JOHNSON OLAMIDE EMMANUEL

F/HD/20/3220051
Unit operation
HND 1
Fst: 313

Application of emulsification process in food industry / food processing

➢ Emulsion

An emulsion is a mixture of two or more liquid that are normally immiscible (unmixable or
unblendable) owing to liquid-liquid phase separation. Emulsions are part of a more general
class of two-phase systems of matter called colloids. Although the terms colloid and emulsion
are sometimes used interchangeably, emulsion should be used when both phases, dispersed
and continuous, are liquids. In an emulsion, one liquid (the dispersed phase) is dispersed in the
other (the continuous phase). Examples of emulsions include vinaigrettes, homogenized milk,
liquid biomolecular condensates, and some cutting fluids for metal working.

An emulsion of Phase II dispersed in Phase I. The unstable emulsion progressively separates

The surfactant (outline around particles) positions itself on the interfaces between Phase II and
Phase I, stabilizing the emulsion

Two liquids can form different types of emulsions. As an example, oil and water can form, first,
an oil-in-water emulsion, in which the oil is the dispersed phase, and water is the continuous
phase. Second, they can form a water-in-oil emulsion, in which water is the dispersed phase
and oil is the continuous phase. Multiple emulsions are also possible, including a "water-in-oil-
in-water"
Emulsions, being liquids, do not exhibit a static internal structure. The droplets dispersed in the
continuous phase (sometimes referred to as the "dispersion medium") are usually assumed to
be statistically distributed to produce roughly spherical droplets

What is emulsification

Emulsification is a scientific process in which two immiscible (unmixable) liquids are mixed
together in a way that makes them stay mixed. You probably know that oil and water don’t mix,
but that mayonnaise on your sandwich? That’s an emulsion. It’s oil and vinegar, like salad
dressing. The egg yolks help bind the two sides that would normally not want to come together;
combining them by force forms something with a texture that’s completely different from its
individual parts.

Emulsifying something means you’re either dispersing fat into water (mayonnaise, pan sauce)
or water into fat (vinaigrette, butter) to make something with a uniform look and feel. In the
case of the vinaigrette on your salad, you’re dispersing oil into water (vinegar is the water
element here). Sometimes you can see the oil floating on top.

Aims of Emulsification

it has to ensure the physicochemical stability of the product. Emulsification determines the
characteristic structure of the batter which greatly influences fat and moisture separation from
the product during cooking. It creates a typical sensory property such as appearance, texture,
flavour or noise. Finely comminuted products are defined by their smooth surface.

➢ Dispersion

is defined as a mixture in which fine particles are scattered in a continuous phase throughout a
different substance or state. This may be classified as one of three main types, these are:

➢ Suspension

A suspension, also known as a coarse dispersion, will have particles that are large enough to be
seen with the naked eye, or under a microscope. Particles within a suspension may become
distributed through mechanical means, but may settle out eventually. The use of binding agents
may prevent this occurrence.
 ➢ Colloid

colloid dispersion contains particles which are larger than ions but still too small to be observed
under a microscope. Particles within this type of dispersion remain statistically distributed and
do not settle

Various types of dispersions can be found in the culinary world. Milk is a common example of a
colloidal dispersion. Saline and simple sugars are both types of solutions while a mixture of oil
and water is considered a suspension. Mayonnaise, which is an emulsion is also a type of
suspension.

➢ Explain water in oil emulsion and oil in water emulsion

Types of Emulsion

Depending upon the nature of the dispersed phase, the emulsions are classified as;

Oil- in- water emulsion

Used in moisturizing products and food products such as milk, mayonnaise and vinaigrette, o/w
emulsions contain a low oil concentration. They are mixable with water, non-greasy, non-
occlusive and will absorb water. This is emulsion in which oil is present as the dispersed phase
and water as the dispersion medium (continuous phase) is called an oil-in-water emulsion. Milk
is an example of the oil-in-water type of emulsion. In milk liquid fat globules are dispersed in
water. Other examples are, vanishing cream etc.

