Method for the preparation of sauces based on cold emulsions

Description

BE2024 / 5958 2 speed between 20 and 30 L / min. The method involves fine mixing and homogenization under controlled temperature and pH conditions, whereby the pH remains between 4.50 and the temperature is maintained between 20 and 35°C. DETAILED DESCRIPTION5 The invention concerns a method for the preparation of cold emulsions. Unless otherwise defined, all terms used in the description of the invention, including technical and scientific terms, have the meaning as they are generally understood by the professional in the technical field of the invention. For a better assessment of the description of the invention, the following terms are explicitly explained. “A”, “the” and “the” in this document refer to both the singular and the plural unless context clearly implies otherwise. For example, “a segment” means one or more than a segment.The terms “include”, “including”, “consist of”, “consisting of”, “provided with”, “contain”, “containing”, “encompass”, “containing”, “include”, “containing” are synonyms and are inclusive or open terms that indicate the presence of what follows, and that do not exclude or prevent the presence of other components, features, elements, members, steps, known from or described in the standard technique. The citing of numerical intervals by the endpoints includes all integers, fractions and / or real numbers between the endpoints, including these endpoints. The term “aqueous phase” in the current invention refers to the aqueous component of the emulsion, which serves as the continuous phase in which other ingredients such as emulsifiers and oils are dispersed. This phase typically comprises water and may contain dissolved salts, acids, or other water-soluble additives to achieve the desired pH and stability of the final product.In the present invention, the term “emulsifiers” refers to substances that assist in the stabilisation and formation of emulsions by reducing the surface tension between the oil and water phases. Examples are egg yolks and egg yolk powder, which are natural emulsifiers containing lecithin. 2024 / 5958 BE2024 / 5958 3 The term “vacuum mixing” refers to the method of mixing under reduced pressure conditions, which helps to remove air and prevent oxidation, thereby improving the stability and texture of the emulsion. This process is preferably facilitated by a homogeniser equipped with a liquid ring pump to maintain the vacuum. 5 In the present invention, the term “homogeniser” refers to a mechanical device used to create a uniform emulsion by applying high shear forces. 10 The term “control valve” refers to a control valve that is integrated into the system to regulate the flow of oils to the water phase.During deemulsification, this is set to an opening degree of 60% to maintain a constant flow of 20 to 30 L / min. 15 In the current invention, the term “pH control” refers to a system to monitor and adjust the acidity of the emulsion so that it remains below a pH of 4.50. The term “temperature sensors” refers to devices such as PT100 sensors which can be mounted on circulation lines, among other places, to monitor and regulate the temperature of the emulsion so that it remains between 20 and 35°C. The term “vegetable oils” in the current invention refers to oils derived from plants, such as 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 castor oil.The term “cold emulsion” refers to the final stable emulsion product30 obtained from the described process, characterized by its stability and texture, suitable for use as mayonnaise or a similar sauce. In a first aspect, it concerns the invention and method for the industrial preparation of a stable cold emulsion, such as mayonnaise.35 Other examples of cold emulsions are fries sauce, basic sauce, cocktail sauce, curry sauce, Andalouse, Samurai, Americana sauce, Algerienne, burger sauce, garlic sauce, 2024 / 5958 BE2024 / 5958 4 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. 5 In a preferred form, the method comprises the steps of: a. preparing an aqueous phase; b. adding emulsifiers to the aqueous phase; c.the mixing of the aqueous phase under vacuum with one or more emulsifiers10 in a homogenizer; d. the addition of one or more oils to the aqueous phase, whereby the one or more oils are added to the aqueous phase at a rate between 20 and 30 L / min; and e. the execution of fine mixing and homogenization under controlled15 temperature and pH conditions. Preferably, during the execution of fine mixing and homogenization, the pH remains lower than 4.50, and the temperature is maintained between 20 and 35°C. 20 In a specific form, fine mixing and homogenization are carried out under controlled temperature and pH conditions for the preparation of a cold emulsion. The pH of the composition is maintained between 3.5 and 4.5. This pH range is beneficial for ensuring the microbiological stability of the emulsion, while also contributing to the desired properties such as taste and texture,25 depending on the intended application. Furthermore, the pH conditions are controlled and maintained within specific limits during the process to ensure the chemical stability of the emulsion.The pH value can preferably vary from 1.0 to 4.5, preferably from 2.0 to 4.5, preferably from 3.0 to 4.5, but most preferably a maximum of 4.5. By keeping the pH value within this range, the risk of microbial growth is reduced and the shelf life of the product is extended. The temperature during the process is regulated between 20 and 35°C. This temperature range is beneficial for maintaining the stability of the emulsion and promoting effective mixing of the ingredients. It prevents temperature-sensitive ingredients from being thermally affected, which is crucial for the texture, stability, and sensory properties of the cold emulsion. The temperature during the process is preferably between 10°C and 40°C, more preferably between 15°C and 38°C, more preferably between 18°C ​​and 36°C, more preferably between 20°C and 35°C, and most preferably between 22°C and 34°C. This temperature range ensures that the physical properties of the ingredients are optimal for emulsion formation and stability.It is