Patent Application
20060141107
This invention relates to a method and system for controlling product density, and particularly, a method and system for controlling finished density in aerated foodstuffs.
In the large-scale continuous production of edible emulsified products such as mayonnaise and salad dressings, it is desirable to provide a product having uniform and palatable organoleptic properties. Consistency in taste, textural appearance, and mouthfeel, for example, in the emulsion products can be important for maintaining consumer satisfaction.
Blending and homogenizing procedures have been used to prepare viscous emulsified products such as mayonnaise and salad dressings. Mayonnaise is a well-recognized oil-in-water emulsion. Mayonnaise customarily has been formulated with contain ingredients including vegetable oil, egg yolk, water, and vinegar. Various other ingredients also have been included such as seasonings (e.g., spices, salt, sugar, flavorings) and/or preservatives. A mayonnaise product traditionally is defined as having at least 65% vegetable oil content by weight. However, variations on the basic recipe are known which can provide mayonnaise type products at lower oil contents. Salad dressings also have been made as an emulsion of vegetable oil in lower amounts than mayonnaise, egg yolk, water, and vinegar, which may be combined with starch base, and which may contain other spicing and flavoring ingredients.
Variations on these mayonnaise and salad dressing recipes also are known. For instance, mayonnaise analogs or light dressings also have been produced in which some or all of the vegetable oil content thereof has been replaced by starch bases and/or gum, and/or some egg yolk been replaced by egg whites, albumen or egg-free emulsifiers.
Numerous kinds of mixers are currently known and widely used for the blending and homogenizing of various types of edible viscous emulsions and similar process flowable foodstuffs. In one prior arrangement for continuous preparation of large quantities of edible viscous emulsions at high rates of output, constituents formulating a base emulsion premix are introduced into an in-line mixing device having an initial rotor/stator stage and a secondary pinned rotor stage. For example, in U.S. Pat. No. 5,114,732, a base emulsion premix is blended in the rotor-stator stage under high shear conditions, followed by processing the emulsion in the pinned rotor stage, which provides a low shear, gentle folding action for blending and homogenizing the base emulsion that has exited the initial rotor/stator stage with an additional ingredient and/or air. Air is introduced in such edible emulsions to modify the texture and appearance in desirable ways.
In the past, physical properties of edible emulsified products have been monitored based on measurements taken on samples of finished packed product. However, final product sampling has the shortcoming that the production line has run and generated more product for some time before an earlier-occurring disturbance in the process conditions may be identified through such finished product sampling.
The invention concerns a method for controlling the density to a predetermined level of an edible aerated foodstuff product during the preparation thereof. In preferred embodiments, a density measurement is acquired on the product at a location sufficiently downstream of a shearing unit used to form the aerated material such that the product is in an equilibrated state when its density is measured. Consequently, an adjustment can be made in the introduction rate of aeration gas at a location upstream of the shearing unit which is calculated to reduce any difference between the predetermined and measured product densities in a precise and reliable manner. In a preferred aspect, the density measurement and gas flow rate adjustment steps are performed repeatedly during a given process run, such as at regular time intervals. This invention also concerns a system operable to implement this method.
It has been discovered that foodstuffs which have been aerated with pressurized gas have an unstable density property upon exiting a shearing unit used to form the aerated product until sufficient time is allowed for the product to equilibrate and gas expansion to stabilize. In one aspect, the aerated product can not equilibrate until the pressure condition of the aerated product is permitted to subside to approximately atmospheric pressure. Once the aerated product is allowed sufficient time to equilibrate after exiting the shearing unit, then it can be reliably monitored as to its density property for process control purposes. As another aspect, the gas selected for aeration of the foodstuff preferably is a gas having a solubility less than air in the given foodstuff, which permits the foodstuff to equilibrate sooner, thereby enabling better control of the process.
In another aspect, the process control can be further improved by measuring upstream disturbances in the density property of one or more formulation feed materials before they are combined with gas or introduced into the shearing unit, and making appropriate adjustments in the gas introduction rate which are effective to pre-empt or at least reduce impacts on the product density that otherwise can be expected to arise therein from the upstream disturbances that have occurred in the one or more formulation feed materials.