Water -in-oil- emulsion

These emulsions are utilized in products including butter, margarine, cold cream and cod liver
oil and are especially useful in products designed for dry or sensitive skin. Common w/o
emulsifiers are sorbitan stearate, polyglyceryl oleate, lecithin, sorbitan monooleate and lanolin.
Sometimes referred to as an inverse emulsion, w/o emulsions mix more easily with oils and
have a high oil concentration. Producing w/o emulsions is more difficult than developing their
o/w emulsion in which water forms the dispersed phase, and the oil acts as the dispersion
medium is called a water-in-oil emulsion. These emulsion are also termed oil emulsions. Butter
and cold cream are typical examples of this types of emulsions. Other examples are cod liver oil
etc.
 ➢ Differences between o/w and w/o emulsions:

1. Suspended vs. continuous phase

The biggest difference between o/w and w/o emulsions is which phase is suspended and which
is continuous. Oil and water are normally immiscible, but with proper mixing and stability
agents, a permanent mixture, or emulsion, can be achieved. Smaller droplet sizes will enhance
the effectiveness of either system; this may translate to increased bioavailability in
pharmaceutical products or extended shelf life in food/beverage products.

2. Type of product that can be created

The chemical nature of an o/w emulsion is distinct from that of a w/o emulsion, each is most
effectively used in different products. O/w emulsions are the basis of water-based products, in
the pharmaceutical industry, they can be found in creams like moisturizers and topical steroid
products. In contrast, w/o emulsions make up oil-based products like sunscreen and most
makeup.

3. How to achieve stability

Stability is key when considering an emulsion synthesis technique; without it, the two phases
will separate, and the product will have lower function. All emulsions require an emulsifier to
assist with stability. O/w emulsions typically require more than one emulsifier, and they can be
acquired separately or in a pre-mixed cocktail. In contrast, while w/o emulsions only require
one emulsifier, there is a limited number from which to select because the hydrophilic balance
must be in a narrow range.

➢ Common emulsifying agent in food industry

Commonly used emulsifiers in modern food production include

1.sorbitan stearate

2. sorbitan monooleate and lanolin

3. soy and egg lecithin

4. mono and diglycerides

5. polyglycerol Esters

6. carrageenan
7. guar gum

8. Canoil

9. Mustard

➢ Application and techniques of emulsifying agent

It is used as stabilizers. I.e it as properties that distribute oil and water molecules evenly
throughout the mixture to prevent separation.

It is used to make food more visually appealing and to improve taste and texture.

Usually used in cosmetics, pharmaceuticals, personal hygiene.

Microemulsions are used to deliver vaccines to kill various microbes.

It is used in chemical synthesis.

It is used in firefighting.

Nanoemulsions such as soybean oil are used to kill microbes.

Mayonnaise is an oil in water emulsion with egg yolk or sodium stearoyl lactylate.

➢ Identify and describe various equipment used in emulsion

Homogenizers( high pressure)

Ultrasonication devices

Rotorstator systems

Low speed stirring machine

High speed shear stirring machine

Static mixing machine

 ➢ Write on mayonnaise, ice cream, margarine, and milk production extensively

Mayonnaise

Mayonnaise is a semisolid oil‐in‐water (O/W) emulsion which is made through the careful
blending of oil, vinegar, egg yolk, and spices (especially mustard). In addition, mayonnaise
traditionally contains 70%–80% oil, and egg yolk is a key ingredient contributing to its stability.It
works as a base for various sauces like thousand island, tartar sauce etc. Mayonnaise is often
used as spreads on sandwiches and burgers, as the creamy base in cold salads, as a dip for
French fries and much more

However, mayonnaise from all over the world can have varying ingredients depending on the
country of origin. Differences can be seen in 4 choices like the type of oil or emulsifier. The oil
type can be changed because of economic reasons while different spices can be used to reflect
the culture. The emulsifier used can vary between whole egg (common in USA), liquid egg yolk
(common in Europe) and spray dried egg yolk.

Role of different Ingredient on the quality and processing of Mayonnaise

Oil- It is the main ingredient in mayonnaise and therefore it has a large influence on the quality
of the final product. The amount of oil dispersed in the mayonnaise contributes to the
viscoelastic behaviour and stability of the product. The oil also impacts the organoleptic
properties by providing creaminess and flavour to the mayonnaise. It is therefore important to
use an oil with a neutral taste, like rapeseed oil, sunflower oil, or grapeseed oil.

Egg- In industries pasteurized liquid egg yolk or powdered egg yolk is generally used. Egg yolk is
more commonly used as compared to egg white because of its greater emulsifier properties,
while egg white also shows some emulsifying ability, but egg yolk is four times more effective.
LDL is often referred to as the primary reason for the excellent emulsifying properties.

Vinegar-Vinegar used in mayonnaise contributes to the flavour of the mayonnaise and it also
decreases the pH, helping in the microbiological safety and preservation.

Salt and sugar- Salt contributes to the flavour and to the stability of the mayonnaise Salt help to
neutralize the charges of the proteins (from eggs) so they can adsorb more efficiently to the
droplet interface. Sugar also contributes to the flavour of the mayonnaise and is added mainly
to counteract the flavour of vinegar.

