Fat-Continuous Spread Preparation Using Vacuum Degassing
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Solution Overview
Problem
Existing processes for preparing edible fat-continuous spreads are energy-intensive, limit the choice of structuring fats, and can result in unstable products with poor spreading characteristics due to gas bubble incorporation when using fat powder, especially when aiming for low fat content and reduced saturated fatty acids.
Innovation Solution
A process involving a mixture of fat powder and water-phase subjected to at least a partial vacuum to reduce gas bubbles, allowing for efficient degassing and preparation of stable, low-fat edible spreads without the need for heating and cooling the entire composition, using pre-crystallized structuring fat and micronized fat powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the complete composition is subjected to heating and cooling steps to induce crystallization, then the structuring fat forms a stable crystal network, but energy consumption increases significantly
Solution Approach 1:
The structuring fat is pre-crystallized into fat powder before being incorporated into the spread composition. This preliminary crystallization action eliminates the need for subsequent heating and cooling steps during the spread manufacturing process, significantly reducing energy consumption while maintaining stable emulsion formation
Solution Approach 2:
The crystallization step is extracted from the main manufacturing process and performed separately in advance to produce fat powder. This separation allows the crystallization to occur under optimized conditions independently, and the pre-crystallized fat is then simply incorporated into the spread without requiring repeated thermal processing
2Use of energy by moving object
If fat powder is used to reduce energy consumption, then heating and cooling steps are eliminated, but gas bubbles are incorporated into the product causing instability
Solution Approach 1:
A water-phase mixture serves as an intermediary medium to incorporate the fat powder. The fat powder is mixed with the water-phase at controlled conditions, allowing gas bubbles to be excluded during the mixing process. This intermediary step ensures stable incorporation of pre-crystallized fat without introducing gas bubbles that would compromise product stability
Solution Approach 2:
The mixing process parameters are specifically controlled when incorporating fat powder into the water-phase. By adjusting mixing speed, temperature, and pressure parameters, the process achieves thorough incorporation of fat powder while excluding gas bubbles, maintaining both low energy consumption and product stability
3Adaptability or versatility
If conventional processes are used to prepare spreads, then the structuring fat can be selected from limited options, but the choice of structuring fats with reduced saturated fatty acids is restricted
Solution Approach 1:
The invention changes the physical state parameter of the structuring fat from liquid or bulk solid form to pre-crystallized powder form. This parameter change allows the use of various fats with different fatty acid compositions, including those with reduced saturated fatty acids, while the pre-crystallized structure ensures stable emulsion formation and product stability
Solution Approach 2:
The pre-crystallized fat powder serves multiple functions: it provides the necessary structuring and crystal network formation, reduces energy consumption during processing, and enables the use of diverse fat types including those with improved nutritional profiles. This multi-functionality expands the versatility of structuring fat selection without compromising product stability
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 processing time, energy consumption, and achieves stable, low-fat spreads with improved spreading characteristics and reduced free water, maintaining product stability and nutritional profile.
Implementation Method 1
subjecting said mixture to at least a partial vacuum
Data Source
AI summary
Process for the preparation of an edible fat-continuous spread comprising at most 45 wt. % of fat using liquid oil, a fat powder comprising structuring fat and a water-phase, comprising the steps of: a. providing a mixture comprising the water-phase and the fat powder; b. subjecting said mixture to at least a partial vacuum; c. mixing the mixture prepared at step ‘b’ to provide a fat-continuous spread, wherein the liquid oil may be added to the mixture at any of steps ‘a’, ‘b’, or ‘c’ or when added in parts in any combination at steps ‘a’, ‘b’ and ‘c’.