenizer; 21 - sanitary marriage tank; 22 - filter; 24 - mixer
Figure 1 - Technological scheme for the production of mayonnaise and salad seasonings on the line "Johnson"

Periodic equipment

The advantages of periodic lines are compactness, efficiency, a wide range of performance. However, it should be said that periodic lines work efficiently only in the presence of full automation.

In the production of mayonnaise, the main technological line devices are homogenizers (or dispersants), which should provide homogeneous fine-dispersed emulsions with a given particle size. High-speed stirrers, high-pressure homogenizers, colloid mills, rotary-stator systems, homogenizing devices, which are combined with vacuuming the product in a hermetically closed apparatus and pumping the product "to return" at high speed, which makes it possible to achieve the desired degree of dispersion finished product.

Imagine equipment for the production of mayonnaise of some leading German firms.

"BUT. Stefan and Sons GmbH & Co. "manufactures modern machines and installations for use in many areas food Industry. For the production of mayonnaisms, universal UMM / SK type machines are of interest, a universal Vacutter-mixer type VM / MC and a Homogenizer "Stefan MSN MSN 10/2". These periodic machines can work both in manual and in semi-automatic and automatic process control modes according to a specified program.

Stefan UMM / SK aggregate has a rational design suitable for integrating in already available equipment, it is easy to maintain and washing, multivariate, allows you to get the stable quality of the product produced. The machine is a sealed container equipped with a double jacket, into which the elongated shaft is omitted, which serves for the nozzle of the working tool - sharp knives or mixing blades. Included, there is also a vehicle blade for removing particularly viscous materials from the walls and the directions of them to the center of the tank. Simultaneously with the mechanical in the machine there may be thermal processes: heating can be carried out both direct steam supply and through a shirt. All processes can pass under vacuum conditions. A minivariant is also produced for small batches of experienced products in laboratories - Umm / SK 5.

Technical data of these machines are shown in Table 1.

Installation "Stefan Wakutm" is designed for the production of sauces, mayonnaise, food emulsions, as well as soup-purees, various meat and fish products. The basis of the modular system of the vacuerma (Figure 2) is a diagonally installed hermetic working capacity with a attached gearbox, on which a stirrer with a scraper is fixed. The drive shaft is compacted by the capacitance side by contact sealing ring of a two-way action, which under sanitation measures steam. The circulation pump serves to uniformly supplying the product through the homogenizer and the recycling system back into the working capacity. At the end of the emulsification and homogenization cycle, additional components are submitted to the sauce and in the final stage there is a homogeneous mixing process. The product circulation can be carried out by choice via a homogenizer or by passing it. The circulation pump is simultaneously the discharge pump.

1 - Stefan Wakutm; 2 - loading hole DN 200; 3 - viewing window DN 125; 4 - vacuum connection; 5 - discharge fitting; 6 - discharge pump; 7 - Stefan Microcut MSN; 8 - Dosing funnel - dry substances; 9 - dosing funnel - liquid; 10 - Control cabinet
Figure 2 - Module "Stefan Wakutm"

The modular vacuer systems are equipped with a shirt for indirect heating and cooling the contents of the container. However, it is also provided for the supply of acute steam and inert gases for rapid heating and cooling in gentle mode.

The vacuum installation system consists of a vacuum pump and an adjustment unit operating in automatically specified mode. The main working element of the installation is a Stefan homogenizer with a rotary-stator system, which can be equipped with various rings with a gap from 0.1 to 3 mm and thereby regulate the process of homogenization and emulsification.

TECHNICAL DATE INSTALLATIONS "STEFAN VACUTERM" is shown in Table 2.

Homogenizers "Stefan Microcut" for energizing and emulsifying soups, sauces, desserts with performance (depending on the degree of grinding) from 3000 to 6000 l / h as the main working body also have a disintegrator.

Fryma manufactures equipment for the production of food emulsions, mashed potatoes, jams and confitures, pasty products.

For the production of mayonnaise and salad sauces, the company has developed MZM / VK "DELMIX" (Figure 3).

Figure 3 - Processing
installation MZM / VK "DELMIX"

The product passes the emulsifying head and through the recycling pipe is returned to the container to achieve the necessary degree of emulsification. The emulsifying head consists of a rotor and a stator, the gear of which is selected with the desired degree of product dispersion. The DELMIX settings are produced 10 modifications, with a capacity of 7 to 3000 liters.

The company "KORUMA" Since 1970, manufacturing installations for obtaining dispersed and homogenized food products. For the production of mayonnaise emulsions, DISHO installations are offered with a capacity capacity from 85 to 1300 liters (Table 3). Installations are equipped with a rotor-stator homogenizer, recirculation and evacuation systems.

The mixing of the product is carried out in horizontal and vertical directions. Control process automatic in accordance with the program.

Equipment of domestic production

Russian manufacturers also produce machines for making mayonnaise products that are distinguished by significant simplicity in placement and operation.

For example, Mini Installation "Mais" manufactured by SPKF "Stroyveest" (Dzerzhinsk Nizhny Novgorod Region) is intended for the production of food emulsions (mayonnaise, creams, pastes, jams, sauces, confitures and other food mixtures of various recipes) at catering establishments, dairy and oil and fat plants, small and medium-sized businesses.

The principle of operation of the installation is based on the sequential two-stage acquisition of mayonnaise: first dispersing all mayonnaise components except the oil, then slow oil supply and homogenization of the mixture.

The installation can be recycled by a dispenser and an electric sealing machine with shift heads.

Installation for the preparation of mayonnaise FLITM is equipped with a homogenizer of the original design of the Bulgarian production with a capacity of 1500 l / h. Installation performance up to 3000 kg / shift.

IS-160 and IP-88 is-80 shredtitelis offers for the production of sauces and mayonnais the company "Consita". The installation is equipped with a stirrer, a shirt, a vacuum chamber, an acute steam injection collector, as well as automatic control.

The company "Elf-4m" produces a module mayonnaise IPKS-056 with a capacity of 3000 kg / day, equipped with a rotor-fuzzy installation of RPA-1.5-5, as well as the mining of mayonnaise based on this module.

In the installation for the production of mayonnaise Ma-0.5, proposed by OJSC TverAgropodmash, a capacity of 500 l / h homogenizer serves a colloid mill of an original design that consumes three times less electricity compared to piston homogenizers.

Equipment sets for the production of mayonnaise with a capacity of 300, 500, 800 and 1000 kg / shift, in which dispersion and homogenization are provided with a rotary pulsation apparatus, offers Agro-3 JSC. The equipment ensures the pasteurization of raw materials and the finished mayonnaise. The duration of the cycle does not exceed 2.5-3 hours.

Installation for the production of mayonnaise offered by the Enomash company is intended for the preparation and packaging of mayonnaise of various varieties in polystyrene cups and glass cans. The kit includes a boss mixer, a rotor-fuzzy apparatus, a pump, a set of locking equipment and a packaging semi-automatic.

Manufacturers of equipment of Russia and the CIS countries offer customers as sets of equipment for the production of mayonnaise and individual homogenizers already known brands, mainly designed for the dairy industry. For example, the company "Agro-3" offers homogenizers of the OGA, Odessa Mechanical Plant - Homogenizers K5-OG2A and A1-OG2M, Flytm company - Homogenizers of Bulgarian production MDX-401, Stupinsky Factory of the Moscow Region - RPA Homogenizers.

Packaging mayonnaise to avoid worsening quality and reduce storage time spend immediately after developing. For this, various packaging equipment is used, depending on the container used, the choice of which, in turn, is dictated by the peculiarities of the technological process, the calorie content of the product and the storage periods.

The range of currently used containers and packaging is very large: from the flask with a capacity of 18 and 25 kg to plastic bags weighing 150 g. It is widely used both traditional glass double-gram "mayonnaise" jars and fiberglass with a "twist-off". Mayonnaise package in plastic cups and buckets, tubes, plastic jars with various lids, polyethylene sachets of various capacity, Pure-Pak packaging, etc. Materials from which these types of containers are manufactured, have high chemical resistance to mayonnaise and its components, and Hygienic indicators do not exceed existing sanitary standards.

Equipment for the packaging of mayonnaise products into polyethylene, polypropylene, laminated, glass container with various types of capping produces many and foreign and domestic firms.

