Industrially produced mayonnaise is created in a high-precision process, where simple ingredients like egg yolk, oil, vinegar, and spices are processed into a stable, creamy emulsion. However, behind this seemingly simple product lies cutting-edge food technology and real science.
The Main Ingredients: Oil, Egg Yolk, Vinegar – and Technology
The industrial production with fresh eggs begins with separating the yolk from the white. In large processing facilities, millions of eggs are processed daily. The egg yolk is pasteurized – heated to 65 to 75 °C – to kill germs, while preserving the natural emulsifiers like lecithin, which are crucial for the stability of the mayonnaise. Instead of fresh egg yolk, pasteurized egg yolk, egg yolk powder, or a ready-made mix of water and egg yolk substitutes are often used – depending on the requirements for shelf life, safety, and process stability.
In parallel, neutral-tasting vegetable oil (e.g., sunflower, rapeseed, or soybean oil) is delivered in large quantities, filtered, and prepared for further processing. Since oil makes up about 80% of the final product, its quality plays a central role.
Emulsification – the Heart of Mayonnaise Production
First, the water phase and fat phase are prepared. The water phase consists of egg yolk, vinegar, mustard, salt, and spices. Then, the oil is slowly added and divided into tiny droplets by powerful rotor-stator systems in the vacuum processing units. These droplets are evenly distributed in the water phase – creating a stable oil-in-water emulsion. The controlled dosing of the oil and high shear force are crucial to prevent the emulsion from breaking. This is the only way the mayonnaise obtains its typical, permanently stable creaminess.
Additives in Mayonnaise for Consistency and Shelf Life
Unlike homemade mayonnaise, which consists of few ingredients, the industrial version often contains additional substances:
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- Modified starch: ensures long-lasting creaminess
- Preservatives such as calcium disodium EDTA: prevent discoloration and oxidation
- Thickeners and flavors: ensure consistent texture and taste
Quality Assurance and Filling
Before the mayonnaise is filled, it undergoes strict quality control: color, pH value, consistency, and taste are checked. Only then is it filled into jars or bottles via high-speed lines, labeled, and prepared for retail – all in a matter of seconds.
Shelf Life of Mayonnaise without Refrigeration?
A widespread misconception is that mayonnaise always needs to be refrigerated. Industrially produced mayonnaise is designed to be so stable that it can last for months without refrigeration – provided it has not been opened or contaminated.
What is Contained in Commercial Mayonnaise?
Commercial mayonnaise mainly consists of vegetable oil, egg yolk or egg preparations, water, vinegar, mustard, salt, and spices. Often, stabilizers, preservatives, and emulsifiers are added to ensure a long shelf life and consistently creamy texture. In industrially produced mayonnaise, pasteurized egg yolk or egg powder is often used instead of fresh egg yolk – depending on the recipe and production method. These ingredients provide a stable emulsion while meeting food safety and shelf life requirements.
Typical Ingredients in Mayonnaise at a Glance:
- Vegetable oil (e.g., sunflower or rapeseed oil)
- Egg yolk (fresh, pasteurized, or as powder)
- Water
- Spirit vinegar or lemon juice
- Mustard
- Salt and sugar
- Spices (e.g., pepper, paprika)
- Emulsifiers and stabilizers (e.g., lecithin)
- Preservatives (e.g., potassium sorbate)
Depending on the manufacturer and product variant, flavors or thickeners may also be included.
