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Mayonnaise production in batch andcontinuous process exploitingmagnetohydrodynamic force

Article in Journal of Food Engineering · September 2011Impact Factor: 2.77 · DOI: 10.1016/j.jfoodeng.2011.04.003

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Mayonnaise production in batch and continuous process exploitingmagnetohydrodynamic force

Stef Kerkhofs a , Heiko Lipkens b , Firmin Velghe b , Pieter Verlooy a , Johan A. Martens a ,⇑

a Centre for Surface Chemistry and Catalysis, Kasteelpark Arenberg 23, 3001 Heverlee, Belgiumb M4E Magnets for Emulsions N.V., Teerlingstraat 14, 9190 Stekene, Belgium

a r t i c l e i n f o

Article history:Received 16 September 2010Received in revised form 4 March 2011Accepted 3 April 2011Available online xxxx

Keywords:EmulsionMagnetic technologyMagnetohydrodynamic dispersionMayonnaise

a b s t r a c t

Mayonnaise currently is produced using high shear stirrers. Here we present a new production methodusing a magnetic emulsication device. According to the new method a stable oil-in-water emulsion isformed by pumping the two immiscible liquids through a magnetohydrodynamic dispersion device con-sisting of a Venturi provided with an orthogonal permanent magnetic eld. As a proof of concept, mag-netically emulsied highly viscous mayonnaise was produced in a batch process and in a continuousprocess. The viscosity of the mayonnaise was signicantly enhanced by applying the magnetic eld.The oil droplet size distribution of mayonnaise produced using the magnetic emulsication methodwas similar to mayonnaise produced with conventional high shear mixers. In contrast to conventionalprocesses no fast moving mixers were needed in this new mayonnaise production scheme.

2011 Elsevier Ltd. All rights reserved.

1. Introduction

Mayonnaise is one of the more popular sauces in the world. It isan oil-in-water (o/w) emulsion containing 70–80% of vegetable oiltypically produced by mixing a waterphase with an oil phaseusingegg yolk as surfactant. Neutral pH conditions facilitate the libera-tion of egg yolk components and the emulsication process ( AntonandGandemer, 1999 ). Therefore, mayonnaise is generally preparedusing egg yolk close to neutral pH prior to an acidication with vin-egar. Traditionally mayonnaise is produced in a batch process byslowly adding the oil to the water phase under vigorous stirringcreating an o/w emulsion (Depree and Savage, 2001 ). Manufactur-ing of emulsions usinghigh shear, high speed mixers is very energyinefcient and innovation is welcome ( Depree and Savage, 2001;Franco et al., 1995 ). In this paper a new approach to produce may-onnaise relying on magnetohydrodynamic forces is presentedavoiding the use of a high shear mixer.

Magnetic elds are being exploited in a variety of technologies.The displacements that diamagnetic and paramagnetic particlesundergo when subjected to strong magnetic eld gradients arebeing exploited e.g. in magnetic separation and purication tech-niques (Moyer et al., 1984 ). Magnetic ltration over ferromagneticlter matrix devices is a powerful method for the removal of evenweakly magnetic particles from uids. Magnetophoresis and iso-magnetophoresis based on magnetic susceptibility differences areused in nano- and biotechnology for sorting and manipulating of

a variety of materials ranging from carbon nanotubes over poly-mers to biomolecules and cells ( Kang et al., 2008; Kang and Park,2007 ).