Mustard– Mustard contributes to the flavour and colour of mayonnaise. Most of the flavour in
mustard comes from the isothiocyanates.
 Flow chart for the production of mayonnaise

Ice cream

Ice cream is a frozen blend of a sweetened cream mixture and air, with added flavorings. A
wide variety of ingredients are allowed in ice cream, but the minimum amounts of milk fat, milk
solids (protein + lactose + minerals), and air are defined by Standards of Identity in the U.S.
Code of Federal Regulations (CFR), section 21 CFR 135.110 for ice cream, 21 CFR 135.115 for
goat's milk ice cream, and 21 CFR 135.140 for sherbet.
 cream must contain at least 10% milk fat, and at least 20% total milk solids, and may contain
safe and suitable sweeteners, emulsifiers and stabilizers, and flavoring materials. The finished
ice cream must weigh at least 4.5 pounds per gallon and there must be at least 1.6 pounds of
total solids (fat + protein + lactose + minerals + added sugar) per gallon, thus limiting the
maximum amount of air (called overrun) that can be incorporated into ice cream. There are
well-defined labeling requirements for the types of flavors used (natural and/or artificial) and
for the presence of egg yolks in the finished product (ice cream can be called custard or
"French" if the content of egg yolks is at least 1.4%). Ice cream may also be labeled as reduced
fat (25% less fat than the reference ice cream), light (50% less fat than the reference), lowfat
(less than 3 g fat/serving), or nonfat (less than 0.5 g fat/serving).

Ice cream is sold as hard ice cream or soft serve. After the freezing process only a portion of the
water is actually in a frozen state. Soft ice cream is served directly from the freezer where only
a small amount of the water has been frozen. Hard ice cream is packaged from the freezer and
then goes through a hardening process that freezes more of the water in the mix.

Role of the ingredients used for the production

There is a wide range of ingredients and formulations (recipes) that can be used in ice cream.
The basic types of ingredients and their functions are briefly described below. For a more
detailed explanation of ingredient function see literature references by Marshall et al. (2013)
and the website by Goff, www.foodsci.uoguelph.ca/dairyedu/icecream.html.

Milk- milk fat provides creaminess and richness to ice cream and contributes to its melting
characteristics. The minimum fat content is 10% and premium ice creams can contain as much
as 16% milk fat. Sources of milk fat include milk, cream, and butter.

Sweetener-sweeteners are used to provide the characteristic sweetness of ice cream.

Sweeteners also lower the freezing point of the mix to allow some water to reamin unfrozen at
serving temperatures. A lower freezing point makes ice cream easier to scoop and eat, although
the addition of too much sugar can make the product too soft. Sweeteners used include sugar
(sucrose) and corn syrups.

Stabilizer-Stabilizers are proteins or carbohydrates used in ice cream to add viscosity and
control ice crystallization. Over time during frozen storage small ice crystals naturally migrate
together and form larger ice crystals. Stabilizers help to keep the small crystals isolated and
prevent the growth of large crystals, which causes ice cream to be coarse, icy and unpleasant to
eat. Stabilizers used include alginates (carageenan), gums (locust bean, guar), and gelatins.

Emulsifier-Emulsifiers are used to help keep the milk fat evenly dispersed in the ice cream
during freezing and storage. A good distribution of fat helps stabilize the air incorporated into
the ice cream and provide a smooth product. Emulsifiers used in ice cream include egg yolks
and mono- and diglycerides.

A wide range of flavorings are used in ice cream. Flavorings include natural and artificial flavors,
fruit, nuts, and bulky inclusions such as chocolate chunks and candies.

Flow chart for the production of ice cream

Margarine

margarine, food product made principally from one or more vegetable or animal fats or oils in
which is dispersed an aqueous portion containing milk products, either solid or fluid, salt, and
such other ingredients as flavouring agents, yellow food pigments, emulsifiers, preservatives,
vitamins A and D, and butter. It is used in cooking and as a spread. Nutritionally, margarine is
primarily a source of calories.

is an emulsified, fatty food product initially created as a substitute for butter. While originally
made from animal fat in the 1800s, today the primary ingredients include vegetable oil, water,
salt, emulsifiers, and milk. Technically, It is a water-in-oil (W/O) emulsion in which the water
phase is finely dispersed as droplets in the continuous fat phase.

