Food Engineering/Manufacturing/Chili Mayonnaise Process

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Question
Hello Mr. Clark,

I would like to manufacture a mayonnaise that contains chili paste and pureed garlic.

I would use pasteurized liquid eggs.

What would you recommend for a basic process to create a safe shelf stable version, in terms of?

- PH Level, acid type(I would like to use citric acid, but I'm not sure that it is as effective as acetic acid)
- does it need to be heated slightly prior to filling? temperatures? times?
- preservatives? I notice many commercial mayonnaise use Calcium Disodium EDTA(any insight into this would be appreciated)

Thanks,

Daniel

Answer
I suggest you formulate to as low a pH as your flavor can tolerate. It needs to be below 4.6 to be safe, but it should be below 4 and preferably even lower to be shelf stable. Acetic is more effective than citric acid, but citric will work. Mayonnaise is an emulsion and cannot stand much heat. You can test to see what it will tolerate. Hot filling is aimed at sterilizing the container and caps. If the product has a low enough pH, it is self protecting and one need not worry about the container. You should evaluate any preservative that is commonly used in similar products. With chili and garlic, you can probably tolerate the potential flavor impact of some preservatives, such as benzoate or sorbates. You should also measure the water activity and control it if possible to be below 0.85, or as low as the texture and flavor will stand.  

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J. Peter Clark

Expertise

How various processed foods are made; ways to improve manufacturing; how to make a new food product.

Experience

Employment history: Research Engineer, U.S.Agricultural Research Service, Associate Professor Chemical Engineering, Virginia Tech, Director of Research, Continental Baking Company, President, Epstein Process Engineering, Inc., Vice Presdent Technology, Fluor Daniel, Inc., Consultant to the Process Industries

Organizations: American Institute of Chemical Engineers (Fellow) Institute of Food Technologists, American Association of Cereal Chemists, American Association of Candy Technologists, American Society of Agricultural Engineers,

Publications: Several Encyclopedias (Kirk and Othmer, Chemical Technology; Food Science, Food Technology and Nutrition; Wiley Encyclopedia of Food Science and Technology; Encyclopedia of Life Support Systems); five books, two book chapters; numerous journals.

Education: BSChE Notre Dame PhD University of California, Berkeley

Awards: AIChE Food, Pharmaceutical and Bioengineering Division Award 1998

Clients: Major food processing and pharamaceutical companies.

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