PROCEDURE FOR PREPARING COLD EMULSIONS BY HEAT TREATMENT

Description

BE2024 / 5959 2 hinders thorough cleaning, which can jeopardize food safety and increase the time required for maintenance. The present invention aims to find a solution to at least some of the above-mentioned problems. 5 SUMMARY OF THE INVENTION The invention concerns a method for preparing an emulsion, such as mayonnaise, in accordance with claim 1. The invention offers efficient production of 10 emulsions with consistent quality through rapid in-line cooling, direct injection of egg yolk for optimal emulsification, vacuum homogenization for a stable and air-free emulsion, and an automated filling line for high capacities and minimal waste. This results in a longer shelf life, improved energy efficiency and scalability, while the risk of thermal degradation and phase separation is minimized. Further forms of implementation are described in conclusions 2 to 14. DETAILED DESCRIPTION The invention concerns a method for preparing cold emulsions.20 In a first aspect, the invention concerns the method for the industrial preparation of a stable cold emulsion, such as mayonnaise. Other examples of cold emulsions are fries sauce, basic sauce, cocktail sauce, curry sauce, Andalouse, Samurai, Americana sauce, Algerienne, burger sauce, garlic sauce, pita sauce, kebab sauce, Brazil, dill dressing, chive vinaigrette, ranch dressing, fish sauce, Hannibal, Gold sauce, onion burger, Yopie, cheese sauce, Cheddar sauce, yogurt sauce, teriyaki, Mammouth, Marocaine, Tunisian, pepper sauce, Pilipili, spicy garlic sauce, Prepare sauce, Filet Tamara sauce, Sauce Blanche, tartar sauce, remoulade, Caesar dressing. All can be prepared according to a method of the present invention. The food industry is a dynamic sector in which innovation and technological progress are essential to meet the growing demand for high-quality, safe and sustainable products. Within this industry, emulsions play an important role, as they form the basis for a wide range of food products, such as sauces, dressings, spreads and desserts.Emulsions offer unique properties, including a creamy texture, a uniform taste, and an attractive 2024 / 5959 BE2024 / 5959 3 mouthfeel, which are essential for the quality and consumer experience of many food products. Producing stable and high-quality emulsions requires a precisely controlled process. This process involves mixing at least two immiscible liquids, 5 such as oil and water, in combination with emulsifiers that ensure long-lasting stability. The delicate balance between the right ingredients, temperature control, and mechanical processing is of great importance to prevent phase separation and to obtain a product that meets consumer expectations. 10 In a preferred form, the procedure includes the steps of: a.a. dosing of basic raw materials and forms of a mixture, whereby the basic raw materials are selected from one or more of the groups water, salt, sugar, one or more starches such as modified or native maize starch, potato starch, rice starch or wheat starch and / or one or more spices such as 15 mustard seed, dill, paprika powder, garlic powder, parsley, chili, curry, or tarragon; b. heating the mixture to approximately 90°C; c. inline cooling of the mixture in a cooling cylinder to 20-25°C in less than 5 minutes; d. directly injecting egg yolks and at least one vegetable oil into the mixture, whereby the egg yolk contains between 8 and 15 wt% salt, a pH between 6 and 7, a fat content between 20 and 30 wt% and a dry matter content of at least 45 wt%; e. the formation of an emulsion by homogenization of the mixture in an emulsifying cylinder and vacuum application, whereby a vacuum pressure between 200 and 500 mbar is maintained; and f. the flow of the emulsion to a filling line. In a mold, cooling is performed inline.Inline cooling is a technique in which a mixture is cooled directly in a continuous production process while it flows through a system. Instead of traditional e-batch cooling, where the mixture is cooled in a tank, inline cooling utilizes specially designed cooling cylinders or heat exchangers. These ensure a rapid and uniform temperature reduction within a short time, which is essential to safeguard the quality and stability of sensitive products, such as cold emulsions. Inline cooling not only offers energy savings through more efficient heat transfer, but also reduces process times and prevents thermal degradation of ingredients. This technique is particularly suitable for large-scale industrial applications where consistency and speed are crucial. Furthermore, the yolk and at least one vegetable oil are directly injected into the mixture of basic raw materials. Direct injection is a method whereby ingredients are directly injected into a mixture during the production process.This technique can be applied in continuously operating systems to promote optimal distribution and direct interaction between the ingredients. Direct injection