Systems and methods for preparing edible fat systems

Abstract

A method to prepare an edible fat system includes heating a fat composition to a molten state; solidifying at least a portion of the fat composition in a scrape surface crystallizer to form an at least partially solidified fat composition; mixing the at least partially solidified fat composition in a pin worker mixer to form a final product; filling the final product into a container; and determining a solid fat content of the fat composition, the molten fat composition, the at least partially solidified fat composition, the final product, or a combination of two or more thereof, using an in-line sonic velocity sensor. The in-line sonic velocity sensor may be placed in a processing unit, a conduit, or the filling stage of the system used to process the fat composition.

Description

SYSTEMS AND METHODS FOR PREPARING EDIBLE FAT SYSTEMSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 583,945, filed 20 September 2023, the disclosure of which is incorporated by reference herein in its entirety.FIELD

[0002] The present disclosure relates to methods and systems for preparing edible fat systems. The present disclosure further relates to methods and systems for monitoring preparation of edible fat systems.BACKGROUND

[0003] Shortenings and margarins are tailored fat systems whose nutritional and functional properties have been manipulated in order to deliver specific consumer needs. Shortenings offer special functional utility to baking applications. Margarins may be formulated for use as table margarin or for use in baking and cooking. Shortenings and margarins may be prepared using processes known in the art, such as votation. Votation refers to a controlled process wherein a molten fat or blend of fats is crystallized and homogenized to form a shortening or other edible fat system. The term “votation” comes from VOTATOR™, which is the name of early equipment used for manufacturing shortenings and margarins used in baking and other food applications. Generally, votation processes for making a shortening include melting an edible fat to form a molten fat and agitating the molten fat at a constant temperature above its melt point; pumping the molten fat through one or more scrape surface crystallizers to crystalize the molten fat; and passing the molten fat through one or more worker units having a set of fixed and a set of rotating fingers across a shaft, which results in break-up of the crystals in the product temperature to indicate crystallization of the fat product (i.e., the shortening).

[0004] The degree of crystallization of a fat system during votation is typically measured by the temperature of the fat, with lower fat temperatures generally indicating a higher percentage of crystallization and greater solidity. However, the correlation between fat temperature and crystallization can vary between batches, resulting in inconsistent levels of crystallization and ultimately inconsistent product. Improvements to controlling the degree of crystallization are desired.SUMMARY

[0005] In one aspect, the present technology provides a method to prepare an edible fat system. The method includes heating a fat composition to a molten state; solidifying at least a portion of the fat composition in a scrape surface crystallizer to form an at least partially solidified fat composition; mixing the at least partially solidified fat composition in a pin worker mixer to form a final product; filling the final product into a container; and determining a solid fat content of the fat composition, the molten fat composition, the at least partially solidified fat composition, the final product, or a combination of two or more thereof, using an in-line sonic velocity sensor. The method may further include mixing an inert gas with the fat composition.

[0006] In one aspect, the present technology provides a system for processing a fat composition. The system includes a tank fitted with a heater; a scrape surface crystallizer in fluid communication with and configured to received flow from the tank via a first conduit; a pin worker mixer in fluid communication with and configured to received flow from the scrape surface crystallizer via a second conduit; a filling stage in fluid communication with and configured to received flow from the mixer via a third conduit and constructed to fill product into a container; and one or more in-line sonic velocity sensors disposed within the first conduit, the second conduit, the third conduit, or a combination of two or more thereof, and configured to determine solid fat content in the flow therein.BRIEF DESCRIPTION OF FIGURES

[0007] FIG. l is a schematic flow diagram of a method consistent with the present technology.

[0008] FIG. 2 is a schematic representation of a system consistent with the present technology.

[0009] FIG. 3 is a graphical representation of results from Example 1, showing correlation between solid fat content and sonic velocity.

[0010] FIG. 4 is a graphical representation of results from Example 1, showing NMR measurement of solid fat content of a sample at five different temperatures.

[0011] FIG. 5 is a graphical representation of results from Example 2, showing correlation between sonic velocity and solid fat content of a sample.

[0012] FIG. 6 is a graphical representation of results from Example 3 showing correlation between solid fat content and sonic velocity.

[0013] FIG. 7 is a graphical representation of results from Example 4, showing correlation between solid fat content and sonic velocity for fat systems with and without nitrogen gas.

[0014] FIG. 8 is a graphical representation showing sonic velocity of P and P’ as a function of solid fat content by NMR.DEFINITIONS

[0015] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein and are not meant to limit the scope of the present disclosure.

[0016] The term “fat” is used here to refer to triglycerides. A “triglyceride” refers to a molecule having a glycerol moiety that is linked to three fatty acid residues via ester bonds. The terms “triacylglycerol,” “triacylglyceride,” “triglyceride,” and “TAG” are used interchangeably herein.

[0017] The term “fatty acid” is used here to refer to a molecule comprising a hydrocarbon chain and a terminal carboxylic acid group. As used herein, the carboxylic acid group of the fatty acid may be modified or esterified, for example as occurs when the fatty acid is incorporated into a glyceride or another molecule (e.g., COOR, where R refers to, for example, a carbon atom). Alternatively, the carboxylic acid group may be in the free fatty acid or salt form (i.e., COO" or COOH). The “tail” or hydrocarbon chain of a fatty acid may also be referred to as a fatty acid chain, fatty acid sidechain, or fatty chain. The hydrocarbon chain of a fatty acid will typically be a saturated or unsaturated aliphatic group. A fatty acid having N number of carbons, will typically have a fatty acid side chain having N-l carbons. However, the subject application also relates to modified forms of fatty acids, e.g., epoxidized fatty acids, and thus the term fatty acid may be used in a context in which the fatty acid has been substituted or otherwise modified as described. Non-limiting examples of fatty acids include C8, CIO, Cl 2, Cl 4, C16 (e.g., Cl 6:0, C16: 1), C18 (e.g., C18:0, C18: 11, C18:2, C18:3, C18:4), C20, and C22 fatty acids. For example, the fatty acids can include caprylic (C8:0), capric (C10:0), lauric (C12:0), myristic (C14:0), palmitic (C16:0), stearic (C18:0), oleic (C 18: 1), linoleic (C18:2) and linolenic (Cl 8:3) acids.

[0018] A “saturated” fatty acid is a fatty acid that does not contain any carbon-carbon double bonds in the hydrocarbon chain. An "unsaturated" fatty acid contains one or more carbon-carbon double bonds. A “polyunsaturated” fatty acid contains more than one such carbon-carbon double bond while a “monounsaturated” fatty acid contains only one carbon-carbon double bond. Carbon-carbon double bonds may be in one of two stereo configurations denoted cis and trans. Naturally occurring unsaturated fatty acids are generally in the “cis” form. Epoxidized renewable oil or fat may include one or more epoxide rings formed from cis or trans carbon-carbon double bonds.

[0019] The terms “edible fat,” “edible solid fat,” and “edible liquid fat” are used here to refer to fats and oils that are suitable for human consumption. The term “edible fat” may be used broadly to refer to both edible solid and liquid fats, including edible oils. Edible fats are typically compositions including triacylglycerols. Edible fats may be obtained from plant, animal, or microbial sources.

[0020] The term “substantially” as used here has the same meaning as “significantly,” and can be understood to modify the term that follows by at least about 90 %, at least about 95 %, or at least about 98 %.

[0021] The term “not substantially” as used here has the same meaning as “not significantly,” and can be understood to have the inverse meaning of “substantially,” i.e., modifying the term that follows by not more than 25 %, not more than 10 %, not more than 5 %, or not more than 2 %.

[0022] The term “about” is used here in conjunction with numeric values to include normal variations in measurements as expected by persons skilled in the art and is understood to have the same meaning as “approximately” and to cover a typical margin of error, such as ±5 % of the stated value. Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “about 0.1 % to about 5 %” or “about 0.1 % to 5%” should be interpreted to include not just about 0.1 % to about 5 %, but also the individual values (e.g., 1 %, 2 %, 3 %, and 4 %) and the sub-ranges (e.g., 0.1 % to 0.5 %, 1.1 % to 2.2 %, 3.3 % to 4.4 %) within the indicated range. As will be understood by one skilled in the art, all language such as “up to,” “at least,” “greater than,” “less than,” and the like, include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in art, a range includes each individual member.

[0023] Terms such as “a,” “an,” and “the” are not intended to refer to only a singular entity but include the general class of which a specific example may be used for illustration.

[0024] The terms “a,” “an,” and “the” are used interchangeably with the term “at least one.” The phrases “at least one of’ and “comprises at least one of’ followed by a list refers to any one of the items in the list and any combination of two or more items in the list.

[0025] As used here, the term “or” is generally employed in its usual sense including “and / or” unless the content clearly dictates otherwise. The term “and / or” means one or all of the listed elements or a combination of any two or more of the listed elements.