important that the temperature remains within these limits to prevent the emulsion from destabilizing or undergoing unwanted texture changes.10 The combination of controlled pH and temperature settings makes it possible to achieve a reproducible process that results in a high-quality, stable cold emulsion. This method minimizes variability between batches and meets the high quality requirements set in commercial applications,15 such as salad dressings and dips. In the procedure, a water phase is first prepared, followed by the addition of emulsifiers to this water phase. This mixture is then mixed into a homogenizer under vacuum conditions. The procedure further involves the slow addition of oils to the water phase, and the execution of fine mixing and homogenization under controlled temperature and pH conditions. This process offers several advantages, including a smoother and more uniform texture of the emulsion, which results in a more pleasant mouthfeel for the consumer.25 In a specific form, the oils are added to the aqueous phase with emulsifiers, whereby the oil addition rate is carefully controlled. This controlled process makes it possible to form a stable emulsion with a uniform texture, because the oil is absorbed evenly into the aqueous phase. The combination of emulsifiers and the correct addition rate prevents phase separation and contributes to the desired product quality. Preferably, the oil addition rate is between 10 and 40 L / min. More preferably, the rate is between 15 and 35 L / min, more preferably between 18 and 32 liters per minute, 35 more preferably between 20 and 30 L / min, and most preferably between 22 and 28 L / min. 2024 / 5958 BE2024 / 5958 6 The controlled addition of oil contributes not only to a smoother and uniform texture, but also to improved stability of the emulsion. Controlling the oil addition rate minimizes unwanted air inclusions and prevents the formation of clumps or instability.This ensures that the emulsion remains consistent in structure, which is essential for applications in both food and cosmetics, where a stable and high-quality end product is required. In one implementation form, the method involves the integration of pH control with a PLC program. This offers improved stability of the emulsion through precise and real-time adjustments, which significantly improves the consistency of the end product.10 pH control is preferably integrated into the PLC program, making it possible to continuously monitor the pH value and adjust it immediately if necessary. This system offers a dynamic response to changes in the pH value, which is beneficial for maintaining the desired properties of the emulsion. 15 Preferably, the PLC program is configured to automatically add one or more acids when the pH value rises above the preset limit. This ensures that the pH value remains within a specific range, which is crucial for the stability and texture of the emulsion.20 The integration of a PLC program with pH control also makes it possible to collect and analyze data, which can lead to further optimization of the production process. This can result in a reduction of waste and improved efficiency, since batches that would otherwise fall outside the specifications can now be kept within acceptable parameters. 25 In a further implementation form, pH control can be combined with other parameters such as temperature and mixing speed to achieve even more precise control of the production process. This results in a final product with consistent quality and increased customer satisfaction. 30 In one implementation form, a homogenizer equipped with a control valve is used. During the addition of oils to the mixture, the opening degree of the control valve is preferably set between 50 and 70%. This setting ensures a controlled supply of the oils to the homogenizer, 35 which contributes to an efficient mixing and a stable emulsion with a uniform texture.2024 / 5958 BE2024 / 5958 7 Preferably, the degree of openness is set between 40 and 80%, more preferably between 45 and 75%, more preferably between 48 and 72%, more preferably between 50 and 70%, and most preferably between 52 and 68%, or even 55 and 65%. Setting the degree of openness not only contributes to better control over the mixing process, but also minimizes the risk of foaming and phase separation. This ensures the quality of the cold emulsion, which is essential for applications where a consistent and stable structure is required, such as in food, cosmetic formulations, or pharmaceutical products. 10 In one implementation form, the method involves the use of a homogenizer with a power between 40 and 50 kW and a rotational speed of 2,500 and 3,500 rpm, which contributes to a uniform distribution of the ingredients within the cold emulsion. This power and rotational speed ensure that the emulsion acquires an improved consistency, which has a significant influence on the final product quality.The homogenizer can preferably be configured to operate within the specific power range, whereby any value within this range can be selected depending on the specific requirements of the production environment. Preferably, the speed of the homogenizer can also be adjusted within a range of 2500 to 3500 rpm, with preference given to a speed between 2750 and 3250 rpm, and even more preference to a speed between 2900 and 3100 rpm. In one configuration, the homogenizer operates at a power of 35 to 55 kW, with preference given to a range of 38 to 52 kW, and even more preference to 40 to 50 kW. Such a configuration can increase the efficiency of the mixing process and ensure that the emulsion maintains a consistent texture and stability during production. 30 The use of such a homogenizer in the production process of cold emulsions, such as mayonnaise, offers significant advantages.It enables the producer to deliver a product that not only meets consumer expectations in terms of taste and texture, but also has a longer shelf life due to improved stability. By applying these preferred configurations,35 the method can be optimized for different scales and production types, thereby increasing the versatility and efficiency of the production process. 