Mayonnaise Manufacturing Machine: Complete Mayonnaise Plant by Prócer
A complete mayonnaise manufacturing plant built around one machine, the Prócer Mixpro vacuum emulsifier with the DRI Dual Rotor Inline Homogenizer. Lump-free gum & starch dispersion, controlled oil dosing into a defined shear zone, and bubble-free vacuum emulsions, from challenging low-fat eggless veg mayonnaise to premium high-fat egg mayonnaise at 70–80% oil. World-class performance at a smarter investment, installed and supported worldwide.
World-class process technology · Engineered & built by Kinemach Engineering and Machines Pvt Ltd · Installed & supported worldwide · Sanitary GMP stainless steel
Mayonnaise is a process result, not just a recipe
The same formulation can come out glossy, heavy-bodied and stable for 12 months, or dull, thin and split in the jar, depending entirely on how the stabilizers were hydrated, how the oil was dosed, and how uniform the final droplet size is. Fine, uniform oil droplets are what prevent separation during packaging and storage. These four guarantees are engineered into the Mixpro itself.
Emulsion stability and body come from a tight oil-droplet size distribution. Forced circulation through the DRI's defined shear zone homogenizes every kilogram identically, so viscosity, gloss and shelf life hold, batch after batch.
Xanthan, guar and starches are drawn under vacuum straight into the rotor-stator shear zone, every particle wetted in milliseconds. No fish-eyes, no rafts, full thickening yield from every gram of gum.
Vacuum processing removes entrained air during emulsification, no foam, no oxidative rancidity of the oil, no fill-weight variation on the filling line, and the dense, glossy finish premium mayonnaise demands.
PLC/SCADA recipe management locks oil dosing rates, shear speeds, temperatures, vacuum levels and times for every product. Guaranteed reproducibility across batches, operators and shifts, audit-ready data logging included.
The two hardest mayonnaises to make, mastered on one machine
The mayonnaise market pulls in two directions at once. The volume market runs on low-fat, eggless veg mayonnaise, the hardest product to get right, because body must come from starches and gums instead of oil. The premium market demands classic high-fat egg mayonnaise, an emulsion packed so full of oil that it lives permanently on the edge of breaking. Most machines are compromised toward one or the other. The Mixpro is engineered for both.
Low-fat & eggless veg mayonnaise
When oil comes down from 80% to as low as 10%, everything the oil was doing, body, creaminess, cling, mouthfeel, must be rebuilt with a thickened water phase of modified starches and hydrocolloids (xanthan, guar), often on an eggless base of milk or plant proteins.
- Vacuum gum & starch induction, powders drawn below the liquid surface directly into the DRI shear zone, hydrated lump-free in a single pass, at full functional yield.
- Hot process on the same vessel, the heating/cooling jacket gelatinizes natural starches (clean-label culi route) and pasteurizes for shelf life, then cools for assembly.
- Low-shear bypass, cooked starch phase and finished emulsion are folded together gently, preserving the starch structure that gives the product its body.
- Cheaper recipe, stable result, less oil, less egg, natural starches: lower cost-price per kg with the stability and gloss of a premium product.
High-fat classic egg mayonnaise
Real mayonnaise, 70–80% oil emulsified into a small water phase with egg yolk as the only emulsifier, packs more oil into the product than uniform droplets can theoretically hold (~74%). The droplets must be fine, uniform and pressed against each other; that crowding is exactly what creates the heavy body and gloss.
- Controlled oil dosing into the shear zone, oil enters directly at the DRI rotor-stator at a recipe-controlled rate, so every increment is instantly atomized and coated with egg-yolk emulsifier.
- Defined shear for every kilogram, the self-pumping DRI draws the whole batch through its shear zone in counted turnovers: tight droplet distribution, no over-sheared hot spots that trigger inversion.
- Temperature protection, jacket cooling and short cycles keep the egg phase cool; vacuum excludes air and protects the oil from oxidation.
- Premium finish, dense, bubble-free, high-gloss mayonnaise with the stand-up body the premium shelf demands.