[0026] The recitations of numerical ranges by endpoints include all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc. or 10 or less includes 10, 9.4, 7.6, 5, 4.3, 2.9, 1.62, 0.3, etc.). Where a range of values is “up to” or “at least” a particular value, that value is included within the range.

[0027] As used here, “have,” “having,” “include,” “including,” “comprise,” “comprising,” or the like are used in their open-ended sense, and generally mean “including, but not limited to.” It will be understood that “consisting essentially of,” “consisting of,” and the like are subsumed in “comprising” and the like. As used herein, “consisting essentially of,” as it relates to a composition, product, method, or the like, means that the components of the composition, product, method, or the like are limited to the enumerated components and any other components that do not materially affect the basic and novel characteristic(s) of the composition, product, method, or the like.

[0028] As used herein, the terms “for example,” “for instance,” “such as,” or “including” are meant to introduce examples that further clarify more general subject matter. Unless otherwise specified, these examples are provided only as an aid for understanding the applications illustrated in the present disclosure and are not meant to be limiting in any fashion.

[0029] The words “preferred” and “preferably” refer to embodiments that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful and is not intended to exclude other embodiments from the scope of the disclosure, including the claims.

[0030] Any direction referred to here, such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other directions and orientations are described herein for clarity in reference to the figures and are not to be limiting of an actual device or system or use of the device or system. Devices or systems as described herein may be used in a number of directions and orientations.

[0031] In the methods described herein, the acts can be carried out in a specific order as recited herein. Alternatively, in any aspect(s) disclosed herein, specific acts may be carried out any order without departing from the principles of the disclosure, except when a temporal oroperational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately or the plain meaning of the claims would require it. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.DETAILED DESCRIPTION

[0032] The present disclosure relates to systems and methods of preparing edible fat systems. In particular, the present disclosure relates to systems and methods that utilize sound velocity measurements to determine and control the degree of fat crystallization.

[0033] Crystallization is a common step in the production of edible solid fats, such as shortening, margarine, and the like. During crystallization, a fat composition is cooled to allow at least part of the fat composition to crystallize and solidify. Typically, fat compositions are mixed or kneaded while being cooled. As part of product quality control and maintaining consistency of the product, it may be desirable to maintain a consistent crystal solid content (e.g., solid fat content) of the product, both within a batch and between batches. When fats are processed, small fluctuations in the process conditions, such as minor changes in the starting temperature of the fat composition or the temperature of a coolant (e.g., cooling medium such as water) can cause meaningful changes to the crystalline structure or the solid fat content or both of the final product. Thus, it is desirable to provide a system and method for processing fats that allows measurement and control of the crystallization of fat in a continuous process. The systems and methods of the present technology allow for improved product quality control and consistency in product quality.

[0034] The systems and methods of the present technology may be used to determine and control the solid fat content as the fat enters the votation process. Generally, it is preferred that the liquid fat entering votation contains no fat crystals. To ensure this, producers often over-heat the fats to make sure all crystals are melted before crystallization during votation. Better control of the temperature of the oil in-line, entering votation may be used to save energy.

[0035] Further, the systems and methods of the present technology may be used to determine and control the solid fat content during votation, such as after the first and / or second scrape surface crystallizers. Conventionally, the intermediate stages are controlled by measuring the temperature of the product and / or monitoring the temperature of the cooling medium. However, there is currently no reliable way to determine the degree of crystallization during the continuous process. The ability to control the degree of crystallization may be used to help withthe rheology, consistency, and texture of the final product. The ability to determine solid fat content may also allow detecting the precise moment of crystal nucleation during the process, allowing even better control of the process. By extension, the ability to control the degree of crystallization may allow for controlling the crystalline structure (e.g., presence of a, P’, or P crystals) of the fat system.

[0036] In addition, the systems and methods of the present technology may be used to determine and control the solid fat content of an edible fat product at filling. Controlling the solid fat content in the edible fat product, rather than only the temperature of the edible fat product, may help provide consistent products from run to run and across manufacturing plants.

[0037] It has been discovered that the systems and methods as described herein surprisingly improved the consistency of solid fat percent in the processed fat. Surprisingly, the inventors discovered that sonic measurement sensors can be used to reliably measure and control the percent solids in a fat composition including water and gas before, during, or after votation.Thus, sonic velocity measurement may be used to improve properties of an edible fat system and to improve batch consistency between edible fat systems produced on an industrial scale.Edible Fats

[0038] The fat composition and edible fat system of the present technology may be solid or semi-solid fat compositions. The fat composition and edible fat system of the present technology may include at least one fat and at least one other component. The fat composition and edible fat system may include solidified fats and crystallized or partially crystallized fats. The edible fat system may be pourable, pumpable, or spreadable, or may be completely solid (that is, not pourable, pumpable, or spreadable). The edible fat system may be an emulsion of an aqueous liquid in a fat, such as a water-in-oil emulsion. Examples of edible fat systems include margarine, butter, and shortening. The edible fat system may be formulated for a specific use, such as use as a table spread, a baking shortening, or puff pastry shortening. Such formulations may have specific desired properties, such as water content and softness or hardness.

[0039] A “pumpable fat system” is a fat system that may be handled in bulk quantities and can be pumped and metered. It should be noted that while a pumpable fat system may be pumpable at filling, it may increase in solidity after filling and storage.

[0040] The edible fat system may be margarine. Margarine typically is a water-in-fat emulsion that includes a milk phase and a fat phase. The fat phase may include refined anddeodorized fats. The edible fat system may be shortening. Shortening may include a mixture of fats but does not include a water phase.

[0041] The edible fat system may a mixture of fats. A mixture of different fats may be selected based on various features, such as desired solid fat content, taste, and crystallization behavior of the fats. The fat crystals in these products may appear in the form of needles or platelets, which can grow together to form a network of crystals. The behavior of the crystals affects the hardness and spreadability of the edible fat product. Spreadability of a fat composition may be characterized by visual behavior, percent crystallization, percent solids, or viscosity. Numerous factors influence the spreadability of an edible fat system, such as water content, fat composition, solid content, and crystalline structure. The term “crystalline structure” is used here to refer to the mixture of the types of crystals, the sizes of crystals (e.g., crystal diameter). Triglycerides typically form three basic crystal types including alpha (a), beta prime (P'), and beta (P) crystals. P crystals are considered the most stable and compact crystal, with the lowest thermodynamic energy state. P' crystals are often the most desirable form for edible fat systems. The type of crystal formed by a fat is influenced by its chemical structure, particularly hydrogenation and distribution of double bonds within a fatty acid chain. Exemplary edible fats / oils having beta (P) crystals include, but are not limited to, soybean oil, canola oil, coconut oil, com oil, Palm kernel oil, lard, Palm stearin or mixtures of two or more thereof. Exemplary edible fats / oils having beta prime (P’) crystals include, but are not limited to, palm oil, milk fat, rapeseed oil, tallow, cottonseed oil, or mixtures of two or more thereof.

[0042] The spreadability of margarines in particular is primarily controlled by two factors: the amount of solid triglycerides and the processing conditions during production, which affects the crystalline structure of the fat composition. The amount of solid triglycerides (the percent fat solids) at a given temperature depends on the choice of the fat blend. A strong correlation between the solid content of the blend and the spreadability is expected when the processing conditions are constant.

[0043] Generally, the edible fat system of the present disclosure includes one or more edible solid fats that are in a solid or semisolid state at room temperature (e.g., approximately about 20°C to about 25°C) and ambient pressure (e.g., approximately 1 atm). The fat system may include one or more edible liquid fats that are in a liquid or semi-liquid state at room temperature and ambient pressure. The fat system may have a solid fat content of about 1.0 wt- % or greater, 5 wt-% or greater, 10 wt-% or greater, 20 wt-% or greater, 30 wt-% or greater, 40 wt-% or greater, or 50 wt-% or greater. Edible solid or liquid fats may include natural fats (e.g., unmodified fats), modified fats, or mixtures thereof. For example, the fat system may include amodified fat such as a hydrogenated fat, a chemically or enzymatically interesterified fat, a fractionated fat, or a mixture thereof.

