Plant-based mayonnaise concept trials have been run via a joint project to prove efficacy for NPD

In-line mixers from Silverson have been used by Ulrick & Short to manufacture a plant-based mayonnaise that carries a clean-label declaration.

In the UK, consumer demand for plant-based products has boomed in the past few years, leading to an explosion in plant-based NPD across a wide variety of sectors. For instance, since 2017, plant-based mayonnaises and dressings have experienced a compound annual growth rate of over 16%.

In response, Ulrick & Short (U&S) and Silverson Machines have worked together to demonstrate the manufacture of a plant-based mayonnaise application, utilising U&S’s latest clean-label egg replacement technologies, and Silverson’s high viscosity in-line mixers.

U&S has developed a new ingredient specifically for plant-based mayonnaise and dressings applications. The ingredient, called ovaprox 11, is the latest addition to the company’s egg replacement range. This new ingredient has dual functionality, firstly acting to replace the emulsification function of egg in mayonnaise, and secondly acting as a stabiliser, meaning the product does not require the addition of hydrocolloids which come with less consumer-friendly declarations, such as guar and xanthan gum.

The new ovaprox 11 carries with it a clean-label declaration, as well as being non-GMO, and allergen free which helps ensure consumer friendly ingredient declarations.

Silverson’s range of high viscosity in-line mixers has been developed for the manufacture of products such as sauces, including ketchup, mayonnaise and sweet sauces and for applications in the pharmaceutical, cosmetics and chemical industries. Silverson’s Flashmix powder/liquid mixers are also suitable for higher viscosity products where large amounts of powders need to be dispersed and hydrated.

The company offers mixers suitable for mayonnaise production volumes from 10 to 500 litre. In addition, a full range of equipment from laboratory scale to full production is available for other applications, to allow any results obtained in the laboratory to be reproduced on the production floor.

“Our ovaprox 11 doesn’t only replace the functionality of the egg in emulsifying, but it also acts as a stabiliser,” explains Tobias Powell, R&D technologist at U&S. “It is one of three formulations which have been tailored to work at different oil content levels – anything from a 50% to 70% oil recipe.

“This ensures the product is stable throughout manufacturing, and that the oil and aqueous phases do not separate, or ‘break’, and also provides the thick texture and creamy mouthfeel characteristic of a ‘conventional’ mayonnaise.”

Lesley Smith, NPD engineer at Silverson said: “Following on from the success of our Flashmix powder/liquid mixers, we’ve developed a pilot scale version. This new mixer is an ideal mixing system for recipe and process development.

“Large enough to represent full scale production and producing sufficient batches for consumer testing, yet small enough to be bench-mounted and used in a test kitchen,” she told Machinery Update.

 “Using the innovative pumping rotor design, high viscosity products such as mayonnaise can be successfully mixed on this hygienic pilot scale mixer,” she continues. “Designed with scale-up in mind, processes can easily be scaled up to larger Silverson mixers such as the mayonnaise plant, achieving consistent results without the need for reformulating.”