Ingredients Guide for Mayonnaise and Sauce Production

The basic structure of mayonnaise and sauces

Mayonnaise is an oil-in-water emulsion in which oil is dispersed as small droplets within the water phase. Its stability depends on emulsifier, thickener and the right process conditions working together. Dressings, burger sauces and cold sauces are made on similar principles; as the oil level falls, ingredients such as starch and fibre become more important for body and stability.

Egg yolk powder: a natural emulsifier

Thanks to its lecithin and lipoproteins, egg yolk is the traditional emulsifier in mayonnaise. Egg yolk powder offers advantages in industrial production: it needs no cold chain, has standardised quality and is easier to store than liquid yolk. Reconstituting it with water and allowing enough hydration time before use improves emulsion performance. Salted or sugared stabilised grades can be considered for resistance to heat treatment and storage.

Body with starch

In reduced-fat (light) mayonnaise and sauces, body is largely provided by starch. Modified starches resistant to acidic conditions and to the mechanical stress of homogenisation maintain body over shelf life. Where clean label is targeted, native starches such as rice starch and potato starch can be considered with fibre support.

Stability with citrus fibre

Citrus fibre stabilises the emulsion by binding water and forming a light gel network, slowing the coalescence of oil droplets. High-shear mixing or homogenisation is needed to activate it. It stands out in fat-reduction and clean-label projects for its contribution to both body and stability.

Egg-free (vegan) mayonnaise

In vegan mayonnaise and sauces, pea protein can take over the emulsifying role of egg yolk. Pea protein stabilises the emulsion by forming a film at the oil-water interface, and body is supported by citrus fibre or starch. High-purity grades and flavour balance are important for a neutral taste.

Managing pH, salt and preservatives

Microbiological safety in mayonnaise and cold sauces is largely ensured by acidity. With vinegar and lemon juice the pH is usually kept below 4.0. Preservatives such as potassium sorbate are more effective at low pH and limit yeast and mould growth. Salt and sugar levels also contribute to safety by affecting water activity. Preservative limits are set by regulation according to product category.

Process notes

The main process factors determining emulsion quality are the oil addition rate, mixer or colloid mill speed, temperature and vacuum. As droplet size decreases, emulsion stability and viscosity increase. Mixing under vacuum reduces air incorporation and also limits oxidation and colour change.

Sourcing notes

PERDIST supplies egg yolk powder, whole egg powder, modified corn starch, rice starch, citrus fibre, pea protein and potassium sorbate to sauce manufacturers with their documents.

Frequently asked questions