Between the two extremes, the same machine runs the whole family: salad dressings, sandwich spreads, garlic and chilli mayo, tartare and cocktail sauces, dips and emulsified condiments, each stored as a PLC/SCADA recipe.
Gum & starch dispersion, where mayonnaise batches are won or lost
Every modern mayonnaise, dressing and sauce leans on hydrocolloids and starches, xanthan gum for cling and shear-thinning flow, guar for viscosity, modified and natural starches for body and cost reduction. They are also the single biggest source of production problems: a gum particle hydrates on its surface within seconds, forming a gel skin that seals dry powder inside. Once a lump ("fish eye") forms, no amount of stirring dissolves it, it must be sheared apart or filtered out, and every lump is paid-for stabilizer delivering zero function.
Vacuum powder induction
The DRI's self-generated vacuum draws gums and starches from the hopper directly below the liquid surface into the rotor-stator shear zone, no dusting, no powder rafts floating on top, no operator shovelling through a manhole.
Wetting in milliseconds
Inside the shear zone, powder is dispersed particle-by-particle into the water before surface gelling can trap dry material. Every particle hydrates fully and individually, lump-free in a single pass.
Full functional yield
Completely hydrated gum delivers its full thickening power, so recipes often need less stabilizer for the same viscosity, a direct raw-material saving on every batch, and a cleaner label.
Gentle after the cook
Once starches are gelatinized, structure must be protected. The DRI's low-shear bypass keeps mixing the batch while letting the delicate cooked-starch phase pass without being ground down.
Hot or cold hydration
Cold-swelling modified starches disperse straight into the cold water phase; natural clean-label starches cook against the jacket in the same vessel, both routes recipe-controlled.
Consistent viscosity, every batch
Because hydration is complete and identical every time, final viscosity stops drifting between batches, no more ad-hoc gum top-ups by operators chasing a thin batch.
The industrial mayonnaise manufacturing process
Whether you specify it as a mayonnaise making machine, a mayonnaise emulsifier or a complete mayonnaise production line, the process is the same, and on a Prócer Mixpro plant it runs in a single vessel, under one recipe program, for cold-process and hot-process, egg and eggless, low-fat and high-fat formulations alike.
Water Phase & Stabilizers
Water, sugar, salt, preservatives charged; gums & starches inducted lump-free through the DRI under vacuum. Hot-process recipes cook the starch culi on the jacket, then cool.
Emulsifier Phase
Egg yolk (liquid or powder), or milk/plant proteins for eggless mayo, blended in under gentle anchor agitation with precise temperature control.
Controlled Oil Dosing
Oil dosed at a recipe-controlled rate directly into the DRI shear zone, each increment instantly emulsified. The critical step for 70–80% oil mayonnaise.
Acidify & Homogenize
Vinegar/acid added to set pH and firm the emulsion; a final DRI pass tightens droplet distribution for gloss, body and shelf life.
Deaerate, Cool & Transfer
Vacuum deaeration for a dense, bubble-free product; jacket cooling where required; hygienic discharge to buffer tank or filling line.
Prócer Mixpro, the complete mayonnaise making machine in one system
The Prócer Mixpro is a vacuum processing, homogenizing, mixing and dispersing system engineered for the food, pharmaceutical, cosmetic and chemical industries. If you've been comparing a vacuum emulsifier, a high shear mixer for sauces or an inline homogenizer for mayonnaise, the Mixpro is all three in one system. For mayonnaise, dressings and sauces it replaces the traditional cluster of premix vessels, pumps and homogenizers with one compact, automated plant.
DRI, Dual Rotor Inline Homogenizer
The heart of the system: a unique three-stage design, centrifugal pumping, lump breaking, rotor-stator homogenization, bottom-mounted for high-flow mixing, viscous product handling and superior emulsification.
High Shear + Low Shear in One
A low-shear bypass lets herbs, mustard seeds, condiment pieces and delicate cooked-starch phases pass intact while the batch keeps mixing, shear when you need it, protection when you don't.
