Co-crystallized Fat Powder for Structured Spreads
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Solution Overview
Problem
Existing edible fat continuous products face challenges in achieving optimal structuring properties without chemical modification, as current methods like hydrogenation and interesterification produce undesirable by-products and require complex processes, while natural fats without modification may not be suitable for structuring due to melting point issues.
Innovation Solution
The development of a co-crystallized fat powder comprising at least two natural fats, which are not subjected to hydrogenation or interesterification, allowing for improved structuring properties through co-crystallization, characterized by a single diffraction peak in X-ray scattering measurements, and prepared using methods like cryo-crystallization or supercritical melt micronization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrogenation is used to modify fat structure, then structuring capabilities are improved, but undesirable by-products (trans fatty acids) are formed and process complexity increases
Solution Approach 1:
The patent extracts and removes the chemical modification step (hydrogenation) from the fat processing sequence, obtaining structuring fat directly from natural sources in a crystallized state. This eliminates the formation of harmful by-products like trans fatty acids while preserving the desired structuring capabilities through physical crystallization rather than chemical alteration.
Solution Approach 2:
The patent converts the natural crystallization behavior of fats into a beneficial process, utilizing the inherent physical properties of natural fats to form structured crystals without requiring harmful chemical modifications. The natural crystallization process is harnessed to achieve the same structuring effect that previously required hydrogenation, but without the harmful by-products.
2Reliability
If hydrogenation is used to modify fat structure, then structuring capabilities are improved, but additional process steps are required
Solution Approach 1:
The patent removes the complex hydrogenation process and associated equipment from the production sequence, simplifying the overall process to direct crystallization of natural fats. This extraction of the chemical modification step reduces process complexity while maintaining structuring functionality through simpler physical processing.
Solution Approach 2:
The patent employs the self-crystallization property of natural fats, where the fat molecules automatically arrange into structured crystals during cooling without requiring external chemical intervention. This self-organizing behavior eliminates the need for complex hydrogenation equipment and multiple process steps, reducing overall system complexity.
3Device complexity
If natural fats without modification are used, then chemical process complexity is reduced, but melting point issues prevent effective structuring
Solution Approach 1:
The patent changes the physical parameters of natural fats by controlling the crystallization process (temperature, cooling rate, shear conditions) to achieve the desired melting point and structuring properties. By adjusting these physical parameters during processing, the natural fats are transformed into effective structuring agents without requiring chemical modification, thus maintaining process simplicity while achieving reliable structuring.
Solution Approach 2:
The patent utilizes phase transitions (melting and crystallization) of natural fats to achieve structuring. By controlling the transition from liquid to solid phase during processing, the natural fats form stable crystal structures with appropriate melting points, enabling effective structuring without chemical modification. This phase change mechanism provides both structural integrity and process simplicity.
4Reliability
If interesterification is used to modify fat structure, then structuring properties are improved, but by-products (free fatty acids, diglycerides) are formed
Solution Approach 1:
The patent extracts and eliminates the interesterification chemical process from the production sequence, obtaining structuring fat through direct crystallization of natural fats. This removal of the chemical modification step prevents the formation of harmful by-products such as free fatty acids and diglycerides, while preserving effective structuring properties through physical crystallization.
Solution Approach 2:
The patent converts the natural crystallization tendency of fats into a beneficial process, utilizing inherent physical properties to achieve structured crystals without requiring interesterification. This approach transforms what would be a harmful chemical process into a beneficial physical process, eliminating by-products while maintaining structuring effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The co-crystallized fat powder provides enhanced structuring capabilities for fat continuous spreads, eliminating the need for chemical modification and simplifying the production process, while maintaining desirable physical properties and consumer acceptance.
Implementation Method 1
a co-crystallized fat powder comprising at least two natural fats
Implementation Method 2
prepared using methods like cryo-crystallization
Implementation Method 3
supercritical melt micronization
Data Source
AI summary
The invention relates to an edible fat powder comprising at least two natural fats wherein the natural fat has a N10 of at least 10% and wherein the fat powder is a co-crystallized fat powder. The invention further relates to the use of said fat powder to prepare a fat containing emulsion. The invention also relates to a process for the preparation of said edible fat powder wherein the edible fat powder is prepared from a molten mixture comprising at least two natural fats.