accelerates mixing at the molecular level, which makes emulsion formation more efficient and consistent. This reduces the risk of uneven distribution of the ingredients and contributes to a stable end product. Furthermore, direct injection makes it possible to add sensitive ingredients to the process only at the right moment, whereby their functional properties are better preserved. This method is particularly valuable in industrial environments where speed and precision are essential. In one execution form, the end product of the method is an emulsion. An emulsion is a mixture of two or more immiscible liquids, such as oil and water, in which one liquid is distributed in the other in the form of small droplets. Emulsions are widely used in the food industry, cosmetics, and pharmaceutical products due to their unique texture, stability, and functionality.To form an emulsion, an emulsifier can be added. This is a substance, such as lecithin in yellow, which reduces the surface tension between the two liquids and ensures a stable distribution of the droplets. Emulsion formation is a process in which two or more liquids are mechanically mixed to obtain a fine distribution of the droplets. This process requires controlled conditions, such as the correct oil-to-water ratio, temperature, and the presence of emulsifiers. Insufficient mixing or incorrect process conditions can lead to unstable emulsions, in which the droplets clump together or the phases separate. Homogenization is a technique to stabilize the emulsion and reduce droplet size. During homogenization, the mixture is forced under high pressure through a small opening, whereby strong shear forces and turbulence break the larger droplets into smaller, uniform particles. This results in a finer emulsion with a smooth texture and improved stability.Through homogenization, the emulsion not only becomes physically more stable, but properties such as mouthfeel and shelf life are also improved, which is desirable for high-quality food products in industrial applications. In a further form, the emulsion is mixed in an emulsifying cylinder; this is a specialized device used for the production of emulsions by means of a controlled mixing and homogenization process. The cylinder is designed to mix liquids with each other into a stable emulsion by applying mechanical forces. In an industrial setting, the emulsifying cylinder may contain a rotor-stator system that provides high speeds and intense shear forces, whereby the particle size is reduced and a fine distribution of the droplets is achieved in the emulsion. An important feature of the demulsifier cylinder is the ability to create vacuum conditions.By applying vacuum pressure, air inclusions in the mixture are prevented, which is essential for a smooth texture15 and longer shelf life of the final product. In addition, the adjustability of parameters such as speed, power, and pressure makes the demulsifier suitable for various types of emulsions, from thin liquids to thicker products such as mayonnaise. 20 The compact and efficient operation of an emulsifier makes it possible to produce emulsions inline, which results in shorter process times and improved product consistency. In one execution form, the method involves mixing a number of25 basic raw materials.These basic raw materials can be selected from the group of, but not limited to, water, lecithin, monoglycerides, diglycerides, modified or native maize starch, potato starch, rice starch, wheat starch, tapioca starch, cassava zest, xanthan gum, guar gum, carrageenan, gelatin, pectin, agar-agar, alginates, salt, sugar, honey, glucose, fructose syrup, vinegar, citric acid, lactic acid, 30 mustard seed, dill, paprika powder, garlic powder, tarragon, cumin, coriander, turmeric, rosemary, thyme, oregano, basil, chili pepper, cayenne pepper, black pepper, white pepper, ginger powder, onion powder, curry powder, sodium benzoate, potassium sorbate, calcium propionate, sodium citrate, ascorbic acid, sodium erythorbate, colorings, flavorings, aromas, maltodextrin, milk powder, whey proteins, casein, soy lecithin, 35 sunflower lecithin, phosphate salts, magnesium chloride, calcium chloride.In a preferred form comprising basic raw materials at least water, salt, sugar, one or more starches such as modified or native maize starch, potato starch, 2024 / 5959 BE2024 / 5959 6 rice starch or wheat starch and one or more spices such as mustard seed, dill, paprika powder, garlic powder, chili, onion powder, parsley, curry powder and tarragon. Water generally forms the continuous phase in an oil-in-water emulsion and may be present in an amount ranging from 10 wt% to 80 wt% of the total mixture.5 The water content influences the viscosity stability of the emulsion and may depend on the type of product, such as a dressing with a lower water content or a sauce with a higher water content. Salt is added to emulsions to both enhance the flavor and contribute to preservation and stability. It plays