"Istok" offers automatic lines "alta-4" for packing and capping homogeneous viscous products into polystyrene cups with a lid of aluminum foil with a thermolam, a capacity of 100 to 500 ml (with a capacity of 900-1400 packs per hour).

Auto machines AU50F (g) - vertical packaging in polypropylene bags weighing from 0.1 to 1.0 kg, 35 packages with a minute, comes with Flyt-M company.

Mayonnaise has the most noble origin. French cuisine is not indiscriminated with the use of sauces, which are more than three thousand. According to tradition, sauces were called the names of inventors or terrain and the people who were attributed to these culinary traditions. So were invented, for example, Tatar sauce (mayonnaise with cucumbers and capers), Russian sauce (mayonnaise with caviar). All Famous sauces were created in the XVII-XIX century. The authorship of many sauces belongs to representatives of titled nobility. Such is the sauce "Beshamel" of the invention of which is attributed to the Marquis Louis de Beshamel, and the modest onion sauce "Subiz" - Princess de Subiz.

There are two versions of the invention of the Mayonnaise sauce. Both are related to the city of Maon, the capital of the Island of Minorca, only they relate to different historical events and outstanding people of that time.

According to one of them, it was in 1757. Duke de Richelieu, commander of the French garrison, won the city of Maon - the capital of the Spanish Island of Minorca, and then the city was besieged by the British. The French has no meal, except for eggs and olive oil, almost left. Omelets and scrambled eggs were prepared from these products. You understand what a "diversity" may be bored not only to the aristocrat accustomed to delicacies. And therefore Richelieu, all the means available to the duke of means showed his discontent his discontent. The resourceful chef Raster with salt and sugar egg yolks added to the resulting mixture oil and spices and all this thoroughly beat.

According to another version, the invention of mayonnaise is associated with the name of the commander Louis of Krönonsky, the first duke Magona. In 1782, being in the Spanish service, Duke dismantled from the British the capital of the Island of Minorca - Maon City. After the battle, a feast was arranged, where the Kushans were served under the sauce made from the products that the island was famous for the first time. Brought to Europe, this sauce was called Maone, in French - mayonnaise, and became a classic dressing for cold snacks.

But a real noble mayonnaise does not compare with what is sold in the store. In order for you to have a reference point in taste, you can independently prepare mayonnaise. The story did not bring to us an accurate formulation, so we propose a generalized from different sources:

olive oil - 150 ml (Note: The oil should not be ruling)

egg yolk (carefully separate from the protein) - 1 pc

sugar - 1.5 teaspoons

salt - 1/3 teaspoon

lemon juice (Freshly squeezed) -1/2 tablespoon, dilute 2 tablespoons of water

Any noble sauce requires the mandatory availability of spices. Therefore, we recommend adding to taste: red pepper, estragon, garlic, curry, mustard, lemon zest. All ingredients must be room temperature. Yolk beaten with a mixer (the higher the turns, the better) with salt and sugar. With continuous whipping, slowly pour diluted lemon juice, then in small portions of the oil (the next portion is poured after a complete stirring of the previous one), at the end add spices.

To date, mayonnaise has become one of the most common industrially manufactured sauces in the world, so as the goals almost any dish, and in some, suchcak, Olivier, Mimosa, Herring under the "fur coat", just do not replace. The word mayonnaise from the title of a certain sauce has become a species named the whole gamut of products.

In Russia, the definition of mayonnaise is very widely, although our favorite classic "Provence" is a sample of "Russian traditions" - in such countries as Germany and the United Kingdom could not be called "mayonnaise" due to their low fatty. In the legislation of these states there are strict requirements aimed at that the consumer is not misled by the title. Depending on fatness, the sauce may be called mayonnaise at 80% fat, lettuce mayonnaise at 70-50% asalate sauce (Dressing) at 49-20%. Also limited the content of egg yolk, which is approximately equivalent to its content in the classic Russian "Provence". Real Mayonnaise are expensive and high calorie, so their consumption even in developed countries does not exceed 5%. The main share falls on salad mayonnaise - about 50%. We have a different classification and mayonnaise are divided into high-calorie with a mass fraction of fat of more than 55%, the average alternatives of the mass fraction of fat 55-40% and low-calorie - less than 40%.

Mayonnaise failed to taste the domestic consumer, it was rapidly accustomed to him, there were certain traditions of consumption. He successfully displaces the traditional sour cream and at the moment is the main universal sauce used in cooking.

Currently, there are a huge amount of mayonnaise on shop windows, a very different composition and quality so that it is not difficult for a specialist to figure out what he really buys. In connection with the reduction of payment demand, the manufacturers in pursuit of profit began to move to the production of mayonnaise with low oil content, with unconventional previously thickening additives, and a decrease in the share of flavoring components - eggs, milk, sugar. All this led to a change in taste to be unrecognizable and discrediting traditional names such as "Provence", "eggs", since the product sold under these brands often only remotely resembles their taste and has little common with classical recipe.

In cases where the manufacturer wants to use the usual name, the authors "sew third ear", i.e. Any epithet is added to the title and receive the phrase type "Provence Easy", which frees them from complying with the recipes specified by GOST and gives a widest field for experiments.

But it is not all that bad. On the change of confusion and falsification, many decent Maoneza brands come again, with a new original tasteworthy of traditional Provence. More mayonnaise appears with taste additives, fatness and composition, allowing the buyer to optimally balance its diet.

Be sure to read the label and first do notice the manufacturer. A solid firm is a quality guarantee, and mayonnaise names often do not speak anything, and, under the same name, you can detect the most different product.

Pay attention to the composition of the products included in it. According to GOST, products are recorded in the order of the mass fraction. Eggs and milk - traditional taste can only provide them, their pale semblance - flavors. Stabilizing (stabilizer and starch) and preservative additives - no harm, as well, and health benefits, although they are much arguing about it. For medium and low-calorie mayonnaise without them, it is not necessary and, if they are not listed on the label, most likely the manufacturer misleads you.

Production date is very important for domestic (imported sterilizes) mayonnaise, since non-sterling natural product long can not be stored.

Storage conditions in the outlet - mayonnaise should be stored at temperatures from 3 to 7 ° C. Freezing, like excessive heating of mayonnaise, destroys its structure. At temperatures above the optimal shelf life is sharply reduced. Buy only in proven outlets, because if you sold mayonnaise from the refrigerator showcase, it does not mean that it was stored in the refrigerator.

Aromatizers, spices, dyes - the choice of taste, the essence does not change.

Weight vigrants and milliliters is not the same thing. 250 ml is approximately 240 g!

Installation for the production of mayonnaise and mayonnaise creams

About 40 prescription compositions and names of mayonnaise have been developed by specialists of the food industry, and only some of them are known to the wide mass of buyers, which are mainly produced by government gipensaminations. For entrepreneurs who want to diversify this market segment, our lines for the production of mayonnaise and mayonnaise creams are designed. It is possible to make various grades of mayonnaise, creams, sauces and seasonings, which by their nature are fat emulsions in water. Installation produces mayonnaise and creams in periodic technology.

The technological sequence contains the following cycles:

water heating;
blasting mustard;
loading water, bulk components and oils into the mixer;
mixing components;
loading the acid solution;
homogenization of the emulsion and issuing to the pot of finished products.

Manufacturing technology:

water used as a mayonnaise component is heated in a water heater tank. The mustard in the form of a paste is placed on pallets and bears in the tank-bimp. Loose components of mayonnaise (milk powder, salt, sugar, etc.) if there are lumps sifted.

In a pasteurizer mixer with a pump, heated water is served. Then, according to the recipe, bulk components and a swimming mustard are loaded. The mixture is stirred for 30-35 minutes. In this case, the pasteurization of the mixture at a temperature of 78-80 ° C occurs.

After cooling the mixture to 45 ° C through the corresponding pressure sleeve in the mixer, vegetable refined deodorized oil is supplied. After mixing the components, a rough mayonnaise emulsion is formed within 15-20 minutes.

At the next stage, a 9% acetic acid solution (or other) acid is introduced into the mixer. The vinegar attaches mayonnaise acute taste and aroma, prevents the development of the bacterial flora (providing the required pH of the environment). It is then homogenization (creating a homogeneous mixture) of the mayonnaise emulsion.