[0044] Suitable edible solid and / or liquid fats may include any fat system can produce solidification or crystalized product upon cooling the fat. Suitable examples of edible solid and / or liquid fats include, but are not limited to, butter, lard, tallow, butter oil, cocoa butter, mango butter, shea butter, milk fat, coconut oil, palm oil, palm olein, palm kernel oil, shea oil, illipe oil, sal oil, kokum gurgi oil, mango kernel oil, hydrogenated vegetable oil (such as hydrogenated fractionated palm kernel oil, hydrogenated cottonseed oil, hydrogenated soybean oil, hydrogenated sunflower oil, hydrogenated canola oil, hydrogenated rapeseed oil, and the like or mixtures thereof), hydrogenated fish oil, and mixtures of two or more thereof. The term “vegetable oils” is used here to refer to oils derived from vegetables and / or oil seeds. In some cases, the edible fat system includes solid and / or liquid fats such as stearin (such as palm stearin, cottonseed stearin, cocoa butter stearin, shea stearin, palm kernel stearin, sunflower stearin), hydrogenated vegetable oil, palm oil, interesterified palm oil, or a mixture of two or more thereof. In some preferred cases, the edible fat system includes solid and / or liquid fats selected from palm stearin, palm oil, interesterified palm oil, hydrogenated soybean oil, or mixtures of two or more thereof.

[0045] The edible fat system may include components other than fats. The other components may include water. In some cases, the edible fat system may include one or more additives. Such additives may include emulsifiers, antioxidants, or mixtures thereof. Suitable emulsifiers may include monoglycerides and / or diglycerides (such as distilled mono and diglycerides from palm oil, soybean oil, or other edible fats or oils, acetylated mono- / diglycerides, lactylated mono- / di- glycerides, or mixtures thereof), polysorbate, sorbitol, glycerine, soy lecithin, egg yolk lecithin, polyglycerol ester, sorbitan ester, propylene glycol ester, sugar ester, or mixtures of two or more thereof. Emulsifiers may be included in the edible fat system in an amount of 0 wt-% to about 2.0 wt-% based on total weight of the fat system. For example, the edible fat system may include about 0.1 wt-% or more, about 0.2 wt-% or more, about 0.5 wt-% or more, or about 1.0 wt-% or more of emulsifiers by weight of the fat system. Preferably, the emulsifier is present in an amount of about 0.1 wt-% to about 1.5 wt-%, about 0.1 wt-% to about 1.0 wt-%, or about 0.2 wt-% to about 0.6 wt-% by weight of the fat system. Any antioxidant suitable for use in edible fats and oils may be used in the edible fat system. For example, suitable antioxidants may include rosemary extract, tocopherols, and the like, or mixtures thereof.

[0046] One relevant factor in the production of edible fat systems is the rate of crystallization of the fat blend. A low rate of crystallization may result in an edible fat systemthat is too soft and may be difficult to pack. The fat will continue to crystallize in the packaging. In the absence of agitation, post-crystallization favors the formation of a strong network of crystals and consequently, severe post-hardening may occur. On the other hand, a high crystallization rate may give rise to too soft and overworked products that lack sufficient body.

[0047] Different fats crystallize at different rates. Many fats crystallize fast, within seconds, whereas some fats crystallize slowly and may take hours to reach complete crystallization. For example, palm kernel fat crystalizes relatively quickly, while palm oil crystalizes relatively slowly. Thus, the specific mixture of fats in the fat composition affects the rate of crystallization of the product. Further, different types of fat crystals may form depending on the crystallization conditions.

[0048] Typically, during crystallization, fats sequentially form a crystals, then P' crystals, then P crystals. Thus, if the desired crystallization form for an edible fat is P' crystals, the amount of crystallization time selected to preferentially form P' may be between the amount of time for forming a crystals and the amount of time for forming P crystals. The methods and systems of the present technology may be used to monitor crystallization progression to increase formation of the desired P' crystals without complete conversion to P crystals.

[0049] Seeding of a particular crystal type may promote formation of additional crystals of that type. This process is often referred to as “nucleation.” A nucleus of a single crystal type encourages formation of additional crystals of the same type. The method of preparing the edible fat system may include seeding with a desired crystal type.

[0050] The edible fat system as described herein may include a desired amount of solid crystals, such as from about 5 wt-% solid crystals to about 35 wt-% of solid crystals, or from about 8 wt-% to about 25 wt-% of solid crystals. The edible fat system at the time of filling may include 5 wt-% or more, about 10 wt-% or more, about 15 wt-% or more, about 18 wt-% or more, about 20 wt-% or more, about 22 wt-% or more, about 23 wt-% or more, about 24 wt-% or more, about 25 wt-% or more, or about 26 wt-% or more of solid crystals. The edible fat system at the time of filling may include about 50 wt-% or less, about 35 wt-% or less, about 30 wt-% or less, about 27 wt-% or less, about 22 wt-% or less, about 21 wt-% or less, about 20 wt- % or less, about 19 wt-% or less, about 18 wt-% or less, about 17 wt-% or less, about 16 wt-% or less, or about 15 wt-% or less of solid crystals. Typically, it is desirable to maximize the percentage of solid crystals while minimizing formation of waxy crystal morphology and viscosity. In some cases, the edible fat system includes about 20 wt-% to about 30 wt-% solid crystals, such as about 25 wt-% to about 27 wt-% of solid crystals.

[0051] The edible fat system may have a viscosity of about 600 cPa s to about 1700 cPa s, such as about 750 cPa s to 1500 cPa s. Additionally or alternatively, the edible fat system may have a viscosity of about 200 cPa s to about 4000 cPa s, such as about 750 cPa s to about 1700 cPa s or about 1700 cPa s to about 3000 cPa s. For example, the viscosity of the edible fat system may be about 4000 cPa s or less, about 3500 cPa s or less, about 3000 cPa s or less, about 2500 cPa s or less, about 2000 cPa s or less, about 1700 cPa s or less, about 1500 cPa s or less, about 1400 cPa s or less, about 1300 cPa s or less, about 1200 cPa s or less, about 1100 cPa s or less, about 1000 cPa s or less, 900 cPa s or less, about 800 cPa s or less, or 700 cPa s or less. The viscosity of the edible fat system may be about 200 cPa s or more, about 300 cPa s or more, about 400 cPa s or more, about 500 cPa s or more, about 600 cPa s or more, about 700 cPa s or more, about 800 cPa s or more, or about 900 cPa s or more. Viscosity may be measured using any method known to the art, such as using a rotary or rotational viscometer. Viscosity may be measured in-line, or a sample of an edible fat system may be removed for measurement of viscosity. Two example suitable viscometers are the BROOKFIELD™ FAST in-line viscometer and the BROOKFIELD™ VTE Electric VISCOSEL in-line viscometer. To measure the viscosity of an edible fat system, a probe may be positioned in an edible fat system. A probe may measure the temperature of the edible fat system. The probe is typically set to rotate at a predetermined rate. Viscosity is typically determined by measuring the resistance of rotation of the probe. Viscosity may be calculated from a measured resistance.

[0052] The edible fat system as described herein may include fat crystals having a geometric average particle size of about 1 pm to about 100 pm. For example, the geometric average particle size of the fat crystals may be about 1 pm to about 50 pm or about 20 pm to about 80 pm. Crystal size may be measured by X-ray diffraction (XRD). The average particle size of the fat crystals may be about 3 pm or greater, about 4 pm or greater, about 5 pm or greater, about 8 pm or greater, about 10 pm or greater, about 15 pm or greater, about 20 pm or greater, about 25 pm or greater, about 30 pm or greater, about 35 pm or greater, about 40 pm or greater, about 50 pm or greater, about 60 pm or greater, about 75 pm or greater, about 90 pm or greater, or about100 pm or greater.Methods of Preparing Edible Fat Systems

[0053] The present technology includes the use of sonic measurement to quantify solid fat content in compositions including fats prior to and / or during a solidification or crystallizationprocess, such as votation. There are multiple steps in the votation process that may benefit from sonic measurement, as will be described below.

[0054] During processing, fats may be crystallized under stirred conditions. Stirring may be achieved by any suitable means, including by mixing or scraping in a dilatometer with scraper blades. Mixing and scraping may be used to distribute crystal nuclei, encouraging formation of additional crystals, and provide even cooling of fats.

[0055] A continuous process used for manufacturing edible fat systems, such as margarine, shortening, or liquid butter, is known as votation, where liquid fat is subjected to chilling with agitation in a processing apparatus known as a VOTATOR™. Conventionally, a VOTATOR™ includes an A-unit, where the liquid fat is fed through one or more thin-walled tubes surrounded by a cooling medium. The tubes are provided with internal rotating blades which remove the film of chilled fat as it forms along the inside walls of the tube. The fat then passes on to a B- unit of the VOTATOR™, where crystallization of the fat is completed.

[0056] As votation progresses, the percentage of solids in the fat typically increases. Often, the percentage of solids is measured by measuring the temperature of the fat. Fat at a lower temperature will typically have a greater percentage of solids than fat at a higher temperature. Alternatively, when fat is cooled using a cooling medium, the temperature of the medium can be measured, with increased medium temperatures indicating decreased fat temperatures and therefore greater percentage of solids. While such non-invasive measurements may be advantageous, they are typically not very precise. Nuclear magnetic resonance (NMR) can also be used to precisely measure percent solids of a mixture. However, NMR is time and resourceintensive and is typically not suitable for continuous measurement of large-scale votation.