an important role in balancing the flavor of the product and can be used in amounts ranging from 0.5 wt% to 5 wt% of the total weight, depending on the desired intensity and specifications of the final product.In addition to adding sweetness, sugar also serves to balance the flavor components, making it a versatile ingredient that can also contribute to the texture of the emulsion. It can be added in amounts from 1 wt% to 40 wt%, depending on the application, such as a sweeter sauce or a more neutral base. Starches are used as thickeners and stabilizers, which ensure a smooth texture and the desired viscosity of the emulsion. Corn starch, modified or native, is a widely used choice due to the stability it offers under various temperature and pH conditions and can be added in a range of 0.5 wt% to 10 wt%. Potato starch, with its unique texture and excellent binding capacity, is used in amounts of 0.5 wt% to 425 wt%. Rice starch, known for its light and neutral properties, can be added in smaller amounts, between 0.2 wt% and 3 wt%. Wheat starch offers versatility and is often used in similar amounts to corn starch, ranging from 0.5 wt% to 10 wt%.30 Spices add flavour variations and complexity to emulsions, and their addition is carefully tailored to the desired flavour profiles. Mustard seed offers a sharp, spicy flavour and can be added in quantities of 0.1 wt% to 1 wt%. Dill provides a fresh and aromatic flavour and is usually used in smaller quantities, ranging from 0.05 wt% to 0.5 wt%. Paprika contributes to both flavour and colour and is added in a range of 0.1 wt% to 1 wt%. Garlic powder offers a savory, pronounced flavor and is used in quantities of 0.1 wt% to 0.5 wt%. Tarragon, with its subtle anise-like 2024 / 5959 BE2024 / 5959 7 flavor, is often added in very small quantities, between 0.05 wt% and 0.5 wt%, to refine the overall flavor balance. The precise quantities and combinations of these ingredients can be adjusted to meet the requirements of specific formulations and consumer tastes. The stated ranges of basic raw material concentrations are not limiting and can be adjusted5 according to the needs of the final product.In a specific form, the egg yolk is injected into the mixture. Egg yolk acts as a natural emulsifier due to the presence of phospholipids, such as lecithin, which are essential for stabilizing the emulsion by reducing the surface tension between the oil and water phases. By injecting the egg yolk directly into the mixture, not only is an even distribution of the egg yolk achieved, but the interaction with the other ingredients is also maximized, resulting in improved stability and homogeneity of the emulsion. 15 The injection takes place under controlled conditions to preserve the integrity of the egg yolk and prevent thermal degradation. This process can be carried out at a mixture temperature of 20 to 25°C, which is ideal for activating the emulsifying properties of the egg yolk without causing denaturation. The egg yolk can be added at a concentration of 1 wt% to 10 wt% of the total weight of the emulsion, depending on the desired texture and stability of the final product.An advantage of this technique is that the egg yolk is added only at a later stage in the production process, thereby exposing it to minimal mechanical and thermal stress. This contributes to a more efficient process and a higher quality end product. Moreover, direct injection makes it possible to accurately dose the amount of egg yolk and minimize waste, which is particularly important in large-scale industrial production. By introducing the egg yolk into the mixture via an injection system, the process is also optimized for continuous production. This eliminates the need for batch processing, shortens process times, and increases consistency between production batches. In a preferred form, the egg yolk contains a salt content between 1 and 20 wt%, more preferably between 1 and 10 wt%, and even more preferably between 1 and 5 wt%.Furthermore, the egg yolk preferably comprises an acidic pH, preferably a pH between 1 and 7, more preferably between 2 and 7, even more preferably between 3 and 7, even more preferably between 4 and 7, even more preferably between 5 and 7, most preferably between 6 and 7. In a preferred form, the egg yolk comprises a fat content between 10 and 50 wt%, more preferably between 20 and 40 wt%, most preferably between 20 and 30 wt%. Furthermore, the egg yolk preferably comprises a dry matter of at least 65 wt%, more preferably of at least 55 wt%, even more preferably of at least 50 wt%, most preferably of at least 45 wt%. In a further form of execution, at least one vegetable oil is selected from the group of, but not limited to, olive oil, sunflower oil, coconut oil, rapeseed oil, sesame oil, avocado oil, linseed oil, walnut oil, argan oil, soybean oil, palm oil, grapeseed oil, peanut oil, corn oil, safflower oil, babassu oil, hemp oil, camellia oil, jojoba oil, and / or castor oil. In a preferred