0091 Preparation of mayonnaise premix in the Dixie
mixer is started by adding mayonnaise from a previ-
ous run to a level which will reach the mixer shaft.
This gives the turbine blades a heavy material to work
against while shearing the oil into fine droplets. Egg
and dry ingredients are then added to the mixer with
low-speed agitation. Oil and vinegar are then pumped
or fed by gravity from supply tanks into the mixer.
Agitation speed is usually increased periodically as
the level of the premix rises. If the oil is added too
slowly the premix will be thick and only partially
emulsified. The subsequent passage through the col-
loid mill causes an overemulsification, resulting in a
less viscous and stable mayonnaise. If the oil is added
too quickly, in relation to agitator speed, the premix
will develop an oily and curdled appearance; and, if
the rate is not reduced, the emulsion will reverse to
the water-in-oil type.
0092 The premix is pumped through the Charlotte mill
as soon as it is made. Timing should be such that the
alternate premix tank should have just finished
emptying. This is critical with many mayonnaise for-
mulations as the premix can gel in the dixie mixer.
The longer the premix is held in the mix tank prior to
milling, the softer the final product will be.
0093 Since salad dressings are similar to mayonnaise
except for the lower oil content and the added starch
paste, the ingredients function as in mayonnaise, and
principles with respect to mixing and emulsion stabil-
ity are similar. Special care must be given to starch
cooking to develop the desired degree of thickening.
0094 Raw starch is not water-soluble, but can be dispersed
in cold water. It requires cooking to form a thickened
suspension or paste. The sugar, salt, and vinegar are
also part of the paste. The process calls for cooking and
cooling the paste before combining it with the egg and
oil emulsion. In batch processing, some of the paste is
usually added to the egg before any oil is incorporated.
This weakens the egg. The oil is thereby prevented from
forming too tight an emulsion. The oil is not whipped
in as vigorously as with mayonnaise. When the balance
of the starch paste is mixed in after the oil is added, the
entire mass must be fairly soft so that it can be pumped.
The colloid mill yields a salad dressing with high vis-
cosity and smooth texture. If the premix is too stiff, it
will break down in the mill.
0095 A batch-type starch paste cooker is essentially a
jacketed vertical stainless-steel tank equipped with
single- or double-acting agitators having side-
scraping blades. A similar vessel is used for cooling
the paste in which cold water or brine solution is used
as the cooling medium. The most modern method for
processing starch paste is a continuous one employing
the concept of energy regeneration resulting from the
use of a plate heat exchanger.
0096No matter what process is employed, starch paste
should be used as soon as possible after preparation.
The longer it stands after cooling, the more readily it
will break down on being worked into the dressing.
This is especially true with high-amylose starches.
Cooking starch in vinegar solution tends to degrade
or hydrolyze the starch to some extent. Modified
starches are usually more resistant to breakdown
than unmodified types. Where feasible, it is best to
cook the starch with a minimum amount of vinegar
in the water solution. (See Starch: Modified Starches.)
0097The continuous method employed in the manufac-
ture of mayonnaise and salad dressing provides con-
tinuous automatic control so that one worker can
process up to 7570 l of mayonnaise, salad dressing,
and pourable dressings per hour. One operator can
monitor the entire system. Manual operation is
almost nonexistent now.
0098Formulae are monitored from a control center. In
the case of salad dressings, the system includes four
probe-controlled surge tanks: one for oil, one for
starch, one for egg, and one for the brine additive.
Each of the surge tanks is probed at a high and low
level so that, when a low level is reached, a signal is
sent to a pump, and the tank will be resupplied with
oil, starch, or egg until it reaches the high point. This
maintains a constant supply of ingredients. Should
any one of the tanks become empty, the entire system
halts. Each controlled surge tank leads to a metering
pump. Each pump is monitored from the control
center so that it delivers the desired volume within
0.5%.
0099By setting the predetermined speed of each pump,
the egg, brine, oil, and starch are metered accurately
at the proper flow rate ratio to the inline mixer or
preemulsifier where the ingredients are thoroughly
mixed and a preemulsion is created. The preemulsion
is then pumped with a sanitary pump to a colloid mill,
where an extremely fine globule emulsion is created,
and then on to the filler. Using this system, up to 25
different varieties of dressing can be made, all within
the accuracy of 0.5% in the formulation.
See also: Colloids and Emulsions; Emulsifiers: Organic
Emulsifiers; Fats: Fat Replacers; Hypertension:
Hypertension and Diet; Mustard and Condiment
Products; Soy (Soya) Beans: The Crop; Stabilizers:
Types and Function; Starch: Modified Starches; Vinegar
Further Reading
Anonymous (1975) Instructions for the Use of Dried Egg
Yolk in Mayonanise, Salad Dressing and French Dress-
ing. New York: Henningsen Foods.
Ford LD, Borwankar R, Martin RW , Jr. and Holcomb DN
(1997) Dressing and sauces. In: Friberg SE and Larsson K
DRESSINGS AND MAYONNAISE/The Products and Their Manufacture 1897