[0057] Sonic quantification of solid percentage presents a high-throughput, precise, inline method of directly quantifying solid percentage of fats during votation. The method and system of the present technology provide more accurate methods of monitoring percentage solids.

[0058] Sonic sensors have been used to quantify solid content of liquid media in dry fractionation of palm oil. Dry fractionation of palm oil is a process of separating oleic acid, which is a liquid at temperatures of at least about 13 °C, from palm stearin, which has a higher melting temperature. At a controlled temperature, solid stearin can be separated from liquid oleic acid. The presence of solid stearin crystals can be measured using a sonic sensor that uses velocity readings of soundwaves inside liquid media to measure concentrations and solid contents of suspensions. The sensor firmware calculates the sonic velocity by using the known distance between the transmitter and receiver. However, while sonic measurement has been used to measure solids in the context of separating solids from liquids, it has not previously been usedto measure the percentage of solids in a mixture. In particular, sonic measurement has not been used to measure the percentage of solids in a mixture including an inert gas. In addition, sonic measurement has not been used to measure solids in a water-in-fat emulsion, such as margarine. The presence of molecules other than solid or liquid fats may interfere with the accuracy of the sonic velocity sensor. In particular, gas bubbles are known to interfere with operation of some sonic sensors. Additionally, adaptation of a sonic velocity sensor for measurement of an emulsion may require significant recalibration and revised calculation of percent solids in an emulsion.

[0059] The methods and systems of the present disclosure surprisingly demonstrate that sonic measurement accurately quantifies the percent solids in an emulsified fat composition including liquids and optionally gases.

[0060] The process of votation is a controlled crystallization process or tempering process in which the fat composition (e.g., transesterified fat product) is agitated under controlled conditions to form a product with a desired consistency and crystalline structure for later use. Votation includes various heating, chilling, flash chilling, and other pressure adjustments to provide the desired consistency and / or structure. Thus, measurement of physical characteristics of a fat composition during votation can be useful to determine whether votation is progressing at an appropriate rate.

[0061] The method of the present technology may be a continuous process. The term “continuous process” is used here to distinguish from a batch process. In a batch process, a predetermined volume of material (a “batch”) is processed at once, and after the processing is done, the batch is removed from the equipment and a new batch may be processed. In contrast, a nonlimited, continuous flow of material may be processed in a continuous process, which may progress without intervention, and may occur across multiple unit operations optionally connected via conduits, such as pipes.

[0062] A schematic of a representative method 100 is depicted in FIG. 1. The method 100 includes heating a fat composition 110, solidifying at least a portion of the fat composition 130 in a first unit, mixing the at least partially solidified fat composition 140 with a second unit to form an edible fat system, and filling the edible fat system into a container 150. Although the mixing steps 120, 140 are shown as separate steps, they may be combined with some of the other unit operations, including heating 110 and solidifying 130. Additional mixing steps may also be included. The method 100 includes at least one step of measuring 115, 125, 135, 145 using a sonic velocity sensor. The measuring 115, 125, 135, 145 using a sonic velocity sensor may be performed during or after one or more of the heating 110, mixing 120, 140, solidifying130, or filling 150 steps. Multiple of unit operations of the method may benefit from the measurement using the sonic velocity sensor. The method 100 may include one, two, three, or four or more steps of measuring. During the method 100, the sonic velocity sensor may be used to measure the sonic velocity in the fat, which may then be correlated using a calibration curve to a solid fat content of the fat composition (e.g., an initial fat composition or mid-process fat composition) or an edible fat system (e.g., the final product immediately prior to filling). The calibration curve may be prepared using sonic velocity measurements of fat compositions with different solids contents and also determining the solids content by other means, such as using NMR.

[0063] The method 100 may further include calculating the sonic velocity of the fat and using a calibration to determine a weight percentage of solid fat content. Velocity generally can be determined by dividing a distance traveled by a sound wave by the amount of time taken to travel the distance. Without wishing to be bound by theory, it is generally understood that a higher concentration of solid fat content in a composition will increase the travel time, thus decreasing the velocity. For many sonic velocity sensors, the distance traveled is a preset and known parameter. The method 100 may further include adjusting one or more process parameters, such as temperature, pressure, mixing speed, pump velocity, or the like, based on the result of the one or more measuring steps 115, 125, 135, 145. The instrument may be calibrated using the calibration curve to output the fat solids content of the fat composition.

[0064] During the process shown in FIG. 1, the temperature and the weight percentage (wt- %) of solid fat content changes. For example, prior to the heating step, the fat composition may have a low temperature and include a high solid fat content. After heating, a molten fat composition may have a high temperature and include a low solid fat content. As the fat composition is processed, the temperature of the composition is lowered and the solid fat content increases. During the method, the fat composition may include 0 wt-% or more, 0.1 wt-% or more, 0.5 wt-% or more, 1 wt-% or more, 2 wt-% or more, 3 wt-% or more, 4 wt-% or more, 5 wt-% or more, 6 wt-% or more, 7 wt-% or more, 8 wt-% or more, 9 wt-% or more, 10 wt-% or more, 11 wt-% or more, 12 wt-% or more, 13 wt-% or more, or 14 wt-% or more of solid fat (e.g., fat crystals). During the method, the fat composition may include 50 wt-% or less, 35 wt- % or less, 30 wt-% or less, 28 wt-% or less, 26 wt-% or less, 25 wt-% or less, 24 wt-% or less, 23 wt-% or less, 22 wt-% or less, 21 wt-% or less, 20 wt-% or less, 19 wt-% or less, 18 wt-% or less, 17 wt-% or less, 16 wt-% or less, or 15 wt-% or less of solid fat (e.g., fat crystals).Heating a fat composition

[0065] Prior to mixing and solidifying, the fat composition may be heated and mixed to create a uniform mixture. Typically, melting fat dissolves many or all of the fat crystals present in the fat composition. Fat heated to a state where many or all fat crystals have melted is referred to as a “molten” fat.

[0066] The fat composition may be heated to a first temperature of about 20 °C to about 50 °C, such as about 30 °C to about 45 °C, or about 35 °C to about 42 °C. In some cases, the fat composition is heated to a first temperature that is about 15 °C less, about 10 °C less, about 8 °C less, about 6 °C less, about 5 °C less, about 4 °C less, about 2 °C less, or about 1 °C less than its melting point.

[0067] Heating may be done using direct heat, such as a flame burner, or indirect heating, such as radiation. The fat composition may be heated, for example, using a gas burner, an electric burner, an induction burner, a hot water bath, a microwave, or the like. Typically, the fat composition is circulated to ensure even heating. The fat composition may be heated to a predetermined temperature. The specific temperature may depend on the combination of fats in the fat composition. The temperature may be selected such that a desired portion (for example, a majority, substantially all, or all) of the fat is in a molten state.Mixing with a gas

[0068] The method may optionally include mixing the fat composition with an inert gas 120 after or during heating the fat composition 110. Mixing the fat composition with an inert gas may change the texture of the fat composition. For example, mixing the fat composition with an inert gas may decrease the solidity of the fat composition, either immediately after mixing with the inert gas, or at another point during the method, such as during filling. Mixing the fat composition with an inert gas may increase the flowability of a fat composition. For example, mixing the fat composition with an inert gas prior to votation may ultimately result in a more flowable product at filling. Additionally, or alternatively, mixing the fat composition with an inert gas prior to votation may result in an increased volume and a less dense product. Suitable gases for mixing with a fat composition include inert gases that are suitable for human consumption, such as nitrogen gas and noble gases such as argon. The gas may be mixed into the fat composition at a rate of 5 % to 12 % of gas in the fat composition by volume.Solidifying

[0069] The fat composition may be pre-chilled using a pre-chilling unit (e.g., a first prechilling unit). The rate of chilling can affect the rate of crystallization and the type of crystalsformed, and is thus typically closely monitored. The fat composition may be cooled prior to processing with an “A-uni ’ such as a crystallizer. The fat composition may be cooled with a heat exchanger. However, in some cases the fat composition is not cooled prior to processing with an A-unit, but is rather cooled during processing with the A-unit.

[0070] Following heating, a solid fat may be added to the fat composition to seed the fat composition with a desired crystal type. For example, an amount of a fat having a P' crystal structure may be added to a heated fat composition and mixed so that the P' crystal structure is distributed throughout the fat composition. This may provide nucleation points to encourage crystallization of the desired crystal structure. A solid fat may be added to a fat composition immediately following heating, or after the fat composition has been chilled to a predetermined temperature. The volume of added solid fat may be about 1 % or greater, about 2 % or greater, about 5 % or greater, or about 10 % or greater of the volume of the heated fat composition. The volume of added solid fat may be about 40 % or less, about 30 % or less, about 20 % or less, or about 10 % or less of the volume of the heated fat composition.