Homogenization of fat-containing mixtures is necessary for the crushing of fat balls, while decreasing their setting during storage (mayonnaise is not resolve). In the homogenizer, a high speed liquid is passed through a narrow slot. At the same time, due to a sharp pressure drop on the edge of the gymnizer, the fat particles are split and evenly distributed in the emulsion.

Different fatty types of mayonnaise require different pressures in the homogenization of the mixture. For high-wheeze mayonnaise, the optimal pressure can be 10 ... 15 kg / sq. Cm, and for low-aluminum (salad seasoning) - 120 ... 130 kg / sq. Cm. The mayonnaise installation can be equipped with a homogenizer with a pressure of 30 atm and a homogenizer that provides a pressure of 100 atm.

Finished products with a pump are supplied to the tank of the packing device or to the storage tank.

Part of the equipment:

Bak water heater
Pasteurizer mixer
Pump with homogenizers
Tank Barrier
Post office
Mustard Blasting Trays
Set of additional snap and fixtures
Frame style stirrer
Rotation speed stirrers, rpm 45
Pasteurization temperature, ° C 50 ... 95

Mayonnaise production recipes

Mayonnaise is a creamy, multicomponent, highly dispersed emulsion of refined and deodorized vegetable oil in an aqueous medium, which is pre-introduced egg powder, powdered milk, mustard, salt, sugar, vinegar, as well as a series of taste, aromatic and gelling additives and spices.

In addition to developing mayonnaise "Provencal", on this equipment, it is possible to manufacture various mayonnaise varieties with the addition of spices and fruit fillers: with horseradish, red pepper, coriander, tomato paste, lemon essence, various kinds of fruit juices, etc.

Mayonnaise is classified by the content of vegetable oil into three groups:

1. High-calorie with oil content of more than 55%.
2. The secondary saline with an oil content in the range of 40% - 55%
3. Low-calorie with oil content of less than 40%.

Characteristic representatives of the first group of mayonnaise with high oil content are mayonnaise: "Provence", "milk" and "diabetic" (see Table 1.)

Name raw	Mass fraction of components by formulations,%
Name raw
Rast oil rafinirov. deodorir	65,40	65,40	64,90	64,70	65,60	65,65	64,20	65,00	65,80	65,80	65,70	65,70	65,40	65,70	65,70	65,90
Egg powder Egg yolk (dry)	5,00	5,00	5,00	5,00	4,30	4,30	5,00	5,00	4,00	4,00	4,00	4,00	4,50	4,00	4,00	3,50
Milk dry degreased	1,60	2,00							1,70	2,10	2,00	2,40	1,60	2,00	2,40
Milk dry whole			2,25	2,82
Cream dry					2,30	2,70	2,80									2,40
Concentrate serum protein (KSB)					2,30	2,70
Soyo protein foodie													0,50
Mustard powder	0,75 -	0,25 -– 0,50	0,75	0,25 -– 0,50	0,75	0,25 -– 0,50	0,75	0,25 -– 0,75	0,75	0,25 - - 0,50	0,75	0,25 - - 0,50	0,75	0,75	0,25 - - 0,50	0,50 - - 0,75
Sodium bicarbonate	0,05	0,05	0,03	0,03	0,03	0,05	0,03	0,05	0,05	0,05	0,05	0,05	0,05	0,05	0,05	0,05
Sugar (Sand)	1,50	1,50	1,50	1,50	1,50	1,50	1,50	1,50	1,60	1,60	1,50	1,50	1,50	1,50	1,50	1,50
Salt cook	1,00 -– 1,30	1,10 -– 1,30	1,00 -– 1,30	1,10 -– 1,30	1,00 -– 1,30	1,10 -– 1,30	1,10 -– 1,30	1,10 -– 1,30	1,10 - - 1,30	1,10 - - 1,30	1,00 - - 1,30	1,10 - - 1,30	1,10 - - 1,30	1,00 - - 1,30	1,10 - - 1,30	1,10 - - 1,30
Acetic acid (80%)	0,55 - – 0,75	0,55 - – 0,75	0,55 - – 0,75	0,55 -– 0,75	0,55 -– 0,75	0,55 -– 0,75	0,55 - – 0,75	0,55 -– 0,75	0,60 - - 0,75	0,60 - - 0,75	0,55 - - 0,75	0,55 - - 0,75	0,55 - - 0,75	0,55 - - 0,75	0,55 - - 0,75	0,55 - - 0,75
Alginate. sodium														0,05 - - 0,10	0,05 - - 0,10	0,05 - - 0,10
Starch potato carboxymethyl									0,20	0,20
Sodium- carboxymethyl- cellulose											0,10	0,10
Water	24,15- - 23,65	24,15- - 23,50	24,00 - - 23,50	24,03 - - 23,38	23,95 - - 23,45	23,90 - - 23,25	24,05 - - 23,65	24,23 - - 23,35	24,20 - - 23,85	24,30 - - 23,70	24,35 - - 23,70	24,35 - - 23,70	24,05 - - 23,65	24,40 - - 23,85	24,40 - - 23,70	24,45 - - 23,75

The following mayonnaise distinguishes the following mayonnaise in the nature of the spices and additives:

Mayonnaise with tomato. Contains 30% tomato paste, which gives mayonnaise a distinct taste of tomatoes. The presence of at least 45% of vegetable oil and other spices makes a tomato mayonnaise of a valuable seasoning to all sorts of vegetable, fish and meat dishes.

Mayonnaise with horseradish. Contains 18% of purified and crushed horseradish and at least 52% of vegetable oil. It has a sharper taste rather than other types of mayonnaise and is a special seasoning for filler and other cold fish and meat dishes.

Mayonnaise "South". Contains 13% sauce "Southern" and at least 56% of vegetable oil. Keeps the taste of the mayonnaise "Provence", enriched with spices available in the South Sauce. Mayonnaise "South" can be recommended for all vegetable, fish and meat dishes.

Mayonnaise Salad. It contains 35% of vegetable oil, has an oily, slightly sharp, weakly sour taste. Recommended for vegetable, fish and meat salads and vinegarets. It can also be used as seasoning to fish and meat dishes.

Maisonist vitaminized. It contains 35% of vegetable oil, enriched with vitamins C and V. It has a pleasant aroma and slightly sour taste. Contains corn oil, rich in vitamin E, having a healing antisclerotic property. Recommended for seasoning meat, fish and vegetable dishes.

Lemon mayonnaise. Contains 35% of vegetable oil. The presence of citric acid and lemon essential oil in mayonnaise reports to him lemon taste. It can be recommended as seasonings for vegetable and meat dishes, fruit salads and in children's nutrition.

The recipes listed mayonnaise are shown in Table 2.

table 2

Raw materials and materials	Majoneza variety
Raw materials and materials	With Tomato	With hell	"South"	Salad	Mustard	Vitaminoxa	Citric
Deodorized oil
Egg powder
Dry milk powder
Sugar (Sand)
Salt cooking food
Mustard powder
Acetic acid (80%)
Soda drinking
Tomato-paste
Khrena crushed
South Sauce
Vitamin C
Vitamin B.
Lemon acid
Lemon Essence (4 Cr.)
Water

Characteristics of the feedstock

Vegetable oil . For the production of mayonnaise, the following vegetable oils are used: Sunflower oil GOST 1129; Soya oil GOST 7825; Corn oil GOST 8808; Oil Peanut GOST 7981; Cotton oil GOST 1128; Salad cotton oil TU 10-04-02-60-89; Olive oil TU 10-04-11 / 13-87 .. For the production of mayonnaise, the following vegetable oils are used: sunflower oil GOST 1129; Soya oil GOST 7825; Corn oil GOST 8808; Oil Peanut GOST 7981; Cotton oil GOST 1128; Salad cotton oil TU 10-04-02-60-89; Olive oil TU 10-04-11 / 13-87.

All vegetable oils must be subjected to complete raffination, including deodorization and comply with the requirements of standards for deodorized oils. For the production of mayonnaise, any of the listed oils should be recycled no later than 1 month from the date of its refining.

Egg powder. GOST 2858. The product of light yellow color, homogeneous throughout the mass, should be easily signed through a sieve of 0.7 - 1.0 mm, should not have an extraneous taste and smell. In the presence of lumps, the latter must be easily crushed.

Instead of the egg powder in the production of mayonnaise can also be used:

the product is egg dry, granulated TU 10.16 of the Ukrainian SSR 15-87;
egg yolk dry OST 49-181-81;

Milk dry. GOST 4495. Small dry powder with a creamy tint having the taste of pasteurized milk. It is allowed to have easily scattered lumps.

