Process for the preparation of structured oil phase

Abstract

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.

Claims

1. A process for the preparation of a spreadable edible emulsion comprising 15-80% fat slurry by weight and 20-85% of an aqueous phase by weight, the fat slurry comprising 3-25% of a micronised fat powder by weight and 75-97% by weight of a fat not in powdered form, the process comprising the steps of: a. providing a micronised fat powder, b. providing a fat not in powdered form, c. mixing the micronized fat powder with the fat not in powdered form to form a fat slurry, such that the slurry contains 3-25 wt. % micronised fat powder based on the total amount of fat slurry, d. adding an aqueous phase to the fat slurry to produce a mixture, in such an amount that the slurry contains up to half of the desired amount of aqueous phase of the final spreadable emulsion, e. storing the mixture from step (d) for a period of from 8 hours to 7 days, f. adding the remainder of the aqueous phase to the stored mixture, g. processing the combined aqueous phase and stored mixture from step (f) into a spreadable edible emulsion.

2. Process according to claim 1, wherein amount of the aqueous phase added is from 3 to 15% by weight, based on weight of the mixture made in step (d).

3. Process according to claim 1, wherein the fat not in powdered form is fat liquid at 20 C.

4. Process according to claim 1, wherein amount of the micronised fat powder is from 5 to 20% by weight of the fat slurry.

5. Process according to claim 1, wherein the micronised fat powder is obtained by a super critical melt micronisation process.

6. Process according to claim 1, wherein the storing in step e. is from 18 hours to 3 days.

7. Process according to claim 1, wherein the storage is at a temperature of from 0 to 20 C.

8. Process according to claim 1, wherein during the storing step e. the product is kept in motion.

9. Process according to claim 1, wherein the slurry is a structured fat.

10. Process according to claim 1, wherein the oil is a vegetable oil.

Description

DETAILED DESCRIPTION

(1) Micronised fat powder is herein to be understood as a particulate matter comprising at least 80% by weight of fat, which particulate matter is solid at 20 C., which micronised fat powder is obtainable by a super critical melt micronisation process, as described in J. of Supercritical Fluids 43 (2007) 181-190 and EP 1651338.

(2) Fat is herein to be understood as one or more lipids, at least 80% by weight composed of fatty acid triglycerides. Preferably said fat comprises at least 80% by weight of vegetable fat. Fat herein includes oil.

(3) Fat not in powdered form is herein to be understood as Fat, but other than in powdered form (including other than micronised fat powder). Preferably such fat not in powdered form is fat liquid at 20 C. (i.e. commonly understood as an oil).

(4) In essence the two processes as set out above are the same, except that the first process contains two additional steps, in that a second amount of a water phase is added, and the product is processed into an emulsion, preferably such as a spread. Regarding the first, the second water phase (in step f) may be of the same as the first (in step d) or of a different aqueous composition. Either of such has its own advantages. Regarding the processing into a spread, such is well known in the art, e.g. by utilizing a so-called pin-stirrer.

(5) In the processes of the present invention, it is preferred that the micronised fat powder utilized herein has a composition such that it is solid at 20 C. It is furthermore preferred that such micronised fat powder is manufactured by a process involving super critical melt micronisation process, and more preferably such as described in J. of Supercritical Fluids 43 (2007) 181-190 and EP1651338.

(6) As to the amount of micronised fat powder used in the processes according to the present invention such is not different from processes as known in the art that structure oil with micronised fat powder. Hence, the amount of the micronised fat powder on the total fat phase is preferably from 5 to 20%, and more preferably from 7 to 15% by weight on the fat phase. In the processes according to the present invention it is preferred that the slurry is a structured fat.

(7) In the processes according to the present invention, without wishing to be bound by theory, it was found that the addition of a small amount of water allows a structured fat (e.g. an oil structured by micronised fat particles) to be stored, without disadvantageous effects on products such as spreads produced therefrom subsequently. Such storing in step e. is preferably from 18 hours to 3 days, and more preferably from 24 hours to 2 days.

(8) The temperature of the mixture containing a slurry of fat and micronised fat powder (e.g. a structured oil phase) and which now contains some water is preferably stored in the processes according to the present invention at a temperature below the melting point of that of the micronised fat particles. More preferably, such is at a temperature of from 0 to 20 C., even more preferably from 4 to 10 C. During such storage step e. in the processes according to the present invention the dispersion that is stored is preferably kept in motion. Such can be carried out by conventional means, e.g. high speed impellers and/or anchor-stirrers.

(9) In the present invention, it is preferred that the fat not in powdered form is fat liquid at 20 C. Such is commonly understood as to be an oil. Preferred fats herein are vegetable fat. Hence, for the fat not in powdered form it is preferred that such is liquid at 20 C., e.g. an oil. Preferably the fat not in powdered form is a vegetable fat, e.g. a vegetable oil. In the present invention, the fat preferably comprises (more preferably for at least 50% of the fat) sunflower oil, rape seed oil, corn oil, palm kernel oil, coconut oil.

EXAMPLES

(10) Spreads Product Composition

(11) Edible spreads with a composition as in Table 1 were made according to the methods as described below.

