Cryogenic Spray Crystallization for Stable Fat Spreads
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Solution Overview
Problem
Existing processes for producing edible fat continuous spreads, such as margarine, require significant energy for heating and cooling, limit the choice of structuring fats, and can result in products with unsatisfactory melting properties and stability, especially when subjected to temperature cycling.
Innovation Solution
A cryogenic spray crystallization process is used to produce solid particles with specific process conditions, including subjecting a molten mixture of structuring agent to a high pressure and then expanding it into a cryogenic cooling medium, resulting in solid particles that can effectively structure oil-containing dispersions with improved stability and handling properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the complete composition is subjected to heating and cooling steps in known processes, then the structuring fat can be incorporated into the emulsion, but a lot of energy is required
Solution Approach 1:
The structuring fat is pre-crystallized into fine particles before being incorporated into the emulsion. This preliminary action eliminates the need for subsequent heating and cooling steps during emulsion preparation, as the pre-formed crystalline structure can be directly mixed into the liquid composition at ambient or refrigeration temperatures, dramatically reducing energy consumption while maintaining emulsion stability
Solution Approach 2:
The invention changes the physical state and size parameters of the structuring fat by converting it from bulk form to fine crystalline particles with specific size distributions (D10, D50, D90 values). This parameter change allows the fat to function effectively at lower temperatures and reduces the thermal processing required, thereby reducing energy consumption while achieving the desired emulsion stability
2Reliability
If the melting point of the structuring agent is too high, then the emulsion stability is improved, but the melting properties in the mouth are unsatisfactory
Solution Approach 1:
The invention creates local quality differences within the fat structure by producing a bimodal or multimodal particle size distribution. Fine particles (lower D50 values) provide the necessary melting properties for good mouthfeel, while the overall crystalline structure and particle morphology maintain sufficient melting point for emulsion stability. Different regions of the fat phase thus exhibit different functional properties
Solution Approach 2:
The structuring fat is formulated as a composite system with particles having specific size distributions and morphological characteristics. This composite structure combines particles with different properties - finer particles that melt easily for mouthfeel and particles with sufficient crystalline order for stability - allowing both contradictory requirements to be satisfied simultaneously
3Reliability
If the amount of saturated fatty acids in the structuring agent is reduced, then the cardiovascular health profile is improved, but the emulsion stability is negatively affected
Solution Approach 1:
The invention changes the physical parameters of the structuring fat by controlling particle size, shape, and crystalline structure rather than relying solely on chemical composition (saturated fatty acid content). By optimizing particle morphology and size distribution, the fat can provide adequate emulsion stability with lower saturated fatty acid content, as the physical structure compensates for the reduced chemical stability
Solution Approach 2:
The invention replaces the chemical mechanism (relying on saturated fatty acids for stability) with a physical mechanism (particle size distribution and crystalline structure). The fine particle morphology and surface characteristics provide steric and physical stabilization to the emulsion, substituting the need for high saturated fatty acid content and enabling healthier fat formulations
4Use of energy by stationary object
If fat powder with microporous structure is used, then the need to heat the whole composition is eliminated, but the powders are not convenient to handle in production
Solution Approach 1:
The invention optimizes the physical parameters of the fat powder, specifically the particle size distribution, density, and flow characteristics. By controlling these parameters during crystallization, the powder achieves good flowability and handling properties while maintaining the energy-saving advantage of not requiring heating. The particle morphology is specifically tuned to balance powder density with flow characteristics
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 process produces solid particles that enhance the structure and stability of fat continuous spreads, particularly in heat stability tests, and allows for the use of convenient, high-density powders that improve spreadibility and hardness while reducing energy consumption and saturated fatty acid content.
Implementation Method 1
contacting the atomized molten mixture with a cryogenic cooling medium
Implementation Method 2
spray crystallization process for making solid particles
Implementation Method 3
expanding it into a cryogenic cooling medium
Data Source
AI summary
The invention relates to a spray crystallization process for making solid particles suitable for structuring an oil containing dispersion, solid particles obtainable by said process and use of said particles for structuring oil containing dispersions.