The preferred method reduces density variability in aerated foodstuff products and thus improves their product quality and consistency. Increased product yields and improved fill consistency may also be possible. The aerated products of some embodiments have a more consistent appearance and texture maintained over the course of a continuous production run. The method and system are useful in the production of edible aerated foodstuffs including, for instance, mayonnaise, mayonnaise analogs, salad dressings, sauces, creamy fillings, confectionary, process cheese, and cream cheese.
Other features and advantages of the invention will become apparent from the following detailed description of preferred embodiments of the invention with reference to the drawings, in which:
Referring to
A first edible food constituent stream A is introduced via feed line 10. Food constituent stream A is pumped via pipe 21 to a dispersing or mixing device 12, which may be a shearing unit, for emulsification. In route, stream A is combined with a gas 30 at location 36 wherein the gas is injected into the flowing stream via a gas control valve 13.
Before gas injection, the food constituent stream A is conducted past an in-line densitometer 11 where a density measurement is made for reasons that will become more apparent from the subsequent descriptions. In this non-limiting illustration, a further food formulation constituent B introduced through line 17 is blended into an aerated dispersion in shearing unit 12. The edible food constituent stream B is conducted past an in-line densitometer 18 in route to the shearing unit 12.
It will be appreciated that these illustrated input food constituent streams A and B, in terms of number and composition, and the type of mixing equipment, are exemplary only. Referring to
Upon treatment in the shearing unit 12, an aerated food structure is created by distributing bubbles of gas substantially homogeneously throughout an emulsion or other type of edible dispersion. The bubbles may be of varying size, including sizes which may be less than and/or more than 10 microns. In one embodiment, the aerated structure produced is an edible dispersion. In a particular embodiment, the aerated structure is produced as an aerated emulsion of a fatty substance in an aqueous medium, i.e., an oil-in-water emulsion, such as mayonnaise, salad dressing, etc.
The resulting aerated dispersion product is conducted via pipe 22 to a first holding tank 14. After residing in the holding tank 14, the product is conducted via pipe 23 to a filler hold tank 24, which supplies a filler station 32 via pipe 25. The product is conducted past an in-line densitometer 15 in route to the filler holding tank 24 from the first holding tank 14.
In one aspect, feedback control is provided in the aerated foodstuff manufacturing system 100 by feeding back information about a controlled variable, viz., density, measured downstream of the shearing unit 12. This measurement is taken at a location sufficiently removed from the shearing unit 12 for equilibration to have occurred in the product, which information is used as the basis for control of the density process variable upstream in the system 100 before shearing by adjusting the gas feed rate via control valve 13. The feedback can be accomplished by use of instruments (automatic control) via a controller 26, or, alternatively, by a human operator (manual control). The installation location of the densitometer 15 where product equilibration has already occurred, as opposed to closer locations relative to the shearing unit where the density of the product is still subject to pressure condition effects, can be determined empirically on a given process system for a given set of process conditions.
It also will be appreciated that the dispersing or shearing unit 12 may not be required in all food aeration production operations to form an emulsion or microbubble or bubble dispersion of the injected gas in the foodstuff. In those situations, as indicated in
For purposes herein, “equilibration” or “equilibrated” refers to a product state in which the product density is not subject to significant change due to effects of the pressure condition of the product and/or the dissolution of gas into the product after the product exits the shearing unit. The present investigators have learned that the density of an aerated flowable foodstuff, such as an aerated emulsion, which is pumped into and out of the shearing unit 12 under a positive pressure, is unstable and subject to change upon exiting the shearing unit until the positive pressure acting on the product sufficiently dissipates and becomes stabilized at a location sufficiently downstream from the shearing unit. In one aspect, product density measuring is conducted at a location in a passageway downstream of the shearing unit wherein the dispersion product is under a pressure condition which is within +1 psig prior to density measurement (psig=lb/in2 gage), although depending on the gas and food composition pressures above 1 psig may yield acceptable results.