[0071] Solidifying, such as crystallizing, is typically accomplished using either a scraped surface heat exchanger or a chilling drum. While scraped surface heat exchangers are more commonly used, chilling drums may be used to produce edible fats with generally higher melting temperatures, such as puff pastry margarine. The system and method of the present technology may include one or more scraped surface heat exchangers, one or more chilling drums, or a combination of two or more thereof. Various arrangements of A-units and crystallizers can be applied for the production of margarines with different temperature profiles and degrees of working for packs or tubs.

[0072] In one or more embodiments, a fat composition is solidified using an “A-unit” machine. Typically, an “A-unit” machine is a “perfector” or a crystallizer, such as a scrapesurface crystallizer. A perfector typically includes one or more chilling tube with a cooling system and one or more intermediate crystallizers.

[0073] The fat composition may be worked into an emulsion in the first A-unit with moderate cooling. A scraped-surface cooler, such as a Girdler A-unit, may be used as an A-unit. This scraped-surface includes a tube and a rotor rotating inside the tube. The product flows within the tube. The tube is cooled by a cooling fluid flowing in an annular jacket surrounding the tube. The rotor may typically carry from 2 to 6 rows of scraper blades. A high rotation speed presses the blades against the cooled inner surface by centrifugal force.

[0074] During the solidifying step, the fat composition may be cooled at a cooling rate of about 0.1 °C / s or greater, about 0.2 °C / s or greater, about 0.3 °C / s or greater, about 0.4 °C / s orgreater, about 0.5 °C / s or greater, about 1 °C / s or greater, about 2 °C / s or greater, about 3, °C / s or greater, about 4 °C / s or greater, about 5 °C / s or greater, about 8 °C / s or greater, about 10 °C / s or greater, about 12 °C / s or greater, or about 15 °C / s or greater. In one or more embodiments, the fat composition is cooled at a cooling rate of about 25 °C / s or lower, about 20 °C / s or lower, about 18 °C / s or lower, about 15 °C / s or lower, about 10 °C / s or lower, about 8 °C / s, or about 5 °C or lower.

[0075] In some cases, the fat composition is cooled during the solidifying step to a second temperature of about 5 °C to about 30 °C, such as about 10 °C to about 25 °C, about 10 °C to about 22 °C, or about 15 °C to about 22 °C.

[0076] Typically, following solidification, the fat composition is mixed using a B-unit, such as a pin rotor machine (also referred to as the pin worker). The method may use more than one pin rotor machine, such as two, three, four, five, or more pin rotor machines. The number of pin rotor machines used typically depends on the type of edible fat system produced.

[0077] The degree of mixing varies by the speed of the pin rotor machine. The pin rotor machine may have a speed of between about 40 and about 600 rotations per minute (rpm), such as about 50 to 300 rpm. Typically, fat compositions with shear sensitivity are mixed at a lower speed.

[0078] The fat composition may be mixed at a controlled temperature. The fat composition may be mixed at any suitable temperature. The fat composition may be mixed at a temperature of at least 10 °C, at least 11 °C, at least 12 °C, at least 13 °C, at least 14 °C, at least 15 °C, at least 16 °C, at least 16.5 °C, at least 17 °C, at least 17.5 °C, at least 18 °C, at least 18.5 °C, or at least 19 °C. The fat composition may be mixed at a temperature of 25 °C or less, 24 °C or less, 23 °C or less, 22 °C or less, 21 °C or less, 20 °C or less, 19 °C or less, or 18 °C or less. The temperature at which the fat composition is mixed typically depends on the types of fat included in the fat composition, the amount and types of other inclusions such as excipients and liquids such as water, and the desired edible fat product.

[0079] The fat composition may be mixed for any suitable amount of time. For example, the fat composition may be mixed for about 5 minutes to about 90 minutes, such as 10 minutes to 60 minutes, or 15 minutes to 30 minutes.

[0080] After solidifying, it may be desirable to hold the temperature of the fat composition at a uniform temperature to prevent dissolution of crystals or control formation of additional crystals. A mixer, such as a B-unit, may include a water jacket or similar insulative structure to maintain a consistent temperature.Sonic measurement of solids after or during heating

[0081] During, before, or after one or more of the unit operations (e.g., heating, mixing, solidifying, filling), the method includes measuring the solid fat content of the fat composition using a sonic velocity sensor. Sonic measurement can be used to determine the velocity of the flow within a line, which in turn can be correlated to the solid fat content (percentage of fat crystals) of a fat composition. Sonic velocity sensors may be placed in a line or conduit leading to or from, or within, one or more of the heating unit, mixing unit, pre-chilling unit, A-unit (e.g., a crystallizer), B-unit (e.g., a pin rotor machine), and filling unit. In some cases, the method includes measuring the solid fat content of the fat composition with a sonic velocity sensor in the line leading to the filling unit or within the filling unit. In response to an obtained measurement of the percentage of solid fat in the fat composition, one or more process parameters may be adjusted.

[0082] Any suitable sonic velocity sensor may be used in the process. An example of a suitable sonic velocity sensor is the SENSOTECH™ LIQUISONIC™ sonic velocity sensor.

[0083] The solid fat content may be quantified using a sonic velocity sensor within a heating container, or as the fat composition is transferred out of a heating container. The sonic velocity sensor may be configured for inline measurement of heated fat composition. For example, a sonic velocity sensor may measure the solid fat content of the heated fat composition in a conduit, such as a tube, as it is transferred out of a heating container. In this way, the solid fat content in the heated fat composition can be measured before the heated fat composition is further processed. The fat may be heated and at least partially melted to include 5 wt-% or less, 4 wt-% or less, 3 wt-% or less, 2 wt-% or less, or 1 wt-% or less of solid crystals.

[0084] Often, votation methods will heat a fat composition to a greater temperature than its melting point in order to ensure dissolution of all crystals. When temperature is used as a proxy to measure crystal presence in a melted fat, it may be preferable to overheat fat to ensure complete dissolution. However, more sensitive quantification methods may allow heating fat to a lower temperature prior to votation. Sonic quantification of fat crystals during melting may enable methods of votation that require less heating of a fat to achieve complete or nearcomplete dissolution. In addition, quantifying the percentage of solids in a melted fat mixture may improve batch consistency by ensuring complete dissolution. Heating fat to a lower temperature may desirably reduce energy usage. Also, heating fat to a lower temperature may decrease fouling and generation of impurities that may be formed at higher temperatures. In addition, sonic quantification of fat crystals during the heating process may allow an operator can actively measure crystal content and further heat the fat composition to achieve complete ornear-complete dissolution. Sonic quantification of fat crystals during heating may increase the dissolution of a crystals, therefore decreasing the formation of a crystals during subsequent crystallization processes.

[0085] The types of fats in a fat composition influence the solidity of the edible fat system. Thus, in response to an obtained measurement of the percentage of solid fat in the fat composition, the composition may be adjusted to achieve a desired percentage of solid fat. For example, the composition may be adjusted by adding more fats with a higher melting point, or adding more fats with a lower melting point. Therefore, precise measurement and standardization of a fat composition prior to solidification, such as votation, between different batches may improve batch consistency.

[0086] The solid fat content may be quantified using a sonic velocity sensor during mixing. For example, sonic quantification of solid fat content may be performed during any of the unit operations that involve mixing, whether or not combined with other functions (heating, cooling, transferring the fat composition, etc.). This measurement may inform whether additional mixing or additional heating or cooling is required, or whether the fat composition should be further processed or be transferred to the next unit operation. The solid fat content may be quantified with a sonic velocity sensor after mixing and solidification, such as crystallization.

[0087] As is described herein, different types of crystals can form as a fat is crystallized. In one or more embodiments, P and P' crystals may be preferable to a crystals in the edible fat composition described herein. Thus, it may be desirable to mix a fat composition for an amount of time to encourage formation of P or P' crystals, rather than a crystals. The solid fat content in the fat composition may be measured during or after mixing using a sonic velocity sensor.

[0088] The solid fat content may be quantified using a sonic velocity sensor during mixing the fat composition with a gas. The solid fat content may be quantified using a sonic velocity sensor after mixing the fat composition with a gas. Surprisingly, a sonic velocity sensor can be used to measure the solid fat content in fat compositions that include gas bubbles.

[0089] Measuring the solid fat content of the fat composition after mixing with a gas may help determine whether an appropriate amount of gas has been mixed with the fat composition. Mixing the fat composition with a gas may change the flowability and texture of the fat composition, thus, it may be more challenging to estimate the solid fat content of a fat composition using viscosity. In addition, mixing with a gas may change the temperature of a fat composition. Thus, it may be more challenging to measure the solid fat content of a fat composition using temperature. Therefore, it may be advantageous to measure the solid fat content of a fat composition mixed with a gas using a sonic velocity sensor.

