Diglyceride Structuring Composition for Trans Fat Elimination
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Solution Overview
Problem
Existing food products face challenges in reducing unhealthy fats while maintaining structuring properties, as previous methods either increase saturated fat content or result in poor crystallization and organoleptic properties.
Innovation Solution
A structuring composition comprising at least 50% by weight diglycerides, 1-5% by weight monoglycerides, and 30-100% by weight β' crystals, formed through a process involving glycerolysis of saturated fats with controlled heating and cooling to achieve high β' crystal levels and small crystallite sizes, replacing unhealthy fats in food products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If partially hydrogenated fats are used to provide structuring properties, then the fat can be converted to solid or semi-solid forms, but trans fatty acids are formed which have negative health consequences
Solution Approach 1:
The patent changes the chemical composition parameters by using fully hydrogenated fat (100% saturated) instead of partially hydrogenated fat, eliminating trans fatty acids while maintaining the solid or semi-solid form through controlled crystallization to achieve 30-100% beta-prime crystals
Solution Approach 2:
The patent creates a composite fat system combining fully hydrogenated fat with liquid oil and diglyceride/monoglyceride mixture, where the fully hydrogenated fat provides structure without trans fats, and the liquid oil provides unsaturated fatty acids for health benefits
2Object-generated harmful factors
If palm oil or palm fractions are used to replace partially hydrogenated fats, then trans fats are eliminated, but the saturated fat content increases to 48% or above
Solution Approach 1:
The patent creates a composite system blending fully hydrogenated fat (saturated) with liquid unsaturated oil and diglyceride/monoglyceride mixture, achieving a balanced fat profile that eliminates trans fats while maintaining lower saturated fat content compared to palm oil alternatives
Solution Approach 2:
The patent applies local quality by using diglyceride/monoglyceride mixture (1-10%) specifically to modify crystallization behavior and promote beta-prime crystal formation, which improves the functional properties without significantly increasing saturated fat content
3Object-generated harmful factors
If fully refined non-hydrogenated non-palm containing liquid oil is used, then trans fats and saturated fats are reduced, but the oil lacks structuring properties
Solution Approach 1:
The patent creates a composite system where fully hydrogenated fat provides the necessary structuring properties and solid fat content, while liquid unsaturated oil provides health benefits, and diglyceride/monoglyceride mixture enhances crystallization to form beta-prime crystals
Solution Approach 2:
The patent changes the physical state parameters by controlling the crystallization process to achieve 30-100% beta-prime crystals, transforming the liquid oil blend into a semi-solid fat with desirable structuring properties without requiring trans fats or excessive saturated fat
4Shape
If fractionation is used to separate stearin fraction, then structuring properties are improved, but the process requires slow cooling and separation equipment
Solution Approach 1:
The patent extracts the structuring function from the complex fractionation process by using fully hydrogenated fat which naturally provides high solid fat content and controlled crystallization, eliminating the need for slow cooling and filter press equipment
Solution Approach 2:
The patent changes the crystallization parameters by using fully hydrogenated fat with specific fatty acid composition that promotes rapid formation of beta-prime crystals, achieving structuring properties without the slow cooling process required by fractionation
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 solution effectively reduces unhealthy fats in food products while maintaining desirable structuring, taste, and texture properties, providing a stable β' crystal structure for applications like baked goods and margarines without the drawbacks of trans or saturated fats.
Implementation Method 1
glycerolysis of saturated fats with controlled heating and cooling to achieve high β' crystal levels
Implementation Method 2
controlled heating and cooling to achieve high β' crystal levels and small crystallite sizes
Data Source
AI summary
Novel structuring compositions and food products including those compositions are provided. The compositions comprise a mono- and diglyceride mixture and have high levels of β' crystals and small average crystallite sizes. They can be incorporated into intermediate food products such as shortenings and margarines, which can then be used to make a final food such as pastries (e.g., puff pastries, Danishes, donuts), doughs (e.g., for cookies, pie crusts), imitation cheese, icings, frozen potatoes (e.g., French Fries), and/or other foods requiring a fat to provide structure. Advantageously, the compositions provide structure to the final food by replacing unhealthy fats that would otherwise be used to provide structure in the same food item.