This arrangement for acquiring product density readings according to embodiments herein is counter-intuitive, as the most apparent point of measurement seemingly would be immediately following the gas injection point upstream of the shearing unit, or, alternatively, immediately after preparing the aerated product in the shearing unit. Conventional thinking generally has been that temperature can significantly influence density measurements taken on liquid products, while pressure effects thereon are generally predicted to be negligible. In addition, the extent of gas solubilization in the liquid part of the product also may not stabilize immediately upon emulsification of the formulation ingredients in the shearing unit, such that an allowance should be made for that possibility as well in selecting a location for taking the product density measurement sufficiently downstream of the shearing unit.
Experiments performed by the present investigators, which are described in the examples below, have shown that no meaningful correlation is observed between the gas feed rate and the measured product density when the density measurement is taken too close to the outlet of the shearing unit where the effects of pressure and gas solubility on product density have not yet fully dissipated, i.e. the product is not equilibrated. Therefore, a location that is sufficiently downstream from the shearing unit for taking product density measurements, where only process variables other than pressure or gas solubility may still impact product density, can be determined empirically for a given process set up and conditions.
For automatic control, a densitometer 15 is installed on a product line at a downstream location sufficiently distant from the shearing unit, when used, such that product equilibration has occurred in the product stream. The densitometer produces a signal (electrical, digital, pneumatic, etc.) that is indicative of the measured density of the equilibrated product. The densitometer is linked via communication line 16 with a controller 26 for inter-communication. The controller 26, in turn, is linked via communication line 20 with gas control valve control 13. The densitometer may be programmed to take measurements at regular intervals or continuously. Alternatively, communication link 16 may permit command signals from controller 26 to dictate when and at what interval the density measurements are taken by the densitometer.
In one implementation, proportional-integral-derivative (PID) control may be applied using the output of the product densitometer to directly control the gas injection rate without reference to the upstream premix and starch base densities. PID controller schemes generally are designed to eliminate the need for continuous operator attention. A controller is used to automatically adjust the gas injection rate, as the controlled process variable, to hold product density measurements at a predetermined set-point. An offset is the difference between the set-point value and a real-time measurement of a process variable. The variable being adjusted, e.g., gas injection rate, usually is equal to the output of the controller. The output of the controller will change in response to a change in measurement or set-point. Depending on the controller manufacturer, integral or reset action is set either time-repeat or repeat/time, as one is merely the reciprocal of the other. As generally known, the three modes of a PID controller typically have the following features: with the proportional band the controller output is proportional to the offset or change in measurement; with integral action the controller output is proportional to the amount of time the offset is present, which is eliminated by integral action; and with derivative action the controller output is proportional to the rate of change of the measurement or offset, and the controller output is calculated by the rate of change of the measurement with time.
Referring to
The controller 26 can also convert the signal received from the densitometer 15 into displayable reading of density, which can be displayed at the densitometer (via return signal communication), on the controller, and/or on a graphical user interface including a computer display monitor (not shown) linked to the controller for inter-communication.
For manual feedback control, an operator periodically measures the instantaneous product density at densitometer 15, such as by observing density readings taken by a sensor installed on the product line 23, which can measure and generate density values or signals indicative of density values in real time. The densitometer 15, again, is installed at a downstream location on the product line from the shearing unit sufficient that product equilibration has already occurred.
In one preferred aspect, for either automatic or manual modes of process control, the density measurements are made intermittently at regular time intervals during a process run, so that density adjustments can be made regularly, if needed, via the feedback control system.
Referring to
Alternatively, if the product density is measured to be below a desired target value, the controller (or operator if manual mode) decreases the gas flow by closing the valve an amount predicted to offset the difference between the most recently measured value and a preselected target value. The next product measurement taken, after time interval Δt has passed, will determine how well the most recent gas flow rate adjustment made has performed in smoothing out the aberration detected in the product density in the preceding measurement. If another aberration is detected in the most current measurement, another gas flow rate adjustment is made that is predicted to eliminate the deviation as was most recently identified, and so on, through the remaining duration of the given process run or a different overall monitoring period desired. In this way, aberrations in the measured product density may be identified and addressed in an iterative manner.
