Multiphase Oil Delivery System for Dough Crispness
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Solution Overview
Problem
Existing methods for delivering milkfat components to dough often result in intersolubility between fat phases, compromising the quality and crispness of final products like crackers, as they fail to maintain the milkfat component's integrity and functionality within the dough system.
Innovation Solution
A multi-phase emulsion system is developed, specifically an oil-in-water-in-oil (o/w/o) emulsion where a solid milk-derived fat is dispersed in an aqueous phase, which is then incorporated into a liquid vegetable oil phase, maintaining the milkfat's separate functionality and enhancing material handling benefits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If melted fats are blended into dough to achieve material handling benefits, then ease of operation is improved, but the milkfat component loses its integrity and functionality due to intersolubility with other fat phases
Solution Approach 1:
The fat component is segmented into distinct phases: milkfat is separated from vegetable oil and encapsulated within aqueous droplets. This segmentation prevents intersolubility between fat phases while maintaining pumpability, as the aqueous phase acts as a barrier between the immiscible fat components.
Solution Approach 2:
The emulsion structure employs a nested configuration where milkfat droplets are embedded within aqueous phase droplets, which are in turn dispersed in the vegetable oil continuous phase. This nested arrangement (o1/w/o2) protects the milkfat component while enabling liquid delivery.
2Ease of operation
If milkfat is delivered in liquid form for pumpability, then ease of operation is improved, but the milkfat loses its functional properties that require solid fat structure
Solution Approach 1:
The system exploits temperature-dependent phase transitions of milkfat. At processing temperatures above its melting point, milkfat is liquid and pumpable; at dough formulation and baking temperatures below its melting point, it solidifies to provide the desired functional properties for crispness and texture.
Solution Approach 2:
The aqueous phase serves as an intermediary medium that enables liquid delivery of milkfat while preserving its solid fat structure within droplets. This intermediary phase allows the milkfat to be pumped in liquid form yet maintain its functional integrity when delivered to the dough.
3Stability of the object's composition
If emulsifiers are added to stabilize the emulsion, then stability of the object's composition is improved, but the complexity of the system increases
Solution Approach 1:
The system leverages the natural emulsifying properties of the aqueous phase and interfacial tension between immiscible phases to stabilize the emulsion structure. The inherent physical chemistry of the oil-water-oil system provides self-stabilization, reducing or eliminating the need for additional emulsifier chemicals and simplifying the overall formulation.
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 approach ensures the milkfat component functions as intended, improving the crispness and flavor profile of dough products by maintaining separation from the vegetable oil phase, resulting in superior dough systems with enhanced taste and texture.
Implementation Method 1
dispersing milk derived fat into an aqueous phase to produce an oil1 in water primary emulsion wherein the milk derived fat is substantially solid
Implementation Method 2
The water primary emulsion is dispersed into a liquid vegetable based fat to produce an oil1 in water in oil2 emulsion in liquid form
Data Source
AI summary
A food ingredient delivery system for delivering food ingredients during manufacture of a food product comprising a multi-phase emulsion including a pumpable oil1 within water or aqueous solution within oil2 emulsion wherein the oil1 comprises solid milk derived fat droplets sequestered in an aqueous phase with the aqueous phase being dispersed in the oil2, the oil2 comprising a liquid, continuous vegetable based fat matrix.