ProxxD® Industrial Homogenizer for Mayonnaise, Dressings and Sauces

The ProxxD® is an industrial homogenizer for the batch production of emulsified and dispersed food products – mayonnaise, salad dressings, tartar sauce, ketchup and comparable sauces. It is built on the proven FrymaKoruma MaxxD platform and combines a redesigned homogenizer, the fastest oil dosing on the market at up to 3.0 kg/s, and full recipe programming through the ProUI interface. In a 500-litre batch the machine reaches up to 6,000 kg/h of full-fat mayonnaise at an average specific energy input of 5 kWh per ton. For manufacturers this means shorter batch times, reproducible droplet size and a measurably lower energy cost per ton produced.

What Is an Industrial Homogenizer?

An industrial homogenizer is process equipment that reduces the droplets or particles of one phase and distributes them evenly through a second phase, so that the resulting product no longer separates. In a mayonnaise or sauce application this means dispersing oil into a water phase until the droplet size distribution is narrow enough to keep the emulsion stable throughout its shelf life. The decisive parameter is not throughput but control: an industrial homogenizer must reach the same droplet size in every batch, at every scale, regardless of oil content or ambient temperature. Homogenizers differ mainly in how they introduce the required energy – through mechanical shear in a rotor-stator gap, through pressure drop across a valve, or through ultrasound – and each principle suits a different viscosity and throughput range.

How a ProxxD Batch Runs: The Process Steps

The ProxxD processes each batch in a defined, fully programmable sequence. Every step is logged, so a batch can be reproduced or traced later:

Recipe selection and preparation: The operator selects a stored recipe on the ProUI touch panel. All process parameters – temperatures, dosing rates, homogenizer speed and holding times – are loaded with it, which removes manual parameter entry as a source of batch variation.
Water phase preparation: Water, vinegar, salt, sugar, stabilisers and egg or plant-based protein are dosed into the vessel and pre-mixed. Temperature is controlled through the closed cooling circuit from this point onward.
Oil dosing: Oil is metered into the running process at up to 3.0 kg/s. Dosing speed is the single biggest lever on batch time in mayonnaise production, because the oil phase has to be introduced gradually enough for the emulsion to form but fast enough not to stall the cycle.
Homogenization and droplet size control: The homogenizer disperses the oil phase into fine droplets and holds the droplet size distribution within the programmed window. This is the step that determines viscosity, mouthfeel and separation stability of the finished product.
Vacuum deaeration: Entrained air is removed under vacuum. Air pockets shorten shelf life through oxidation, cause density variation at the filler and dull the visual appearance of the product.
Temperature control and discharge: The batch is brought to discharge temperature through the closed cooling circuit and transferred to buffer or filling. Closed circuits keep water consumption to a minimum compared with once-through cooling.
Process logging and cleaning: Every batch is logged through ProUI for quality documentation and traceability. The system is then cleaned before the next recipe, which is where the ability to store and recall recipes pays off in multi-product plants.

Key Challenges in Industrial Sauce and Emulsion Production

Producers of mayonnaise, dressings and cold sauces face a recurring set of technical and commercial constraints:

Holding droplet size distribution constant across batches, shifts and raw material lots
Preventing emulsion breakdown during storage, transport and temperature cycling
Producing low-fat and reduced-fat recipes, which are far less forgiving than full-fat formulations because there is less oil to stabilise
Cutting batch time without losing emulsion quality – oil dosing speed is usually the bottleneck
Reducing specific energy consumption per ton at a time when energy is a visible cost block
Switching between recipes and pack formats without long cleaning and setup downtime
Documenting every batch for quality management and customer audits
Scaling a recipe from development to full production without reformulating it

The ProxxD addresses these constraints through programmable process control rather than operator experience: recipes are stored, parameters are locked to the recipe, and every batch is logged. That is what makes a result repeatable across shifts.