Although not shown in
For a given set of process conditions and equipment set-up, the manufacturing system 100 can be pre-sampled and programmed to develop a predictive model, which embodies a mathematical algorithm, of the relationship between the future value of the finished product density as indicated by the densitometer and the present values of the finished product density, upstream component densities, and gas introduction flow rate. In this manner, the predictive model developed can take into account the present values of all the density inputs to predict the future product density and make the appropriate adjustments. To implement such a predictive model, the controller may comprise a programmable logic controller (PLC) having access to computer code, embodied in microelectronic hardware mounted on a motherboard or the like and/or in software loaded on a remote computer in communication therewith. PLC modules having these functionalities are commercially available. The controller may be operated as a proportional-integral-derivative (PID) controller or a predictive controller setup (PSC) controller, the latter being preferred. The code comprises an algorithm which inter-relates, in mathematical terms, the measured product density, the gas introduction flow rate, and preferably also certain measured feed material densities. In one aspect, the algorithm is used in developing the predictive model applied to an aerated foodstuff production line. The algorithm can also be a type which may adapt to changes sensed during a process run in certain other process control variables, in addition to gas feed rate, which may also impact product density, such as temperature changes in feed materials and/or at the product density measuring site.
A non-limiting example of a controller system having both the hardware and software which may be adapted to develop and implement such an algorithm for process control for an aerated foodstuff as described herein is a QUICKSTUDY™ process controller system, developed by Adaptive Resources, Pittsburgh, Pa. It works from normal operating data, either real-time or historical, and it automatically generates process models which can be used to predict the direction the process is taking and take corrective action immediately after, or before in the case of feedforward monitoring, to eliminate or pre-empt deviations from the product density set point. As explained and shown elsewhere herein, such a commercially marketed process control system per se can not properly model and control an aerated foodstuff production line without the benefit of the current discovery and understanding that the product density of aerated foodstuffs and measurements thereof are acutely sensitive to the measurement site chosen within the system and that only certain locations within the system (as described herein) may be successfully used.
Referring to
The feedback control and/or model predictive control are independently used for a part or parts of a given process run, but not necessarily over the entire process run. For instance, during start-up of a process run, before relatively steady state conditions are achieved in the system 100, feedforward control may be activated, but not the feedback control arrangement which is activated subsequently during the same process line as the system approaches or achieves relatively steady state conditions. “Relatively steady-state conditions”, for purposes herein, generally refers to a process state in which changes in the variable of interest, e.g., density, can still occur, but have subsided to within the range of the predictive model being applied for the feedback control or feedforward control arrangement as applicable.
For purposes herein, the “density” of a sample of material is defined as the mass of the material to a given volume of the sample. The density of an aerated material is affected by pressure and temperature effects. As indicated above, although conventional thinking has been that pressure effects on densitometer measurements are negligible, the present investigators have found that gas solubility effects also can impact density measurements in an edible emulsion if made immediately subsequent to the shear or dispersion operation used in preparing an aerated emulsion.
In a preferred embodiment, a densitometer is used to derive density values for various feed and product streams in the aerated foodstuff production operation. The use of densitometers in accordance with embodiments herein provides accurate and complete control of the process. This eliminates the need for separate flow, temperature, and pressure measurements to derive density values, although that alternate approach is not excluded.