In the area of uid hydrodynamics an orthogonal magnetic eldapplied on a laminar ow of electrically conducting solvent en-hances the velocity gradients and shear rates near the walls of the conduct (Van Kleef et al., 1983 ). This magnetohydrodynamiceffect was found to be responsible for an enhanced occulationrate of suspensions of cholesterol in aqueous sodiumchloride solu-tion circulated through an orthogonal magnetic eld ( Busch et al.,1996; Van Kleef et al., 1983 ). Whereas a magnetic eld applied onlaminar ow favours aggregation of suspended particles, a mag-netic eld combined with turbulent ow recently has been foundto assist disaggregation of suspended particles ( Stuyven et al.,2009 ). Adequate magnetohydrodynamic forces in the turbulent re-gime can be obtained by applying an orthogonal magnetic eldover a Venturi (Stuyven et al., 2009 ). The observed disintegrationof aggregated particles was ascribed to Lorentz forces which underthe turbulent regime enhance the shear stresses causing deforma-tion of the aggregates. Stress uctuations are amplied by the Lor-entz force acting in opposite directions on opposite sites of spinning particles carrying surface charges. Regarding particle sizereduction and energy efciency the magnetic eld assisted disper-sion technique was found to present advantages over planetaryball milling, jet-milling, ultrasonic and ultraturrax techniques(Stuyven et al., 2009 ).

Oil in water emulsion droplets are stabilized by surfactant mol-ecules presenting dipole moments and ionised organic functions.Inspired by the earlier observation of aggregate disruption in a

0260-8774/$ - see front matter 2011 Elsevier Ltd. All rights reserved.doi: 10.1016/j.jfoodeng.2011.04.003

⇑ Corresponding author. Tel.: +32 16 321637; fax: +32 16 321998.E-mail address: [email protected] (J.A. Martens).

Journal of Food Engineering xxx (2011) xxx–xxx

Contents lists available at ScienceDirect

Journal of Food Engineering

j ou rna l homepage : www.e l sev i e r. com/ loca t e / j foodeng

Please cite this article in press as: Kerkhofs, S., et al. Mayonnaise production in batch and continuous process exploiting magnetohydrodynamic force. Jour-nal of Food Engineering (2011), doi: 10.1016/j.jfoodeng.2011.04.003

http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-https://www.researchgate.net/publication/248485299_Physical_and_flavor_stability_of_mayonnaise?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/248485299_Physical_and_flavor_stability_of_mayonnaise?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/248485299_Physical_and_flavor_stability_of_mayonnaise?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==http://-/?-http://-/?-https://www.researchgate.net/publication/224533302_Particle_capture_by_an_assemblage_of_spheres_in_high-gradient_magnetic_separation?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/224533302_Particle_capture_by_an_assemblage_of_spheres_in_high-gradient_magnetic_separation?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/224533302_Particle_capture_by_an_assemblage_of_spheres_in_high-gradient_magnetic_separation?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==http://-/?-http://-/?-https://www.researchgate.net/publication/241617508_Flocculation_of_diamagnetic_particles_in_high_magnetic_fields?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/241617508_Flocculation_of_diamagnetic_particles_in_high_magnetic_fields?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/241617508_Flocculation_of_diamagnetic_particles_in_high_magnetic_fields?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==http://-/?-http://-/?-http://-/?-http://-/?-https://www.researchgate.net/publication/23662804_Magnetic_field_assisted_nanoparticle_dispersion?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/23662804_Magnetic_field_assisted_nanoparticle_dispersion?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/23662804_Magnetic_field_assisted_nanoparticle_dispersion?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/23662804_Magnetic_field_assisted_nanoparticle_dispersion?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/23662804_Magnetic_field_assisted_nanoparticle_dispersion?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/23662804_Magnetic_field_assisted_nanoparticle_dispersion?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==http://dx.doi.org/10.1016/j.jfoodeng.2011.04.003mailto:[email protected]://dx.doi.org/10.1016/j.jfoodeng.2011.04.003http://www.sciencedirect.com/science/journal/02608774http://www.elsevier.com/locate/jfoodenghttp://dx.doi.org/10.1016/j.jfoodeng.2011.04.003https://www.researchgate.net/publication/241617508_Flocculation_of_diamagnetic_particles_in_high_magnetic_fields?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/224533302_Particle_capture_by_an_assemblage_of_spheres_in_high-gradient_magnetic_separation?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/248485299_Physical_and_flavor_stability_of_mayonnaise?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/23662804_Magnetic_field_assisted_nanoparticle_dispersion?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==https://www.researchgate.net/publication/23662804_Magnetic_field_assisted_nanoparticle_dispersion?el=1_x_8&enrichId=rgreq-2bf90c21-be67-422b-bf1c-52852137914a&enrichSource=Y292ZXJQYWdlOzI1MTUzOTk1NTtBUzoxODI2Njk2ODE4OTc0NzJAMTQyMDU2MzI1NDEzMg==http://dx.doi.org/10.1016/j.jfoodeng.2011.04.003http://www.elsevier.com/locate/jfoodenghttp://www.sciencedirect.com/science/journal/02608774http://dx.doi.org/10.1016/j.jfoodeng.2011.04.003mailto:[email 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magnetohydrodynamic device (Stuyven et al., 2009 ), we conceivedthe idea of evaluating the potential of this technique in emulsica-tion. Mayonnaise was an obvious choice. In this paper we presentour rst experiences with mayonnaise production using a magne-tohydrodynamic device in a batch process and in a continuous pro-duction scheme.

