Micronized Hardstock Fat for Stable Emulsions
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Solution Overview
Problem
Existing processes for preparing spreadable water-in-oil emulsions, such as margarine, require energy-intensive heating and cooling steps, which can deteriorate ingredients and result in products with undesirable properties like waxy mouthfeel and instability upon temperature cycling.
Innovation Solution
A hardstock fat blend comprising at least 90% triglyceride fat with specific triacylglyceride compositions (PPP, H2M, H2U) is used, which does not contain hydrogenated fats, and is processed using the Super Critical Melt Micronisation (ScMM) method to create a micronized fat powder that can be blended with oil to form a stable emulsion without the need for extensive heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional heating and cooling steps are used to prepare spreadable water-in-oil emulsions, then the structuring fat can be properly incorporated and emulsion formed, but energy consumption increases and ingredient deterioration occurs
Solution Approach 1:
The patent changes the physical state parameter of the structuring fat from liquid (requiring heating) to solid powder form (micronized fat), allowing incorporation at lower temperatures. This parameter change eliminates the need for energy-intensive heating and cooling steps while maintaining emulsion stability through the controlled particle size and solid fat content.
Solution Approach 2:
The structuring fat is pre-micronized into fine particles before incorporation into the emulsion. This preliminary action of micronization allows the fat to be evenly distributed and incorporated at lower temperatures without requiring subsequent heating steps, thereby reducing energy consumption while ensuring proper emulsion formation.
2Stability of the object's composition
If conventional heating and cooling steps are used, then the fat phase can be properly structured, but product quality deteriorates due to temperature changes
Solution Approach 1:
The patent changes the temperature parameter during processing by using micronized solid fat instead of liquid fat, allowing the emulsion to be prepared at lower temperatures. This prevents thermal deterioration of ingredients while the controlled crystallization of micronized fat particles forms a stable fat crystal network that structures the emulsion properly.
3Reliability
If hydrogenated fats are used as hardstock, then the fat has improved stability and structure, but trans-fatty acids are formed which are undesirable
Solution Approach 1:
The patent changes the chemical composition parameter by selecting specific triglyceride profiles (high PPP, H2M, and H2U content) that provide emulsion stability and structure without requiring hydrogenation. This natural composition approach achieves the desired stability while avoiding the formation of harmful trans-fatty acids associated with conventional hydrogenated fats.
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 hardstock fat blend achieves improved properties like small water droplet size, good spreadability, and stability after temperature cycling, reducing energy consumption and maintaining product quality.
Implementation Method 1
processed using the Super Critical Melt Micronisation (ScMM) method to create a micronized fat powder
Implementation Method 2
cooling of the mixture under high shear to induce crystallization of the structuring fat to create an emulsion; formation of a fat crystal network to stabilize the resulting emulsion
Data Source
AI summary
A hardstock fat composition for use in making edible water-in-oil emulsions such as spreads, in particular (but not exclusively) when produced using the hardstock in the form of micronized fat powder, and process to use such hardstock fat to make a fat slurry and to make a water-in-oil emulsion (like spreads) using such hardstock fat. The hardstock fat may give improved properties of the resulting emulsion.