[0090] The solid fat content may be quantified using a sonic velocity sensor during prior to (e.g., immediately prior to) or during packaging or filling. For example, an inline sonic velocity sensor may be used to quantify solid fat content in the edible fat system (e.g., the final product) prior to or during filling the edible fat composition into containers.

[0091] Often, formation of the structure of the edible fat system occurs over an extended period of time during the process and may continue after packaging. While the bulk of crystallization may occur prior to filling and packaging of the edible fat system, the structure often continues to develop over time. That is, the fat is tempered after filling at a tempering storage temperature from about 15 °C to about 23 °C. During tempering, more crystals are formed and the solid fat content increases. For example, the edible fat system may include about 10 wt-% to about 20 wt-%, about 10 wt-% to about 16 wt-%, or about 15 wt-% solid fat content (e.g., crystallized fats) when it is packaged into a container, but may include about 25 wt-% solid fat content (e.g., crystallized fats) several weeks after it has been packed and stored at a suitable tempering temperature (e.g., from about 15 °C to about 23 °C). The rate of formation of new crystals over time is often the result of the concentration of crystals at packaging and the type of crystals present at packaging. Thus, it can be desirable to prepare the edible fat composition to include the desired crystal type at a predetermined amount when it is packaged.

[0092] Without the ability to control crystallization, significant variations may exist over time and between production lines, particularly when votation progression is only measured by temperature. Sonic measurement of the solid fat content may be used to improve consistency over time and between production lines.

[0093] The sonic velocity measurement may be used in combination with one or more additional measurement methods. For example, the viscosity of the fat composition may be measured. Additionally, or alternatively, the temperature of the fat composition may be measured. Additionally, or alternatively, if the fat composition is mixed and solidified in a container including a cooling medium, the temperature of the cooling medium may be measured.Filling

[0094] A method of the present technology may include filling the processed fat composition (e.g., the edible fat system) in a container. The container may be a bag within a box. For example, the container may be a pail, a drum, a tote, a piston tanker, and the like or combinations thereof. Generally, the pail, drum, and / or tote may have a capacity sufficient for transporting volumes of a pumpable fat system for use in commercial preparation of products (e.g., food items as described herein). Preferably, the container may have a volume of about 100mL to about 2 L, about 200 mL to about 1 L, about 1 gallon (3.8 L) to about 13 gallons (49 L) (e.g., a pail), about 55 gallons (208 L) (e.g., a drum), about 275 gallons (1041 L) to about 330 gallons (1249 L) (e.g., a tote), or about 20,000 L (e.g., a tank or tanker, such as a piston tanker).

[0095] In one or more embodiments, filling may include transferring the fat composition from the votation system via a conduit to the container. The conduit may include a sonic velocity sensor configured to measure the fat composition prior (e.g., immediately prior) to filling. The filling may further include one or more pumps to feed the fat composition into the container. For example, the one or more pumps may include, but are not limited to, a high pressure pump, a lobe pump, a piston pump, gear pump, Moyno pump, auger pump, and the like or combinations thereof. Additionally, or alternatively, the one or more pumps may be part of the production apparatus (e.g., votation system).

[0096] At the end of processing and at the time of filling the fat composition (e.g., the final product) to the container, the fat composition may have a temperature of about 5 °C to about 40 °C, about 8 °C to about 30 °C, about 10 °C to about 25 °C, about 10 °C to about 22 °C, or about 15 °C to about 22 °C. In a given process, the temperature of the fat composition may be controlled such that it is within a narrower sub-range, such as about 18 °C to about 20 °C, about 20 °C to about 22 °C, or about 22 °C to about 24 °C.

[0097] The conduit may be connected to a feed port (or other suitable inlet) on the container such that the fat composition can be transferred (e.g., pumped) into the container. The conduit may be fluidly connected to or in fluid communication with the container. As used herein, the terms “fluidly connected,” “in fluid communication,” and the like mean the two components or objects have a pathway formed between the two components or objects in which a fluid, such as the fat composition, water, air, etc., may be supplied, either with or without intervening components or objects.

[0098] The method may further include recycling residual amounts of the fat composition back to the process. For instance, unused amounts of the fat composition remaining in the conduit line may be transferred (e.g., via pumping or purging with an inert gas) back to one or more of the unit operations of the process, such as the heating or mixing step.

[0099] During filling, the fat composition may be delivered to an outlet via a temperature- controlled conduit. The temperature-controlled conduit may be a conduit equipped to maintain the fat composition at a temperature of about 5 °C to about 30 °C, about 8 °C to about 30 °C, about 10 °C to about 25 °C, about 10 °C to about 22 °C, or about 15 °C to about 22 °C. For example, the temperature-controlled conduit may be a water jacketed pipe. Heated or cooledwater may be used to maintain the temperature of the pumpable fat system at a pre-determined temperature.

[0100] The method may further include storing the fat composition (e.g., the edible fat system) in the container. The storing may occur over a period of about 1 hour to about 4 weeks or even longer, such as up to 6 months. For example, the fat composition (e.g., the edible fat system) may be stored over a period of about 1 hour, about 6 h, about 12 h, about 18 h, about 1 day, about 2 days, about 3 days, about 4 days, about 5 days, about 6 days, about 1 week, about 1.5 weeks, about 2 weeks, about 4 weeks, or any range including and / or in between any two of the preceding values. Generally, the storing occurs at a temperature of about 4 °C to about 30 °C, about 10 °C to about 30 °C, about 10 °C to about 25 °C, about 10 °C to about 22 °C, or about 15 °C to about 22 °C. The container may be a temperature-controlled container, such as a well-insulated temperature-controlled container to maintain product temperature during transport and storage before use. For example, the temperature-controlled container may be a container equipped to maintain the contents therein within a designated temperature. A temperature-controlled container in keeping with the method described herein is a container equipped to maintain the fat composition at a temperature of about 4 °C to about 30 °C, about 10 °C to about 30 °C, about 10 °C to about 25 °C, about 10 °C to about 22 °C, or about 15 °C to about 22 °C.Systems for preparation of edible fat systems

[0101] The system may be configured to run a continuous fat crystallization process is provided. Each stage or unit operation of the system may be connected such that an input fat can be heated, cooled, crystallized, mixed, and prepared for filling without being removed from the system. The system may include any suitable configuration of pumps, valves, and conduits or pipes to move a fat composition through the system. In one or more embodiments, a system is configured for production of a food product. A system may be compliant with a food safety or sterility standard. For example, a system may be configured to prevent contamination with chemical or microbiological contaminants.

[0102] An exemplary system 10 consistent with the systems disclosed herein is depicted in FIG. 2. This system includes a tank 20, an optional gas feed 30, an A-unit 40, a B-unit 50, a filling stage 70. The system includes a first conduit 25 connecting the tank 20 and the A-unit 40. The system includes a second conduit 45 connecting the A-unit 40 to the B-unit 50. The system includes a third conduit 55 connecting the B-unit 50 to the filling stage 70. The system 10 mayinclude a homogenization valve 68 prior to the filling stage 70. The homogenization valve 68 may be in the third conduit 55. The third conduit 55 may include a split point 60 that connects to an optional fourth conduit 65. The optional fourth conduit 65 connects the B-unit 50 to the tank 20. The system includes at least one of in-line sonic velocity sensor 21, 31, 41, 61, 66. The in-line sonic velocity sensor 21, 31, 41, 61, 66 may be placed between the tank 20 and the gas feed 30, between the gas feed 30 and the A-unit 40, between the A-unit 40 and the B-unit 50, or after the B-unit 50 and prior to the filling stage 70, optionally immediately prior to the filling stage 70 or at the filling stage 70. The in-line sonic velocity sensor 21, 31, 41, 61, 66 may be placed in the first conduit 25, the second conduit 45, or the third conduit 55.

[0103] Each conduit typically includes a wall defining an inner lumen suitable for fluid flow. For example, a conduit may be a plastic or metal pipe, such as a stainless steel pipe. A conduit may have any appropriate diameter and shape. Typically, a conduit is compatible with installation of an in-line device, such as a sonic velocity sensor, a temperature sensor, a velocity sensor, or a valve. The conduits may optionally include insulation and / or temperature control.

[0104] Typically, fat is heated to predetermined temperature using a heater. The heater may be fitted to the tank 20 or to a feed line into the tank 20 or in the first conduit 25. Multiple heaters may be used. The heater may use any suitable heat source, such as heating coil, water jacket, a gas burner, an electric burner, an induction burner, or the like, or a combination of two or more thereof. Multiple types of fats and optionally non-fat components may be combined in the tank 20 to form a fat composition. For example, excipients, water, flavorings, or colorants may be added to the fat composition. The heated fat composition may be mixed in the tank 20. The heated fat composition may be held in the tank 20.