Vacuum Powder & Liquid Induction
The homogenizer's self-generated vacuum draws gums, starches and liquid ingredients directly into the shear zone, contamination-free intake without vessel vacuuming, faster processing, less product loss.
Jacketed Heating & Cooling
Indirect jacket delivers precise thermal control, gelatinize starches and pasteurize for hot-process low-fat recipes, keep egg phases cool for high-fat emulsions.
Advanced Agitation
Anchor agitator with flow breaker for wall-to-wall mixing of viscous mayonnaise without dead zones; counter-rotating agitator systems available for complex, high-viscosity formulations up to 100,000 cP.
PLC/SCADA + Self-CIP
Recipe management, real-time control and data logging, plus self-cleaning CIP performed by the homogenizer itself, with no external pump. Fast, validated changeover between mayo, dressings and sauces.
Mixpro DRI vs the conventional locally fabricated mayonnaise plant
Most mayonnaise lines in the market are built the conventional way: a fabricated vessel with a stirrer, a batch homogenizer welded into the bottom, or an external inline homogenizer / colloid mill looped in with a transfer pump and piping, plus a separate premix vessel for gums. It works for basic products, but it fights you on exactly the things that make low-fat and high-fat mayonnaise hard.
Vessel + stirrer + bottom homogenizer / external colloid mill loop
- Random shear exposure. The homogenizer shears whatever happens to be near it, some product over-processed, some never sheared. Droplet size, viscosity and stability drift within and between batches.
- Top powder addition. Gums and starches dumped from the manhole, dusting, floating rafts, fish-eye lumps that need multiple recirculation passes (or a sieve) to remove.
- Uncontrolled oil addition. Oil poured or pumped onto the surface, far from the shear zone, coarse droplets, weak body, and constant risk of inversion on high-fat recipes.
- Air entrainment. Open processing whips air into the emulsion, foam, oxidative rancidity, dull appearance, fill-weight variation.
- Separate premix vessel & transfer pump to buy, power, clean and maintain, plus hold-up losses in the external loop and dead legs.
- Operator-dependent quality. Pass counts, dosing speed and timing vary by shift, so the product varies too. A split high-fat batch is oil and egg written off.
One bottom-mounted DRI, pump, lump breaker & homogenizer in a single unit
- Defined shear for every kilogram. The self-pumping DRI draws the batch through its three-stage shear zone in counted turnovers, tight droplet distribution, consistent viscosity and gloss.
- Vacuum powder induction. Gums and starches drawn below the liquid surface straight into the shear zone, lump-free, dust-free, full stabilizer yield.
- Recipe-controlled oil dosing into the shear zone, every increment of oil atomized and coated the moment it enters. High-fat batches build safely, every time.
- Bubble-free by design. Vacuum high-shear processing delivers dense, air-free, oxidation-protected emulsions with a premium gloss.
- One machine replaces the cluster. Premixer + homogenizer + transfer pump functions in a single compact unit, minimal piping, minimal hold-up, self-CIP without an external pump.
- Recipe-locked reproducibility. PLC/SCADA runs the same program every batch, up to 80% shorter mixing & dispersion cycles, lower power, water and raw-material cost per batch.
| Decision factor | Prócer Mixpro with DRI | Conventional vessel + stirrer + homogenizer loop |
|---|---|---|
| Emulsifying architecture | One bottom-mounted Dual Rotor Inline unit, pump · lump breaker · rotor-stator in a single body | Stirrer plus separate homogenizer / colloid mill, transfer pump and external piping |
| Shear exposure of the batch | Forced, counted passes, every kg drawn through the shear zone | Random, some product over-sheared, some never processed |
| Gum / starch dispersion | Vacuum induction into shear zone, lump-free in one pass, full yield | Top addition, rafts, fish-eyes, sieving, wasted stabilizer |
| Oil addition (high-fat mayo) | Recipe-controlled dosing directly into the shear zone, inversion-safe | Surface addition at operator's pace, coarse droplets, inversion risk |
| Air in product | Vacuum processing, bubble-free, gloss, oxidation-protected | Air entrainment, foam, rancidity risk, dull product |
| Particulates (herbs, seeds, pieces) | Low-shear bypass keeps pieces intact while mixing continues | Everything passing the mill is ground down |
| Batch cycle time | Up to 80% reduction in mixing & dispersion time | Long premix, recirculation and deaeration cycles |
| Cleaning & changeover | Self-CIP without external pump; minimal hold-up volume | External loop and dead legs, manual cleaning, product loss |
| Footprint & utilities | Compact, modular, minimal external piping; lower power & water per batch | Premix vessel + main vessel + pump + mill, larger footprint, more drives |
| Quality control | PLC/SCADA recipes, data logging, GMP documentation | Manual, operator-dependent |
Running a conventional mayonnaise plant today?
