Plant-Based Frozen Confection Premix With Rotor-Stator Mixing
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Solution Overview
Problem
The production of high-quality, plant-based frozen confections faces challenges in formulating concentrated premixes that avoid undissolved stabilizers, protein aggregates, and large oil droplets, while requiring energy-efficient manufacturing at scale.
Innovation Solution
A concentrated premix is formulated as an oil-in-water emulsion with specific ingredient ratios, using a rotor-stator mixer for emulsification, allowing for dilution with water to create a premix suitable for plant-based frozen confections, and can be stored and shipped in intermediate bulk containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If concentrated premix is formulated with high total solids content, then storage and shipping efficiency is improved, but risk of undissolved stabilizers and protein aggregates increases
Solution Approach 1:
The stabilizer is added to the aqueous phase before concentration, allowing it to pre-hydrate and form a stable network that can accommodate high solids content without aggregating. This preliminary action ensures that when the premix is concentrated to high total solids (60-85%), the stabilizer is already in position to prevent protein aggregation and maintain uniform dissolution upon reconstitution.
Solution Approach 2:
The patent optimizes the stabilizer concentration range (0.3-1.2 wt%) and adjusts the aqueous phase composition to balance ionic strength and pH, creating parameters that favor stabilizer solubility and effectiveness at high concentrations. This parameter optimization allows the premix to maintain stability even with high total solids content.
2Quantity of substance
If concentrated premix is produced to reduce shipping volume, then transportation efficiency is improved, but equipment capital outlay and manufacturing complexity increase
Solution Approach 1:
The patent extracts the fat phase as a separate component, formulating the concentrated premix as an oil-in-water emulsion where the aqueous phase contains all the stabilizers, proteins, and sugars. This extraction allows the concentrated premix to be manufactured with simpler equipment since the fat can be added separately during reconstitution, avoiding the need for complex high-pressure homogenization equipment at the concentration stage.
Solution Approach 2:
The premix manufacturing process is segmented into two stages: (1) concentration of the aqueous phase with stabilizers and proteins, and (2) emulsification with fat phase during reconstitution. This segmentation allows each stage to use optimized, simpler equipment rather than requiring all equipment simultaneously, reducing capital outlay.
3Manufacturing precision
If standard homogenization equipment is used for emulsification, then oil droplet size control is improved, but energy consumption increases
Solution Approach 1:
The patent changes the physical parameters of the emulsion by optimizing the aqueous phase viscosity through stabilizer selection and concentration. The stabilizers create a network that facilitates oil droplet breakup at lower shear stresses, allowing effective emulsification with less energy input while maintaining controlled droplet size distribution.
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 solution enables high-quality, energy-efficient production of plant-based frozen confections with controlled oil droplet sizes and reduced equipment capital outlay, facilitating remote dilution and handling, and improving manufacturing efficiency.
Implementation Method 1
combining the mixture of aqueous solids with oil and emulsifying to form the concentrated premix
Implementation Method 2
In order to facilitate hydration of the stabilizer, the stabilizer is added after at least one of the more readily soluble ingredients has been combined with water
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 2c~2d
AI summary
The invention relates to concentrated premixes for the manufacture of plant-based frozen confections. The concentrated premixes are oil-in water emulsions having a high total solids content.