Condiment Emulsion Viscosity via Pre-emulsion Cooling
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Solution Overview
Problem
Current methods for producing condiments like mayonnaise face limitations in achieving high viscosity due to the operational constraints of homogenizers, leading to potential product degradation and catastrophic phase inversion, especially when trying to exceed the maximum viscosity within the device's operational range.
Innovation Solution
A method involving the preparation of a pre-emulsion with a temperature below 14°C, followed by emulsification using a colloid mill, which increases viscosity significantly without additional ingredients or special equipment, allowing for the production of condiments with viscosities beyond the normal operational range of homogenizers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the rotor-stator distance of the colloid mill is reduced to increase viscosity, then the viscosity of the condiment increases, but the device reaches its minimum setting limit and cannot achieve further viscosity increase
Solution Approach 1:
The invention changes the temperature parameter of the pre-emulsion from ambient temperature to below 14°C before emulsification. This temperature parameter change enables the colloid mill to produce condiments with viscosity exceeding 100,000 mPa·s, even at minimum rotor-stator distance settings, thereby resolving the contradiction between achieving high viscosity and device operational limits
Solution Approach 2:
The invention performs preliminary cooling of the pre-emulsion to below 14°C before the emulsification step. This preliminary action prepares the system in advance to achieve ultra-high viscosity outcomes without requiring further adjustment of the rotor-stator distance beyond the device's minimum setting
2Stability of the object's composition
If the homogenizer operates at maximum capacity to achieve high viscosity, then the viscosity increases, but product degradation and catastrophic phase inversion occur
Solution Approach 1:
By changing the temperature parameter of the pre-emulsion to below 14°C, the invention enables high viscosity production (exceeding 100,000 mPa·s) under milder homogenization conditions. This avoids the catastrophic phase inversion and product degradation that occur when conventional homogenizers operate at maximum capacity
Solution Approach 2:
The invention converts the typically harmful effect of low temperature (which would normally increase viscosity undesirably) into a beneficial control mechanism. By precisely controlling the pre-emulsion temperature to below 14°C, the low temperature effect becomes a tool to achieve ultra-high viscosity without the harmful side effects of excessive homogenization
3Stability of the object's composition
If additional ingredients or special equipment are used to increase viscosity beyond homogenizer limits, then the viscosity can be increased, but the process complexity and cost increase
Solution Approach 1:
The invention enables the colloid mill to serve itself by operating within its existing operational parameters (minimum rotor-stator distance) combined with the temperature-controlled pre-emulsion. No additional equipment or ingredients are needed - the system uses its own capabilities enhanced by the temperature parameter change to achieve ultra-high viscosity
Solution Approach 2:
The single parameter change of cooling the pre-emulsion to below 14°C replaces the need for additional ingredients (such as thickeners) or special equipment. This simple parameter modification enables the existing colloid mill to achieve viscosity levels previously unattainable with conventional methods
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
This method effectively increases the viscosity of condiments to ranges of 340,000 - 420,000 mPa·s, maintaining high viscosity even after packaging, thus overcoming the limitations of traditional homogenization processes and preventing product degradation.
Implementation Method 1
wherein the temperature of the pre-emulsion at the start of the emulsification step (iii) is less than 14°C
Implementation Method 2
The product is subjected to great shear force in the slit between the rotor and stator, which causes emulsification
Data Source
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AI summary
The invention relates to a method for the preparation of a condiment in the form of an oil-in-water emulsion containing water, an emulsifier and a plant-based oil involving combining the necessary ingredients into a pre-emulsion followed by the emulsification of the pre-emulsion into the condiment, wherein the temperature of the pre-emulsion at the start of the emulsification step (iii) is less than 14°C.