Tell us your current setup, recipes and batch size, our engineers will show you exactly what a DRI-based Mixpro would change in your process, with a trial on your own formulation.
Or reach us directly: +91 94473 39284 · WhatsApp · procersales@kinemach.com
Mixpro vs premium European vacuum emulsifier systems
Premium European vacuum emulsifiers set the global benchmark for mayonnaise processing, and they earned it: vacuum processing, forced circulation through a defined rotor-stator shear zone, controlled oil dosing and recipe automation. The Prócer Mixpro is built on the same processing architecture and delivers comparable emulsion quality and batch times, at a fraction of the investment, with faster delivery and responsive support wherever your plant is.
If you are benchmarking the Mixpro against a premium European system, put it on your shortlist and judge it the honest way: run your own recipe on it first, then compare the finished mayonnaise, the batch time and the total installed cost side by side.
| Decision factor | Prócer Mixpro | Premium European vacuum emulsifiers |
|---|---|---|
| Core technology | Vacuum vessel + bottom-mounted DRI dual-rotor inline homogenizer, forced circulation, defined shear | Vacuum vessel + rotor-stator homogenizer with external or bottom circulation, same architecture class |
| Emulsion quality | Fine, tight droplet distribution; glossy, stable low-fat and high-fat mayonnaise | Fine, tight droplet distribution, the established benchmark |
| Gum & starch handling | Vacuum induction directly into shear zone, lump-free single-pass hydration | Vacuum/hopper induction systems, comparable capability |
| Batch speed | Up to 80% reduction in mixing & dispersion time vs conventional plants | Comparable high-speed processing (e.g. 1,000 L class batches in minutes) |
| Automation | PLC/SCADA recipes, data logging, GMP documentation | PLC recipe systems |
| Capital investment | A fraction of the European price, significantly lower total installed cost per litre of capacity | Premium European pricing, plus freight, agency margins and, in most markets, import duty |
| Delivery time | Short lead times, weeks, not months, with worldwide shipping | Typically many months ex-works plus shipping |
| Spares & service | Spares and service engineers dispatched worldwide within days, backed by remote video diagnostics | Specialist engineers and spares scheduled from European facilities, longer lead times, travel costs |
| Trials before purchase | Free trials on your own recipe at our technology centre, visit in person or join live on video from anywhere | Technology centres in Europe/USA/Asia, travel and scheduling required |
| Scale-up path | 20 L pilot to production scale on identical DRI technology | Lab-to-industrial ranges available at European pricing at every step |
Watch: the Prócer mayonnaise plant in production
The complete turnkey mayonnaise solution on the Mixpro at our technology centre, gums and starches inducted lump-free under vacuum, oil dosed straight into the DRI shear zone, and the finished mayonnaise coming out glossy, dense and completely bubble-free.
Run the same trial with your own formulation, visit us in person, or ship us your raw materials and join on video from anywhere in the world. We process your recipe on the actual machine and send you the finished mayonnaise.
One sauce making machine, an entire condiment portfolio
A mayonnaise line rarely stays a mayonnaise line. Because the Mixpro handles free-flowing dressings to 100,000 cP pastes with recipe-controlled changeovers and validated CIP, the same sauce manufacturing machine doubles as your dressing plant, dip plant and condiment plant, one machine at the core of a complete food process plant for:
Planning a multi-product sauce factory? Prócer configures complete turnkey plants, water phase preparation, Mixpro processing, buffer tanks, and transfer to filling, engineered, built and commissioned for customers worldwide.