2. Materials and methods

The mayonnaise had a classic composition comprising78.05 wt.% rapeseed oil (Resto, Colruyt, Belgium) dispersed in awater phase composed of 3.84 wt.% water; 3.94 wt.% mustard(Econom, Colruyt,); 8.55 wt.% egg yolk (12 wt.% salted; Quomak/Vleminck). Vinegar 7 (Every Day, Colruyt) was added at the end of the preparation to an amount of 5.62 wt.%. The ingredients wereadded using worm pumps (NORD SK71 L/4 TF, 1390 rpm;0.37 kW). Circulation was achieved using a lobe pump (NORDSK80 S/4 TF; 0.55 kW).

The magnetohydrodynamic device (M4E N.V.; DN10) presentedin Fig. 1 consisted of a restriction, forcing the mixture through aVenturi. This device converts a cylindrical tube with an inner diam-eter of 6 mm to a rectangular aperture of 2 6 mm 2 over a lengthof 12 mm. Across this Venturi two permanent block magnets weremounted in order to create a magnetic eld of 0.6 T perpendicularto the ow direction over a length of 6.5 mm. The same Venturiwithout the block magnets was used in comparative experiments

as a control. The magnetic device was mounted at short distancedownstream of the lobe pump.

The experimental setup for batch and continuous mayonnaisepreparation is shown in Fig. 2 . The unit comprised oil and waterphase reservoirs, worm pumps for oil and water addition, lobepumps for circulation, the magnetohydrodynamic device, three-way valves and buffer drums. In the experimental setup for batchproduction, the water phase reservoir, water phase addition pump,three-way valve and second circuit were left out. A reference may-onnaise sample was prepared in batch using a MaxxD Lab highshear mixer with usable volume of 12 L (FrymaKoruma).

Mayonnaise samples were collected in polypropylene contain-ers and stored overnight in a refrigerator (4 C). Viscosity was eval-uated after 1 day, 1 week and 1 month for mayonnaise produced inbatch experiments and after 1 day for mayonnaise produced in thecontinuous setup. Different types of viscosity measurements giverise to different apparent viscosity readings, due to the non-New-tonian behaviour of mayonnaise. Two different viscosity measure-ments were performed using a Brookeld Viscometer DV-II, similarto quality control measurements in industrial mayonnaise manu-facturing (Stern et al., 2001 ). For a rst measurement, the apparentviscosity was recorded after 5 min using a spindle velocity of 0.3 rpm. A mean static apparent viscosity (SV) was determined asthe average viscosity recorded at four different spindle positionsin the sample.

A dynamic apparent viscosity was determined right after thedetermination of the SV. The same setup (spindle and spindlevelocity) was used, except for an additional oscillating verticalmovement of the spindle. The spindle moved upwards for 90 s

Fig. 1. Magnetohydrodynamic device. Side view (a) and front view (b) of theVenturi; (c) photograph of dispersing device.