It is allowed to use the following varieties of dairy products:

milk cow skimmed dry spray GOST 4495;
cream dry GOST 1349, highest grade;
product Milk Dry "SMP" TU 49-934-82;
serum concentrate, protein TU 49 939-82 or TU 49 979-85;
pakhta dry TU 49 247-74.

It is allowed to use other dairy products according to regulatory documents and in accordance with the technical description for a particular grade of mayonnaise, authorized by state sanitary and epidemiological supervision authorities for the manufacture of food products.

Granulated sugar. GOST 21. Bulk, dry to the touch, without extraneous tastes and smells, white color with glitter. Must be completely dissolved in water. Sugar solution must be transparent.

Salt cook. GOST 13830, Extra variety. Pure white color, odorless and contamination. Salt solution (5%) should not have an extraneous lift. The content of sodium chloride - 99.7%, not soluble in water components - no more than 0.03%, moisture is not more than 0.1%.

Powder mustard. OST 18-308-77, first grade. Intensively yellow, dry to the touch, bitter taste. When rubbing in water should have an acute smell of allyl oil. The magnitude of the powder particles must be no more than 0.3 mm.

Vinegar. The following varieties of vinegar are allowed:

acid acetic acid GOST 61;
acid of acetic wood chemical food GOST 6968, top grade;
acid acetic acid 6-09-4191-76;
the acid is acetic synthetic purified, the food TU 13-0279907-2-90;
vinegar Alcohol Food Natural OST LITSSR 422-79;
apple natural vinegar TU 10-04-03-02-86.

Vinegar must be transparent without precipitation. Large-yellow staining is allowed. The taste must be sour, strong and clean, characteristic of vinegar. Tartness is not allowed. Allowed to use in the production of mayonnaise and other acetic acids permitted by state sanitary and epidemiological surveillance authorities for the manufacture of food products.

Tomato paste. Uniform, without particles of peel or seed, orange-red. Dry substances at least 30%. The taste is characteristic of tomato, without bitterness or an extraneous taste.

Horseradish. Freshlylined, should not contain individual pieces. Do not have extraneous mechanical pollution. Khreni roots before grinding should be clean with a smaller number of recesses, in which sand or earth can remain when cleaning. Before grinding, horseradish is subjected to steam processing for 3-5 minutes to destroy the enzyme peroxidase.

Chicken fruit food food. GOST 908, Extra varieties and the highest. Colorless or weakly yellowish crystals. Weak solutions have a pleasant sour taste.

Soybean food protein. TU 10-04-02-31-88. The following varieties of protein products are allowed:

sodium alginate food tu 15-544-83;
the basis of the soy food TU 10-04-02-37-88;
concentrate soy food TU 10-04-02-22-87;
soybean food protein (PMP) TU 10-04-02-58-89.

Taste and stabilizing additives.

essential oil ukropoy TU 10.04.13.68-88. Solution with a mass fraction of 20% in deodorized vegetable oil;
pepper black ground OST 18-279-76;
cumin Ost 18-37-71;
essence of the orange OST 18-103-84;
starch corn phosphate brand B TU 18 RSFSR 279-79;
starch potato carboxymethyl TU 10 BSSR 111-86.

Drinking water. GOST 2874. There should not have bacterial contaminants, solids in suspension. It should be transparent, without color, taste and smell. Water for mayonnaise is used raw and pasteurized. Raw water It is used if it has an impeccable taste, color, odor and overall rigidity not higher than 2 mM-eq / l. The water used in the production of mayonnaise through organoleptic indicators must meet the requirements specified in Table 3.

Table 3.

The name of indicators	Norm	Test methods
Smell at 20ºС and when heated to 60ºС, points, no more		GOST 33P-41
Taste at 20ºС, points, no more		GOST 33P-41
The color of the platinum-cobalt scale, degrees, not more than		GOST 33P-41
Turbidity according to standard scale, mg / l, no more		GOST 33P-41

According to biological requirements, water must correspond to the indicators and standards specified in Table. four. Table 4.

The name of indicators

Norm

Test methods

The total number of bacteria in 1 ml of undiluted water, not more than

GOST 33P-41

The number of bacteria of the group of intestinal sticks:

Determined on a dense, elective medium, using concentrations of bacteria on membrane solutions in 1 liter of water (cashe index), no more

When using liquid accumulation media, due time, not less

GOST 33P-41

Technological production process.

The technological process involves the creation of optimal conditions to obtain a homogeneous (close to homogeneous) and a stable system of practically insoluble in each other in the other components (oil - water). Factors such as the concentration of dry components, the rate of oil supply, the conditions of swelling and pasteurization of dry components, the intensity of mechanical exposure are also taken into account.

The production of mayonnaise develops from the following technological operations:

Preparation of paste (emulsifying and structuring bases);
Preparation of rough emulsion.
Preparation of fine-dispersed emulsion (homogenization).
Transportation of finished products to the warehouse.

Preparation of a 10% solution of acetic acid.

A 10% acetic acid solution is prepared by dissolving the concentrated composition in the calculated amount of water. To capture droplets and vapor vapor acetic acid, a trap is filled with a solution of soda calcined soda. In the case of making mayonnaise with aromatic and flavors, they are prepared. Aromatized vinegar by insisting in a solution of acetic acid of various spices (bay leaf, black and fragrant pepper, nutmeg, cardamom, cinnamon, carnation, etc.).

Pre-grinding spices are placed in a linen bag, which is placed in a container with acetic acid. Then all contents are adjusted to a temperature of 80ºС, after which, without removing the bag, cooled. Next spices are removed.

Preparation and dosing of bulk components.

Main bulk components: egg powder, dry degreeshell, mustard powder, sugar, salt. As needed to be sieved through sieve. Sifting is necessary not only from a sanitary point of view, but also with technological, since the absence of lumps ensures that resistant emulsions are obtained. So than the disperser of the mustard powder, the higher its moisture intensity and emulsifying properties, the better the consistency of the mayonnaise and above its durability.

Next, the components are walked and entered into the load zone into the P3-RMO-0.35 faucets. It is obvious that the P3-RAM-0.35 faucets should be relying two units for their consistent use. Loading bulk components is carried out in manual.

Preparation of mayonnaise paste.

The mayonnaise paste is prepared alternately in two faucets as follows: water is set in the first mixer, then dry milk, mustard powder, salt, sugar sand and soda. Water is set in quantity, based on the provision of the ratio to the mustard powder as 2.5 to 1, and to dry milk as 3 to 1 (for high-calorie mayonnaise). The loading of dry components is carried out with a working stirrer, then heating (through a water "mixer shirt) and bring the mixture temperature to 90-95ºС to better dissolve and pasteurize components. At this temperature, the milk-mustard pasta is maintained 15 - 20 minutes, then cooled (flowing cold water through the "shirt" of the mixer) to a temperature of 30-40ºС, after which water and egg powder in the ratio of 1.4 - 2 are supplied to the milky mustard pasta 0 K 1 for high-calorie mayonnaise and 2.2 - 2.8 K 1 for medium and low-calorie mayonnaise. Loading is produced when working stirrer; Next, they turn on the heating again and the paste temperature is adjusted to 60-65ºС at which it is maintained 15 to 20 minutes, after which the paste is cooled to a temperature of 25-30ºС, after which the paste is pumped into the second mixer. The readiness of the paste in the first mixer is determined visually in a sample taken in the mixing process. The test taken on the wooden plate must be completely homogeneous, without visible lumps and evenly drain from the plate.

Preparation of "coarse" emulsion.

In the second mixer (P3-RAS-0.35), a "coarse" mayonnaise emulsion is prepared, for which it is necessary to ensure uniform stirring in all layers of the mixer, without stagnant zones.

After pumping the mayonnaise paste from the first mixer in the second, the estimated portion of vegetable oil with a temperature of 20-25ºС is supplied to the latter with constant stirring. In the first 7 - 10 minutes, the oil serves slowly at a speed of 10 - 12 liters per minute, then more quickly (25 l / min). It is allowed to start the oil supply for 3 to 7 minutes until the end of the pumping of the entire mayonnaise paste from the first mixer in the second one. Deodorized oil is supplied to the mixer of the V3-OR-2 rotary pump (if it is stored in tanks), or is loaded manually (if it enters production and stored in the canisters).