(12) TABLE-US-00001 TABLE 1 Spreads product formulation (wt. %). wt % on batch Fat phase (fat slurry) composition inES48 powder 10 RP 78.68 PK 10 Dimodan RT/B 1.07 Colourant 0.25 Total 100 Water phase composition Demi-water (incl. acidifier) 99 Salt 0.83 Potassium sorbate 0.17 Total 100

(13) The water phase was acidified to pH of 4.8 using 20% citric acid solution. inES48 is an interesterified mixture of 65% dry fractionated palm oil stearin with an Iodine Value of 14 and 35% palm kernel oil. For examples 1 to 4 a micronised fat powder of inES48 was used that was obtained using a supercritical melt micronisation process, as described in J. of Supercritical Fluids 43 (2007) 181-190 and EP1651338.

(14) PK is palm kernel oil.

(15) RP is rape seed oil.

(16) Dimodan RT/B is a molecularly distilled mono/diacylglyceride mixture derived from fully hardened palm oil (90% monoglyceride) ex Danisco.

Preparation of Spreads According to the Invention (Example 1-4)

(17) Preparation of fat phase (=slurry).

(18) Cold oil and colorant are added to a stirring tank, mixed, and degassed. A stock solution of the emulsifier also comprising the liquid hardstock was prepared by mixing the emulsifier and the liquid hardstock with about 1% of the oil and heating it up to 75 degrees Celsius. The stock solution, cooled to about 70 degrees Celsius, was added to the degassed oil, with a temperature of about 14 degrees Celsius, and mixed. The temperature of the oil mixed with the stock solution will be about 18 degrees Celsius. Next, the inES48 micronised fat powder was added to the oil and mixed-in under vacuum. The micronised fat powder and oil mixture is mixed under high shear, using a reflux pipe until a slurry was obtained which appeared smooth and translucent. The maximum temperature increase observed due to mixing was about 21.5 degrees Celsius. Before being fed into the C-unit see below the temperature of the oil-slurry was about 20 degrees Celsius. The so-obtained slurry (fat phase) was transported to the fat run tank.

(19) Preparation of the Water Phase

(20) The water phase was prepared by dissolving the sodium chloride in the water and adjusting the pH to about 4.8 using 20 wt. % citric acid solution. Before being fed into the C-unit, see below, the water-phase was cooled to about 12-13 degrees Celsius.

Example 1

(21) A part of the fat slurry and water phase as prepared above was used to produce a fat continuous spread containing 45% fat, shortly after production (time=t0). This was done by feeding the fat phase and water phase to a C-unit (volume 75 ml) operating at a flow-rate of 15 kg per hour and at 2400 rpm. Tubs were filled and stored at 5 degrees Celsius for a period of up to 5 weeks.

Example 2-4

(22) The remainder of the fat slurry was divided into 3 portions. Demi water was added to two of the three portions of fat slurry and mixed in to form mixtures which contain 5% (158 gr water in 2998 gr fat/water mixture, example 3) and 10% demi water (401 gr water in 3612 gr fat/water mixture, example 4).

(23) The third portion of fat slurry (for example 2) was kept in the fat run tank.

(24) Both the two mixtures of examples 3 and 4 containing fat slurry and demi water as well as the fat slurry without demi-water (example 2) (and also the water phase separately) were agitated and kept at 15 C. for about 20 hours (time=t1).

(25) After this period the mixtures of examples 3 and 4 and the slurry of example 2 were used to make spreads using the same equipment, water phase and settings as was used for example 1 the day before.

(26) As the fat phase was dosed in all 4 spreads at 45%, the final products consist of the ingredients and levels as in table 2.

(27) TABLE-US-00002 TABLE 2 Spreads product formulation (wt. %). Ingredient wt % on total composition inES48 powder 4.5 RP 35.36 PK 4.5 Dimodan RT/B 0.48 Colourant 0.11 Demi-water 54.5 Salt 0.46 Potassium sorbate 0.09

Results

(28) Spreads produced according to the processes and compositions described above were analyzed on Stevens value. Stevens values give an indication about the hardness (also called firmness) of a product. The Stevens value is determined according to the following protocol.

(29) Products were stabilized at 5 degrees Celsius. The hardness of the product is measured with a Stevens penetrometer (Brookfield LFRA Texture Analyser (LFRA 1500), ex Brookfield Engineering Labs, UK) equipped with a stainless steel probe with a diameter of 6.35 mm and operated in normal mode. The probe was pushed into the product at a speed of 2 mm/s, a trigger force of 5 gram from a distance of 10 mm. The force required was read from the digital display and is expressed in grams.

(30) The results for the examples 1-4 are set out in table 3, and graphically in figure 1.

(31) TABLE-US-00003 TABLE 3 results Stevens value measurements. Stevens value, Stevens value, Stevens value, 2 weeks 3 weeks 5 weeks Example at 5 C. at 5 C. at 5 C. 1 (no water, 176 184 170 no storage) 2 (no water, 150 160 163 20 h storage) 3 (5% water, 144 175 162 20 h storage 4 (10% water, 144 182 170 20 h storage)

(32) Firmness development in the spreads during storage at 5 C. shows a remarkable trend. After the initial lowering of the firmness due to slurry aging, the firmness of the spreads made with aged slurry recovers again during 5 C. storage. The recovery of the firmness is faster for samples where water was added to the slurry.

CONCLUSION

(33) Addition of a small amount of water allows a fat slurry comprising oil and a micronised fat powder as structuring agent to be stored, without detrimental effects in the end on firmness as expressed as Stevens value of a spread prepared from such slurry.