High Pressure Homogenization for Emulsion Viscosity
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Solution Overview
Problem
Conventional mayonnaise products face challenges in achieving high viscosity and creamy mouthfeel while reducing fat content and minimizing the use of added thickeners, which can affect taste and consumer acceptance.
Innovation Solution
A high pressure homogenization process is used to create an emulsion with enzyme-modified egg, edible acidulant, and oil, resulting in a product with 55-72% fat and smaller oil droplet sizes, providing superior creamy mouthfeel and viscosity with reduced protein and starch content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional colloid mill homogenization is used, then the process is simple and easy to operate, but the oil droplet size is large (3-50 microns) and viscosity is insufficient
Solution Approach 1:
The patent applies high pressure homogenization (10-200 MPa) to dramatically reduce oil droplet size from 3-50 microns to sub-micron sizes (0.1-10 microns). This parameter change in pressure intensity transforms the homogenization process to achieve the desired manufacturing precision for small droplet size while maintaining operational simplicity
Solution Approach 2:
The patent replaces conventional mechanical colloid mill homogenization with high pressure homogenization technology. This substitution uses pressure-driven flow through narrow gaps rather than mechanical shear, achieving superior droplet size reduction without complex mechanical components
2Quantity of substance
If egg content is reduced to lower protein levels, then health benefits and cost savings are achieved, but viscosity and emulsion stability deteriorate
Solution Approach 1:
The patent modifies the emulsifier properties by using enzyme-treated egg yolk (phospholipase treatment) to create lysophospholipids with enhanced emulsifying capacity. This parameter change in molecular structure allows lower egg content (0.1-5% vs conventional 3-7%) while maintaining or improving emulsion stability
Solution Approach 2:
The patent creates a composite emulsion system combining enzyme-modified egg yolk with specific oil phases and optional hydrocolloids. This composite approach enhances emulsifying efficiency, allowing reduced egg content while maintaining stability through synergistic interactions between components
3Stability of the object's composition
If starch or gum thickeners are added to increase viscosity, then the desired texture and consistency are achieved, but mouthfeel and flavor are adversely affected
Solution Approach 1:
The patent replaces chemical thickening (starch/gum) with physical-chemical emulsification enhancement through high pressure homogenization and enzyme treatment. This substitution achieves viscosity (20-500 cP) through controlled droplet size and interfacial properties rather than macromolecular thickeners, preserving mouthfeel and flavor
Solution Approach 2:
The patent changes the fundamental mechanism of viscosity generation from polymer-based thickening to emulsion-based thickening through ultra-fine droplet dispersion. By controlling droplet size distribution and interfacial area, the system achieves desired viscosity without compromising sensory properties
4Stability of the object's composition
If chemical emulsifiers are incorporated to maintain emulsion stability with reduced egg content, then emulsion stability is maintained, but off flavors are imparted and the product is perceived as artificial
Solution Approach 1:
The patent transforms natural egg yolk through enzymatic treatment (phospholipase) to create lysophospholipids with enhanced emulsifying properties. This parameter change in molecular structure improves emulsifying efficiency without introducing chemical emulsifiers, maintaining natural flavor and consumer acceptance
Solution Approach 2:
The patent enables the egg yolk itself to provide enhanced emulsifying function through enzymatic modification. The enzyme-treated egg yolk serves its own emulsification needs more effectively, eliminating the requirement for additional chemical emulsifiers and their associated off-flavors
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 process achieves a viscosity of 200-400 Pa·s and oil droplet sizes of 0.8-10 microns, offering improved emulsification and stability, allowing for lower fat content products with similar creaminess and viscosity to conventional products.
Implementation Method 1
high pressure homogenization
Implementation Method 2
high pressure homogenization process
Implementation Method 3
enzyme-modified egg
Implementation Method 4
enzyme-modified egg yolk that has been treated with phospholipase
Implementation Method 5
emulsifying agent and a deformable liquid distributed in small globules throughout the body of a second liquid
Implementation Method 6
The globules of the discontinuous phase may be held together by London-van der Walls attraction forces
Data Source
Figure 1
Figure 2
Figure 3(A)
AI summary
An emulsified food product and method of making and using are provided herein. The emulsified food product has a small oil droplet size while also providing increased viscosity in a stable emulsion having a high fat content. The method achieves the increased viscosity and small oil droplet size by use of high pressure homogenization with enzyme-modified egg with a high fat content. The emulsified food product can be used directly as a mayonnaise product or combined with further ingredients to provide other products, including mayonnaise products with lower fat content but desirable creamy mouthfeel and viscosity.