Mayonnaise manufacturing machinery, frequently asked questions
Which machine is used to manufacture mayonnaise industrially?
Industrial mayonnaise is made in a vacuum emulsifier, a jacketed vessel with agitation, vacuum and a high-shear homogenizer that disperses stabilizers, doses oil under shear and builds a fine, stable oil-in-water emulsion. The Prócer Mixpro combines all of these functions with a DRI Dual Rotor Inline Homogenizer, so one system handles gum and starch dispersion, controlled oil emulsification, vacuum deaeration, heating/cooling and hygienic discharge for every style of mayonnaise.
How is low-fat mayonnaise manufactured?
Low-fat mayonnaise (typically 10–40% oil) replaces oil with a thickened water phase built on starches and hydrocolloids such as xanthan, guar and modified starches. The stabilizers must hydrate completely without lumps, and in hot-process recipes the starch is gelatinized (cooked into a culi), cooled, then gently blended with the emulsion base. On the Mixpro, gums and starches are inducted by vacuum directly into the DRI shear zone for lump-free hydration, the jacket cooks and cools the starch phase, and the low-shear bypass folds the culi into the base without destroying the starch structure. See the full low-fat section above.
How is high-fat (70–80% oil) egg mayonnaise made without breaking the emulsion?
High-fat mayonnaise packs more oil into the emulsion than uniform droplets can theoretically hold, so it sits permanently close to its phase-inversion point. The oil must be dosed at a controlled rate into an active shear field with sufficient egg-yolk coverage at every moment, and temperature must stay low. The Mixpro doses oil directly into the DRI rotor-stator at recipe-controlled rates and gives every kilogram a defined number of shear passes, building a glossy, heavy-bodied, stable premium mayonnaise batch after batch. Details above.
How do you disperse gums and starches without lumps?
Gums hydrate so fast that surface gelling traps dry powder inside, the classic fish-eye. The Mixpro wets every particle before it can clump: the DRI's self-generated vacuum draws powders below the liquid surface directly into the rotor-stator shear zone, separating and wetting each particle in milliseconds. Full hydration, full thickening yield, no lumps, no sieving, no wasted stabilizer. See the stabilizer science section.
Can one machine make both low-fat veg mayo and high-fat egg mayonnaise?
Yes. Vacuum gum/starch induction plus jacketed heating and cooling covers low-fat and eggless recipes (cold or hot process); controlled oil dosing into the DRI shear zone covers premium 70–80% oil egg mayonnaise. Each product is stored as a PLC/SCADA recipe, changeover is a program selection plus validated CIP.
Does the Mixpro support both cold-process and hot-process mayonnaise?
Yes. Cold processing, the simple, energy-efficient all-in-one route, runs entirely in the Mixpro vessel. Hot processing, used for lower-cost clean-label low-fat recipes where natural starches are gelatinized and pasteurization extends shelf life, uses the indirect heating/cooling jacket in the same vessel. Both are recipe-controlled.
Is the Prócer Mixpro an alternative to FrymaKoruma, IKA or ASO machines?
Yes. The Mixpro uses the same processing architecture that made European vacuum emulsifiers the industry reference, vacuum vessel, forced circulation through a defined rotor-stator shear zone, controlled oil dosing, recipe automation, CIP, and delivers comparable emulsion quality and batch times. The difference is commercial: a fraction of the investment, delivery in weeks instead of months, spares and service engineers dispatched worldwide within days, and free trials on your own recipe. See the full comparison.
What batch sizes and capacities are available for a mayonnaise plant?
Mixpro systems scale from pilot units of just 20 litres for R&D and recipe development up to full production vessels of several hundred to 1,000+ litres per batch, with buffer tanks and transfer systems configured to feed your filling line continuously. The same DRI technology runs at every scale, so recipes transfer from lab to production without rework.