Raw materials used and processing procedure of margarine

Preparation of Ingredients: When the ingredients arrive at the margarine manufacturing facility,
they must first undergo a series of preparatory measures. Like safflower, corn, or soybean, the
oil used, like safflower, is treated with a caustic soda solution to remove unnecessary
components known as free fatty acids. Next, the oil is sometimes bleached with a mixture of
bleaching earth and charcoal in another vacuum chamber. The bleaching earth and charcoal
absorb any unwanted colorants and are then filtered out from the oil. Whatever liquid is used
in the manufacturing process—milk, water, or a soy-based substance—it too must undergo
preparatory measures like milk will undergo pasteurization to remove the microbial load.

Hydrogenation: The oil is then hydrogenated to ensure the correct consistency for margarine
production. In this process, hydrogen gas and a metal catalyst are added to the oil under
pressurized conditions. All this heavy processing will lead to the production of trans fats.

Melting of oils: oils are transferred to a tank (say tank 1) to obtain a homogenous melt ensured
by continuous stirring at 60°C-70°C.

Preparing the aqueous phase: The aqueous phase is generally milk, water, salt and other
water-soluble ingredients are dissolved and mixed in tank 2 to make up the final vol. which
constitutes 16% of the final wt. of Margarine.

Mixing: Contents of both the tank 1 and tank 2 are sent to the emulsifying tank (say tank 3)
where they are mixed.

Emulsifier and other fat-soluble ingredients: Emulsifier such as lecithin, mono or diglycerides
are generally used. Lecithin should be first dissolved in a small vol. of oil and fat blend
preferably in a ratio 1:4 at 65°C-70°C. The mix is than poured in the main tank i.e., tank 3 and
mixed. Apart from this antioxidant, color, flavor are also added at this point. At this phase, we
get a semi-liquid kind of consistency.

Pre-crystallization: The contents are then transferred to the pre-crystallizer where the scrapper
speed of 300-1000 rpm and a temp. of 10°-22°C is maintained. The pre-crystallized fat is then
passed through a pin worker. The rotating pin helps the pre-crystallized fat to get adequately
homogenized crystallized fat.

Packing: Margarine is filled in containers and packed.

Tempering: done at 5°C-7°C to stabilize the texture of Margarine.

Milk

A milk is white liquid produced by the mammary glands of female mammals to nourish their
young. From certain animals, especially cows, it is also called dairy milk and is a common food
for humans as a beverage or used to produce various dairy products such as butter, cheese, and
yogurt.

A white (or whitish) liquid obtained from a vegetable source such as almonds, coconuts, oats,
rice, and/or soy beans. Also called non-dairy milk. [from circa 1200]. There are different
methods and technologies used for efficient processing of milk.

Cows are milked using vacuum cups which are attached to the cow's teats. The milk is sent
through stainless steel pipes to large refrigerated vats, then stored at 5°C or less. Within 48
hours, milk is taken in tankers to a milk factory where it's pasteurised and homogenised.

Pasteurisation

This technique heats milk to 72°C for no less than 15 seconds, then cooled immediately to
destroy any harmful bacteria and micro-organisms. This also extends the shelf life.

Homogenisation

Milk is put under pressure through fine nozzles, which evenly disperses fat globules. This stops
the cream separating and rising to the top, allowing a more consistent texture and taste. Some
manufacturers produce unhomogenised milk for people who prefer the cream to separate and
rise to the top of the bottle.

Centrifugal separation

This removes some or all of the cream to make reduced-fat, low-fat or skim milk. Skim milk
solids can be added back to improve the test and texture, and increase nutrients like protein
and calcium.

Ultrafiltration

This moves milk across a membrane under moderate pressure, which holds back protein, fat
globules, and a large amount of calcium complexes.

Water and lactose (the sugar in milk) pass through, leaving behind a very protein and calcium-
rich product. The fat content can be adjusted to suit consumer preference.
Reverse osmosis

This is very similar to ultrafiltration, but the membrane holds back most of the milk solids and
only lets water pass through. Lactose remains in the product. There is no impact on flavour.

Ultra osmosis

This is a combination of ultrafiltration and reverse osmosis, but it holds back milk solids and
allows both water and salt to pass through.

Spray drying

This removes water from milk in order to make powdered milk products. Milk’s nutritional
value remains the same.

Permeate

In order to standardise milk year-round, some manufacturers use a process called ultrafiltration
where a membrane filter separates certain elements from milk (just like in the descriptions
above). Milk is passed through a very fine filter, and the lactose (milk sugar), vitamins and
minerals that filter through are referred to as "permeate".

Permeate is a technical term which applies to all membrane filtration processes used across
food production and other industries.

That filter helps milk producers make milk with consistent properties, which helps it conform to
the Food Standards Australia New Zealand Food Standards Code.
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