The Mayonnaise Emulsion

Mayonnaise is a classic oil-in-water emulsion containing 70–80 % vegetable oil, egg yolk (as natural emulsifier), vinegar, mustard, and seasoning. The challenge lies in incorporating a large volume of oil into a small aqueous phase while maintaining a stable, creamy texture with droplet sizes below 5 µm. Too-rapid oil addition causes phase inversion; insufficient shear leaves coarse droplets that separate within hours.

Industrial-Scale Production

In a PVA Systems vacuum process plant, the aqueous phase (egg yolk, vinegar, mustard) is prepared in the main vessel while oil is metered from the pre-mix vessel through the high shear homogenizer at a controlled rate. The rotor–stator assembly emulsifies the oil immediately upon entry, producing a fine, uniform droplet distribution without the risk of phase inversion. Vacuum conditions (−0.6 bar) eliminate air inclusions that would cause oxidative rancidity and reduce shelf life. A 1 000 L batch of mayonnaise can be produced in approximately 45 minutes with consistent texture, colour, and stability across batches.