<![CDATA[The results indicate strong dependence of mayonnaise emulsion stability and quality on optimized homogenization parameters (e.g., rotor-stator operating conditions), but systematic quantitative investigation of these factors remains limited in the scientific literature. A 4 x 3 full factorial experimental design (n = 3) with a 500-Watt high-shear rotor-stator homogenizer evaluated the effects of rotational speed (1200–9000 rpm) and mixing time (5–15 minutes) on emulsion dynamic viscosity, impeller Reynolds number (Re), and visual physical stability. Dynamic viscosity (Re = 12.14) can be directly correlated with emulsification parameters, where the best condition (Run 1) was achieved when stirring at 1200 rpm for 5 minutes, generating a dynamic viscosity of 1512 cP, which is squarely within commercially specified limits (1210–3346.7 cP). At longer mixing times (≥ 10 min) and at higher speeds (≥ 3600 rpm), severe over-processing occurred, decreasing dynamic viscosity to as low as 1010–1182 cP because of both viscous dissipation heating and thermal denaturation of egg proteins. Predicted impeller Reynolds numbers ranged from strictly Re = 1.74 to 77.66, indicating rotor-stator processing of these high-viscosity food emulsions in this configuration spans the laminar-to-transitional regime. Direct processing windows are provided to aid food manufacturers in reducing energy footprints while ensuring batch reproducibility.]]>
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