Fig. 2. Experimental setup for continuous mayonnaise production: (a) oil worm pump; (b) water phase worm pump; (c and c 0) lobe pumps; (d and d 0) magnetic devices; (e

and e0

) three-way valves; (f) drum acting as a buffer with slowly moving stirrer; (f 0

) drum for vinegar addition; (g) oil reservoir; (h) water phase reservoir. In batch wisemayonnaise preparation, the oil reservoir (g), oil addition worm pump (a), lobe pump (c), dispersing device (d) and drum (f) were used.

Table 1

Apparent static (SV) and dynamic viscosity (DV) of mayonnaise batches producedwith magnetohydrodynamic device (magnetic) and with the same device withoutmagnets (control). SV and DV of commercial mayonnaise samples of different brandswith similar composition.

SV (kPa s) a DV (kPa s) b

Magnetic 1 2.43 ± 0.20 0.79 ± 0.10Magnetic 2 2.03 ± 0.11 0.89 ± 0.09

Magnetic 3 2.20 ± 0.08 0.83 ± 0.07Magnetic 4 2.11 ± 0.06 0.95 ± 0.11

Control 1 1.68 ± 0.19 0.58 ± 0.14Control 2 1.62 ± 0.09 0.70 ± 0.07Control 3 1.77 ± 0.11 0.69 ± 0.08Control 4 1.98 ± 0.06 0.75 ± 0.10

Commercial1 0.78 ± 0.08 0.25 ± 0.02Commercial2 1.10 ± 0.17 0.37 ± 0.08Commercial3 1.04 ± 0.10 0.43 ± 0.12Commercial4 2.00 ± 0.06 0.67 ± 0.06

a Standard deviation over 4 measurements.b Standard deviation over 6 measurement.

2 S. Kerkhofs et al. / Journal of Food Engineering xxx (2011) xxx–xxx

Please cite this article in press as: Kerkhofs, S., et al. Mayonnaise production in batch and continuous process exploiting magnetohydrodynamicforce. Jour-nal of Food Engineering (2011), doi: 10.1016/j.jfoodeng.2011.04.003

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followed by a downward motion for a same time. The spindlemoved vertically throughout the entire 1 L sample. A mean dy-namic apparent viscosity (DV) was calculated from 6 measure-ments recorded in 60 s intervals over a period between 90 and390 s at one position in the sample.

The upper limit of the Viscometer was 3.12 kPa s. In measure-ments where the viscosity exceeded this value the viscosity was ta-ken as 3.12 kPa s. The SV and DV of four commercial mayonnaisescontaining vinegar and with similar oil content were determinedas a reference ( Table 1 ).

Emulsion droplet size distribution were characterised eitherusing a laser diffraction instrument (Mastersizer Micro plus, Mal-vern Instruments) or with optical microscopy via particle sizedetermination on microscopic pictures. Samples were diluted andsubsequently spread between two glass slides. They are observedwith an Olympus IX71 inverted microscope, equipped with a Ham-amatsu C4742-95 CCD camera. Images were analysed using ImageJ1.44 software.

3. Results and discussion

3.1. Batch tests

The experimental setup for batch mayonnaise production isshown in Fig. 2 . The water phase was loaded in the buffer drum (f)and circulated at 6 L/min. Rapeseed oil was added with a worm

pump (a) from the oil reservoir (g) to the water phase at 0.6 L/min. After all the oil was added, vinegar was added manually tothe buffer drum containing the mayonnaise. The mayonnaise wascirculated for one additional minute. Four times 3 kg mayonnaisewas produced using this batch process with magnets mountedand four times with magnets dismounted from the dispersingdevice ( Table 1 ).

The evolutionof the apparent static and dynamic viscosity uponstorage of the obtained mayonnaise is shown in Fig. 3 . The appar-ent static and dynamic viscosity was higher when the magneticeld was applied. Monitoring of the decay of the apparent viscosityupon storage revealed the magnetically produced mayonnaise toremain superior ( Fig. 3 ). A high apparent viscosity is a desirableproperty.

