Mayonnaise Production Line and Factory Setup

A mayonnaise production line is an integrated industrial system designed to prepare aqueous and oil phases, create a stable oil-in-water emulsion with high-shear mixing, homogenize under high pressure, pasteurize and fill the finished product into jars or bottles. The line produces consistent mayonnaise with the desired texture and shelf life.

From an industrial perspective, mayonnaise manufacturing is important because it combines precise phase preparation, high-shear emulsification, high-pressure homogenization (100–200 bar) and thermal treatment to achieve a stable emulsion with fine oil droplet size and food safety. The process relies on a defined sequence of unit operations that must be correctly engineered and integrated.

Primary raw materials typically include edible oil, egg yolk, vinegar, water, sugar, salt, mustard and citric acid. Core machinery consists of emulsion tanks (1000–5000 L, SS 316), high-shear mixers, homogenizers (100–200 bar), pasteurizers, filling machines (2000–5000 units/h) and capping machines. Typical capacity 5000–20 000 jars/day.

The Industrial Department supports investors establishing a new mayonnaise factory as well as existing plant owners requiring repair, overhaul, capacity expansion or automation of current lines. Projects can start from an empty site or from an operating facility that needs technical upgrading.

Whether the goal is a green-field turnkey mayonnaise plant in Iraq, Kurdistan Region, Afghanistan or other regional markets, or the modernization of an existing line in Iran, engineering, machinery supply or manufacturing, installation, commissioning and ongoing technical support can be provided under defined contractual scopes.

Production Line Overview

The mayonnaise production line is engineered as an integrated process system covering phase preparation, high-shear emulsification, homogenization, pasteurization, filling and packaging. Design capacity is determined during the engineering phase and can typically range from 5000 to 20 000 jars/day depending on final product mix and market requirements.

Product types include classic and light mayonnaise in various pack sizes. The overall process flow follows a defined sequence: preparation of aqueous and oil phases, high-shear emulsification, high-pressure homogenization, pasteurization, filling and packaging.

Main machinery groups include emulsion tanks, high-shear mixers, homogenizers, pasteurizers, filling machines and capping machines. Supporting infrastructure covers electrical power, steam or gas and process water.

Manpower requirements depend on the degree of automation. Quality control covers emulsion stability, droplet size, acidity, microbial safety and packaging integrity. Finished mayonnaise is stored under cool conditions before distribution.

Technical Specifications

The following technical data represent typical ranges for an industrial mayonnaise production line. Final values are defined during basic and detailed engineering and may vary according to selected technology, level of automation, product portfolio and factory layout. For precise project-specific figures, contact the Industrial Department.

Specification	Description
Product	Mayonnaise (classic and variants)
Production Capacity	5000–20 000 jars/day (depending on project capacity and selected equipment sizing)
Required Area	300–800 m² (subject to final layout and capacity)
Electrical Power	380 V three-phase, 50–100 kW (depending on equipment selection and automation level)
Steam / Gas	100–300 kg steam per hour (or equivalent)
Water Consumption	10–20 m³/day
Manpower	5–10 persons per shift (depending on automation level)
Main Machines	Emulsion tank (1000–5000 L, SS 316), high-shear mixer, homogenizer (100–200 bar), pasteurizer, filling machine (2000–5000 units/h), capping machine

All figures are indicative. Detailed utility balances, equipment lists and layout drawings are prepared after process definition and capacity confirmation.

Products

An industrial mayonnaise production line can manufacture classic and variant mayonnaise in various pack sizes according to market requirements.

Raw Materials for Mayonnaise Factory

Raw material selection and quality control are critical for emulsion stability and shelf life. The main materials used are described below.

Main Raw Materials

Edible oil, egg yolk, vinegar, water, sugar, salt, mustard, citric acid – Form the emulsion and provide flavor and acidity.

Secondary / Optional Materials

Packaging materials (jars, bottles, caps) and cartons

Storage and handling conditions must be controlled to preserve ingredient quality.

Sahi Rasa For Factories raw material

The Supply Chain Department is prepared to support identification, evaluation and supply of the main and auxiliary raw materials required by mayonnaise factories. Depending on the contractual scope, services may include supplier identification and evaluation, procurement and purchase coordination, specification control, logistics coordination, supply-chain design for continuous production, ongoing supply arrangements, and supply of materials from Iran for projects located in regional markets.

