Improving performance in mayonnaise production

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1 Making better mayo Report on the Innovative mixing of mayonnaise and other emulsified sauces seminar, Reaseheath College Food Centre, Nantwich, 20 th September Published September 2017

2 Improving performance in mayonnaise production Representatives from across the UK mayonnaise and emulsified sauce sector have come together at Reaseheath College Food Centre to examine ways of enhancing quality and improving productivity within their sector. A seminar organized by Tetra Pak Processing provided an opportunity to discuss the latest developments in processing science and technology with members of the company s international team. Speakers included Food Technologist Ulrika Brintje and Hans Henrik Mortensen, Manager of Tetra Pak s Centre of Expertise. The latest research and product innovation was supported by practical demonstrations of the updated Tetra Pak High Shear Mixer. Tetra Pak has supplied advanced mixing solutions to the global mayonnaise and prepared foods market for many years. Product improvement is continuous and is approached from two directions. Firstly, food technologists have conducted a long term study of the way in which ingredients behave during the mixing process and the impact on the final product. Secondly, the company s engineers have developed their understanding of the fluid dynamics and mechanical processes within the mixing operation. Putting the two together helps ensure predictable outcomes and the highest quality. 1

3 Meeting the challenges The challenges facing UK mayonnaise and sauce producers are made increasingly complicated by the demand for lower fat products that must still meet textural and taste standards similar to full fat mayonnaise. Price pressure is likewise continuous. Understanding the interaction between ingredients and the impact of each aspect of the mixing process is essential for effective control. Ulrika Brintje reported on methods of predicting product outcomes. The significance of droplet size in achieving optimum quality and stability is generally well understood but there are several variables to match in order to achieve the final product objectives. By understanding the effects of oil content, egg quantity, egg type and thickeners, and their complex interactions during the mixing process, it is possible to meet quality and production targets. Tetra Pak s methods and mixing procedures enable innovation and product development to be completed in a more systematic manner. Reverse engineering provides a guide to achieving small droplet sizes and the required texture levels for each recipe. For example, smaller oil droplets result in improved texture but droplet size increases as oil content is reduced. Adding stabilizers in the form of starch and gum can reduce droplet size and give a firmer texture. Egg also has a dual role as an emulsifier and a texturizer and can be used in several different forms eg liquid or powder, salted or unsalted, enzymatically modified, egg yolk, whole eggs and blends. Different forms of egg affect texture and droplet size but will also behave differently during mixing. Increasing egg yolk content improves texture. Switching from powder to liquid egg (seen being added below during the demonstration) can make the product more robust which means less risk for over shearing during emulsification. By applying a specific mixing procedure and knowing the various outcomes it is therefore possible to deliver controlled and predictable results. The Tetra Pak team have also reviewed methods of protecting the starch in the mix and using it more efficiently. This enables producers to reduce cost by limiting the quantity of some of the most expensive ingredients. Preventing excessive dosing of thickener and stabilizer and ways in which different recipes can be translated to give the same mixing time have likewise been scrutinized. 2

4 Reducing batch times However good the ingredients and the recipe, product quality remains dependent on the mixer. Delegates saw 450 kg batches of full-fat and reduced fat mayonnaise being produced in a Tetra Pak High Shear Mixer as well as mayonnaise with carrot cubes and peas to demonstrate particulate mixing. Controlled vacuum in the mixing tank draws in powder below the liquid line, giving immediate wetting and effective initial mixing at high intake rates. The vacuum also provides efficient product de-aeration and enables flash cooling if required. Rotor and stator are highlighted at the base of the tank, below the agitators. With the stator raised, particles can be blended quickly, gently and evenly throughout the product (sweetcorn, peas and carrots were used to illustrate the technique). Intensive mixing is achieved by a dynamic rotor and stator in the base of the tank. A range of patented stators can be used to provide optimum mixing for many different types of product. The stator can also be raised during mixing to enable blending without shear, such as when adding sensitive particles including berries and vegetables or mixing starches and gums. A double agitator system ensures excellent tank circulation with no dead spots and scrapes the inside of the tank. The High Shear Mixer handles all mixing operations in one tank, from dissolving the powder, through emulsification to blending particles and can therefore match the versatility demanded by recipes in the condiment and dressings category. Effective CIP is via spray balls at the top of the tank and jets in the tank wall. The complete mixer range is 3A approved and cleanability of the mixer units is verified by EHEDG tests. Tank volumes for mayonnaise and emulsified sauces are from 25 litres to 3000 litres. Solutions for continuous production are also available and the portfolio enables outputs well in excess of 10t/h. Options include steam and jacket heating and bin-lift ingredient feed systems, among others. An intuitive touch screen control panel gives the operator full control and can be set up to record useful data. 3

5 Having seen the process and tasted the product following each demonstration, over 85% of delegates stated they believed Tetra Pak technology would benefit their production, according to anonymously recorded feedback. Hans Henrik Mortensen also reviewed the financial efficiency of the unit compared to a range of common mixing solutions. The Tetra Pak High Shear mixer is substantially quicker than benchmarked systems which typically have a total batch time of around 17 minutes. In contrast, the mid-range High Shear Mixer model B VAA has a batch time for an equivalent mix of under 10 minutes. Energy consumption is thus around 64% of the benchmark model and the total cost of ownership can be as little as 54% of the benchmark unit, assuming the systems are run to full capacity. Carbon footprint is also reduced. Our White Paper Navigating the Mayonnaise Maize is available to download. A companion White paper Optimize your mixing process and food quality by using CFD on Computational Fluid Dynamics illustrates how this modelling resource helps in designing the most efficient mixing solutions. Use this link for video clips on the mayonnaise maize and the Tetra Pak High Shear Mixer. For further information on the complete range of Tetra Pak mixing solutions and on the other forms of support Tetra Pak can provide contact Matthew Chard, Business Development Manager matthew.chard@tetrapak.com