After entering the vegetable oil, the recipe number of 10% of the acetic acid solution is supplied to the second mixer at a speed of 6 to 8 liters per minute. The supply of a 10% solution of acetic acid can be organized by self, using a special overtaken with a scale. The supply of acetic acid solution can be started simultaneously with the introduction of the last portions of vegetable oil.

After supplying a 10% solution of acetic acid, stirring continues 5 - 7 minutes. The order of entering into the mayonnaise paste of vegetable oil and a 10% acetic acid solution should be strictly observed. This is due to the fact that a one-time or not alternate input of them can lead to a stratification of the emulsion.

The coarse emulsion obtained in the second mixer must correspond to the installed type of the emulsion "oil in water", it is strong enough and not to smear it to pass through the homogenizer. Visually, such an emulsion has a homogeneous species and is not separated in the selected sample with weak stirring.

Homogenization of the "coarse" emulsion mayonnaise.

An important step in obtaining a quality mayonnaise is the homogenization process carried out on the RPA rotor and pulsation apparatus, combining the principles of operation of the centrifugal pump, the dismembrator, the disintegrator and the colloid mill. By pulsational, shock and other hydrodynamic effects occurring in the RPA apparatus, the physico-mechanical properties of the mayonnaise emulsion, which ensures the receipt of the mayonnaise the required consistency.

The process of homogenization is carried out in the mode of circulation of the mayonnaise emulsion according to the scheme: the mixer is a rotary-pulsation apparatus - the mixer. Minimum circulation multiplicity - 2 volume / cycle.

The homogenization process is recommended in parallel with the process of mixing the components in the second mixer. The process of homogenization is allowed in the first mixer in the preparation of mayonnaise paste in the first mixer, in parallel with the process of pasteurization of components (also in circulation mode), not excluding the homogenization of mayonnaise in the second mixer.

Packing and packaging of the finished product.

Ready mayonnaise, after the homogenization process, from the second Mixer of P3-OGU-0.35 is sent to the packaging into polypropylene cups, glass jars, or in polyethylene packets.

Mayonnaise has the most noble origin. French cuisine is not indiscriminated with the use of sauces, which are more than three thousand. According to tradition, sauces were called the names of inventors or terrain and the people who were attributed to these culinary traditions. Thus were invented, for example, Tatar sauce (mayonnaise with cucumbers and capers), Russian sauce (mayonnaise with caviar). All famous sauces were created in the XVII-XIX century. The authorship of many sauces belongs to representatives of titled nobility. Such is the sauce "Beshamel" of which is attributed to the Marquis Louis de Beshamel, and the modest onion sauce "Subiz" - Princess de Subiz.

Mayonnaise is the most common industrially manufactured sauce. I have no data in Ukraine, but in Russia its consumption reaches 3 kg per person per year, and this figure tends to increase.

The production of mayonnaise in small enterprises is considered one of the most cost-effective. In addition, the equipment used is easy to operate, and the production technology is quite simple. All this allows you to fully establish the production process and start making a profit for a short term in 1 - 2 months.

Mayonnaise is made of refined vegetable oils with the addition of flavoring additives and spices. Mayonnaise is an emulsion: it consists of a variety of microscopic droplets of vegetable oil, placed in aqueous mixture of a certain composition.

For making mayonnaise, the following raw materials are used:
Vegetable oil (sunflower, soy, corn, cotton). This is the main component of the mayonnaise (from 40 to 60 percent of weight);
egg powder;
Milk cow;
starch corn and potato;
Sugar sand, salt, acetic acid, drinking soda, water.
Other flavoring and stabilizing additives are also applied. By the way, the taste of mayonnaise is determined by the quality of raw materials and recipe.

In the Middle Ages, the mayonnaise and sauces were the secret secrets of European royal cuisine, but also now branded recipes are commercial secrets.

Therefore, deciding to engage in the production of mayonnaise, you must first consider how the recipes it will be prepared.

Of course, the equipment of the equipment includes the accompanying documentation, including the recipes of mayonnaise, but it is desirable to find an experienced technologist and develop their unique recipes.

For choosing equipment For the mayonnaise manufacturing workshop, first of all, it is necessary to determine the desired volume of production, that is, such that would have given the opportunity to complete and fairly quickly implementing the product.

Further decide on fashion packing mayonnaise .
The easiest way is to packing plastic containers. It uses the least expensive set of equipment.
However, the shelf life when using this type of packaging is minimal.

Packing in glass jars is the most hygienic, gives the maximum shelf life. Reparatively inexpensive equipment. However, this is the most time-consuming method of packing.

Finally, the most expensive equipment is used to pack mayonnaise into polymer packages. At the same time, this method is the least time consuming.

For example, I will tell about the line for the production of mayonnaise with packing to plastic containers (cups) with aluminum foil covers.

Such a line consists of the following equipment:
§ Module (mixer) for making mayonnaise (about 1000 USD) - there is a mixing of components and preparation of mayonnaise emulsion;
§ Capacity for the finished mayonnaise, 500 liters (150-180 USD) - here at the end of each cooking cycle comes from the mixer ready mayonnaise, after which it is bottled into the glasses;
§ Installation for the mayonnaise filling in the cups (about 1500 USD);
§ Installation for welding cups of foil covers (500 USD);
§ In addition, you can purchase a machine for group packaging cups with mayonnaise in a heat shrink film (about 500 USD).

So, general cost of equipment - About 3500 USD.

Performance The considered line is 300 kg per cycle (the duration of the Mayonnaise production cycle is 5 hours).

To place it enough room 15 square meters of production area (plus, of course, a place for warehouses - about 50 square meters. M.).

Two employees can serve the line. Director, and most often, he and the owner, he carries an administrative and sales load, negotiating with customers, purchases raw materials, etc.

Practice shows that real payback period of equipment Time to debug production and access to project productivity - three to four months. $ $ $

Profitability:
Mayonnaise production
Equipment cost: 3500 USD
Payback period: 3-4 months.
Performance: 300 kg / cycle
Number of employees: 2
Premises: from 65 square meters. m.

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Introduction

1. Characteristics of raw materials for the production of mayonnaise

2. Maoneza production technology

2.1 Dosing of components

2.2 Preparation of egg pasta

2.3 Preparation of mustard dairy paste

2.4 Feeding vegetable oil to the main mixer

2.5 Preparation of acetic-soybean solution

2.6 Preparation of a homogeneous emulsion

2.7 Packing mayonnaise

2.8 Laying of the packed mayonnaise in the transport packaging

3. Equipment for the production of mayonnaise

3.1 Maoneza production flow diagram

3.2 Preparation of mayonnaise on a rotary-vacuum installation "hot", "cold" ways

4. Mayonnaise quality assessment systems. Range

Conclusion

Introduction

Mayonnaise has the most noble origin. French cuisine is not indiscriminated with the use of sauces, which are more than three thousand. According to tradition, sauces were called the names of inventors or terrain and the people who were attributed to these culinary traditions. Thus were invented, for example, Tatar sauce (mayonnaise with cucumbers and capers), Russian sauce (mayonnaise with caviar). All famous sauces were created in the XVII - XIX centuries. The authorship of many sauces belongs to representatives of titled nobility. Such is the sauce "Beshamel" of which is attributed to the Marquis Louis de Beshamel, and the modest onion sauce "Subiz" - Princess de Subiz.

In Russia, the definition of mayonnaise is very wide, although our favorite classic "Provence" is a sample of "Russian traditions" - in such countries as Germany and the United Kingdom could not be called "mayonnaise" due to their low fatty. In the legislation of these states there are strict requirements aimed at that the consumer is not misled by the title. Depending on fatness, the sauce can be called mayonnaise at 80% fat, lettuce mayonnaise at 70-50% and Salad sauce (Dressing) at 49-20%. Also limited the content of egg yolk, which is approximately equivalent to its content in the classic Russian "Provence". Real Mayonnaise are expensive and high calorie, so their consumption even in developed countries does not exceed 5%. The main share falls on salad mayonnaise - about 50%. We have a different classification and mayonnaise are divided into high-calorie with a mass fraction of fat more than 55%, the average alternating with a mass fraction of 55-40% and low-caloric - less than 40%.

The goal of the course work is the consideration of technology and equipment in the production of mayonnaise, and standards requirements for the quality assessment system mayonnaise.