2024 / 5958 BE2024 / 5958 8 In one execution form, the method for producing a cold emulsion is further improved by the use of a liquid ring pump to maintain a vacuum during mixing. This vacuum contributes to reducing air bubbles in the emulsion, which in turn can significantly improve the texture and stability of the final product. By maintaining a vacuum, air inclusions5 can be minimized, giving the emulsion a smoother and more consistent profile. The use of a liquid ring pump is preferably aimed at creating a stable vacuum environment that supports emulsion formation.By reducing air inclusions, the emulsion can acquire an improved texture, which translates into a silky smooth mouthfeel and an even distribution of the oil droplets in the water phase. This process can also contribute to a longer shelf life of the product, since a reduced amount of air bubbles can help limit oxidation. In a further preferred configuration, the vacuum created by the liquid ring pump lies within a pressure range between 0.1 and 1.0 bar. More preferably, the pressure range can lie between 0.5 and 0.9 bar, even more preferably between 0.5 and 0.8 bar, and most preferably between 0.5 and 0.7 bar. Moreover, the use of a liquid ring pump in this context can provide a consistent process environment, thereby reducing variability between production batches. This aspect can optionally contribute to improved reproducibility of product quality, which is essential for industrial production processes.By applying this preferred design, the producer can deliver a product that consistently meets the expected sensory and physical properties, which can increase end-user satisfaction. In one design form, the method for producing a cold emulsion includes a vacuum gauge on the homogenizer. This vacuum gauge is preferably designed to enable accurate monitoring and adjustment of the vacuum conditions, which in turn contributes to a significant improvement in the quality of the emulsion. Through the use of a vacuum gauge, the pressure inside the homogenizer can be closely monitored, allowing deviations to be corrected quickly. 35 In addition, the vacuum gauge can preferably be integrated with an automated control system, such as a PLC (Programmable Logic Controller), which is designed to automatically adjust the vacuum conditions based on the vacuum gauge measurements.This system can optionally be programmed to activate alarms or even take corrective action if the pressure falls outside the desired parameters. The integration of the vacuum gauge with such a control system offers an extra layer of process control and further contributes to the consistency and quality of the produced emulsion. In one design form, the vacuum gauge can also be used in combination with other process parameters, such as temperature and pH, to offer a holistic approach to process control. For example, the temperature can preferably be kept between 15°C and 40°C, more preferably between 18°C ​​and 38°C, and even more preferably between 20°C and 35°C, with an alarm that is activated if the temperature falls outside these limits. The pH value can also be monitored and adjusted within a range of 3.5 to 4.5, more preferably between 3.7 and 4.5, and even more preferably between 3.8 and 4.5, to further ensure the stability of the emulsion.By managing these parameters in conjunction, the production of cold emulsions such as mayonnaise can be optimized, resulting in a product with superior texture and stability. In one implementation form, the method for producing a cold emulsion includes temperature sensors on all circulation lines. These sensors are preferably of the PT100 type and are strategically placed to ensure accurate temperature control throughout the entire production process. By monitoring the temperature at multiple points within the system, temperature control can be further optimized, resulting in more consistent product quality. Preferably, temperature control lies within a range of 10°C to 40°C, more preferably between 15°C and 38°C, even more preferably between 18°C ​​and 37°C, even more preferably between 20°C and 35°C, and most preferably between 22°C and 34°C. This temperature control ensures that the emulsion retains its stability and texture, which is essential for the quality of the final product.30 The temperature sensors can optionally be integrated into an automated control system, such as a PLC program, which continuously processes the temperature data and takes corrective measures if necessary. This system can, for example, automatically adjust the heating or cooling to keep the temperature within the desired range. The use of such an automated system makes it possible to react more quickly to any deviations, thereby minimizing the risk of quality loss. 2024 / 5958 BE2024 / 5958 10 In addition, these temperature sensors can contribute to the energy efficiency of the production process. By heating or cooling only when necessary, energy consumption can be reduced, which leads to lower operating costs and a reduced ecological footprint. The improved temperature control also contributes to the safety of the production process, as the risk of overheating or undercooling of the equipment is reduced.In a further implementation form, the temperature sensors can be equipped with an alarm function that emits an audible signal if the temperature falls outside the set range. This offers an extra layer of security and ensures that operators are immediately notified of any problems, so that they can be remedied quickly. In one implementation form, if the pH is higher than 4.50, one or more acids are added. In one implementation form, the method involves the controlled addition of acids to the emulsion to keep the pH consistently within the desired specification. This aspect of the invention can optionally be integrated into an automated system that uses a PLC program to continuously monitor and adjust the pH levels. The addition of acids can preferably take place by means of a dosing system capable of adding small and precise amounts of acid, depending on the measured pH value. The use of a PLC program offers an advanced method to regulate the pH-25 value of the emulsion.In a further form of implementation, the PLC program can be configured in such a way.