Flanders FOOD Technology day 2010

Transcription

1 Encapsulated Ingredients: Possibilities and Applications Dr. Bernd Weinreich FLANDERS FOOD Technology Day 2010; 29 th to 30 th of September 2010; Brussels EXPO Encapsulated Ingredients: Possibilities and Applications A G E N D A: Customer requirements Technical possibilities Available encapsulation technologies Application areas Specific technologies: - Fluid Bed Technology - High Pressure Spraying Processes Conclusion

2 Customer requirements Why encapsulation of ingredients... Prevention of flavour losses or off-flavour formation Protection of ingredients against moisture Protection of ingredients against temperature during processing Avoiding interaction of sensitive ingredients In general: creating a controlled release system... Technical Possibilities Which encapsulation principles are disposable... Matrix encapsulation: - encapsulation in matrices like starch, maltodextrine, gum arabic,... Extrusion: - encapsulation via an extrusion process using specific additives Coating: - protection of the ingredients by coating; e.g. using lipophilic coatings Core/Shell principle: - encapsulation of liquids or melts using a protective shell material...

3 Available Encapsulation Technologies Spray Drying Technology: - principle: matrix encapsulation - main application areas: flavours, natural colours,... Fluid Bed Technology: - principle: matrix encapsulation & hot melt coating - main application areas: non-volatile ingredients, organic acids... Core/Shell Technologies: - principle: shell material encapsulates the core material - main application areas: liquids, melts, sensitive solids... High Pressure Spraying Processes: - principle: impregnation & coating, core/shell principle - main application areas: high viscous liquids, melts, emulsions... Areas of Application confectionery instant baking blends deep-frozen food meat industry pet feed convenience food instant drinks and soups dry mixtures

4 FLUID BED TECHNOLOGY Coating and Micro-Encapsulation of Ingredients p jet : 5 bar Tproduct: C means of transport: air (T: C) m³ air / kg powder single and double nozzle loading capacity up to 20% water-soluble carriers FLUID BED TECHNOLOGY - COATING Technology: The coating material is sprayed onto a fluidized carrier until the required degree of coating is achieved and if necessary dried in a hot air stream simultaneously product container tube spray nozzle air stream delivery device Bottom Spray Procedure Coating material is added onto the fluidized carrier circulation through the tube Particles: (0.1 to 2.0 mm)

5 FLUID BED TECHNOLOGY COATING Carrier: anorganic material organic material Coating: hydrophilic hydrophob Additive: flavours colours COATING PROCESSING PRINCIPLE ingredients are covered with a coating for protection depending on the application either hydrophilic or hydrophobic coating materials are applied hydrophilic coatings - sugar - casein - gums - gelatine hydrophobic coatings - fats - emulsifiers - waxes (melting point: 35 C 85 C)

6 MICRO-ENCAPSULATION PROCESSING PRINCIPLE sensitive and volatile ingredients (e.g. flavours) are dispensed in an aqueous solution of modified starch the starch slurry is sprayed onto a carrier (e.g. maltodextrin) to achieve an encapsulation an additional coating can be applied flavour release: - extremely delayed in products with high moisture content - when reaching a certain temperature (soups and canned products) MICRO-ENCAPSULATION / COATING PROCESS ADVANTAGES protection against moisture protection against oxidation prevention of undesired reactions temperature-controlled release prevention of flavour loss

7 CONFECTIONERY coated malic acid and citric acid for Gum Bears no formation of moisture in the packaging during storage time attractive appearance non-reacting fizzy powder homogenous flavoured sugar homogenous coloured deco components CONVENIENCE FOOD coated baking powder for deepfrozen Pizza and Tortilla dough the activity is maintained during storage time temperature-controlled release of the baking powder the dough is not pre-baked, it will rise only in the oven micro encapsulated flavours (Instant-soups)

8 FROZEN FOOD coatec salt for sauces and soups no shift of dew point due to the addition of salt sauces will be solid under deep-frozen conditions encapsulated ingredients (deep frozen food) High Pressure Spraying Processes Micro- encapsulation of Liquids Creation of Powdery composites Morphologies << Core Shell principle >>

9 High Pressure Spraying Process: CPF(Concentrated Powder Form) - TECHNOLOGY Liquid Gas Carrier Process parameters: - 0 C to 10 C - inert atmosphere (CO 2 ) - CO 2 saturated liquid Powderized liquid Applicable Liquids viscosity: polarity: composition: ingredients: low viscous to high viscous hydrophilic and lipophilic single- & multi-component, emulsions, suspensions oxygen sensitive, temperature sensitive, highly volatile plant extracts flavours & fragrances oils & fats vitamins alcoholic solutions aqueous solutions emulsions suspensions

10 Emerging Binding Mechanisms Sorption Capillary forces Impregnation Flüssigkeitskonzentration [Gew.-%] Beladungsdiagram m Stam pfdichte [kg/m 3 ] Messwerte Grüner Messwerte Lankes Lit.: Diss. Grüner, Erlangen, 1999 Diss. Lankes, München, 2002 High Pressure Spraying Process: PGSS(Particles from Gassaturated Solutions) - TECHNOLOGY core material shell material gas cyclone spray tower < Core Shell principle >

11 Applicable Materials Shell materials: Polymers Waxes Fats Core materials: Polymers (liquid) Oils Aqueous solutions of Fat encapsulated water 10 % 30 % 50 % 60 % number of micro-pores rises with increasing portion of water Dissertation Tobias Wendt, in preparation, Bochum

12 Special PGSS - Application: Emulsion-filled particles Oil Water Shell Material - Online - Generation of emulsions - Formation of droplets and high speed freezing by expanding gas Gas Powder Formation of Emulsion - Composites Emulsions: Stable (no phase separation) Instable (phase separation)

13 Formation of Emulsion - Composites Emulsions: Stable (no phase separation) Instable (phase separation) Solidification: Faster than separation Matrix encapsulation (a) Formation of Emulsion - Composites Emulsions: Stable (no phase separation) Instable (phase separation) Solidification: Faster than separation Matrix encapsulation (a) Fast solidification of the shell Core/Shell morphology (b)

14 Formation of Emulsion - Composites Emulsions: Stable (no phase separation) Instable (phase separation) Solidification: Faster than separation Matrix encapsulation (a) Fast solidification of the shell Core shell morphology (b) Slower than separation Open composites (c) Encapsulated Liquids: Core / Shell - Principle Advantages: Protection against stress factors Better product handling Controlled release systems Powderform emulsions

15 Application of fat encapsulated water-soluble ingredients Spreads: Encapsulation of water-soluble active ingredients Structuring of food emulsions e.g. marinades Cosmetics: Powderous ointments and creams with cooling effect Application of liquor filled powdery chocolate High liquid concentration possible (up to 50%) Flavour burst

16 Conclusion: The choice of the right encapsulation process depends on the ingredient matrix and its sensitivity The ingredient application finally determines the most appropriated encapsulation form Matrix-encapsulation and core/shell-models enable tailor-made encapsulation-systems Encapsulation benefits are: protection against oxidation / moisture / flavour loss / cross-reactions In general: controlled release systems can be generated... THANK YOU!!