Process for preparing a spread
A process for manufacturing an edible water-in-oil spread, which process has the advantages of the cool blending process for manufacturing spreads, with improved rework capabilities. This is achieved by combining a stirred tank with recirculation means.
1 . A process for preparing an edible fat-continuous spread comprising 15-65% fat and 35-85% water, said process comprising the steps of:
a) providing a fat powder, an aqueous phase, and an oil phase;
b) mixing said oil phase and said fat powder to form a fat slurry in a tank or recirculation means to which such tank is connected, and treating the resulting fat slurry by applying a stepwise reduction in absolute pressure from 500 mbar to 100 mbar, over a period of up to 12 minutes, while recirculating the fat slurry between the tank and the recirculation means;
c) combining the aqueous phase with the fat slurry outside said tank in the recirculation means, to form a pre-emulsion; and
d) forming the edible fat-continuous spread by recirculating the pre-emulsion at least once between the tank and the recirculation means;
wherein steps c) and d) are performed at a temperature below 23° C.
2 . The process of claim 1 , wherein the aqueous phase and the fat slurry are mixed by an in-line dynamic mixer outside said tank in the recirculation means.
3 . The process of claim 1 , wherein recirculation is continued after all of the aqueous phase is added until at least a point wherein no free water is detectable in the pre-emulsion.
4 . The process of claim 1 , further comprising:
e) directing the edible fat-continuous spread to a packaging process at a stage wherein no free water is detectable.
5 . The process of claim 1 , wherein prior to all of the aqueous phase having been combined in step c), at least part of the fat slurry or pre-emulsion is recirculated through the recirculation means.
6 . The process of claim 1 , wherein the provided aqueous phase has a pH of 4.8.
7 . The process of claim 1 , wherein the fat powder is a micronised fat powder.
8 . The process of claim 1 , wherein the amount fat powder in the total fat slurry is from 5 to 20% by weight, based on the total fat slurry.
9 . The process of claim 1 , wherein the amount of fat in the total composition in the tank and final product are from 20 to 45%, based on the total composition.
10 . The process of claim 1 , wherein the mixing in step b) in the tank or recirculation means to which such tank is connected, is carried out by an anchor stirrer and/or an impeller.
11 . The process of claim 1 , wherein the overall composition in the tank after all of the aqueous phase is added is the same as in the edible fat-continuous spread formed in step d).
12 . The process of claim 1 , wherein the provided aqueous phase has a temperature of approximately 15° C. when combined with the fat slurry at step c).
13 . The process of claim 1 , wherein the provided aqueous phase has a temperature of approximately 15° C. and a pH of 4.8 when combined with the fat slurry at step c).
14 . The process of claim 1 , wherein mixing said oil phase and said fat powder at step b) further comprises contacting the oil phase at a temperature of approximately 11° C. with the fat powder, and wherein the fat powder is initially provided to the tank or recirculation means at an absolute pressure of 500 mbar.
15 . The process of claim 1 , wherein the recirculation means is an assembly comprising a tube connected from an exit of the tank to an inlet of the tank, with an intervening connection to an inlet configured to provide the aqueous phase.
16 . The process of claim 1 , wherein the tank or the recirculation means is further connected to a packaging line.
17 . The process of claim 1 , further comprising step e) transporting the edible fat-continuous spread from the recirculation means to a packaging line through a 3-way valve.
18 . The process of claim 17 , wherein the 3-way valve comprises two ports connected to the recirculation means, and one port connected to the packaging line.
19 . The process of claim 1 , wherein the tank further comprises an anchor stirrer configured to operate at 20 RPM, and a high shear disk mixer; and
the aqueous phase and the fat slurry are mixed by an in-line variable speed dynamic mixer configured to operate at from 600 to 3,000 RPM, outside said tank in the recirculation means.
20 . The process of claim 1 , wherein the recirculation means is configured to perform 80% recirculation during step d).