"METHOD TO MAKE FAT- SUBSTITUTE AND/OR FAT-IMITATOR

COMPOUNDS"

¾ %

FIELD OF THE INVENTION

Embodiments described here concern a method for the production of fat- substitute and/or fat- imitator compounds. In particular, embodiments described here concern a method for making a solid plastic emulsion with a limited content of saturated fats and free from trans isomers of fatty acids usable in, for example but not limited to, the food sector, such as a fat-substitute and/or fat-imitator compound.

BACKGROUND OF THE INVENTION

It is known that the term food fats, or glycerides (mono-, di-, or tri-glycerides) refers to those lipids that are formed from aliphatic carboxylic acids (fatty acids) bound with an ester bond to a glycerol molecule.

Fatty acids can be saturated if their molecule has only single C-C bonds, or unsaturated if they have double C = C bonds.

In particular, a triglyceride is defined as any glycerol ester in which all three hydroxyl groups of alcohol have been esterified; triglycerides are the most common lipids in nature and represent, in both plants and animals, an important source of energy reserves.

In general, natural fats are complex mixtures of triglycerides characterized by the presence of fatty acids different in chain length and number of unsaturations. The physical properties of fats depend on their composition in fatty acids. The melting temperature of saturated fatty acids increases progressively as the hydrocarbon chain increases. Saturated fatty acids with a number of carbon atoms up to 9 are liquid at room temperature, while those with a higher number of carbon atoms are solid. The melting temperature of unsaturated fatty acids is lower than that of the respective saturated fatty acids and decreases as the number of double bonds increases. In nature these are predominantly in the cis form. The melting temperature of a food fat is therefore not univocally defined but is generally represented by a range of melting temperatures determined by the chemical composition of the triglycerides of which it consists. In this temperature range, solid and liquid triglycerides can coexist. In general, animal fats and fats deriving from tropical plants (for example palm, coconut, cocoa) are rich in saturated fats and are solid at room temperature, while those of plant origin, rich in saturated and polyunsaturated fats, commonly referred to as oils, are liquid at room temperature.

The technological performance of solid fats in foods is essentially correlated to the formation of a crystalline network able to confer structure on the system. To this purpose, it is important to obtain a desired quantity of lipid crystals, with an adequate average size and a defined polymorphic structure. Polymorphism is a peculiar characteristic of triglycerides which, depending on process conditions, can form crystalline structures of different shape. From a technological point of view, the presence of one polymorphic form rather than another is of fundamental importance in order to obtain the desired qualitative and sensory characteristics.