The stability of mayonnaise and of emulsions in general islinked with droplet size and uniformity of the oil droplets ( Franco

et al., 1995; Stern et al., 2001 ). Oil droplet size was investigatedusing optical microscopy ( Fig. 4 ). Microscopic images showed thepresence of oil droplets varying in size between 2 and 6 l m formayonnaise produced with the magnetic devise ( Fig. 4 a). Similaroil drop sizes were determined in mayonnaise prepared with ahigh shear mixer using laser diffraction ( Fig. 4 b). The oil dropletsize distribution ( Fig. 5 ) was in the range of 1.5–20 l m for mayon-naise produced by high shear mixer and 1–30

lm for mayonnaise

produced with the magnetohydrodynamic device. Both mayon-naises showed a mean droplet size of 4 l m in agreement with

Fig. 3. Evolution upon storage of the viscosity of mayonnaise produced with themagnetohydrodynamic device (diamonds) and the same device without magnets(triangles) in batch process. Static viscosity (SV) and dynamic viscosity (DV) areindicated by solid and dash lines. The two mayonnaise preparations were repeated

four times. SV was determined four times and DV six times on each batch.

Fig. 4. Microscopic images of mayonnaise produced in batch with the magneto-hydrodynamic device (a) and with a high shear mixer (b).

Fig. 5. Oil droplet size distribution of mayonnaise produced in batch with themagnetohydrodynamic device (a) and with high shear mixer (b).

S. Kerkhofs et al. / Journal of Food Engineering xxx (2011) xxx–xxx 3


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the microscopic analysis of Fig. 4 . In another experiment mayon-naise was prepared in an experimental batch setup with a disper-sion device from which the magnets could be dismounted. Theparticle size distribution of oil droplets in mayonnaise preparedin presence and absence of magnetic eld were determined usingmicroscopic pictures are shown in Fig. 6 . The particle size distribu-tion obtained in absence of magnetic eld was substantially broad-er with particles reaching sizes up to approximately 40 l m. Thiscomparative experiment conrmed that the magnetic eld effec-tively contributed to the emulsication process and the uniformityof the particle size. Based on the viscosity enhancement and thedroplet size similar to high shear mixer ( Figs. 4–6 ) it was con-cluded that the magnetic Venturi device was effective for mayon-naise production.

The scientic explanation for the observed benecial effect of the combinationof a Venturi and a magnetic eld in emulsicationmight be similar to the one offered for the earlier observed aggre-gate disruptionin a similar device (Stuyven et al., 2009 ). The strongacceleration and pronounced velocity gradients in the Venturishould already cause deformation and break up of large oil drops,but insufcient for producing viscous mayonnaise ( Fig. 3 ). Ourinterpretation is that the electric charges at the oil–water interfacewere sufcient to provoke Lorentz forces that created an extraoscillatory stress contributing to the breakup of the larger oil drop-lets. Lorentz forces act on moving electric charges. In an emulsion,the emulsier molecules have a polar and apolar moiety. The polarmoiety may be charged by dissociation of an organic function, buteven a partial charge on atoms in chemical bonds with dipole mo-ment can be sufcient. Under turbulent ow the drops of the pre-emulsion are spinning in the moving uid with velocity vectors inopposite direction on opposite sites of the drop such that depend-ing on the sign of the electric charge, compressive and disruptiveforces act on interfaces upon passage through the magnetic eldassisting emulsication. Further research will be necessary how-ever to pinpoint the detailed mechanism.

3.2. Continuous mayonnaise production

In a rst experiment on continuous mayonnaise preparation we

were using a single recirculation. Vinegar addition turned out to bea critical step. Literature species that emulsions containing egg

yolk should be made at neutral pH and acidicationshould be doneat the end of the process (Anton and Gandemer, 1999 ). Introducingthe vinegar together with the water phase from the beginning ledto mayonnaise of too low a viscosity.