1 . Characteristics of raw materials for the production of mayonnaise

For the production of mayonnaise, the following raw materials are used: vegetable oil, egg powder, milk dry, sugar sand, salt, powder mustard, vinegar, tomato paste, horseradish, lemon food, soy food, soybean water, drinking water.

Vegetable oil. For the production of mayonnaise, the following vegetable oils are used: sunflower oil GOST 1129-93; Soybean oil GOST 7825-96; Corn oil GOST 8808-2000; Oil Peanut GOST 7981-68; Cotton oil GOST 1128-2002; Salad cotton oil TU 10-04-02-60-89; Olive oil TU 10-04-11 / 13-87.

All vegetable oils must be subjected to complete raffination, including deodorization, and meet the requirements of standards for deodorized oils. For the production of mayonnaise, any of the listed oils should be recycled no later than 1 month from the date of its refining.

Egg powder. GOST 2858-82. The product of light yellow color, homogeneous throughout the mass, should be easily signed through a sieve of 0.7 - 1.0 mm, should not have an extraneous taste and smell. In the presence of lumps, the latter must be easily crushed.

Instead of the egg powder in the production of mayonnaise can also be used:

· Egg-dry product, granulated TU 10.16 USSR 15-87;

· Egg yolk dry OST 49-181-81;

Milk dry. GOST 4495-87. Small dry powder with a cream tint having the taste of pasteurized milk. It is allowed to have easily scattered lumps.

It is allowed to use the following varieties of dairy products:

· Milk cow skimmed dry spray GOST 4495-87;

· Cream dry GOST 1349-85, highest grade;

· Milk dry product "SMP" TU 49-934-82;

· Serum concentrate, protein TU 49 939-82 or TU 49 979-85;

· Pathel dry TU 49 247-74.

Granulated sugar. GOST 21-94. Bulk, dry to the touch, without extraneous tastes and smells, white color with glitter. Must be completely dissolved in water. Sugar solution must be transparent.

Salt cook. GOST 13830-97, Extra variety. Pure white color, odorless and contamination. Salt solution (5%) should not have an extraneous lift. The content of sodium chloride - 99.7%, not soluble in water components - no more than 0.03%, moisture is not more than 0.1%.

Powder mustard. OST 18-308-77, first grade. Intensively yellow, dry to the touch, bitter taste. When rubbing in water should have an acute smell of allyl oil. The magnitude of the powder particles must be no more than 0.3 mm.

Vinegar. The following varieties of vinegar are allowed:

· Acetic acid GOST 61-75;

· Acid of acetic wood chemical food GOST 6968-76, highest grade;

· Acetic acid GOST 6-09-4191-76;

· The acid is acetic synthetic purified, the food TU 13-0279907-2-90;

· Vinegar alcohol food Natural OST LITSSR 422-79;

· Apple natural vinegar TU 10-04-03-02-86.

Vinegar should be transparent, without precipitation. Large-yellow staining is allowed. The taste must be sour, strong and clean, characteristic of vinegar. Tartness is not allowed. Allowed to use in the production of mayonnaise and other acetic acids permitted by state sanitary and epidemiological surveillance authorities for the manufacture of food products.

Tomato paste. Uniform, without particles of peel or seed, orange-red. Dry substances at least 30%. The taste is characteristic of tomato, without bitterness or an extraneous taste.

Horseradish. Freshlylined, should not contain individual pieces. Do not have extraneous mechanical pollution. Khreni roots before grinding should be clean with a smaller number of recesses, in which sand or earth can remain when cleaning. Before grinding, horseradish is processed by steam for 3-5 minutes to destroy the enzyme peroxidase.

Chicken lemon food. GOST 908, Extra varieties and the highest. Colorless or weakly yellowish crystals. Weak solutions have a pleasant sour taste.

Soybean food protein. TU 10-04-02-31-88. The following varieties of protein products are allowed:

· Sodium alginate food TU 15-544-83;

· Soy nutritional base TU 10-04-02-37-88;

· Soy food concentrate 10-04-02-22-87;

· Soybean food protein (PMP) TU 10-04-02-58-89.

Taste and stabilizing additives:

· Essential water oil TU 10.04.13.68-88;

· Solution with a mass fraction of 20% in deodorized vegetable oil;

· Pepper black ground OST 18-279-76;

· Tsmin Ost 18-37-71;

· Essence of orange OST 18-103-84;

· Starch corn phosphate brand B TU 18 RSFSR 279-79;

· Potato carboxymethyl starch TU 10 BSSR 111-86.

Drinking water. GOST 2874-82. Should not have bacterial contaminants, solids in suspension. It should be transparent, without color, taste and smell. Water for mayonnaise is used raw and pasteurized. Crude water is used if it has impeccable taste, color, smell and overall rigidity not higher than 2 mM-eq / l. The water used in the production of mayonnaise, according to organoleptic indicators, must meet the requirements specified in Table 1.

Table 1

Organoleptic water indicators

According to biological requirements, water must correspond to the indicators and standards specified in Table 2.

table 2

Biological requirements

A specific list and ratios of raw materials for all types and names of mayonnaise are set by recipes.

2 Mayonnaise production technology

mayonnaise Paste Production Emulsion

The technological process involves the creation of optimal conditions to obtain a homogeneous (close to homogeneous) and a stable system of practically insoluble in each other in the other components (oil - water). Factors such as the concentration of dry components, the rate of oil supply, swelling conditions and pasteurization components, the intensity of mechanical exposure are also taken into account.

The technological process of making mayonnaise consists of the following stages:

1. Dosing components.

2. Preparation of egg pasta.

3. Preparation of mustard dairy paste.

4. Feeding vegetable oil.

5. Preparation of acetic salt solution.

6. Preparation of a rough emulsion.

7. Preparation of a fine emulsion.

8. Packing of the finished mayonnaise.

9. Laying the finished mayonnaise in the transport packaging.

10. Transportation to the warehouse of finished products.

Sample technology system Cooking mayonnaise is presented in Figure 1.

Figure 1 - Maison meter preparation scheme

The mayonnaise module scheme is presented in Figure 2. The figure shows blocks:

1. Small mixer;

2. Rotary and pulsation apparatus;

3. Large mixer;

4. Butter tank.

Figure 2 - Egg Module Scheme

2.1 Dosing of components

The production of mayonnaise begins with the preparation and dosing of prescription components. Bulk components: egg powder, dry skimmed milk, mustard powder, sugar, salt, soda enter the shop in bags, stacked on pallets and deteriorate as needed. Dosing dry components is made on platform technological scales. The vegetable deodorized oil enters the capacity provided for it, the volume of oil is determined using a measuring cylinder. Dosing the required amount of water in a small mixer is performed using a meter meter.

2.2 Preparation of egg pasta

To do this, in a small mixer, water and egg powder are served (in accordance with the recipe).

Stirring with the help of RPA (rotary-pulsation apparatus) lasts no more than 2-3 minutes. The mixture is then heated to a temperature of 60-65 ° C, withstand 15-20 minutes at a given temperature and pumped into the main mixer.

Before pumping, a visual test is taken to determine the readiness from egg paste. The test, taken on a wooden plate, should be completely homogeneous, without a lump, evenly drain from the plate.

The cooling of the egg paste to 20-30 ° C occurs in the main mixer during the preparation and cooling of the mustard-milk paste through the heat exchange with the air of the environment.

2.3 Preparation of mustard dairy paste

After pumping egg pasta from a small mixer in it begins the preparation of mustard dairy paste. To do this, water is supplied to a small mixer, dry milk, mustard powder, sugar sand and soda (mass fraction of components, respectively, recipe). Water is supplied in an amount recommended in the recipe. The loading of dry components is made when stirring with a wooden spatula, then include the mixing system, similar to the above. Then the mixture is heated to a temperature of 80-85 ° C, withstand 15-20 minutes at a given temperature and cooled to 25-30 ° C (according to the passport per small mixer). Next, turn off the mixing system and pump the cooled mustard-milk paste into the main mixer according to the scheme, similar to the egg paste. Before pumping from mustard dairy paste, a visual test is also taken to be readiness.