[0105] The solid fat content of the heated fat composition may be determined using sonic velocity measurement. The solid fat content may be determined after or during heating. The system may include a sonic velocity sensor 21 in the first conduit 25 between the tank 20 and the A-unit 40.

[0106] The fat composition may be pre-chilled in a pre-chiller. For example, the fat composition may be pre-chilled in a plate and frame heat exchanger or a shell and tube heat exchanger. The heat exchanger typically uses a cooling medium. The cooling medium may be tempered water. Typically, the cooling medium is held at a temperature slightly higher than the melting point of the fat composition. The cooling medium may have a temperature of 2 °C to 15 °C above the melting point of the fat composition, such as 5 °C to 10 °C above the melting point of the fat composition, or 6 °C to 8 °C above the melting point of the fat composition.

[0107] The system may include a gas feed 30 configured to inject a gas into the fat composition. The gas may be any food-safe inert gas as described herein, such as nitrogen or argon. The gas feed 30 may be connected to the first conduit 25 between the tank 20 and the A- unit 40. Thus, the fat composition may be mixed with gas prior to chilling. The system may include a gas feed 30 and a sonic velocity sensor 31 in the first conduit 25 between the gas feed 30 and the A-unit 40.

[0108] The system includes an A-unit 40. As is described herein, an A-unit is typically a “perfector” or a crystallizer, such as a scrape-surface crystallizer. A perfector typically includes one or more chilling tube with a cooling system and one or more intermediate crystallizers.

[0109] The system typically includes a B-unit 50. As is described herein, the B-unit is typically a pin rotor machine or a “pin worker”. The B-unit 50 is connected to the A-unit by a second conduit 45. The B-unit is connected to a third conduit 55 that connects to a filling stage 70.

[0110] The system 10 may also include an optional an optional remelter 80. Optionally, the remelter 80 is disposed within the fourth conduit 65. The fourth conduit 65 may be used to recirculate fat composition back into an earlier stage in the process, e.g., the tank 20. The remelter 80 may be used to heat (e.g., remelt) fat composition being recirculated to the tank 20. It may be desirable to reheat and melt a fat composition to dissolve many or most crystals before it is reintroduced to the tank 20 to prevent formation of undesirable crystal types. The fourth conduit 65 optionally includes an in-line sonic velocity sensor 66.

[0111] The system includes a filling stage 70 connected to the third conduit 55. The filling stage 70 pumps the edible fat composition product into containers for storage and shipping. Optionally, the system includes a sonic velocity sensor 61 disposed in the third conduit 55, typically after the branch point 60. The sonic velocity sensor 61 may measure the solid fat content in the edible fat composition prior to filling. This measurement may indicate whether the edible fat product is ready to be filled, or whether it needs to be further processed. Measurement of the edible fat product prior to filling may improve batch consistency by allowing operators to identify solid fat content that is outside of an intended range. The filling stage 70 may be connected to a pump configured to move the edible fat composition.EXAMPLESExample 1:

[0112] In this Example, the interval of error for solid fat content measurement of a sample using a benchtop NMR at five temperatures was evaluated.

[0113] A fat composition was prepared using a votation system consistent with the present disclosure.

[0114] Following votation, a sample of each fat product was taken for measurement of solid fat content using NMR. 4-6 technical replicates were measured with NMR for each fat product. Measurements were taken shortly following votation to keep the temperature of the fat product consistent.

[0115] A plot showing the solid fat content as measured by NMR and the sonic velocity of representative samples is shown in FIG. 3. An interval plot showing the solid fat content of the sample at each temperature is shown in FIG. 4 and quantified in Table 1.Table 1Example 2:

[0116] Fat products were prepared as described in Example 1. Multiple runs were completed using the same conditions to determine consistency between runs. The R-squared value of the relationship between solid fat content and sonic velocity for each run is shown in Table 2 below. A plot showing the sonic velocity measured for each sample and the known solid fat content is shown in FIG. 5.Table 2Example 3:

[0117] Fat products were prepared as described in Example 2. The sonic velocity of each sample was measured. In addition, the solid fat content of each sample was measured using NMR. A graph showing sonic velocity of samples having a solid fat content of greater than 11% is shown in FIG. 6.Example 4:

[0118] In this Example, sonic velocity was used to measure solid fat content of samples, including a sample that had been mixed with nitrogen gas (N2). A plot showing sonic velocity of samples with or without nitrogen gas having increasing solid fat content is shown in FIG. 7.

[0119] It was observed that as temperature approached the temperature of crystallization (75 °F) for palm oil, the attenuation stabilized. Surprisingly, signal attenuation remained relatively constant in samples including nitrogen gas and samples not including nitrogen gas. As is described herein, it has previously been thought that samples including gas bubbles are typically not compatible with sonic velocity measurement. Thus, these findings support the novel idea that the solid fat content of samples, particularly fat samples, including gas bubbles can be accurately measured using a sonic velocity sensor.

[0120] It was concluded that the solid fat content of samples including gas bubbles can be accurately measured using a sonic velocity sensor.Example 5:

[0121] Fat compositions were prepared as described in Example 1. One fat composition was made from palm oil (beta prime type oil), while the other fat composition was made from a blend of soybean oil and hydrogenated soybean oil (beta type oil). The compositions made from the P’ type oil and P type oil were evaluated using the same conditions to determine consistency over multiple runs. Solid fat content of the crystalized oil was measured as a function of fat temperature and sonic velocity. As shown in FIG. 8, a distinct difference was observed between the two fat compositions comprising P’ and P type oils, respectively, as a function of sonic velocity, solids fat content, and temperature.Exemplary Aspects

[0122] Exemplary aspects of the present technology are provided below. The numbering of the exemplary aspects is not to be construed as designating levels of importance.

[0123] Aspect 1 is a method to prepare an edible fat system, the method comprising: heating a fat composition to a molten state; solidifying at least a portion of the fat composition in a scrape surface crystallizer to form an at least partially solidified fat composition; mixing the at least partially solidified fat composition in a pin worker mixer to form a final product; filling the final product into a container; and determining a solid fat content of the fat composition, themolten fat composition, the at least partially solidified fat composition, the final product, or a combination of two or more thereof, using an in-line sonic velocity sensor.

[0124] Aspect 2 is the method of aspect 1, further comprising mixing an inert gas with the fat composition.

[0125] Aspect 3 is the method of aspect 2, wherein the inert gas comprises nitrogen.

[0126] Aspect 4 is the method of aspect 2 or 3, wherein the inert gas is mixed into the fat composition at a rate of 5 % to 12 % of gas in the fat composition by volume.

[0127] Aspect 5 is the method of any one of the preceding aspects, wherein the method is a continuous process.

[0128] Aspect 6 is the method of any one of the preceding aspects, wherein during the solidifying, the fat composition is cooled at a cooling rate of about 0.1 °C / s or greater, about 0.2 °C / s or greater, about 0.5 °C / s or greater, l°C / s or greater, or 2 °C / s or greater.

[0129] Aspect 7 is the method of any one of the preceding aspects, wherein during the solidifying, the fat composition is cooled at a cooling rate of about 30 °C / s or less, about 25 °C / s or less, about 20 °C / s or less, about 15 °C / s or less, about 10 °C / s or less, about 5 °C / s or less, about 2 °C / s or less, or about 1 °C / s or less.

[0130] Aspect 8 is the method of any one of the preceding aspects, wherein the fat composition is cooled from a first temperature to a second temperature in a time period, wherein: the first temperature is in a range of about 30 °C to about 45 °C or about 35 °C to about 42 °C, the second temperature is in a range of about 10 °C to about 25 °C or about 15 °C to about 22 °C, and the time period ranges from about 10 s to about 60 s or from about 15 s to about 40 s.

[0131] Aspect 9 is the method of any one of the preceding aspects, wherein the fat composition is mixed at a temperature of at least 10 °C, at least 11 °C, at least 12 °C, at least 13 °C, at least 14 °C, at least 15 °C, at least 16 °C, at least 16.5 °C, at least 17 °C, at least 17.5 °C, at least 18 °C, at least 18.5 °C, or at least 19 °C, optionally wherein the fat composition is mixed at a temperature of 25 °C or less, 24 °C or less, 23 °C or less, 22 °C or less, 21 °C or less, 20 °C or less, 19 °C or less, or 18 °C or less.

[0132] Aspect 10 is the method of aspect 9, wherein the fat composition is mixed for about 5 minutes to about 90 minutes, such as 10 minutes to 60 minutes, or 15 minutes to 30 minutes.

[0133] Aspect 11 is the method of any one of the preceding aspects, wherein the fat composition comprises interesterified fat, partially hydrogenated fat, fully hydrogenated fat, or a combination of two or more thereof.

