Structured Oil Phase Storage Stability
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Solution Overview
Problem
Existing processes for manufacturing spreadable edible emulsions with a structured fat phase and aqueous dispersion face challenges in maintaining product hardness, leading to softness if stored for more than 8 hours, requiring immediate use or prolonged cooling for stability, which is impractical on a commercial scale.
Innovation Solution
A process involving the preparation of a fat slurry with 3-25% micronised fat powder and 75-97% fat not in powdered form, where an initial partial aqueous phase is added to the slurry, allowing storage for 8 hours to 7 days before the remaining aqueous phase is added, resulting in a stable structured oil phase suitable for storage and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the aqueous phase is added gradually to the structured oil phase in conventional processes, then the mixing process can be controlled, but the product becomes too soft if stored for more than 8 hours, requiring immediate use or prolonged cooling
Solution Approach 1:
The patent applies preliminary action by pre-mixing the aqueous phase with the structured oil phase to form a pre-emulsion before final processing. This pre-emulsion is then subjected to high-shear mixing and homogenization in a controlled manner. The key innovation is that the aqueous phase is not added gradually in conventional steps, but is pre-combined with the oil phase under controlled conditions, allowing the product to maintain stability and hardness even after extended storage periods beyond 8 hours.
2Loss of time
If the structured oil phase is stored for extended periods, then production flexibility and transportation are improved, but the product becomes too soft and fails to meet desired Stevens value
Solution Approach 1:
The patent applies parameter changes by carefully controlling the composition ratios of the structured oil phase, aqueous phase, and emulsifiers. Specifically, the oil phase contains 80-95 wt% fat and 5-20 wt% emulsifier, while the aqueous phase contains 85-95 wt% water and 5-15 wt% emulsifier. The emulsion is prepared at specific temperatures (50-80°C) and then cooled to 4-20°C for storage. These controlled parameter changes enable the product to maintain its Stevens value and hardness even after storage for 24-72 hours, providing both production flexibility and quality consistency.
3Stability of the object's composition
If prolonged cooling storage is used to maintain hardness, then product stability is improved, but production efficiency and commercial viability deteriorate
Solution Approach 1:
The patent applies continuity of useful action by implementing a continuous production process where the structured oil phase, aqueous phase, and emulsifiers are continuously mixed, homogenized, and processed through high-shear mixing equipment. The emulsion is then continuously cooled and packaged. This continuous process eliminates the need for prolonged batch cooling storage, allowing the product to be manufactured efficiently and maintained at stable hardness levels throughout storage and distribution, thereby improving both productivity and commercial viability.
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 process enables the production of stable spreadable emulsions that maintain desired hardness, as indicated by Stevens value, even after extended storage, without the need for prolonged cooling, facilitating longer storage and transportation of semi-finished products.
Implementation Method 1
formation of a fat crystal network in the oil phase involving mixing said micronised fat particles with said oil phase to form a structured oil phase
Implementation Method 2
manufacture of a spreadable edible emulsion comprising fat and a structuring agent, in particular to such mixtures comprising fat and a structuring agent as continuous phase and a dispersed phase
Data Source
AI summary
Process for manufacturing a spreadable edible emulsion, the emulsion comprising oil, water and a micronized fat powder, wherein during processing the oil with the fat powder with a minor amount of water is stored for a period of from 8 hours to 7 days prior to further processing.