An improved continuous mayonnaise production scheme wasconceived comprising two circuits ( Fig. 2 ). The recirculation circuitmade it possible to foresee a second magnetic dispersing device(d 0) in the installation, doubling the number of passes through themagnetic eld aiming at stabilizing the emulsion even further. Thebuffer drum (f) was lled with mayonnaise, prepared as explainedin a batch experimentusing themagnetic dispersingdevice.No vin-egar was added. The mayonnaise mixture was circulated with thelobe pump (c) at a ow rate of approximately 8 L/min, while thewater phase (h) and rapeseed oil (g) were fed by means of wormpumps (a and b). The water phase was added at a ow rate of 100 mL/min; the oil at ca. 520 mL/min. By means of a three-wayvalve (e)620 mL/minof preliminarymayonnaise,matchingtheinletow ofoilandwater,was transferredto the second circuit.Themainpart of the ow was circulated via drum (f) acting as a buffer. Thesecond circuit (right part in Fig. 2 ) also contained a buffer drum (f 0)with a slow moving stirrer. Vinegar was addedmanually in the bar-relat 35 mL/minandcirculatedthroughthe circuitwitha lobepump(c 0). Mayonnaise was sampled at valve (e 0).

The double recirculation system gave satisfactory results incontinuous mayonnaise production. Within the 30 min of thisexperiment about 16 kg of mayonnaise with a sufciently high vis-cosity was produced ( Fig. 7 ). In the continuous test the apparentviscosity was higher in comparison to commercial samples, dem-onstrating the potential of the magnetic emulsication technology.(SV and DVdata of Fig. 7 compared to commercial samples of Table1). At three measurements the upper limit of viscosity determina-tion of 3.12 kPa s was exceeded. The SV and DV of the producedmayonnaise uctuated around 2.8 kPa s and 1.1 kPa s, respectively(Fig. 7 ).

Stuyven et al. (2009) estimated that the hydromagnetic dispers-ing technology presented an energetic advantage over conven-tional dispersing techniques like ultraturrax, ultrasonic ballmilling and jet milling. In the here presented continuous mayon-naise production scheme the two lobe pumps for circulation pre-sented a total power of ca. 1.1 kW. The power of the lab scalehigh shear mixer used in this work was 7.5 kW which revealedthe potential energy savings.

Fig. 6. Oil droplet size distribution of mayonnaise produced in batch with themagnetohydrodynamic device (a) and with a similar device without magnets

mounted (b).

Fig. 7. Apparent static viscosity (SV) ( j ) and dynamic viscosity (DV) ( d ) of mayonnaise sampled in a continuous mayonnaise production experiment using the

magnetohydrodynamic device. The SV and DV were determined after 1 day storageat 4 C. Standard variation over 4 (SV) and 6 (DV) measurements.

4 S. Kerkhofs et al. / Journal of Food Engineering xxx (2011) xxx–xxx

Please cite this article in press as: Kerkhofs, S., et al. Mayonnaise production in batch and continuous process exploiting magnetohydrodynamicforce. Jour-nal of Food Engineering (2011), doi: 10.1016/j.jfoodeng.2011.04.003

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4. Conclusions

The applicability of magnetic dispersion devices in the prepara-tion of mayonnaise being an example of an oil-in-water emulsionwas demonstrated. The emulsication device consisted of a Ven-turi and an orthogonal magnetic eld. Experiments with and with-out magnetic eld revealed the positive effect of the magnetic eld

on the emulsication process. Mayonnaise with a sufciently highviscosity and a mean oil droplet size of ca. 4 l m was produced,similar to mayonnaise obtained using a high shear mixer. Althoughno energy saving calculations were made, the absence of fast mov-ing mixers is expected to lower the energy cost of mayonnaise pro-duction. The magnetohydrodynamic device can be operated in acontinuous mayonnaise production process.

Acknowledgements

The authors acknowledge the Flemish IWTfor nancial support. J.A.M. acknowledges the Flemish Government for long-term struc-tural funding (Methusalem). G.C. Hahn & Co is acknowledged forsynthesizing reference mayonnaise using high shear mixer. G.C.Hahn & Co and Rob Van Hooghten and Jan Vermant, Chemical engi-neering Department, K.U. Leuven are acknowledged for performingoil droplet size measurements. The authors thank George Danaufor his help during mayonnaise preparation.

References

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