form, the emulsion comprises refined rapeseed oil.In an oil-in-water emulsion, vegetable oil acts as the dispersed phase, whereby small oil droplets are distributed in a continuous water phase. This structure not only contributes to the creamy textures and mouthfeel of the product, but also has a direct influence on the taste, stability, and nutritional value of the emulsion. One of the most important properties of vegetable oil is its high fat content, which is usually between 90 wt% and 100 wt%. This fat content is crucial for achieving the desired textures and viscosity of the emulsion. Furthermore, oil helps stabilize the emulsion through interaction with emulsifiers, such as lecithin in egg yolk, which reduce the surface tension between the oil-and-water phases. This results in a homogeneous mixture in which the phases do not separate, even during prolonged storage. Vegetable oils offer flexibility in production due to their variable properties. Refined oils are particularly suitable because of their neutral taste and low impurity content, which is important for a consistent end product.The viscosity of the oil determines how easily the oil can be mixed and incorporated into the emulsion during the production process. This makes vegetable oil a versatile ingredient that can be tailored to specific production requirements. In addition to functional properties, vegetable oil contributes to the organoleptic qualities of the emulsion. The fat in the oil enhances the flavor of other ingredients, such as herbs and spices, and ensures a rich, full flavor experience. Furthermore, the oil offers a platform for dissolving fat-soluble flavorings and colorants, which is important for creating an attractive and tasty end product. Vegetable oil also plays an important role in the nutritional value of the emulsion. Depending on the chosen oil, the product can be enriched with essential fatty acids, such as omega-3 and omega-6, and vitamin E, which are naturally present in many vegetable oils. This makes the oil not only functional but also a valuable addition from a health and marketing perspective.In a preferred form, refined rapeseed oil has a viscosity between 30 and 100 mPa at 20°C, more preferably between 40 and 90 mPa, even more preferably between 50 and 80 mPa, and most preferably between 60 and 70 mPa. Furthermore, refined rapeseed oil preferably has a fat content between 80 and 100 wt%, more preferably between 90 and 100 wt%, and most preferably between 95 and 100 wt%. 15 In one execution form, the mixture of basic raw materials is heated to a temperature between 70 and 100°C, more preferably between 79 and 95°C, even more preferably between 79 and 92°C, even more preferably between 80 and 92°C, even more preferably between 85 and 92°C, most preferably between 88 and 92°C. In a further execution form, the mixture maintains this temperature for at least 320 minutes, such as, for example, 3 minutes, 4 minutes, 5 minutes, 6 minutes, ... It is clear to the professional that this heating time should not take place to a rounded number of minutes, but can assume any possible duration between the mentioned times.Controlled heating within this temperature range plays a crucial role in inactivating unwanted microorganisms and enzymes, thereby guaranteeing the microbiological stability of the product. This is particularly important in industrial applications where shelf life and food safety are essential. 30 In addition, heating the mixture helps to dissolve and activate certain ingredients, such as sugars, salts, and hydrocolloids, which dissolve better at higher temperatures. This process ensures an even distribution of the soluble components in the mixture, which improves the texture and stability of the emulsion. The heating process also plays an important role in the initial viscosity build-up, particularly when thickeners such as modified or native corn starch or xanthan gum are used. At these temperatures, these thickeners begin to hydrate and exercise their function as structure enhancers.The temperature range of 88 to 92°C was chosen because it is high enough to achieve the desired results without causing thermal damage to the ingredients. Ingredients such as egg yolk, which are sensitive to denaturation, retain their emulsifying properties within this range, while their microbial safety is enhanced. Precise temperature control is of crucial importance here; excessively high temperatures can lead to undesirable changes in the taste, texture, or color of the final product. In one mold, the product is rapidly cooled after heating to prevent thermal degradation and increase processing efficiency. This can be done in cooling cylinders. Cooling cylinders are industrial devices that quickly and efficiently cool liquids or mixtures during a continuous production process. They consist of a cylindrical housing with a system of tubes or plates in which a coolant circulates. This coolant extracts heat from the product as it flows