Fat Continuous Emulsion Preparation via Pre-Crystallization
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Solution Overview
Problem
Existing processes for manufacturing fat-continuous emulsions, such as margarines and spreads, require significant energy for heating and cooling, and involve complex equipment, making it difficult to rework finished products without generating waste.
Innovation Solution
A process that combines a water-continuous dispersion at 0-15°C with melted hardstock fat at 30-60°C and a fat-continuous dispersion containing 0.2-10% fat crystals, subjected to high shear mixing below the hardstock's melting point, allowing for the production of fat-continuous emulsions with improved stability and reworkability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating and cooling of the entire formulation is used to manufacture water-in-oil emulsions, then the fat crystal network can be properly formed and stable, but energy consumption increases significantly
Solution Approach 1:
The patent applies preliminary action by pre-crystallizing hardstock fat into fat powder before blending with liquid oil and aqueous phase. This pre-prepared fat powder contains the necessary crystal structure, eliminating the need for subsequent heating and cooling cycles to form the fat crystal network, thus significantly reducing energy consumption while maintaining emulsion stability
Solution Approach 2:
The patent changes the physical state parameter of hardstock fat from liquid to solid powder form through pre-crystallization. By controlling the crystallization process to produce specific particle sizes and crystal structures, the fat powder can be directly incorporated into the emulsion without requiring extensive thermal processing, thereby reducing energy consumption while ensuring proper fat network formation
2Use of energy by moving object
If pre-crystallized fat powder is used to reduce energy consumption, then heating and cooling of the entire formulation is avoided, but new complex equipment is required for pressurizing and handling CO2 and spraying melted fat
Solution Approach 1:
The patent extracts the crystallization step from the main emulsion formulation process and performs it separately on the hardstock fat before blending. This separation allows the use of simple mixing equipment for the final product assembly, avoiding the need for complex pressurizing and CO2 handling systems that would be required if crystallization were performed in-situ during emulsion manufacturing
Solution Approach 2:
By performing the crystallization of hardstock fat as a preliminary step before emulsion formulation, the patent simplifies the main manufacturing process to basic mixing and blending operations. The pre-crystallized fat powder is simply blended with liquid oil and aqueous phase, eliminating the need for complex equipment and reducing overall process complexity
3Productivity
If the processing line continues running during packaging breakdown, then productivity is maintained, but product quality deteriorates due to excessive working and heat buildup
Solution Approach 1:
The patent applies preliminary action by pre-crystallizing the hardstock fat before emulsion formulation, which creates a stable fat crystal network structure in advance. This pre-formed structure is more resistant to degradation from excessive mechanical working, allowing the processing line to continue running during packaging breakdown without significant quality deterioration, thus maintaining both productivity and product quality
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 process reduces energy consumption, eliminates the need for complex equipment, and enhances product quality by achieving smaller water droplet sizes and improved stability, while enabling efficient reworking of manufactured products.
Implementation Method 1
subjecting the mixture obtained after step d. to a high shear device to provide a fat-continuous emulsion
Implementation Method 2
formation of a fat crystal network to stabilize the resulting emulsion and give the product some degree of firmness
Implementation Method 3
providing part of hardstock fat in melted form and at a temperature of between 30°C. and 60°C.
Data Source
AI summary
A process for preparing a water-in-oil emulsion which emulsion comprises oil and a hardstock fraction next to an aqueous phase. The process involves blending the melted hardstock fraction with a water-continuous dispersion comprising part or all of the oil and part or all of the aqueous phase and with a fat-continuous dispersion comprising the remainder of the oil and the remainder of the aqueous phase. The combined stream is mixed by a high shear mixer with short residence time.