In one aspect, the density measurements may be taken using a radiation source meter or a Coriolis meter. The radiation source meter may be a conventional radiation gauge for measuring density, including commercially available devices such as ALARA radiation source meters. Radiation meters suitable for in-line installation which are useful for measuring product density in a product stream are commercially-available, such as from Berthold Industrial Systems (e.g., meter LB379). Radiation gauges generally can provide contactless continuous density measurement independent of color, temperature, pressure, viscosity, conductivity or the chemical properties of the process product. Density measurement in radiation gauges is based on the measurement of the absorption of gamma radiation as it passes through the process material. The radiation emitted by a gamma source is attenuated as it passes through matter. This absorption is an exponential function of measuring distance and density. Thus, if the measuring path is constant, the attenuation of radiation is an indication of the product density. That is, absorption is proportional to changes in material density, and as the measuring path is held constant, and this provides an indication of product density. In one aspect, the radiation gauges are adapted to send signals to microprocessor-based evaluation electronics. The above-mentioned commercially-available radiation gauges may include a scintillation crystal for automatic drift compensation, which compensates for the effects of temperature variation and component aging. Use of the scintillation counters as a detector supports a digital design. These radiation gauges also may have single-point calibration and a current loop signal proportional to density.
In an alternative aspect, the density measurements are taken with a Coriolis meter. A Coriolis meter, also often referred to as a Coriolis mass flow meter, is especially useful on light slurries or clean fluids with reduced solids content, such as mayonnaise products. A Coriolis meter can dynamically measure the flowing density of a stream in a continuous manner. A Coriolis meter has two main parts: a sensor and a transmitter. The sensor is made up of one or two tubes through which the fluid passes. An electromagnetic driving mechanism vibrates the tube(s). The flow through the tube(s) exerts a Coriolis force proportional to the mass flow rate. The natural resonance frequency of the tube structure is a function of its geometry, materials of construction, and the mass of the tube assembly (mass of the tube plus the mass of the fluid inside the tube). The mass of the tube is fixed. Since mass of the fluid is its density multiplied by its volume (which is also fixed), the frequency of vibration can be related to the density of the process fluid. Therefore, the density of the fluid can be determined by measuring the resonant frequency of oscillation of the tubes. Moreover, as the density of the material changes, it affects the frequency of vibration of the tube. This is a measurable quantity. The change in frequency is proportional to the density of the material. The magnitude of the force is detected by the transmitter and converted to a mass flow rate.
The transmitter powers the sensor, processes the signals from the sensor, generates output signals, and totalizes the flowing units. The transmitter for each sensor is typically programmed with two unique numerical values: the manufacturer's flow and density calibration factors. While manufacturers may address these values in different ways, they usually have numerical inputs to the transmitter that convert the sensor outputs to common units. This enables the meter to perform to stated specifications. After programming the transmitter with the calibration factors, the output signals are programmed.
The transmitters can be integrally or remotely mounted relative to the associated meter sensor, and can operate on either ac or dc power. The transmitters may require separate wiring for their power supply and for their output signals. The pipeline mounts often require either in-line or “strap-on” installations. Transmitters may offer standard electrical connections for power and signal, and data interfaces also are provided in a preferred embodiment. Analog and/or digital outputs can be provided and used.
Transmitters optionally may include some front end signal processing electronics mounted on the tube itself to support generation of digital outputs from the meter to the controller. Such front end electronics, which can include an A/D converter, processor, software, and sensor coefficients and settings, may be mounted on the tube with a direct connection to the instrument's temperature, strain, drive and phase shift measurements. The signals may be transmitted via RS-485 to a main electronics converter mounted on the instrument itself or remotely some distance away via wire or cable.
The radiation source or Coriolis meter may communicate with the controller via a communication wire, an Ethernet cable, or a wireless communication system (e.g., via radio frequency communications), or by other means. In one non-limiting implementation, the frequency output of the densitometer instrument to the controller, and optionally to other accessory equipment (e.g., flow computer, pulse counter for proving, or totalizer), may be expressed as a pulse-scaling factor (PSF). This coefficient (or coefficients) defines the relationship between the flow rate and the frequency output. It is usually expressed as Hertz (Hz), a number representing pulses per second, for a given flow rate. These values should represent the maximum value for the operation, but not exceed the sensor's range. Nonlimiting examples include: 5000 Hz=5000 pounds per minute, 3000 Hz=3000 kilograms per second, and so forth. The transmitters usually have all the common units of flow preprogrammed as selectable items. The program not only includes mass units but also units for volume flow.
