Method of encapsulating liquid products
The invention relates to a method for encapsulating a liquid product, the method comprising blending together a solution of alginate and a thickener and extruding through an appropriately shaped die to form a membrane, applying a calcium rich ion solution to crosslink the membrane and create a water insoluble membrane, filling the water insoluble membrane with the liquid product; and sealing the membrane around the liquid product, encapsulating the liquid product therein.
1. A method for encapsulating a liquid product having a viscosity of less than 20000 cP (measured at 20° C. and a shear rate of 10 s −1 ), the method comprising:
blending together a solution of alginate and a thickener and extruding through an appropriately shaped die to form a membrane;
applying a calcium rich ion solution to crosslink the membrane and create a water insoluble membrane;
filling the water insoluble membrane with the liquid product having a viscosity of less than 20000 cP (measured at 20° C. and a shear rate of 10 s −1 ); and
sealing the membrane around the liquid product through a pinch process, encapsulating the liquid product therein, wherein
the pinch process comprises pinching the membrane while crosslinking propagates through the membrane to provide a liquid-tight flat seal in the absence of heat.
2. The method of claim 1 wherein the blending occurs at room temperature.
3. The method of claim 1 , wherein the pinch process further comprises: pinching the membrane at predetermined intervals therealong to individually seal and form a plurality of liquid-based products in series.
4. The method of claim 3 , wherein the method further comprises:
cutting at each seal to separate the products or cutting at predetermined intervals within the series to form distinct chains of encapsulated products.
5. The method of claim 1 , wherein the encapsulated product is rinsed and dried.
6. The method of claim 1 , wherein the solution of alginate is 1-10% alginate.
7. The method of claim 1 , wherein the thickener is xanthan or cellulose gum.
8. The method of claim 1 , wherein the solution of alginate and the thickener is blended with a further plasticizing additive.
9. The method of claim 1 , wherein the calcium rich ion solution has a concentration of 1 to 10%.
10. The method of claim 1 , further comprising an additional pre-step of treating the product with a solution of 0.5 to 10% calcium ions, prior to filling the membrane with the product.
11. The method of claim 1 , further comprising undertaking a membrane reinforcement step in which the encapsulated product is heated to at least 40 degrees C.
12. The method of claim 1 , further comprising undertaking a membrane reinforcement step in which the encapsulated product is heated to at least 80 degrees C.
13. The method of claim 1 , further comprising undertaking a membrane reinforcement step in which the encapsulated product is compressed under a load of 100N or more.
14. The method of claim 1 , further comprising the step of applying a brand, identification or label onto the membrane.
15. The method of claim 1 , wherein the method further comprises:
applying a secondary temporary layer to the membrane of the encapsulated product.
16. The method of claim 15 , wherein the secondary layer is a cross-linked alginate membrane.
17. The method of claim 15 wherein the membrane and the secondary layer are distinguishable from one another by a preformed label or color applied to the membrane and/or to the secondary layer.