2.4 Feeding vegetable oil to the main mixer

The next stage of the preparation of mayonnaise is the supply of vegetable oil to the main mixer. This process is carried out of the provided capacity using a centrifugal pump. Also possible is an option for supplying vegetable oil from a small mixer, the above method. The amount of oil supplied to the main mixer must match the recipe. To ensure uniform distribution, oil is served through a special shower, fixed on a large mixer, with a centrifugal pump.

2.5 Preparation of acetic salt solution

Preparation of acetic-salt solution consists of two stages:

In specially provided capacitance, a saline solution is prepared as follows. The amount of water, the amount of water with a temperature of 15-16 ° C is poured into the container, the recipe amount of the cooking salt is made there. The solution is thoroughly mixed with a wooden spatula and give it to settle (for sedimentation of impurities). If the solution was satisfied, it can be used without filtering, carefully merging with a precipitate. A muddy solution is filtered in front of two layers of gauze.

A 10% acetic acid solution is prepared in a small mixer. To do this, water is supplied to a small mixer in an amount required to dilute a solution of 80% acetic acid to a 10% solution (mass fraction of the solution in accordance with the formulation). Acid is added when stirring with a wooden blade.

Next, a saline solution is added to a small mixer with a 10% acetable solution. The obtained acetic salt solution is stirred for 5-10 minutes using the mixing system and are fed to the main mixer. The supply of acetic salt solution can be started simultaneously with the introduction of the last portions of vegetable oil.

2.6 Preparation of homogeneous emulsion coarse and finely dispersed

In the main mixer, equipped with a mixing device with a small frequency of rotation (semi-grade-type mixer) prepare a coarse emulsion. The mixer should ensure uniform stirring in all layers of the mixer without stagnant zones.

The order of input into the paste of oil and acetic salt solution should be strictly observed. This is due to the fact that the one-time or high-speed entry can lead to the preparation of the inverse type emulsion, and at a certain stage of emulsification to phase treatment.

The coarse emulsion obtained in the main mixer must correspond to the installed type of the emulsion "oil in water", to be sufficiently strong and not to smear it to its circulation through a rotary and pulsation apparatus. Visually, such an emulsion has a homogeneous species and is not separated in the selected sample with weak stirring.

The resulting coarse emulsion for the conversion into finished mayonnaise should pass the process of homogenization, which is carried out using a rotary and pulsation apparatus.

The homogenization process is carried out until a homogeneous emulsion is obtained. There is a single passage of a rough emulsion. Upon completion of homogenization, the rotor-pulsation apparatus is turned off.

After homogenization from the party of the finished mayonnaise, samples are selected. The sample, taken on a wooden plate, should be completely homogeneous, without lumps, visible bundles, evenly drain from the plate and have a viscosity characteristic of mayonnaise, as well as color, taste and smell.

2.7 Packing mayonnaise

From the tank for finished products, mayonnaise is fed to the packaging. Packing is made on any packing machine intended for this.

Packing should be made immediately after manufacture, since contact with air oxygen worsens the taste and safety of mayonnaise.

2.8 Laying of the packed mayonnaise in the transport packaging

Finished products fit into drawers from corrugated cardboard according to GOST 13516-86 No. 52-1, which are put on pallets and are transported to a warehouse of finished products.

2.9 finished product warehouse

Finished products should be kept until the consumer is departed at a warehouse at a temperature of 0 to +18 ° C.

2.10 Terms and deadlines for the storage of mayonnaise

The storage of mayonnaise in accordance with the requirements remain 18-222-75 "mayonnaise" is carried out in darkened rooms at relative air humidity 75%. Storage and transportation of mayonnaise is not allowed when exposed to direct sunlight and at temperatures below 0 ° C. The shelf life from the date of development, depending on the formulation, is allowed from 3 to 18 days.

3 Equipment for the production of mayonnaise

In the production of mayonnaise, a mayonnaise paste is prepared, consisting of egg yolk, dry milk, mustard powder, sugar, salts and water. Mustard powder pre-brew hot water (To remove the bitter taste and ensure the complete swelling of the powder in water). All components of the paste are thoroughly stirred and sent to the mixer where oil, water and other additives are injected. The coarse emulsion obtained in the mixer is additionally homogenized and acquires a homogeneous sour cream-like consistency (thin emulsion). Packing mayonnaise is carried out in various consumer containers (glass jars, polyethylene packages, plastic bottles, etc.)

3.1 Maonez production flow diagram

Figure 3 shows the flow diagram for the production of mayonnaise. This scheme shows all the main components of the production line with the equipment included in it.

Figure 3 - Maoneza production flow diagram

Figure 4 shows the Maoneza production line.

Figure 4 - Mayonnaise Production Line

General technological characteristics The preparation lines mayonnaise are presented in Table 3.

Table 3.

Specifications

The main technological equipment is presented in Table 4.

Table 4.

Basic equipment


Installation of making emulsions and suspensions, UEAS model, including:
Capacity (reactor) with water "shirt", frame stirrer and control panel, l
Homogenizer pump, NGD model, kW
Boot device
Unloading device
Capacity for finished mayonnaise, l

Auxiliary technological equipment is presented in Table 5.

Table 5.

Auxiliary equipment

Filling and packaging equipment is presented in Table 6.

Table 6.

Filling and packaging equipment

Equipment / Feature Name

Installation of welding cups covers, UCU-2, pcs

Semi-automatic installation of bottling, dd-2, pcs
Carding device cans with a twist-off lid, UU-5, pcs
Semi-automatic labeling machine, EM-1C, pcs
Machine group packaging, TPC-450 (550), pcs

3.2 Cooking mayonnaise on rotary - vacuum installation"hot", "cold" ways

The scheme of rotary vacuum installation is presented in Figure 5.

Figure 5 - Rotary - Vacuum Installation Scheme

Cooking mayonnaise "hot way".

The preparing and pasteurization site is primarily introduced. In the first container, mixing and pasteurization of coarse mayonnaise emulsion to 90 ° C is performed. For this, the components are manually poured into a container with a pre-prepared water temperature not lower than 40 ° C. The mixture is stirred and heated to a temperature of 80-85 ° C (stage of pasteurization), at the storage phase - sugar sand is added manually. The second container serves to prepare a solution with egg powder, with a mixture temperature to 63 ° C. After the coarse emulsion is prepared on the preparation and pasteurization site, the mixture is filtered from foreign, non-dissolved particles - according to the recycling system. All heating processes are controlled by thermoregulation devices in automatic mode. Vacuuming site. After the vacuum kit in the tank (the vacuum kit and maintenance is carried out in automatic mode), the cranes from the pasteurization site and under the action of the vacuum, a mixture of a coarse emulsion is drawn into a container. After that, the screw pump is driven by a screw pump through a shell-and-tube heat exchange device, a solution with egg powder is drawn with a vacuum with a vacuum, and the entire mixture is processed through the cooler, the solution in the vacuum container is cooled with flowing water until the temperature is obtained at 30 ° C. In the resulting coarse mayonnaise emulsion, with further stirring, vegetable oil from the measurement is introduced by vacuum. After receipt of the entire dose of oil and obtain a homogeneous emulsion, acetic salt solution is introduced and all other components that are pre-stirled in the VDP on the processing area, the mixture is passed through the recycling system and filtering for additional mixing, then the mixture is passed through a rotary - cavitation homogenizer (effect Cavitation is a microacuum explosion with a gap of fat balls). All heating processes are controlled by thermoregulation devices in automatic mode. After sampling, the screw pump or homogenizer mayonnaise is pumped into a storage tank for further packaging.

Cooking mayonnaise "Cold way"

It differs from the above that does not require heating when preparing a coarse mayonnaise emulsion. This increases productivity and reduces energy consumption, but at the same time increases the costs of preservatives and reduces the shelf life of the product.

3.3 Equipment

Used an emulsion device

Figure 6 - Used

The installations of the UEAS are used as technological equipment in the production of mayonnaise, ketchups, confectionery and cosmetic creams, gels, pastes, ointments, household chemicals, paint products, pharmaceutical substances, emulsions and special-purpose suspensions.

By design, the installation is made in the form of a cylindrical capacity of the vertical type with a conic bottom, a circulation pipeline with a homogenizer pump and a discharge device and is equipped with a thermal control panel of product preparation. The capacity is equipped with a heat exchanging hairdryer with a block of electric heating elements, as well as a low-rotated frame-type stirrer. The pipeline circuit connects the lower production of the container with the input of a homogenizer intended for thin mixing and dispersion with the simultaneous supply of a homogenized mixture back to the tank.