What is the price of a mayonnaise making machine?
Mayonnaise making machine price, and complete mayonnaise plant cost, depends on batch size, automation level (PLC/SCADA), vacuum, heating/cooling options, oil dosing configuration and downstream equipment. As a benchmark, a complete Mixpro plant typically costs a fraction of an equivalent European system for the same emulsion quality and throughput class. Contact us with your target capacity and recipes for a configured quotation.
Can the same machine make eggless (vegetarian) mayonnaise?
Yes, eggless veg mayonnaise is one of the Mixpro's core applications and one of the fastest-growing mayonnaise categories worldwide, driven by vegetarian, vegan and halal markets. Milk or plant proteins replace egg as the emulsifier, supported by starch and gum systems, exactly the stabilizer chemistry the DRI's vacuum powder induction is built for. Vegan formulations run the same way.
Can I run a trial with my own mayonnaise recipe before buying?
Yes, and we recommend it. Bring your formulation to the Prócer technology centre for a live trial on the actual machine, or ship your raw materials and join the trial on video from anywhere in the world. You evaluate the finished mayonnaise, texture, gloss, viscosity, stability, before you invest.
Do you export mayonnaise manufacturing plants?
Yes. Prócer exports mayonnaise and sauce processing plants worldwide, the Middle East (UAE, Saudi Arabia, Oman, Qatar, Kuwait, Bahrain), South Asia (Bangladesh, Sri Lanka, Nepal), Southeast Asia (Indonesia, Malaysia, Thailand, Vietnam, Philippines), Africa (Egypt, Nigeria, Kenya, Ethiopia, Ghana, Tanzania, South Africa) and Western markets (USA, UK, Canada, Australia). Export machines are configured for destination voltage and frequency, shipped in seaworthy packing with full documentation, and commissioned with remote video-guided installation and training.
FrymaKoruma, ProXES, IKA and ASO are trademarks of their respective owners, referenced only to identify the machine classes customers ask us about. Performance references are drawn from the manufacturers' published materials.
Mayonnaise plant manufacturer & exporter, Pune, India
Prócer machines are built on world-class process technology platforms of the kind trusted by global food and pharmaceutical multinationals, vacuum high-shear processing, dual rotor inline homogenization, recipe-driven automation and hygienic design engineered to international sanitary and GMP standards. Precision-machined rotor-stator tooling and CIP-ready stainless construction put every Mixpro in the same technology class as imported European equipment.
Kinemach Engineering and Machines Pvt Ltd builds every machine at our works in Pune, Maharashtra, India. As a mayonnaise making machine manufacturer in Pune, we supply, commission and service mayonnaise, sauce and dressing plants across every major Indian food-processing cluster, Mumbai, Thane & Navi Mumbai, Pune, Delhi NCR (Noida, Ghaziabad, Sonipat, Bahadurgarh), Ahmedabad, Vadodara & the Vapi–Daman belt, Hyderabad, Bengaluru, Chennai, Kolkata, Indore, Jaipur, Ludhiana and Kochi, with spares and service engineers shipping from Pune, so your plant never stands still.
Export-ready mayonnaise plants for global markets
The same plants are engineered for export from day one, targeted at every market where local sauce and condiment manufacturing is growing. Prócer supplies food manufacturers across the Middle East (UAE, Dubai & Sharjah, Saudi Arabia's Vision-2030 local-manufacturing drive, Oman, Qatar, Kuwait, Bahrain), South Asia (Bangladesh, Sri Lanka, Nepal), Southeast Asia (Indonesia, Malaysia, Thailand, Vietnam, Philippines), Africa's fast-growing production hubs (Egypt, Nigeria, Kenya, Ethiopia, Ghana, Tanzania, South Africa) and Western markets (USA, UK, Canada, Australia), where QSR chains, private-label producers and indie condiment brands are bringing production in-house. Every export machine is configured for the destination market: local voltage and frequency (220/380/415 V, 50/60 Hz), seaworthy export packing, complete documentation, and remote commissioning with video-guided installation and training.
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