It will be appreciated that the radiation source or Coriolis meters also may have displays that can be locally or remotely mounted. The transmitters also may be provided with a local display and keypads to allow easy access to process data. It also will be appreciated that other types of densitometers may be used in lieu of radiation source or Coriolis meters. These other devices include other types of direct mass vibration measurement instruments in lieu of a Coriolis meter such as, e.g., a vibrating spool, a tuning fork, hydrometers, displacement floats, capacitance probes, and so forth.
In one embodiment, the aerated foodstuffs which may be manufactured in the process and system described herein providing improved product density management comprise edible dispersions. In a particular embodiment, the edible dispersions are edible emulsions, and particularly oil-in-water emulsions. The edible dispersions include spoonable products, such as mayonnaise, mayonnaise analogs, salad dressings, light dressings, sandwich spreads, and also to other products such as pourable dressings, sauces, cream fillings, and the like.
As described herein, a gas used to aerate an edible emulsion or other foodstuff. For purposes herein, “aerate” refers to supplying or charging a liquid with a gas. The gas preferably has a lower solubility than air in the foodstuff being produced under process conditions. For purposes herein, the term “air” refers to a gas composed of approximately 21% oxygen and 79% nitrogen. The gas may be, for example, nitrogen, helium, air, and so forth. These gases may be used individually or in a combination thereof. Preferably, the gas used contains no air or only very small amounts of air. The solubility of various gases in aerated foodstuffs, and mayonnaise and salad dressings in particular, has been observed to decrease in the order of air, nitrogen, and helium. The rate of equilibration and stabilization in the aerated product is generally related inversely to the gas solubility involved.
Aerated foodstuffs which have been aerated with a gas, such as nitrogen or helium, having lower solubility than air in the foodstuff equilibrate and stabilize more effectively and rapidly after exiting the shearing unit in terms of the measured density property. Gases having a lower solubility than air also have been observed to provide more predictable relationships between the density parameter of aerated foodstuffs and the rate of gas introduction, from a process control standpoint. That is, when a gas is used having a solubility less than air, adjustments in the gas introduction rate are more rapidly and reliably reflected by changes in the density values measured in the sheared foodstuff in a more predictable manner. It also is preferable that the aeration gas be an inert gas, which does not interact (bio)chemically with the food product. Nitrogen gas is desirable both from inertness and reduced solubility standpoints. It also is readily available and typically is less costly than other inert gases, such as helium.
In another embodiment, the present invention also encompasses processes for aerating foods in which a gas having a food solubility greater than air, such as carbon dioxide, is used. These aerated foods generally will taken longer to equilibrate than the same food aerated with oxygen, all other things equal. However, a common goal with reduced solubility gas scenarios still applies in that the density measurement should be acquired on the product at a location sufficiently downstream of a shearing unit used to form the aerated material such that the product is in an equilibrated state when its density is measured. A non-limiting example of a food type for which it may be useful in certain applications to inject and disperse a gas having higher solubility than air includes the production of certain chocolate compositions, in which aeration gas is injected but which do not require use of the shearing unit. The density measurement must be implemented far enough downstream from the final injection site to enable measurement of an equilibrated density value in the aerated food stream.
The percent (%) of gas incorporated into the aerated foodstuff, for a given set of process conditions, may be calculated as follows:
percent gas=100−(D1/D2×100), where D1 is the density of the aerated product and D2 is the density of a non-aerated product of the same except non-aerated formulation.
The examples described infra involve edible spoonable products on which the process is illustrated. Mayonnaise type products and salad dressings are included among these products. Mayonnaise type products include mayonnaise and mayonnaise analogs. Mayonnaise is an emulsified semi-solid, non-pourable food dressing which may be prepared, for example, from vegetable oil, water, sugar, a food grade emulsifier exemplified by egg yolk, and an acidulent, and, optionally, various other seasoning additives such as salt, spices, flavors, and other ingredients imparting taste characteristics to the composition. Also, preservatives, colors (not simulating egg yolk color), and stabilizers may be included. Modified versions of mayonnaise, sometimes referred to as mayonnaise analogs, may include a starch base and/or gum in lieu of some or all of the oil content, and/or some or all the egg yolk may be replaced by egg whites, albumen, or egg-free emulsifiers.