Figure 7 -Pasos -Gomogenizer NGD

NGD-homogenizers pumps (dispersant) are designed for thin mixing and dispersion of emulsions or suspensions (gels, creams, paste, ointment, paints, etc.) in food, cosmetic, pharmaceutical, chemical and other industries with simultaneous pumping of a homogenized product . The HGD series homogenizers are hydrodynamic devices of a rotary-pulsation type with a single end seal. Constructively, the pumps-homogenizers (dispersants) are made with remote supports, which creates additional amenities when assembling, commissioning and maintaining the device and increases the period of its trouble-free operation. Dispensed design-- electric motor, intermediate coupling, bearing unit on conical bearings-- allows you to accurate minimal gaps in the homogenizing head in the manufacture and assembly of the product in the factory setting, and in the case of the output of the electric motor, to replace it without disturbing the factory settings of the homogenizing head in conditions consumer.

The installation is manufactured with the dosing cylinders with a volume of 50.250 and 500 ml. There is the possibility of smooth adjustment of the dose volume in the range from 20 to 100% of the volume of the dosing cylinder. The product in the cylinders comes through flexible hoses by suction from the consumables. For bottling small doses of the product (10-50 ml), the installation is made with special handouts and with an additional consumable capacity of stainless steel with a volume of 50 l, which is located above the installation. At the installation of UD-2, the product was bottling simultaneously on two channels. Doses are automatically displayed once every six seconds. Tara (cups, bottles, banks) are installed on the position of the pouring and removes the operator manually. Serve installation one person. There is a hygienic conclusion and certificate of conformity. Deadline for completing the installation of installation 2-4 weeks after payment or on the day of payment if there is in stock.

4 Assortment and Maonez Quality Assessment Systems

4.1 Assortment

According to GOST R 50174-92, mayonnaise shall be divided into groups depending on the mass fraction of fat: high-calorie - more than 55%, secondary calorie - 40--50%, low-calorie - less than 40%.

Depending on the purpose, mayonnaise is divided into two groups: snack bars and for children and diet food.

The diner includes mayonnaise table, with spices, sharp with taste and gelling additives. For children and diet foods are intended mayonnaise with flavoring and gelling additives, sweet, mayonnaise cream, dietary.

Abroad adopted conditional classification of emulsion products such as mayonnaise - mass fraction of fat more than 75%, content egg protein as an emulsifier, without thickeners; Emulified sauces - with a mass fraction of fat less than 75%, with thickeners.

Depending on the consistency, mayonnaise products are divided into creamy, pasty, creamy and liquid.

Currently, the domestic market presents a wide range of mayonnaise domestic and imported production.

Domestic mayonnaise. The traditional views of mayonnaise are Provence and Milk with a mass fraction of fat at least 67%, which belong to the group of high-calorie mayonnaise. In the mayonnaise formulation, Provence includes (in%): Vegetable oil - 65.4, egg powder - 5.0, dry skimmed milk - 1.6, sugar sand - 1.5, salt cook - 1.2 , drinking soda - 0.05, mustard powder - 0.75, acetic acid is 80% - 0.55-0.75, water, - 24.0. Milk mayonnaise is characterized by a reduced compound of egg powder (2%) and elevated dry low fat milk (1.8%), 3% of dry whole milk is added to it. These products have a gentle slightly sharp taste without traces of bitterness, smell and taste of mustard, sour cream-shaped consistency.

Currently, based on the mayonnaise formulation, Provence is produced by mayonnaise with a reduced mass fraction of fat belonging to the group of the Middle Alert Mayonnaise: New, Admiralty, with horseradish, sharp, Yenisei. These mayonnaise are characterized by good taste properties due to the introduction of flavoring additives.

The group of high-calorie includes mayonnaise with spices, which retain flavoring and consistency, but enriched with taste and spice smell. These are mayonnaise dill spring, with pepper, Tmina, friendship (contains about 10% puree from red pepper and parsley extracts, dill, celery and laurel sheets), fragrant (with parsley extracts, dill, celery), oriental (with a red composition, Black, fragrant pepper, cinnamon and carnations).

The group of the mid-calorie mayonnaise includes a table mayonnaise amateur with a mass fraction of fat at least 47% and a reduced content of mustard powder (0.25%), characterized by a mild taste, a sour creamy consistency.

Maisonist Tomato with a mass fraction of fat 46.1% contains an increased amount of acetic acid (2%) and 3% tomato paste, It has sharp taste with a tomato taste.

Low-calorie mayonnaise - Salad, mustard, Moscow with a mass fraction of fat at least 37%, which have a pronounced taste of mustard, vinegar, red pepper. In Mayonnaise, Moskovsky, corn phosphate starch brand b and the extract of red bitter pepper is introduced as a gelling additive.

TO low-calorie mayonuzam Also relate sweet mayonnaise honey, crimson, orange with a mass fraction of fat at least 35%. These mayonnaise have a sweet taste with the taste of the respective essences. Acetic acid is replaced with lemon (0.4%). Gelling additive - corn phosphate starch brand B (3%). A preservative serves sorbic acid (0.02%).

4.2 Methods for assessing the quality of mayonnaise

The quality of mayonnaise is determined by organoleptic, physico-chemical and microbiological indicators.

From organoleptic indicators determine: appearance, consistency, taste and smell, color. Mayonnaise must be a sour creamy product, single air bubbles are allowed, the presence of particles of added spices, the weld of the mustard - in accordance with the technical description of the mayonnaise of a particular name. The mayonnaise color should be white or creicism - yellow, homogeneous with the entire mass with shades specified in the technical descriptions. The taste and smell must also comply with the technical description on a specific type of product.

Of the physicochemical indicators, the mass proportion of fat, moisture, cooking salt, sorbic acid, the acidity in terms of acetic or citric acid, the resistance of the emulsion, the pH value, effective viscosity is normal.

Mass fraction of fat in high-calorie mayonnaise is more than 55%, the average alternation - 40--55%, low-caloriene - less than 40%. Mass fraction of moisture, table salt, sorbic acid, acidity is determined by the technical description of a particular type of mayonnaise. The resistance of the emulsion of the high-calorie and mid-angle mayonnaise should be at least 98%, low-calorie - at least 97%. The pH value is 4.0--4.7. Effective viscosity - 5.0-20.0 PAS.

From microbiological indicators, the BGPP (number) is normal - not allowed in 0.01 g; pathogenic microorganisms, including salmonella - are not allowed in 25 g; Yeast is no more than 1000 sort of 1 cm, mold - no more than 10 kone.

The most important defect of mayonnaise is to resolve the emulsion, as a result of which fat is distinguished from the masses. The separation of mayonnaise is a consequence of the destruction of the emulsion. The essence of this process consists in violating the integrity of the protein shells of the emulsifier around the dispersed diesel droplets under the action of unfavorable factors: sharp drops of storage temperature, non-compliance with temperature regime, etc. In this case, individual drops of oil, not limited by the membranes of the emulsifier, merge, is released by layer of oil, and mayonnaise is separated .

In addition, mayonnaise defects include: the presence of a large number of air bubbles; Round taste caused by a porch porcity; Uncharacted mayonnaise Tribuses and smells of various origin; Heterogeneity coloring.

The examination of mayonnaise is carried out mainly in order to identify falsification of the mass fraction of fat, which is one of the reasons for the unjustified overestimation of the price of low-calorie mayonnaise.

Vegetable oil in mayonnaise is partially replaced by making starch or starch products that increase the viscosity of mayonnaise. At the same time, the effective viscosity of the product is significantly increasing. A qualitative reaction to the addition of starch is the reaction with iodine.

On the freshness of mayonnaise are judged by organoleptic indicators, the pH is also determined. As a result of the hydrolytic and oxidative reactions of the fat base, free fatty acids are accumulated, and the pH value decreases. In the case of the introduction of soda in exceeding the norm, the pH value increases.

For dietary mayonnaise, it is important to determine the mass fraction of the table salt, which is due to its appointment.

Conclusion

In this term paper Such questions were considered as:

Characteristics of the raw materials mayonnaise;

The main stages of the Maoneza production technology;

Equipment used in the production of mayonnaise;

The quality assessment system mayonnaise.

Based on the foregoing, it can be concluded that the production of mayonnaise is an automated process. It can also be noted that there are many ways to control mayonnaise.

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