Low Fat Emulsion Process Using High Shear Mixing
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Solution Overview
Problem
Manufacturing low-fat spreads with fat levels between 15 and 50% by weight is challenging due to instability issues, requiring strong emulsifiers like polyglycerol polyricinoleate (PGPR) or carbohydrate-based thickeners such as starch or gelatine, which are undesirable for a 'clean label', and existing processes are energy-intensive or require complex equipment.
Innovation Solution
A process involving the preparation of a fat phase with vegetable oil and hardstock fat at a temperature below 60°C, combined with an aqueous phase using a high shear mixer with a rotor and stator, achieving emulsification with droplet sizes less than 15 micrometers without the need for PGPR, starch, or gelatine, and minimizing energy consumption by avoiding further processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If strong emulsifiers like PGPR or carbohydrate-based thickeners are used to stabilize low-fat spreads, then emulsion stability is improved, but the product declaration becomes less clean with more functional ingredients
Solution Approach 1:
The patent extracts and eliminates the need for strong emulsifiers like PGPR and carbohydrate-based thickeners from the formulation. By using a specific combination of fatty acid monoglyceride emulsifier (0.1-2%) and controlling the fat phase composition (vegetable oil and hardstock fat in specific ratios), the invention achieves stability without requiring these additional functional ingredients, thus achieving a cleaner label while maintaining emulsion stability
Solution Approach 2:
The patent changes the chemical and physical parameters of the emulsion system by controlling the fat content (15-50%), adjusting the temperature below 60°C, and optimizing the ratio of vegetable oil to hardstock fat. These parameter changes enable the emulsion to achieve stability through the inherent properties of the fat phase and basic emulsifier, eliminating the need for additional functional ingredients
2Ease of manufacture
If conventional votator or churn processes are used to manufacture water-in-oil emulsions, then emulsion formation is achieved, but energy consumption increases due to heating and cooling requirements
Solution Approach 1:
The patent changes the temperature parameter by conducting the emulsification process at temperatures below 60°C, avoiding the need for extensive heating and cooling cycles required by conventional processes. This temperature control reduces energy consumption while maintaining effective emulsion formation through the optimized fat phase composition and high-shear mixing
Solution Approach 2:
The patent employs continuous high-shear mixing throughout the process, eliminating the need for separate heating and cooling steps. The continuous action of the high-shear mixer ensures uniform emulsification while maintaining temperature control, reducing overall energy consumption compared to conventional batch processes
3Object-generated harmful factors
If fat continuous low fat spreads are manufactured without additional ingredients, then the label becomes cleaner, but emulsion stability deteriorates
Solution Approach 1:
The patent creates a composite fat phase system combining vegetable oil and hardstock fat in specific ratios, which provides inherent stabilizing properties. This composite approach, combined with the fatty acid monoglyceride emulsifier, enables the emulsion to maintain stability without requiring additional functional ingredients like PGPR or thickeners, thus achieving both clean label and stable emulsion
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 produces stable, spreadable low-fat emulsions with improved stability and reduced energy usage, allowing for the creation of low-fat spreads without strong emulsifiers or complex equipment, meeting consumer preferences for a cleaner label and energy efficiency.
Implementation Method 1
subject such to a high shear mixing process in a high shear mixer having a rotor and a stator, with a residence time of less than 3 seconds, and sufficient shear to effect emulsification of water droplets in oil having a droplet size d3,3 of less than 15 micrometer
Implementation Method 2
preparing a fat phase comprising vegetable oil, hardstock fat and fatty acid monoglyceride emulsifier, which fat phase is at a temperature such that the whole fat phase is liquid, and wherein the temperature is below 60°C, preferably below 50°C
Data Source
AI summary
A process for preparing a low fat water-in-oil emulsion which emulsion comprises water, oil and a hardstock fat. The process involves combining an aqueous phase and a fat phase, wherein the fat phase comprises the hardstock fat and which fat phase is at a temperature such that the fat phase is liquid, followed by subjecting the obtained mixture to high shear mixing effected a high shear mixing device, and wherein the product exiting the high shear mixing process the product is packed without having been subject to any further mixing or working process.