Microporous Structuring Agent for Spreadable Edible Dispersion
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Solution Overview
Problem
Existing processes for preparing edible dispersions, such as margarines and spreads, require significant energy due to heating and cooling steps, limit the types of structuring agents that can be used, result in high saturated fatty acid content, and are challenging for incorporating heat-sensitive ingredients, especially in low-fat spreads which often require inversion steps that are difficult to control.
Innovation Solution
A process involving the gradual addition of an aqueous phase to a mixture of oil and micronised solid structuring agent particles with a microporous structure, eliminating the need for inversion and allowing the use of a wider range of structuring agents, reducing saturated fatty acid content, and enabling the incorporation of heat-sensitive ingredients, resulting in products with improved microbiological stability and firmness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating and cooling steps are used to prepare edible dispersions, then emulsion stability and melting properties are improved, but energy consumption increases significantly
Solution Approach 1:
The invention changes the temperature parameter from high-temperature heating/cooling cycles to ambient temperature processing. The micronised structuring agent particles are mixed with oil and aqueous phase at or near ambient temperature, eliminating the need for energy-intensive thermal processing while maintaining emulsion stability through the microporous structure of the particles.
Solution Approach 2:
The invention replaces the thermal system (heating and cooling apparatus) with a mechanical mixing system. The micronised particles provide structuring through their physical structure rather than through thermal processing, substituting mechanical mixing for thermal processing to achieve the desired emulsion stability.
2Reliability
If traditional structuring agents with high melting points are used, then emulsion stability is improved, but mouthfeel becomes heavy and waxy
Solution Approach 1:
The invention changes the particle size parameter from conventional large particles to micronised particles with submicron thickness (0.01-0.5 μm). This size reduction allows the structuring agent to provide stability while melting more easily at mouth temperature, eliminating the heavy and waxy mouthfeel associated with traditional high-melting-point structuring agents.
Solution Approach 2:
The invention uses micronised structuring agent particles with a microporous structure. The porous structure increases surface area and provides more interaction sites for stabilizing the emulsion, while the small particle size ensures easy melting in the mouth. The microporous structure allows the particles to effectively structure the dispersion without requiring high melting points.
3Reliability
If inversion step is used in low-fat spread preparation, then water-in-oil emulsion is achieved, but process control becomes difficult and rework problems occur
Solution Approach 1:
The invention performs preliminary action by pre-micronising the structuring agent particles before mixing. The micronised particles are prepared in advance with the desired submicron size and microporous structure, so that when mixed with oil and aqueous phase, they directly form the water-in-oil emulsion without requiring a subsequent inversion step. This eliminates the difficult-to-control inversion process entirely.
Solution Approach 2:
The invention inverts the traditional process sequence. Instead of forming an oil-in-water emulsion and then inverting it to water-in-oil, the micronised structuring agent particles directly structure the dispersion to form water-in-oil emulsion in a single mixing step. This reverse approach eliminates the inversion step and its associated control difficulties.
4Reliability
If heating steps are used to prepare dispersions, then structuring agent functionality is activated, but heat-sensitive ingredients deteriorate
Solution Approach 1:
The invention changes the temperature parameter from elevated heating temperatures to ambient temperature processing. The micronised structuring agent particles provide their structuring functionality at or near ambient temperature through their microporous structure and large surface area, eliminating the need for heating that would deteriorate heat-sensitive ingredients such as vitamins, antioxidants, and flavor compounds.
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 reduces energy consumption, expands the range of usable structuring agents, decreases saturated fatty acid content, and allows for the production of low-fat spreads without thickeners or gelling agents, achieving increased microbiological stability and firmness with smaller water droplet sizes.
Implementation Method 1
The solid structuring agent particles, also described as secondary particles have a microporous structure
Implementation Method 2
said particles are agglomerates of primary particles of submicron size, said primary particles are platelets having an average thickness of 0.01-0.5 μm
Implementation Method 3
The solid structuring agent particles, also described as secondary particles have a microporous structure
Data Source
AI summary
Process for the preparation of a spreadable edible dispersion wherein a mixture of oil and solid structuring agent particles is subjected to stirring and an aqueous phase and/or solid phase is gradually added to the mixture until a dispersion of the desired oil content is obtained, wherein the solid structuring agent particles have a microporous structure of submicron size particles.