The ProxxD Series: Technical Data

The ProxxD is available in a basic configuration that can be extended in modules. The following figures apply to the basic concept:

Parameter	Wert
Production capacity, full-fat mayonnaise	up to 6,000 kg/h*
Production capacity, low-fat mayonnaise (30 % oil)	up to 4,000 kg/h*
Oil dosing rate	up to 3.0 kg/s
Specific energy input	5 kWh/ton on average
Batch volume	500 l
Dimensions (basic concept)	L 230 × H 280 × W 210 cm
Weight	approx. 2,000 kg
Control system	ProUI process user interface with recipe management and process logging
Base technology	FrymaKoruma MaxxD platform with redesigned homogenizer

* Based on FrymaKoruma standard recipes for full-fat mayonnaise.

What Distinguishes the ProxxD

Maximum productivity

The redesigned homogenizer raises output per batch, which either increases plant capacity or reduces the number of shifts needed for the same volume.
Reproducible product quality

Droplet size control follows the proven MaxxD principle, so the same recipe yields the same product across batches and operators.
Energy and water efficiency

The latest class of electric motors, higher batch volumes and shorter cycles bring specific energy input to an average of 5 kWh per ton. Closed cooling circuits keep water consumption to a minimum.
Fastest oil dosing on the market

At up to 3.0 kg/s, oil dosing stops being the bottleneck of the batch cycle – the main reason for the ProxxD's short batch times.
Operable without specialist training

ProUI presents recipes, parameters and process logs on a touch panel, so the machine does not depend on a single experienced operator.
Modular and extendable

The system is adapted to the specific process rather than sold as a fixed configuration, which protects the investment as the product portfolio changes.

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FAQ – Industrial Homogenizers and the ProxxD

Below you find answers to common questions.

What is an industrial homogenizer?

An industrial homogenizer is process equipment that breaks one phase into fine droplets or particles and distributes them evenly through another, so the finished product stays stable and does not separate. In food production it is what turns oil and a water phase into mayonnaise, dressings or sauces with a defined texture and shelf life. The defining requirement is reproducibility: the same droplet size distribution in every batch.
What are the different types of industrial homogenizers?

Three principles dominate. Rotor-stator homogenizers generate mechanical shear in a narrow adjustable gap and cover a wide viscosity range, which makes them the standard for sauces and emulsions. High-pressure homogenizers force the product through a valve at high pressure and reach very fine droplet sizes, mainly for low-viscosity products such as dairy. Ultrasonic homogenizers use cavitation and are largely limited to laboratory and small-batch use. The ProxxD works on the rotor-stator principle in a batch process.
Which industries use industrial homogenizers?

Food producers use them for mayonnaise, dressings, sauces, spreads and dairy products. The pharmaceutical industry uses them for ointments, creams and suspensions, and the cosmetics industry for lotions and emulsions. Chemical manufacturers apply the same principle to paints, coatings and lubricants. The requirement is always the same: a stable, reproducible dispersion of two phases that will not separate.
What is the difference between homogenizing and emulsifying?

Emulsifying describes the goal – combining two liquids that do not normally mix, such as oil and water, into one stable product. Homogenizing describes the mechanical means of getting there: reducing droplet size and distributing it evenly. Every emulsion produced mechanically is homogenized, but homogenizing is also used on products that are not emulsions, for example to disperse solid particles in a suspension.
How much mayonnaise can the ProxxD produce per hour?

The ProxxD reaches up to 6,000 kg/h of full-fat mayonnaise and up to 4,000 kg/h of low-fat mayonnaise at 30 % oil content, based on FrymaKoruma standard recipes. Batch volume is 500 litres and specific energy input averages 5 kWh per ton. Actual output depends on recipe, oil content and the required droplet size specification.
What is the difference between the ProxxD and the FrymaKoruma MaxxD?

The ProxxD is built on the MaxxD platform but uses a redesigned homogenizer and reaches a higher production capacity. It also adds the ProUI process interface with recipe management and process logging, and the latest class of electric motors, which lowers specific energy consumption. The droplet size control principle that made the MaxxD reliable is retained unchanged.