Mayo production emulsification - Cutting costs and boosting quality

Customer brief

A prominent U.S. food manufacturer producing classic mayonnaise blends was facing major productivity and maintenance challenges. Multiple production lines utilized a competitor’s colloid mill that could not be cleaned in place (CIP). The requirement for manual Clean-Out-of-Place (COP) drastically increased labor time and exposed staff to safety risks, as well as driving frequent wear and damage to the mill. This resulted in approximately $100,000 per year in spare parts and maintenance costs.

The manufacturer needed an inline mixing solution that would:

• Support CIP capability to streamline cleaning and reduce labor
• Allow real-time adjustment of shear intensity during production
• Produce a stable, high-quality colloidal suspension required for mayonnaise
• Minimize downtime and spare parts consumption from repeated maintenance cycles