MAYOMILL
OVERVIEW
In the bustling US market, the love for seasonings, sauces, and condiments has culminated in a staggering $22 billion industry, with mayonnaise alone commanding a $2 billion slice of the culinary pie each year. Navigating the intricate world of mayonnaise and salad dressing production presents its own set of hurdles, notably with the rise of innovative low fat and egg-free options.
Traditional mayonnaise, whipped salad dressings, and select creamy dressings require a meticulous milling process post-mixing to achieve a consistently smooth and stable emulsion. Enter the Admix Mayomill, a revolutionary inline milling device engineered to address and resolve prevalent challenges encountered with standard colloid mills in the industry. This innovation stands as a testament to our commitment to providing solutions that enhance product quality and production efficiency.
Features/Benefits – Mayomill vs. Colloid Mills
Harnessing the power of rotor-stator machines for wet milling opens up a realm of benefits that are designed to meet your continuous operation needs. Our wet mills are not just machines; they are your reliable partners, operating tirelessly 24/7 to mix, disperse, emulsify, pulverize, macerate, crush, homogenize, and finely reduce solids particles. They accomplish all these with minimal dust generation, ensuring a cleaner work environment. Moreover, these mills are built to thrive amidst the challenges of uneven flow patterns, sudden jolts, and fluctuating pressures, embodying the innovative, trustworthy, supportive, and helpful ethos our brand is known for. With a professional, informative, and thoughtful approach, we ensure our machinery helps you achieve not just efficiency, but also excellence in every particle processed.
- Cleanability
- Stability
- Mechanical Seals
- Cost Reduction
- Shear Rate Adjustments
- Increased Throughput
Conventional colloid mills are not CIP-able which forces manual cleaning. This increases total cost of ownership due to:
- Additional labor costs associated with cleaning
- Potential equipment damage during CIP
- Line start-up delays after cleaning due to improper reassembly and adjustment
- Wasted time and product while resetting the mills
The Mayomill is truly CIP and eliminates all manual cleaning which equates to a huge cost savings in repair parts (especially seals) and increased filler efficiency due to faster line start-ups.
Mayonnaise is a very fragile emulsion. The egg yolk in a formula coats the oil droplets, and a textbook mayo emulsion has 3-5 micron oil droplets with a 99.999 distribution in that range.
Reducing the amount of egg in a formula can mean big cost savings, but as egg is reduced, the emulsion gets fragile. Customers note that the Mayomill has a “very wide sweet spot,” producing emulsions that are much more stable and less susceptible to breaking or separation.
Mayonnaise can reach viscosities of 300,000+ CPS and is often pumped great distances from the kitchen to the filler. Blown seals in conventional mills are common and costly, resulting in higher maintenance costs, more downtime, and loss in filler efficiency.
While typical seals in colloid mills max out at 300 PSI or less, the Admix Mayomill’s seals are rated for a 725 PSI, eliminating seal failures caused by over pressurization.
As soybean oil prices continue to climb, making up a significant 80% of mayonnaise's composition, coupled with the unpredictable nature of egg supplies and costs, which account for about 4% of mayo, manufacturers are increasingly seeking ways to cut back on these expenses. Traditional methods, such as using conventional colloid mills, often fall short in addressing these challenges effectively.
The Mayomill shear stands at the forefront of innovation, expertly designed to cater to both traditional and cost-effective formulas. This allows manufacturers unparalleled flexibility in achieving cost savings across their product lines, without compromising on quality.
Mayonnaise requires a very specific shear, which is adjusted on conventional colloid mills by changing the gap. This is done by dialing an external ring mechanism that is not always accurate or repeatable. Tightening the gap also causes increased and fluctuating back pressure which leads to added stress on seals and texture changes in the mayonnaise. Many times during a run, the shear rate needs to be adjusted for minor changes like egg temperature fluctuation.
The Admix Mayomill needs no gap adjustment. The gaps in the 9 individual points in the Mayomill are fixed and have been optimized to create the right shear for mayonnaise, dressings, and other products. Shear rate adjustments are simply made by adjusting RPM electronically through the speed control. Basic settings are provided for each product family and then simple tweaks to hertz (Hz) are made as each formula is run the first time, and a final Hz level then set and used going forward.
Current colloid mill designs have limited throughput, forcing manufacturers to install multiple mills in parallel for higher throughput. Use of multiple mills may adversely cause:
- Inconsistent product between the different mills reaching the filler
- Additional cleaning issues
- Higher overall total cost of ownership
- Product to become fragile due to increased BP
- Seal issues
A single Admix Mayomill delivers throughput up to 110 GPM.
HOW IT WORKS
While a colloid mill or inline mixer is judged by how well it does its job, it is just as important that the machine is able to operate continuously, with low service and maintenance costs. The Admix Mayomill is designed for 24/7 operation, through critical processing schedules when downtime is costly and distruptive.
Combining the proven Boston Shearmill technology with the latest innovations in rotor-stator designs, Admix engineers have created a series of inline mills specifically developed for balancing shear rate and flow. Simple in design but manufactured to be durable and robust, the Admix Mayomill substantially reduces downtime typical of conventional colloid mills.
Sizing and Engineering Data
Scroll to the right if needed to view all information.TRY BEFORE YOU BUY
Our trial program offers a hands-on opportunity to test our state-of-the-art equipment, ensuring it meets your standards for quality and performance. Take advantage of this risk-free option to see firsthand how our solutions can benefit your business operations.
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