Fatty Preparation Using Discontinuous Emulsification
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Solution Overview
Problem
The food industry faces challenges in finding alternatives to palm oil that do not contain high levels of saturated fats, trans fats, or other harmful fatty acids, while also requiring a more efficient and cost-effective production process.
Innovation Solution
A new fatty preparation is developed, composed of a vegetable oil and an emulsifying agent, such as E-471, E-472, or E-475, which is produced using a discontinuous process that reduces the need for multiple reactors and high-temperature operations, thereby offering a stable and less oxidized product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If palm oil is used as a fat substitute in food products, then the production cost is reduced and the texture is improved, but the saturated fat content increases to higher than 40% by weight
Solution Approach 1:
The patent combines multiple vegetable oils (sunflower oil, olive oil, rapeseed oil, or a mixture thereof) with specific emulsifying agents (E-471, E-472, or E-475) to create a fatty preparation that achieves the desired texture and functional properties without relying on single high-saturated-fat oils like palm oil
Solution Approach 2:
The patent changes the compositional parameters by specifying exact proportions of vegetable oils (50-99% by weight) and emulsifying agents (1-50% by weight), ensuring the saturated fat content remains below 40% while maintaining the functional properties needed for food processing
2Productivity
If a continuous process with multiple reactors is used to produce fatty preparation, then the production capacity is increased, but the device complexity and operational cost increase
Solution Approach 1:
The patent segments the production process into discrete operational steps (heating oil, adding emulsifier, mixing, cooling, packing) that can be performed sequentially in a single reactor, eliminating the need for multiple reactors while maintaining production efficiency
Solution Approach 2:
The patent employs periodic action by using a discontinuous process where the single reactor is emptied, cleaned, and refilled between batches, allowing the same equipment to handle multiple production cycles without requiring continuous operation across multiple units
3Ease of manufacture
If high-temperature operations are used during fatty preparation, then the emulsifying agent dissolves completely, but the oxidation of the product increases
Solution Approach 1:
The patent optimizes the temperature parameter by heating the vegetable oil to specific ranges (80-90°C for sunflower oil, 70-80°C for olive oil, 80-90°C for rapeseed oil) which are sufficient to dissolve the emulsifying agent but remain below temperatures that would cause significant oxidation
Solution Approach 2:
The patent minimizes the time the emulsifying agent is exposed to high temperatures by adding it to the heated oil and immediately proceeding to mixing and cooling, rushing through the dissolution phase before oxidation can occur
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
The proposed solution provides a stable and less oxidized fatty preparation that can be used as a substitute for palm oil in food products, reducing the risk of health issues associated with saturated and trans fats, while also simplifying the production process and reducing costs.
Implementation Method 1
heating an oil in an amount between 50 and 99% by weight with respect to the total preparation... in a reactor up to 90° C.
Implementation Method 2
adding a fatty acid mono- and diglycerides-type emulsifier... to the oil of step a) until obtaining a complete dissolution
Implementation Method 3
cooling the mixture to 60-70° C.
Data Source
AI summary
The present invention relates to a process for making a fatty preparation to be incorporated in a food product, wherein said fatty preparation does not comprise fats with a saturated fat content higher than 40% by weight nor trans fats, nor totally or partially hydrogenated oils or fats, nor interesterified fats. The present invention further relates to a fatty preparation and to a food product comprising the same.