Low Calorie Composite Sweetener Crystallization Process

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Solution Overview

Problem

Existing methods for producing low-calorie composite sweeteners face challenges such as high power consumption, batch variability, and instability under heat, which affect the quality and consistency of the final product.

Innovation Solution

A process involving granulated sugar with specific moisture content distributed on a vibrating surface, where a high concentration solution of steviol glycosides in a water-alcohol mixture is dispersed using pressure atomization, ensuring even distribution and attachment to the sugar granules, followed by controlled drying to produce a low-calorie sugar-high intensity sweetener blend.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high temperature (120°C) is used in co-crystallization process, then mixing and crystallization efficiency is improved, but color darkening and product appearance quality deteriorate

Engineering Contradiction:

Improvecrystallization efficiencyVSAvoidproduct appearance quality

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The invention changes the temperature parameter from high (120°C) to low (below 60°C, preferably 0-40°C) to prevent color darkening while maintaining crystallization efficiency through extended processing time and controlled cooling rates

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The process uses periodic cooling cycles with controlled rates (0.1-5°C per minute) to achieve gradual crystallization, allowing the system to maintain productivity while preventing thermal degradation and color changes

Inventive Principle:

Principle #19Periodic action

2Device complexity

If simple dry mixing process is used to blend sugar and high intensity sweetener, then manufacturing complexity is reduced, but product homogeneity and stability deteriorate due to stratification during transportation and storage

Engineering Contradiction:

Improvemanufacturing process complexityVSAvoidproduct homogeneity

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The invention merges sugar and high intensity sweetener into a unified co-crystallized structure where both components are distributed at molecular level within the crystal lattice, eliminating stratification issues while maintaining simple manufacturing processes

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention creates a composite co-crystallized material where sugar and high intensity sweetener form a stable integrated structure with enhanced homogeneity and stability during storage and transportation

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If vacuum pan co-crystallization is used to control pressure and temperature, then crystallization control is improved, but batch to batch variability in sweetness level increases due to uneven distribution of high intensity sweetener

Engineering Contradiction:

Improvecrystallization controlVSAvoidsweetness level consistency

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The process implements controlled cooling rates (0.1-5°C per minute) and monitoring of crystallization progression to ensure uniform distribution of high intensity sweetener throughout the crystal structure, reducing batch variability

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The high intensity sweetener is pre-dissolved in the sugar solution before crystallization begins, ensuring uniform initial distribution that is maintained throughout the controlled crystallization process

Inventive Principle:

Principle #10Preliminary action

4Productivity

If spray drying process is used to produce low calorie sweetener composition, then production speed is improved, but power consumption and equipment cost increase

Engineering Contradiction:

Improveproduction speedVSAvoidpower consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The invention replaces expensive, energy-intensive spray drying equipment with simpler, lower-cost crystallization vessels and cooling systems, achieving acceptable production rates without high power consumption

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 results in a product with improved homogeneity, heat resistance, and taste profile, maintaining the sweetness power three times higher than sugar while minimizing thermal degradation and color change, suitable for various food and beverage applications.

Implementation Method 1

a high concentration solution of steviol glycosides in a water-alcohol mixture is dispersed using pressure atomization, ensuring even distribution and attachment to the sugar granules

Methodology Applied

Scientific EffectPressure atomization:

Implementation Method 2

followed by controlled drying to produce a low-calorie sugar-high intensity sweetener blend

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS8591980B2Low calorie composite sweetener as sugar alternative and methods for producing the same

Publication Date: 2013.11.26 PURECIRCLE SDN BHD

AI summary

The invention provides a process for producing a low calorie composite sweetener as a sugar alternative. The invention further provides a low calorie composite sweetener that can be used in many products. The low calorie composite sweetener is useful as non-caloric sweeteners in edible and chewable compositions such as any beverages, confectionaries, bakeries, cookies, chewing gums, and alike.