Registering an order for raw materials for the factory Mayonnaise
Sahi Rasa Supply Chain Department

Raw-material supply chain support can be examined for industrial projects located in Iran, Iraq, the Kurdistan Region of Iraq (including Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Manufacturing Process

The industrial mayonnaise process follows a defined sequence of unit operations.

Phase Preparation – Aqueous phase (water, vinegar, sugar, salt, mustard, citric acid) and oil phase (edible oil + egg yolk) are prepared.
High-Shear Emulsification – Oil phase is slowly added to the aqueous phase under high-shear mixing to form the oil-in-water emulsion.
Homogenization – Emulsion is homogenized at 100–200 bar to reduce oil droplet size to the micron range.
Pasteurization – Product is thermally treated for food safety.
Filling and Packaging – Mayonnaise is filled into jars or bottles, capped and packaged.

Machinery & Equipment

Each main machine performs a specific function. Support is available for design, manufacturing or procurement, customization, installation, commissioning, repair, overhaul, refurbishment, automation and spare-parts supply according to the agreed project scope.

Emulsion Tank (SS 316) – Prepares and holds the phases (1000–5000 L). Position: first stage. Importance: controlled mixing environment. Quality impact: phase homogeneity. Maintenance: agitators, seals and jackets. Sahi Rasa support covers design and spare parts.
High-Shear Mixer – Creates the primary emulsion. Core machine for emulsion formation. Position: during phase combination. Quality impact: shear intensity determines droplet size and stability. Maintenance: rotor-stator, seals and drive. Sahi Rasa provides specialized high-shear mixer support and overhaul.
Homogenizer – Reduces droplet size under 100–200 bar. Core machine for final texture. Position: after high-shear mixing. Quality impact: pressure and number of stages control mouthfeel and stability. Maintenance: valves, plungers and seals. Sahi Rasa provides specialized homogenizer support and overhaul.
Pasteurizer – Provides thermal treatment. Position: after homogenization. Quality impact: microbial safety and shelf life. Maintenance: heat exchangers and sensors.
Filling and Capping Machines – Fill and close containers (2000–5000 units/h). Position: end of line. Quality impact: fill accuracy and seal integrity. Maintenance: dosing valves, sealing heads and sensors.

Factory Layout & Building Requirements

Typical functional areas include ingredient storage, emulsion and homogenization hall, pasteurization and filling, packaging, finished-goods cold storage, quality-control laboratory, utility rooms, maintenance workshop, staff facilities and loading docks. Layout must respect hygienic zoning and process flow. Exact area allocation is determined during the engineering phase according to capacity and product range.

Utilities

Electricity: 380 V three-phase, typically 50–100 kW
Steam / gas: 100–300 kg steam per hour (or equivalent)
Water: 10–20 m³/day
Compressed air as required
HVAC and drainage according to hygiene and local regulations

Turnkey Factory Setup

An investor can start from an empty site. Depending on contractual scope, the project can be accompanied through: Idea → Feasibility → Engineering → Factory Design → Machinery → Procurement → Manufacturing → Installation → Commissioning → Training → Raw Material Supply → Packaging → Trial Production → Commercial Production. The objective is an operational factory ready for production.

EPC & PMC

Projects can be executed under EPC (Engineering, Procurement, Construction) or PMC (Project Management Consultancy) approaches. Engineering, machinery supply or manufacturing, installation supervision and commissioning are coordinated within the defined contract boundaries.

Machinery Repair

Existing mayonnaise factories can request inspection, troubleshooting, mechanical and electrical repair, component replacement, spare-parts supply and line maintenance support for emulsion tanks, high-shear mixers, homogenizers, pasteurizers and filling machines.

Machinery Overhaul & Refurbishment

Older equipment can be evaluated for comprehensive overhaul, replacement of worn rotors and seals, control-system upgrades, improved reliability and modest capacity or quality improvements where technically feasible.

Capacity Expansion

Capacity of an existing line can often be increased by addressing bottlenecks, upgrading key machines (homogenizer, filler) or introducing selective automation.

Industrial Automation

Typical applications include PLC sequence control, temperature and pressure monitoring, automatic dosing, HMI, data logging and optional SCADA integration.

