Fat-Continuous Emulsion Process Using Low-Temperature High Shear Mixing
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Solution Overview
Problem
Existing processes for manufacturing fat-continuous emulsions, such as spreads and margarines, that contain protein are energy-intensive and require complex equipment, as they typically involve heating and cooling the entire formulation, which is inefficient and costly, and may not produce stable emulsions effectively.
Innovation Solution
A process that involves creating a water-continuous dispersion with protein at low temperatures, combining it with melted hardstock fat, and subjecting the mixture to high shear using a high shear device followed by pin-stirring, without heating the entire formulation, to produce a stable fat-continuous emulsion with controlled crystal formation and droplet size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the votator or churn process is used to manufacture fat-continuous emulsions containing protein, then the emulsion can be produced, but the energy consumption is high due to heating and cooling the entire formulation
Solution Approach 1:
The process divides the emulsion formation into two separate stages: first creating a water-continuous dispersion at low temperature, then adding melted hardstock fat and subjecting to high shear. This segmentation avoids heating the entire formulation while achieving stable fat-continuous emulsion.
Solution Approach 2:
The water-continuous dispersion is prepared in advance at low temperature with protein already incorporated, eliminating the need for subsequent heating and cooling cycles. This preliminary action resolves the energy consumption issue while maintaining emulsion stability.
2Reliability
If the votator or churn process is used to manufacture fat-continuous emulsions, then the emulsion can be produced, but complex equipment is required for heating and cooling operations
Solution Approach 1:
The process separates emulsion formation from fat crystallization, using simple low-temperature mixing equipment followed by high shear mixing. This eliminates the need for complex heating and cooling equipment while producing stable emulsions.
Solution Approach 2:
The process replaces thermal processing (heating and cooling) with mechanical processing (high shear mixing and pin-stirring) to achieve emulsion stabilization and fat crystal network formation, thereby simplifying equipment requirements.
3Ease of operation
If protein is added to fat-continuous emulsions, then taste and mouthfeel are improved, but emulsion stability becomes more difficult to achieve
Solution Approach 1:
Protein is incorporated into the water-continuous dispersion before fat addition, allowing it to be properly hydrated and positioned to stabilize the emulsion interface. This preliminary incorporation ensures both improved mouthfeel and emulsion stability.
Solution Approach 2:
The water-continuous dispersion acts as an intermediary medium that properly incorporates protein before the fat phase is introduced. This intermediary step ensures protein is correctly positioned to stabilize the final fat-continuous emulsion while maintaining operational ease.
4Ease of manufacture
If hardstock fat is added at high temperature, then mixing is easier, but uncontrolled crystal formation occurs
Solution Approach 1:
The process changes the temperature parameter dynamically: hardstock fat is melted for easy mixing, then the mixture is cooled to controlled temperatures during high shear and pin-stirring to achieve precise crystal network formation. This parameter control resolves both mixing ease and crystal precision requirements.
Solution Approach 2:
The process maintains continuous controlled cooling and mechanical working (high shear followed by pin-stirring) to ensure uniform and controlled crystal formation throughout the emulsion. This continuous action prevents uncontrolled crystallization while maintaining manufacturing efficiency.
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 reduces energy consumption, eliminates the need for complex equipment, and produces stable fat-continuous emulsions with improved mouthfeel and texture, suitable for spreadable products with optimal fat and protein content.
Implementation Method 1
subjecting the mixture obtained after step c. to high shear imparted by a high shear device to provide a fat-continuous emulsion
Implementation Method 2
subject the emulsion obtained from step d. to working by a pin-stirrer
Implementation Method 3
cooling of the mixture under high shear to induce crystallization of the hardstock fat to create an emulsion; formation of a fat crystal network to stabilize the resulting emulsion
Data Source
AI summary
A process for preparing a water-in-oil emulsion which emulsion comprises protein, oil and a hardstock fat. The process involves blending the melted hardstock fat with a water-continuous dispersion comprising protein and oil, wherein the temperature of the aqueous dispersion being mixed with the melted hardstock fat is below 15° C., and said mixing is carried out by a high shear mixing device followed by a pin-stirrer.