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Preventing “Breakdown” in Mayonnaise Production: Causes and Solutions
Making mayonnaise is a delicate process that requires precise control of ingredients, mixing techniques and emulsion stability. One of the most common challenges manufacturers face is “breaking” – when the emulsion separates, causing oil to build up and the mixture to lose its creamy, stable consistency. This can result in significant waste, increased production costs and product inconsistency.
Understanding the causes of breakdown and implementing preventative best practices ensures a smooth, high-quality product every time.
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What causes mayonnaise to break down?
Mayonnaise is an oil-in-water emulsion stabilized by egg yolk or other emulsifiers. The key to a stable emulsion is to ensure that the oil droplets are properly dispersed and suspended in the water phase. Breakdown occurs when the emulsion becomes destabilized, leading to phase separation. Here are the main causes of this problem:
1. Incorrect oil addition speed
Oil must be introduced gradually to allow for proper emulsification. Adding too much oil too quickly overwhelms the emulsifier, preventing it from covering the oil droplets, leading to separation.
2. Incorrect mixing speed and shear rate
Mixing speed plays a key role in emulsification. Too much shear can break the emulsion, while too little shear may not disperse the oil droplets effectively.
3. Temperature fluctuations
Both the temperature of the ingredients and the process must be controlled. If the mixture is too cold, the emulsifiers may not activate properly. If it is too warm, the oil droplets may combine, leading to separation.
4. Incorrect pH
Acidity stabilizes mayonnaise by enhancing the emulsifying properties of egg yolks or other emulsifiers. Too high or too low a pH can weaken the emulsion, causing instability.
5. Insufficient or incompatible emulsifiers
Egg yolks, mustard, and hydrocolloids such as xanthan gum help stabilize mayonnaise. If the emulsifier content is too low or an incompatible emulsifier is used, the emulsion will break down.
6. Water-oil imbalance
The correct water to oil ratio is crucial. Too much oil can overwhelm the emulsifiers, leading to separation, while too much water can prevent proper emulsification.
7. Storage and handling problems
Post-production handling affects stability. Exposure to high temperatures or excessive agitation during packaging and shipping may cause the emulsion to break down.
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How to prevent cracking when making mayonnaise
1. Optimization of oil addition
• Always introduce the oil slowly and evenly to avoid overloading the emulsifiers.
• Use high shear mixers or linear emulsifiers to ensure proper dispersion.
2. Use the right mixer and shear rate
• High Shear Mixers: Ensure thorough emulsification and prevent the formation of large oil droplets.
• Inline homogenizers: provide continuous processing and constant droplet size distribution.
• Vacuum Emulsifiers: Help eliminate air ingress, reducing oxidation and instability.
3. Temperature control throughout the process
• Maintain ingredient temperature between 10–25°C (50–77°F) for optimal emulsification.
• Use jacketed mixing tanks with precise heating and cooling capabilities to control product temperature. 4. Maintain proper pH balance
• The ideal pH range for stable mayonnaise is 3.6 to 4.0.
• Use acidifiers such as vinegar or citric acid to maintain stability without over-acidifying the product.
5. Choose effective emulsifiers
• Egg yolk is the traditional emulsifier, but lecithin, mustard and hydrocolloids (xanthan gum, guar gum) can increase stability.
• Make sure emulsifiers are fully hydrated before adding oil.
6. Maintain the correct water to oil ratio
• The optimal ratio is typically 80% oil and 20% water phase, although this can vary depending on the formula.
• Pre-mixing the water phase ingredients ensures even distribution before adding the oil.
7. Proper storage and handling of the product
• Store mayonnaise at cool, stable temperatures (below 5°C/41°F) to extend its shelf life. • Avoid excessive shaking or mechanical stress during storage and transportation.
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Hardware solutions to prevent cracking
PerMix mayonnaise production solutions
At PerMix, we offer industry-leading high shear mixers, in-line emulsifiers and vacuum emulsifiers to ensure stable and consistent mayonnaise production. Our vacuum emulsifiers prevent air absorption, and our jacketed tanks with precise temperature control help maintain stable emulsions.
If you're struggling to break down your mayonnaise production, improving your mixing process with PerMix technology can help eliminate waste, increase yields, and produce a higher quality product.
Contact us today to learn more about how PerMix mixers can improve your mayonnaise production!
