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Case studies: Plant for batch production of mayonnaise sauce


Customer

The end user is a fast food chain from Saudi Arabia.

The client wanted to build a plant for producing different types of sauces for their outlets. 

Project

They had a very clear idea how the sauces should be and they needed the right equipment to produce these sauces. Before the purchase of the equipment, they wanted to test different recipes and check if the product obtained met their expectations.

Plant for batch production of mayonnaise sauce
  • Plant for batch production of mayonnaise sauce
  • Plant for batch production of mayonnaise sauce
  • Plant for batch production of mayonnaise sauce

The key point was to prove that the product obtained will exactly meet their requirements concerning texture, viscosity and taste using the expected ingredients

  • Plant for batch production of mayonnaise sauce
  • Plant for batch production of mayonnaise sauce
  • Plant for batch production of mayonnaise sauce

The key point was to prove that the product obtained will exactly meet their requirements concerning texture, viscosity and taste using the expected ingredients

Why INOXPA?

INOXPA has a wide experience in food production plants and we made a proposal adapted to the customer requirements.

 

But the key point was to prove that the product obtained would exactly meet their requirements concerning texture, viscosity and taste using the expected ingredients.

 

So, a test was carried out in the Pilot Plant located at INOXPA’s headquarters in Banyoles, Spain, the customer participated in the test and witnessed that the required product could be easily obtained with our equipment. 


INOXPA solution

Our competitors offered equipment for mayonnaise production only, while INOXPA additionally offered to carry out the engineering works and definition of the CIP components, and also manage the communication with other parts of the installation, remote control of equipment and recording all parameters in process (during production and CIP) and the parameter report can be accessed in other computer devices, providing a more comprehensive solution.

 

The project was composed of 3 modules: sauce preparation equipment, CIP system, and pigging system to recover product from the production area to the filling machines.

 

It was provided with the SCADA system management, with storage and export of data and recipes. It also allowed connection for remote assistance from our offices in Valencia and any part of world. 

Installation characteristics

Sauce preparation equipment:

  • 500L pressure/vacuum mixing tank with anchor, bottom sawtooth propeller and multitooth in-line high shear mixer. Including heating/cooling jacket, cell loads, valves for its operation, lobe pump for discharge and hydraulic lifting system.
  • 2 x 80 L hoppers with anchor for dosing solids: one for spices and egg powder and the other for garlic paste.
  • 400 L hopper with cell loads for dosing liquids (water, vinigar, etc)
  • Oil will be delivered directly to the mixer unit after releasing the vacuum
  • Other minor ingredients can be introduced directly through the inlet.
  • Control system by industrial PC with recipes and recording system. VPN for remote control included. 

 

CIP system:

  • Prolac HCP pump for CIP supply
  • Prolac HCP-SP Pump for return of chemicals from mixer, buffer tanks, etc.
  • Heating system for hot water tank
  • Double membrane pumps for chemical products
  • Butterfly valves and seat valves with actuator and C-TOP+ control unit
  • PHE for heating by steam
  • Instrumentation like conductivity sensor, temperature probes, pressure transmitter, level sensors, flowmeters, flow switch
  • Automation system with Siemens PLC and CPU including recipes and VPN system for remote control
  • Tanks were acquired locally 

 

Pigging system: 

  • 6 SilPig stations DN-65: 3 launchers and 3 receivers
  • 3 pig spheres
  • 12 automatic butterfly valves and 6 KH single seat valves
  • 18 magnetic detectors for speed control of balls for different viscosity products.
  • Control panel with PLC and the operation can be controlled in same touch screen of mixer.

Special features

  • Installation totally adapted to the customer requirements

  • Customer had the possibility to test his recipes in the INOXPA’s Pilot Plant before purchasing the plant. During the FAT at our facilities in Vale de Cambra and before shipping the equipment,  the customer tested again their recipe (in manual mode) with satisfactory results.

  • Installation and tank supply were made by a local company according to INOXPA’s instructions.

  • Easy introduction of main ingredients by the means of vacuum through hoppers. Minor ingredients (like leafs) through handhole.

  • Direct introduction of oil, without going through the liquid hoppers after releasing the vacuum in the mixer.
  • High level of hygiene due to the design of the production plant and automatic CIP system
  • Optimal global operation of the whole set thanks to the correct communication between all the components of the different working areas of the plant: raw materials, preparation equipment, storage tanks, filling area, product transfer equipment, cleaning system, hauling equipment. All areas must be properly communicated and coordinated to avoid problems in the production process and damage to the equipment and batches manufactured.

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Plant for batch production of mayonnaise sauce