Mayonnaise Production Line and Factory Setup

A mayonnaise production line is a complete industrial system designed to transform oil, egg, vinegar and other ingredients into a stable emulsion under controlled hygienic and process conditions. The line produces mayonnaise and related emulsion sauces depending on the selected formulation and packaging equipment.

From an industrial perspective, mayonnaise manufacturing is important because it combines precise emulsification under vacuum, homogenization, thermal treatment and accurate filling to achieve consistent texture, stability and shelf life. The process relies on a defined sequence of unit operations that must be correctly engineered, sized and integrated.

Primary raw materials typically include liquid oil, egg (or egg powder), vinegar, water, sugar, salt, mustard, citric acid, xanthan gum and packaging materials. The core machinery set consists of vacuum homogenizer mixers, emulsion tanks, homogenizers, pasteurizers, filling machines and sealing equipment.

The Industrial Department supports investors who want to establish a new mayonnaise factory as well as existing plant owners who need repair, overhaul, capacity expansion or automation of their current lines. Projects can start from an empty site or from an operating facility that requires 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, emulsification under vacuum, homogenization, thermal treatment, filling and packaging. Design capacity is determined during the engineering phase and can typically range according to market requirements.

Product types include standard mayonnaise, light mayonnaise and related emulsion sauces. The overall process flow follows a defined sequence: aqueous phase preparation, oil phase preparation, vacuum emulsification, homogenization, pasteurization where required, filling and sealing.

Main machinery groups include vacuum homogenizer mixers (10–100 L), emulsion tanks (1000–5000 L), high-pressure homogenizers, pasteurizers, fillers and cappers. Supporting infrastructure covers electrical power, process water, steam or hot water and compressed air.

Manpower requirements depend on the degree of automation. Quality control covers emulsion stability, viscosity, pH, microbiological safety and package integrity.

Technical Specifications

Specification	Description
Product	Mayonnaise and emulsion sauces
Production Capacity	Depending on project capacity (to be determined during engineering phase)
Required Area	300–800 m² (subject to final layout)
Electrical Power	380 V three-phase, 50–100 kW
Main Machines	Vacuum homogenizer mixer, emulsion tank, homogenizer, pasteurizer, filling and sealing machine

Products

Typical products include classic mayonnaise, reduced-fat mayonnaise and flavoured emulsion sauces according to market formulation.

Raw Materials for Mayonnaise Factory

Raw material selection is critical for emulsion stability and flavour. Main materials include liquid oil, egg yolk or powder, vinegar, water, sugar, salt, mustard, citric acid and xanthan gum.

Sahi Rasa For Factories raw material

The Supply Chain Department supports identification, evaluation and supply of the main and auxiliary raw materials required by mayonnaise factories.

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

Support is available for projects in Iran, Iraq, Kurdistan Region, Afghanistan and other regional markets.

Manufacturing Process

1. Aqueous Phase Preparation – Water, vinegar, sugar, salt, mustard and hydrocolloids are mixed and hydrated.
2. Oil Phase Preparation – Oil and egg components are prepared.
3. Vacuum Emulsification – Phases are combined under vacuum in a homogenizer mixer to form a stable emulsion.
4. Homogenization – Further size reduction of oil droplets at 100–200 bar if required.
5. Pasteurization – Thermal treatment for microbiological safety where specified.
6. Filling and Sealing – Product is filled into jars, bottles or pouches and sealed.

Machinery & Equipment

• Vacuum Homogenizer Mixer – Creates the primary emulsion under vacuum. Position: core process stage. Importance: determines emulsion quality. Quality impact: incomplete emulsification causes separation. Maintenance: seals, agitator and vacuum system. Sahi Rasa support covers design, installation, repair and spare parts.
• Emulsion Tank – Holds and finishes the emulsion. Position: after mixing. Importance: batch holding and temperature control. Quality impact: temperature stability affects viscosity. Maintenance: agitators and jackets.
• Homogenizer – Reduces droplet size further. Position: after primary emulsification. Importance: improves long-term stability. Quality impact: inadequate pressure leads to oiling off. Maintenance: valves and plungers.
• Pasteurizer – Applies thermal treatment. Position: before filling. Importance: food safety. Quality impact: incorrect temperature-time combination affects safety and flavour. Maintenance: heat exchangers and controls.
• Filling and Sealing Machine – Doses and closes packages. Position: end of line. Importance: net weight and seal integrity. Quality impact: inaccurate filling or weak seals cause complaints. Maintenance: dosing valves and sealing heads.

Factory Layout & Building Requirements

Typical areas include raw-material storage, preparation, emulsification, filling, packaging, quality control, utilities and staff facilities. Hygienic zoning is essential. Exact area is determined during engineering.

Utilities

• Electricity: 380 V three-phase, 50–100 kW
• Steam or hot water as required
• Compressed air and process water

Turnkey Factory Setup

Projects can be accompanied from idea through feasibility, engineering, design, machinery, installation, commissioning, training and commercial production.

EPC & PMC

Execution under EPC or PMC approaches is possible within defined contracts.

Machinery Repair

Existing mayonnaise lines can request inspection, repair and spare-parts support for mixers, homogenizers, pasteurizers and fillers.

Machinery Overhaul & Refurbishment

Older equipment can be overhauled and control systems upgraded.

Capacity Expansion

Capacity can be increased by addressing bottlenecks in emulsification or filling.

Industrial Automation

PLC control of mixing sequences, temperature loops, vacuum and filling is typical.

Supply Chain

The Supply Chain Department supports ingredient and packaging material supply.

Packaging

Jars, bottles, pouches, labelling and secondary packaging are integrated according to market needs.

Branding & Product Development

Support for formulation development, packaging design and branding is available when required.

Market & Country Sections

Services are available in Iran, Iraq, Kurdistan Region, Afghanistan and other listed regional markets.

Sahi Rasa Services

Service	Application in This Project
Feasibility Study	Technical and economic assessment
Factory Design	Layout and process design
Machinery Design / Manufacturing	Equipment specification and supply
Procurement	Sourcing of machinery and materials
Installation & Commissioning	Start-up and testing
Automation	PLC and process control
Raw Material Supply	Via Supply Chain Department
Repair / Overhaul	Restoration of existing equipment
Capacity Expansion	Throughput increases
Staff Training	Operational training

Why Sahi Rasa

Integrated process engineering, machinery, installation and training provide a clear path from concept to operating production line.

From Empty Land to Production

Typical sequence from feasibility through commercial production.

Who Should Contact Sahi Rasa?

• Investors planning a new mayonnaise factory
• Existing owners needing repair, overhaul or expansion
• Industrial buyers requiring machinery or ingredients

Final CTA

Contact the Industrial Department for factory setup, machinery, repair, overhaul or raw-material coordination.

Registering an order for raw materials for the factory Mayonnaise

FAQ

1. What capacity can be designed?
   Depending on project requirements and equipment sizing.
2. Which main machines are required?
   Vacuum homogenizer mixer, emulsion tank, homogenizer, pasteurizer and filling machine.
3. How much space is needed?
   Approximately 300–800 m².
4. Can existing lines be repaired?
   Yes.
5. Are turnkey projects available?
   Yes under defined contracts.
6. Are services available in Iraq and Afghanistan?
   Yes.
7. Can ingredients be supplied?
   Yes via the Supply Chain Department.
8. Is installation included?
   It can be included according to the package.
9. What about automation?
   PLC and process control can be provided.
10. How is capacity expanded?
    By upgrading emulsification and filling stages.