Oil-in-Water-in-Oil Emulsion for Low-Temperature Spreadable Butter
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Solution Overview
Problem
Existing methods for producing low-temperature spreadable butters are inefficient, often requiring multiple fractionation steps, result in unstable products, and cannot be legally defined as 'butter' due to the use of stabilizers, and are not stable under fluctuating temperature conditions.
Innovation Solution
A butter-based product is created using an oil-in-water-in-oil emulsion by dispersing a high melting butterfat component into a butter serum to form a primary emulsion, which is then dispersed into a lower melting butterfat component to form a secondary emulsion, stabilized by naturally occurring emulsifiers and processed to maintain spreadability at refrigeration temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple fractionation components are used to produce low temperature spreadable butter, then spreadability at low temperatures is improved, but device complexity and manufacturing time increase due to multiple fractionation steps
Solution Approach 1:
The patent segments the butterfat into distinct functional components (stearine fraction for structure, olein fraction for spreadability) and processes them separately through selective fractionation, then combines them in a controlled emulsion process to achieve the desired spreadability without requiring multiple sequential fractionation steps
Solution Approach 2:
The patent changes the physical state parameters of butterfat components by controlling temperature and phase transitions during fractionation, separating stearine and olein fractions through melting point differences, then recombining them in an emulsion to achieve low-temperature spreadability
2Ease of operation
If stabilizers and gums are added to produce spreadable butter, then spreadability is improved, but the product cannot be legally defined as 'butter' according to USDA definitions
Solution Approach 1:
The patent uses naturally occurring emulsifiers present in dairy proteins and milk solids to stabilize the emulsion structure, eliminating the need for added stabilizers and gums, thereby maintaining the product's qualification as legal butter while achieving the desired spreadability
Solution Approach 2:
The patent creates a composite emulsion system combining fat globules, aqueous phase with dairy proteins, and naturally occurring emulsifiers that work synergistically to provide spreadability without requiring synthetic additives, maintaining both functional performance and legal compliance
3Productivity
If high-fat cream undergoes phase inversion to butter, then production efficiency is improved, but the resulting dairy products are unstable and do not remain spreadable after exposure to fluctuating temperature conditions
Solution Approach 1:
The patent incorporates naturally occurring emulsifiers and dairy proteins into the emulsion structure beforehand to cushion against temperature fluctuations, preventing phase separation and maintaining spreadability stability without requiring post-processing stabilization
Solution Approach 2:
The patent controls the emulsion parameters including droplet size distribution, phase composition, and interfacial properties to create a thermally stable structure that resists breakdown under temperature cycling while maintaining production efficiency
4Ease of manufacture
If only a small portion of fractionation components are used during production, then production cost is reduced, but the remaining components require disposal or complex distribution to keep the process economical
Solution Approach 1:
The patent recovers and utilizes the previously discarded fractionation components by incorporating them into the emulsion structure, where they serve functional roles in maintaining stability and texture, thereby eliminating waste and improving overall process economics
Solution Approach 2:
The patent assigns multiple functional roles to the fractionation components, using both stearine and olein fractions as structural and functional elements in the emulsion, making full use of the fractionation output and eliminating the need for disposal or complex distribution of unused components
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 product remains stable and spreadable from 32°F to 45°F and withstands temperature cycling up to 72°F, maintaining a smooth consistency and legal definition as 'butter' with enhanced emulsion stability and penetrometer values.
Implementation Method 1
dispersing a high melting (stearine) butterfat component into a butter serum or dairy protein solution to form a primary emulsion
Implementation Method 2
The primary emulsion is then dispersed into an olein butterfat component to form a secondary emulsion
Implementation Method 3
The secondary emulsion is cooled to a temperature that ranges from about 33° F. to about 38° F. to form the butter-based product that is spreadable at refrigeration temperatures
Implementation Method 4
The secondary emulsion is cooled to a temperature that ranges from about 33° F. to about 38° F. to form the butter-based product
Data Source
AI summary
A method of forming a butter product comprises forming a primary oil-in-water emulsion by dispersing liquefied stearine butterfat in a butter serum, the liquefied stearine butterfat forming stearine globules within the butter serum. The primary oil-in-water emulsion is dispersed into an olein butterfat component forming an oil-in-water-in-oil emulsion, and the oil-in-water-in-oil emulsion being cooled to form the butter product which is spreadable at a temperature of less than about 45° F.