Supply Chain

Factory = Machinery + Raw Materials + Utilities + People + Process + Supply Chain + Market. The Supply Chain Department supports supplier sourcing, procurement, logistics and ongoing material supply for mayonnaise projects.

Packaging

Jar/bottle filling, capping, labeling, coding, cartoning and palletizing are integrated according to product format and market requirements.

Branding & Product Development

When required, support can be provided for product development, packaging design, graphic design, industrial design, branding and related marketing preparation.

Market & Country Sections

Engineering, machinery, installation, overhaul and supply-chain support are available for mayonnaise projects in Iran, Iraq, Kurdistan Region (Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Sahi Rasa Services

Service	Application in This Project
Feasibility Study	Technical and economic assessment of capacity, product mix and investment
Factory Design	Layout, process flow and utility design
Machinery Design / Manufacturing	Specification and coordinated supply or manufacturing of process equipment
Procurement	Sourcing of machinery, components and materials
Installation & Commissioning	Mechanical/electrical installation, start-up and performance testing
Automation	PLC, HMI, process control and optional SCADA
Raw Material Supply	Coordination via Supply Chain Department
Repair / Overhaul / Refurbishment	Restoration and modernization of existing machinery
Capacity Expansion	Engineering and implementation of throughput increases
Staff Training	Operational and basic maintenance training

Why Sahi Rasa

Process engineering, machinery-related capabilities, procurement support, supply-chain coordination, installation, commissioning, training, maintenance support and automation are combined. The practical advantage is a more integrated execution path from concept to an operating production line.

From Empty Land to Production

Typical sequence: Feasibility → Engineering → Factory Design → Equipment Design → Machinery Manufacturing/Procurement → Logistics → Installation → Commissioning → Staff Training → Raw Material Supply → Trial Production → Commercial Production. Operational support for a defined initial period can be examined as a contractual option.

Who Should Contact Sahi Rasa?

Investors – planning a new mayonnaise factory or production line
Existing Factory Owners – needing repair, overhaul, refurbishment, modernization, automation or capacity expansion
Industrial Buyers – requiring machinery, spare parts, raw materials or engineering services

Final CTA

If you intend to set up a mayonnaise production line or factory, if your existing plant needs repair, overhaul or capacity expansion, if you require new machinery or automation, or if you need coordination of raw-material supply, contact the Industrial Department.

Submit your request for: Factory Setup / Machinery / Repair / Overhaul / Refurbishment / Automation / Capacity Expansion / Raw Materials.

Registering an order for raw materials for the factory Mayonnaise

FAQ

What is the typical cost of setting up a mayonnaise factory?
Cost depends on capacity, product range, automation level, building and utility scope. A detailed estimate is prepared after process definition.
Which main machines are required?
Emulsion tank, high-shear mixer, homogenizer, pasteurizer, filling machine and capping machine.
What production capacity can be designed?
Typical capacity ranges from 5000 to 20 000 jars/day, determined during the engineering phase.
How much space is needed?
Typical process area ranges from approximately 300 to 800 m², subject to final layout.
What are the main raw materials?
Edible oil, egg yolk, vinegar, water, sugar, salt, mustard, citric acid and packaging materials.
Can raw materials be supplied?
Yes, via the Supply Chain Department according to project scope.
Is machinery manufacturing or procurement supported?
Design, manufacturing or coordinated procurement according to the agreed scope.
Can existing machines be repaired?
Yes – inspection, troubleshooting, mechanical/electrical repair and spare parts.
Is overhaul or refurbishment possible?
Yes – comprehensive restoration and control upgrades.
Can capacity of an existing line be increased?
Often yes, by addressing bottlenecks and upgrading key equipment.
Are turnkey projects executed?
Turnkey or partial turnkey scopes can be offered under defined contracts.
Are services available in Iraq and Kurdistan Region?
Yes, including Erbil, Sulaymaniyah, Duhok and other locations.
Are services available in Afghanistan?
Yes, including Kabul, Herat and Mazar-e-Sharif.
Can raw materials be supplied from Iran for regional projects?
Yes, coordination of material supply is part of possible supply-chain scope.
Is installation and commissioning included?
They can be included according to the selected contractual package.