Fat Continuous Spread Preparation via Pre-Crystallized Powder
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Solution Overview
Problem
Existing processes for preparing fat continuous spreads are energy-intensive and limited in their ability to produce spreads with desirable properties such as spreadability, heat stability, and low saturated fatty acid content, often resulting in unpredictable quality and sensitivity to temperature changes.
Innovation Solution
A process involving the use of fat powder with specific viscosity and gel strength aqueous phase, where the fat powder and oil are mixed to form a slurry, and then combined with a gel-forming aqueous phase to create an oil continuous emulsion, without the need for heating and cooling the entire composition, allowing for improved energy efficiency and predictable quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the complete composition is subjected to heating and cooling steps to crystallize structuring fat, then the fat crystal network is formed to stabilize the emulsion, but energy consumption increases significantly
Solution Approach 1:
The structuring fat is pre-crystallized into fat powder before being incorporated into the emulsion. This preliminary crystallization action eliminates the need for subsequent heating and cooling steps to form the fat crystal network, significantly reducing energy consumption while maintaining emulsion stability.
Solution Approach 2:
The crystallization step is extracted from the emulsion preparation process. Instead of crystallizing structuring fat within the complete composition through heating and cooling, the fat is crystallized separately beforehand and introduced as pre-formed fat powder, removing the energy-intensive thermal processing from the main process.
2Strength
If conventional heating and cooling processes are used to prepare low-fat spreads, then the product may achieve desired firmness, but the product quality deteriorates due to temperature changes
Solution Approach 1:
The fat crystal network is formed in advance during fat powder production rather than during the emulsion preparation. This preliminary formation of the crystal network protects it from degradation during subsequent processing and storage, maintaining consistent product quality and firmness without exposure to damaging temperature cycles.
3Use of energy by moving object
If fat powder with microporous structure is used to eliminate heating steps, then energy consumption is reduced, but the choice of structuring agents is limited and saturated fatty acid content remains high
Solution Approach 1:
The invention changes the physical state parameter of the structuring fat from liquid or bulk solid to fine powder form. This parameter change enables the use of a broader range of fats and oils that can be effectively micronized, including those with lower saturated fatty acid content and more favorable melting profiles, thus expanding fat selection flexibility while maintaining energy 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 approach reduces energy consumption, enhances spreadability and heat stability, and minimizes free water in the final product, resulting in a low-fat continuous spread of predictable quality suitable for industrial production.
Implementation Method 1
mixing fat powder and oil wherein the fat powder comprises structuring fat to provide a slurry
Implementation Method 2
mixing the slurry and aqueous phase to form an oil continuous emulsion
Implementation Method 3
providing a gel forming aqueous phase wherein the aqueous phase has a specific viscosity and gel strength
Data Source
AI summary
The invention relates to process for the preparation of an edible fat continuous spread comprising an aqueous phase and up to 45 wt% fat, comprising the steps of: a. mixing fat powder and oil wherein the fat powder comprises structuring fat to provide a slurry; b. providing a gel forming aqueous phase; c. mixing the slurry and aqueous phase to form an oil continuous emulsion; wherein the aqueous phase has a specific viscosity and gel strength.