through the cylinder, thereby achieving a rapid and uniform temperature drop.In one configuration, the method comprises at least one cooling cylinder. In this configuration, the cooling cylinders preferably have a capacity between 100 and 500 kW, more preferably between 200 and 400 kW, and most preferably between 300 and 400 kW. This capacity is suitable for the rapid and effective extraction of heat from the mixture during the production process. It enables the cooling cylinder to dissipate large amounts of heat, even at high throughput rates, and ensures that the mixture is cooled back to the desired temperature within a short time. A capacity in this range is ideally suited for industrial applications where consistency and speed in the cooling process are of crucial importance. With this capacity, between 10 and 30 kg per minute of emulsion can be cooled. These parameters are controlled via a Programmable Logic Controller, a digital electronic device that functions as a central unit that receives signals from sensors and switches, processes them, and gives commands to actuators based on them.In a further design form, the cooling cylinder comprises a housing made of material selected from the group of, but not limited to, stainless steel (SS), SS Duplex, 35 aluminium, coated carbon steel, copper, nickel-based alloys, titanium, polymers with high thermal conductivity, composite materials and / or galvanized steel. Preferably, the housing comprises SS Duplex. 2024 / 5959 BE2024 / 5959 11 Stainless Steel Duplex combines high strength with excellent corrosion resistance, making it ideal for use in the food industry and other sectors where hygiene and durability are essential. Furthermore, the material offers higher resistance to stress corrosion and chloride-ion corrosion compared to standard stainless steel, making it resistant to demanding conditions, such as contact with aggressive substances or high humidity. In addition, Stainless Steel Duplex is particularly resistant to corrosion from acidic foods, such as sauces, dressings, and marinades, making it ideal for equipment used in the processing of such products.10 The strength of stainless steel duplex makes it possible to make the walls of the cooling cylinder thinner without compromising structural integrity. This can improve thermal efficiency, because heat is transferred more quickly between the product and the coolant. In addition, the long service life of stainless steel duplex ensures a cost-effective solution, because maintenance and replacement are required less frequently. 15 In a further design, the cooling cylinders are equipped with sensors for continuous temperature and flow rate monitoring, which guarantees accurate control of the cooling process. These sensors measure the temperature of the mixture in real time as it flows through the cylinder and register any deviations that could affect the quality and consistency of the final product. Based on the temperature measurements, the valves regulating the flow of steam are automatically controlled to ensure that the temperature remains within the desired margins, for example between 20 and 25°C.This automated control system enables rapid and accurate adjustment, thereby preventing thermal instability in the process. In addition to temperature monitoring, the flow control sensors provide insight into the speed at which the mixture flows through the cooling cylinders. This is essential to ensure that the mixture has sufficient time to cool down effectively without the risk of overheating or insufficient cooling. In the event of deviations in flow rate or temperature, the system can immediately take corrective actions, such as adjusting the steam supply via the valves, to maintain optimal cooling performance. The combination of sensors and an automated control system not only increases process stability but also enables a higher degree of efficiency and automation. This reduces the need for manual intervention and minimizes the risk of human error.Moreover, the collected data can be used for 2024 / 5959 BE2024 / 5959 12 process analysis and quality control, whereby trends in temperature and flow rate fluctuations provide insight into possible areas for improvement in the production process. In one form, the emulsion is formed in an emulsifier cylinder, a specialized device designed to mix liquids with each other and create a stable emulsion. The emulsifier cylinder uses powerful mechanical forces, such as high speeds and intense turbulence, to bring oil and water phases together and reduce the droplet size of the oil to the micron level. This results in a fine, homogeneous emulsion that remains consistent, even during prolonged storage or transport. The deemulsifier cylinder can operate with a rotor-stator mechanism, in which the rotor rotates at high speed inside a stationary stator. This creates strong shear forces suitable for breaking the oil droplets and achieving an even distribution in the water phase. This.