Overcoming the Challenges of Using Dry Starches in Mayonnaise Production with PerMix Mixers

In mayonnaise production, dry starches are often added to improve texture, stability, and mouthfeel. However, incorporating dry starches into the process presents several challenges, including lump formation, inefficient hydration, and difficulty in achieving a smooth, uniform consistency. PerMix industrial mixers are specifically designed to address these challenges, ensuring efficient starch incorporation and optimal mayonnaise production.

Challenges of Using Dry Starches in Mayonnaise Production

  1. Lump Formation & Poor Dispersion
    • Dry starches have a tendency to clump when added directly to liquid ingredients, leading to uneven dispersion and potential defects in texture.
  2. Incomplete Hydration
    • Proper hydration is essential for starch functionality in mayonnaise, affecting viscosity and stability. If starch granules are not fully hydrated, the final product may have inconsistent thickness and mouthfeel.
  3. High Shear Requirements
    • To fully activate starches and integrate them into the emulsion, high shear mixing is required. Standard mixers may not provide enough shear force to break down starch granules efficiently.
  4. Air Incorporation & Foaming
    • Improper mixing of dry starches can introduce excess air, leading to foaming and instability in the final emulsion.

How PerMix Mixers Solve These Issues

PerMix offers a range of mixers tailored to handle the challenges of dry starch integration in mayonnaise production, ensuring smooth, consistent, and high-quality emulsions.

  1. High-Shear Emulsifiers for Rapid Starch Hydration
    • PerMix Inline High-Shear Emulsifiers and High-Shear Batch Mixers efficiently break down dry starches into fine particles, ensuring complete hydration without lumps. The rapid shearing action ensures uniform dispersion and prevents localized thickening.
  2. Vacuum Powder Induction for Lump-Free Dispersion
    • The PerMix Inline Powder Induction Mixer allows for the controlled addition of dry starches under vacuum, pulling the powder directly into the liquid phase without introducing air. This eliminates clumping and foaming while improving hydration.
  3. Multi-Stage Mixing for Consistent Texture
    • The combination of PerMix High-Shear Mixers with Scraped Surface Agitation ensures complete starch dispersion and activation while maintaining the required viscosity and smoothness in the mayonnaise.
  4. Sanitary & CIP-Ready Construction for Easy Cleaning
    • All PerMix mixers are built with hygienic, food-grade stainless steel and feature Clean-In-Place (CIP) capability, making them ideal for high-production mayonnaise facilities where quick and effective cleaning is critical.
  5. Customizable Shear Control for Precision Mixing
    • PerMix high-shear mixers come with adjustable speed control, allowing operators to fine-tune the mixing process to achieve the perfect balance of shear force and gentle agitation to maintain emulsion stability.

PerMix: The Ultimate Mixing Solution for Mayonnaise Production

PerMix mixers offer a superior solution for handling dry starches in mayonnaise production, ensuring efficient hydration, smooth texture, and stable emulsions. Whether you need a high-shear emulsifier, vacuum powder induction system, or a complete turnkey mixing solution, PerMix delivers engineering excellence, innovation, and cost-effective performance that sets your production apart.

Upgrade your mayonnaise production process with PerMix – where precision meets perfection. Contact us today to learn more!