The total water content may vary depending on the type of aerated product being manufactured. The amount of starch base added to a particular formulation may vary depending on the amount of vegetable oil being used and replaced by the starch, in the formulation.
As indicated, the aerated foodstuff also may be a salad dressing. Salad dressings may comprise a similar formulation as many mayonnaise type products but usually contain a lower level of oil than mayonnaise formulations and more water, and often are formulated with a starch base. The aerated foodstuff also may be a sauce. Sauces include those containing oil, butter, and/or cream, which may include, for example, Sauce Hollandaise and Sauce Carbonara. The aerated foodstuff also may be a creamy dessert, such as a dispersion containing oil and sugar. Creme Anglaise is an example of such a creamy dessert.
In one embodiment, an aerated spoonable food product is manufactured with the process and system described in accordance with
As a non-limiting illustration, the starch composition B introduced at the pinned rotor stage of the shearing unit may contain, e.g., water, starch, sugar, and some or all of the formulation vinegar, and flavors. Additional ingredients may be included. The formulation vinegar also may be injected in-line into the premix prior to the shearing unit via an injector installed on line 21 (not shown). Eggs may be used as the emulsifier in this illustration, but products also may be manufactured as non-emulsified dispersions in which starch base and/or gum replaces all egg content. In one embodiment, a premix stream A is pumped into the shearing unit 12 at a pressure of about 40 to about 60 psig, and the emulsified product subsequently exits the unit 12 at an outlet pressure of about 17 psig or greater, particularly about 17 psig to about 23 psig, and more particularly about 19 to about 21 psig. The emulsion exiting the shearing unit 12 generally is a relatively viscous spoonable material (or viscous pourable material in other embodiments), but includes pockets or cells of the gas to form a three-dimensional celled structure, which substantially retains that structure in a shelf-stable manner after packaging.
The mass of the gas incorporated into the aerated foodstuff product is generally negligible. The product density of an aerated foodstuff may vary depending on the particular formulation. For aerated spoonable mayonnaises and salad dressings, for instance, it may range from about 0.85 to about 1.15 g/mL, more particularly about 0.88 to about 1.05 g/mL. These aerated foodstuffs generally have a storage stable, and lightened yet stiff texture.
The foregoing descriptions illustrated embodiments of the invention in which a continuously-running production run was generally at a steady-state condition when density measurement and process control scheme was applied as described. That is, the process control modality described herein is applied after density measurements are generally uniform other than disturbances not associated with start-up or shut-down intervals which occur, which, in turn, are counter-acted and smoothed out by the inventive process.
In another embodiment of the present invention, the process control is applied to a discontinuous production run in which upstream product preparation has been terminated and hold tank 14 (
Referring to
All percentages, ratios, parts, and amounts used and described herein are by weight unless indicated otherwise. The examples that follow are intended to further illustrate, and not limit, embodiments in accordance with the invention.
As an initial control study, an aerated spoonable foodstuff was produced in a process system which was generally the same as that shown in
The base emulsion premix was fed into the shearing unit at a rate of approximately 350-650 lbs./minute. The base emulsion premix was suitable for preparation of a mayonnaise type product and contained primarily water, oil, and emulsifier, which was mixed in the shearing unit with a starch base comprised of water and starch.
For limited purposes of this control study, density values for the aerated product were continuously recorded in a conventional manner over a period of time, but feedback control was not implemented in this control study. The results are plotted in
The results shown in
In these experiments, the densitometer was situated further downstream of the shearing unit at a location similar to what is generally illustrated in
Otherwise, the process materials, equipment, and manner of recording the product density measurements were similar to that described in Example 1.