[0134] Aspect 12 is the method of any one of the preceding aspects, wherein the fat composition comprises one or more of butter, lard, tallow, butter oil, cocoa butter, mango butter, shea butter, milk fat, coconut oil, palm oil, palm olein, palm stearin, cottonseed stearin, cocoa butter stearin, shea stearin, palm kernel stearin, sunflower stearin, palm kernel oil, shea oil, illipe oil, sal oil, kokum gurgi oil, mango kernel oil, hydrogenated vegetable oil, hydrogenated fish oil, or a combination of two or more thereof.

[0135] Aspect 13 is the method of any one of the preceding aspects, wherein the final product comprises shortening, liquid butter, or margarine.

[0136] Aspect 14 is the method of any one of the preceding aspects, wherein the final product comprises a pumpable fat, a pourable fat, or other edible fat system.

[0137] Aspect 15 is the method of any one of the preceding aspects, wherein the final product at the time of the filling comprises 8 wt-% or more, 10 wt-% or more, or 12 wt-% or more of solids crystals.

[0138] Aspect 16 is the method of any one of the preceding aspects, wherein the final product at the time of the filling comprises 20 wt-% or less, 18 wt-% or less, 17 wt-% or less, or 15 wt-% or less of solids crystals.

[0139] Aspect 17 is the method of any one of the preceding aspects, wherein during the method, the fat composition comprises 0.1 wt-% or more, 1 wt-% or more, 5 wt-% or more, 8 wt-% or more, 10 wt-% or more, or 12 wt-% or more of solids crystals.

[0140] Aspect 18 is the method of any one of the preceding aspects, wherein during the method, the fat composition comprises 30 wt-% or less, 25 wt-% or less, 20 wt-% or less, 18 wt- % or less, 17 wt-% or less, or 15 wt-% or less of solids crystals.

[0141] Aspect 19 is the method of any one of the preceding aspects further comprising seeding the fat composition with P' crystals at a rate of about 1 % or greater, about 2 % or greater, about 5 % or greater, or about 10 % or greater by volume of the fat composition, optionally wherein the rate of is about 40 % or less, about 30 % or less, about 20 % or less, or about 10 % or less by volume of the heated fat composition.

[0142] Aspect 20 is solid fat may be about 1 % or greater, about 2 % or greater, about 5 % or greater, or about 10 % or greater of the volume of the heated fat composition. The volume of added solid fat may be about 40 % or less, about 30 % or less, about 20 % or less, or about 10 % or less of the volume of the heated fat composition

[0143] Aspect 21 is a system for processing a fat composition, the system comprising: a tank fitted with a heater; a scrape surface crystallizer in fluid communication with and configured to received flow from the tank via a first conduit; a pin worker mixer in fluid communication withand configured to received flow from the scrape surface crystallizer via a second conduit; a filling stage in fluid communication with and configured to received flow from the mixer via a third conduit and constructed to fill product into a container; and one or more in-line sonic velocity sensors disposed within the first conduit, the second conduit, the third conduit, or a combination of two or more thereof, and configured to determine solid fat content in the flow therein.

[0144] Aspect 22 is the system of aspect 21, further comprising a source of gas configured to inject an inert gas into the first conduit, optionally wherein the gas comprises nitrogen.

[0145] Aspect 23 is the system of aspect 21 or 22, wherein the processing comprises crystallizing.

[0146] Aspect 24 is the system of any one of aspects 21 to 23, wherein the fat composition comprises margarine or butter.

[0147] Aspect 25 is the system of any one of aspects 21 to 24, wherein the system is configured to run a continuous fat crystallization process.

[0148] Aspect 26 is the system of any one of aspects 21 to 25, further comprising a fourth conduit extending from the mixer to the tank and one or more in-line sonic velocity sensors disposed within the fourth conduit.

[0149] Aspect 27 is the system of any one of aspects 21 to 26, further comprising a homogenization valve disposed within the fourth conduit.

[0150] Each of the non-limiting aspects above can stand on its own or can be combined in various permutations or combinations with one or more of the other aspects or other subject matter described in this document. While the invention has been illustrated and described in certain aspects, a person with ordinary skill in the art, after reading the foregoing specification can effect changes, substitutions of equivalents and other types of alterations to the present technology as set forth herein. Each aspect described above can also have included or incorporated therewith such variations or aspects as disclosed in regard to any or all of the other aspects.

[0151] All references and publications cited herein are expressly incorporated herein by reference in their entirety into this disclosure, except to the extent they may directly contradict this disclosure. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and / or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. It should be understood that this disclosure is not intended to be unduly limited by the illustrative embodiments andexamples set forth herein and that such examples and embodiments are presented by way of example only with the scope of the disclosure intended to be limited only by the claims set forth here.

Claims

Claims1. A method to prepare an edible fat system, the method comprising: heating a fat composition to a molten state; solidifying at least a portion of the fat composition in a scrape surface crystallizer to form an at least partially solidified fat composition; mixing the at least partially solidified fat composition in a pin worker mixer to form a final product; filling the final product into a container; and determining a solid fat content of the fat composition, the molten fat composition, the at least partially solidified fat composition, the final product, or a combination of two or more thereof, using an in-line sonic velocity sensor.2 The method of claim 1, further comprising mixing an inert gas with the fat composition.3 The method of claim 1, wherein the method is a continuous process.4 The method of claim 1, wherein during the solidifying, the fat composition is cooled at a cooling rate of about 0.1 °C / s or greater, about 0.2 °C / s or greater, about 0.5 °C / s or greater, l°C / s or greater, or 2 °C / s or greater.5 The method of claim 1, wherein during the solidifying, the fat composition is cooled at a cooling rate of about 30 °C / s or less, about 25 °C / s or less, about 20 °C / s or less, about 15 °C / s or less, about 10 °C / s or less, about 5 °C / s or less, about 2 °C / s or less, or about 1 °C / s or less.6 The method of claim 1, wherein the fat composition is cooled from a first temperature to a second temperature in a time period, wherein: the first temperature is in a range of about 30 °C to about 45 °C or about 35 °C to about 42 °C, the second temperature is in a range of about 10 °C to about 25 °C or about 15 °C to about 22 °C, and the time period ranges from about 10 s to about 60 s or from about 15 s to about 40 s.7 The method of claim 1, wherein the fat composition comprises interesterified fat, partially hydrogenated fat, fully hydrogenated fat, or a combination of two or more thereof.

8. The method of claim 1, wherein the fat composition comprises one or more of butter, lard, tallow, butter oil, cocoa butter, mango butter, shea butter, milk fat, coconut oil, palm oil, palm olein, palm stearin, cottonseed stearin, cocoa butter stearin, shea stearin, palm kernel stearin, sunflower stearin, palm kernel oil, shea oil, illipe oil, sal oil, kokum gurgi oil, mango kernel oil, hydrogenated vegetable oil, hydrogenated fish oil, or a combination of two or more thereof.9 The method of claim 1, wherein the final product comprises shortening, liquid butter, or margarine.10 The method of claim 1, wherein the final product comprises a pumpable fat, a pourable fat or other edible fat system.11 The method of claim 1, wherein the final product at the time of the filling comprises 8 wt- or more, 10 wt-% or more, or 12 wt-% or more of solids crystals.12 The method of claim 1, wherein the final product at the time of the filling comprises 20 wt- or less, 18 wt-% or less, 17 wt-% or less, or 15 wt-% or less of solids crystals.13 The method of claim 1, wherein during the method, the fat composition comprises 0.1 wt- or more, 1 wt-% or more, 5 wt-% or more, 8 wt-% or more, 10 wt-% or more, or 12 wt-% or more of solids crystals.14 The method of claim 1, wherein during the method, the fat composition comprises 30 wt- or less, 25 wt-% or less, 20 wt-% or less, 18 wt-% or less, 17 wt-% or less, or 15 wt-% or less of solids crystals.15 A system for processing a fat composition, the system comprising: a tank fitted with a heater; a scrape surface crystallizer in fluid communication with and configured to received flow from the tank via a first conduit; a pin worker mixer in fluid communication with and configured to received flow from the scrape surface crystallizer via a second conduit; a filling stage in fluid communication with and configured to received flow from the mixer via a third conduit and constructed to fill product into a container; andone or more in-line sonic velocity sensors disposed within the first conduit, the second conduit, the third conduit, or a combination of two or more thereof, and configured to determine solid fat content in the flow therein.

16. The system of claim 15, further comprising a source of gas configured to inject an inert gas into the first conduit.

17. The system of claim 15, wherein the processing comprises crystallizing.

18. The system of claim 15, wherein the fat composition comprises margarine or butter.

19. The system of claim 15, wherein the system is configured to run a continuous fat crystallization process.

20. The system of claim 15, further comprising a fourth conduit extending from the mixer to the tank and one or more in-line sonic velocity sensors disposed within the fourth conduit.

21. The system of claim 20, further comprising a homogenization valve disposed within the fourth conduit.

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