In a first process run, air was used as the gas. The results are plotted in
In a second process run, nitrogen was used as the gas. The product density again was observed to rise when the air flow rate was decreased, and vice versa, in a predictable manner.
The results of Example 1 and 2 revealed quite surprisingly that the product density parameter of aerated foodstuffs was highly sensitive to where the density measurement was taken downstream of the shearing unit. Although not desiring to be bound to any theory, it is postulated that the food product density is impacted by gas solubilized in the product upon exiting the shearing unit and for some period of time until it sufficiently dissipates so that the product can equilibrate and stabilize.
Experiments were performed to investigate and compare the possible effects of the choice of aeration gas on the density retention of aerated emulsions. Nitrogen and air were studied in this respect. Also, the effects of the choice of aeration gas were studied in two different types of aerated emulsions: A) a mayonnaise, and B) a mayonnaise analog. The process system used to manufacture each type of aerated emulsion studied corresponds to that described in Example 2.
A) Study on Mayonnaise:
A mayonnaise premix comprising approximately 80% oil and 6% eggs with the remainder comprising water, sweeteners, and flavors. Gas (either nitrogen or air, depending on the run) was combined with the base emulsion premix at a rate of 10-15 SCFH. The product density was measured both at the outlet of the shearing unit as the “initial product density” (see Example 1), and separately at the downstream intermediate the first and second holding tanks as the “Pre-filler product density” (see Example 2). The density measurements observed for the aerated mayonnaise product are reported in Table 1. Each density value reported in Table 1 is an average of three data points taken over a given process run using the respective gas.
The results in Table 1 clearly show the superiority of the density retention in the aerated mayonnaise using nitrogen as the aeration gas as compared to
B) Study on Mayonnaise Analog:
A mayonnaise analog was prepared using a base emulsion premix formulation and a starch base formulation similar to those described in Example 1. Gas (either nitrogen or air, depending on the run) was again combined with the base emulsion premix at a rate of 20-60 SCFH. The product density was measured both at the outlet of the shearing unit as the “initial product density” (see Example 1), and separately at the downstream intermediate the first and second holding tanks as the “Pre-filler product density” (see Example 2). The density measurements observed for the aerated mayonnaise analog product are reported in Table 2. Each density value reported in Table 2 is an average of three data points taken over a given process run using the respective gas.
The results in Table 2 clearly show the superiority of the density retention in the aerated mayonnaise analog using nitrogen as the aeration gas as compared to air.
The effects of recording and responding to changes in density measured in upstream components was investigated. The process materials and set up of Example 2 were used. Air was used as the aeration gas. A Coriolis meter was also installed on the starch base feed line 17 to permit density measurements thereon. A Coriolis meter also was installed on piping 23 to measure product density at an equilibrated product location.
A QUICKSTUDY™ process controller system, developed by Adaptive Resources, Pittsburgh, Pa., was installed and operated as an automated control system for the process, which communicated with, i.e., received density measurement signals, from the Coriolis meter used to measure product density and a separate Coriolis meter used to measure the density of the starch base feed line. Deviations sensed in the starch base feed material were identified by the controller system and appropriate corrective adjustments were made at the gas feed rate controller predicted to offset and pre-empt the deviations otherwise predicted in the product density if no immediate corrective action is taken upstream in the gas flow rate. Deviations sensed in the product material also were identified by the controller system, and the system was automated to make appropriate corrective adjustments at the gas feed rate controller, if needed, predicted to eliminate the deviations.
During the process run, the density of the starch base feed material was arbitrarily changed by 0.2%. An increase made in starch base density was responded to automatically by the controller before the product density was impacted by making a corresponding decrease in the gas feed rate, and, conversely, a reduction made in starch base density was automatically responded to by the controller before the product density was impacted by making a corresponding decrease in the gas feed rate. The product density was recorded throughout each event. The results obtained are plotted in
As shown in
While the invention has been particularly described with specific reference to particular process and product embodiments, it will be appreciated that various alterations, modifications and adaptations may be based on the present disclosure, and are intended to be within the spirit and scope of the present invention as defined by the following claims.