Historically, in the home, animal origin fats (for example butter, lard/dripping) have been used, and are still used, in the preparation of foods whose structure and sensory characteristics depend on the lipid matrix present. Think about biscuits, creams, pastries, ice cream, sweet and savory cereal-based products, etc. These fats, however, are expensive and may not be compatible with a global spread of food products. For these reasons, hydrogenated fats have been widely diffused. Hydrogenation is a chemical or enzymatic process that allows to convert unsaturated fatty acids into saturated fatty acids, and thus allows to convert a liquid oil into a solid fat. This type of product has been very successful in the past years and is still very much used in the field of food, due to its low cost compared with animal fats. However, it is now scientifically proven that the hydrogenation process leads to the formation of trans isomers of fatty acids, which are not normally present in nature. For example, a typical hydrogenated fat product used in bakery products can contain more than 15% in weight of trans fatty acids on the total weight of the fat used. It should be noted that twenty years ago it was not difficult to find margarines or shortenings in Italy with 25% in weight of trans fatty acids, to obtain the desired melting point. Numerous clinical studies have shown the adverse effects on health of trans fatty acids, to such an extent that some countries have introduced specific regulations limiting their content in final products, or oblige the producer to show the content of trans fatty acids on the label (USA). Moreover, the information is now widespread among consumers that hydrogenated fats can be harmful to the health. As a result, many food companies have gradually replaced hydrogenated fats in their products with palm oil derivatives. Palm oil contains more than 50% in weight of saturated fatty acids, of which the main one is palmitic acid (C: 16) and is completely liquid at temperatures above 45°C. One technological aspect that makes it particularly interesting and justifies its widespread diffusion is that, through the physical fractionation process, palm oil derivatives with different melting points can be obtained. This aspect is fundamental to obtain the desired consistency of the fat fraction for its use in different products (biscuits, puff pastry, breadsticks, coating fats, ice creams, creams, etc.) without resorting either to animal fats or to hydrogenated fats. Palm oil is now the subject of a media campaign that indicates it is dangerous to health because it is too rich in saturated fatty acids, resulting in possible damage to both the cardiovascular system and the pancreas. In addition, this product is under investigation because of the environmental impact of its production. The objections regarding the sustainability of palm oil are due to deforestation processes that accompany the expansion of palm oil plantations. This is a completely different problem from the nutritional or technological problem, of course, but has a great impact on the consumer. Finally, in recent months there have been warnings regarding the presence in this oil of significant quantities of a contaminant, 3-monocloropropane- 1 2-diol (3-MCPD), which is considered to be carcinogenic and genotoxic. The EFSA (European Food Safety Agency) has assessed the risks to public health deriving from this substance and its derivatives and the corresponding fatty acid esters. These substances are formed during food processing processes, in particular when vegetable oils, including palm oil, are refined at high temperatures (about 200°C). The EFSA working group on food safety concluded that these compounds are a potential health problem for all younger age ranges subjected to average exposure, as well as for consumers of all ages with high exposure.

From here begins the pressing and urgent demand to find substitutes for palm oil and its derivatives. Many food companies aim to completely eliminate palm oil from their labels, which according to current legislation (REGULATION (EU) No 1 169/201 1) must clearly indicate the type of fat used in formulation of the product. In Europe now it is no longer enough to write "non-hydrogenated vegetable oil" on the label, but the specific indication of "palm oil" must be inserted. At the moment, valid alternatives to palm oil are not easily identifiable, especially for products that require the fat-rolling process, such as for example baked pastry products. Some companies are taking action by replacing palm oil with other tropical fats, such as coconut, or returning to the use of animal fats, such as butter. However, the technological performance of coconut oil is often not comparable to that of palm oil due to the different compositional characteristics. The use of butter, on the other hand, could contribute to a significant increase in the price of the final product.

Several authors have therefore studied possible fat substitutes. In particular, the international application WO-A-2005/089568 describes a structured emulsion with surfactants and containing a liquid oil. This emulsion is proposed as an alternative to the use of hydrogenated fats or palm oil derivatives in baked products and spreadable creams. The product generally has values of elastic modulus G' comprised between 10 ² and 10 ^J Pa and is creamy and not very plastic. It does not therefore have the structural characteristics suitable for use as rollable fat. One implementation of this matrix is shown in the international application WO-A-2014/043778, in which waxes are added up to a maximum of 15% in weight in order to increase their plasticity and approach that of rollable margarines. According to European legislation on additives (Regulation EC 1331/2008), some waxes (E901, E902, E903) can only be used for glazing of certain categories of product. The system proposed in WO-A-2014/043778 also has a lower final fat content (up to 60% in weight) compared to margarines (fat content > 80% in weight) and therefore a higher water content.

It is therefore evident that there is a substantial shortage of processes intended to obtain margarine substitutes containing hydrogenated fats or palm oil derivatives which have suitable processing characteristics also in the light of their application in rolling processes, for example to produce baked pastry products. The documents Ashok R. Patel et al.: "Alternative Routes to Oil Structuring", 1 January 2015, and Ashok R. Patel et al.: "Edible oil structuring: an overview and recent updates - Food & Function (RSC Publishing) DOI:10.1039/C5FO01006C", 19 August 2015. describe known methods for the production of oleogels, creamy or solid anhydride systems, that is, structured oils where there is no water; they consist of more than 98% oil and the remainder consists of structuring molecules. There are diverse possible structuring molecules and diverse preparation modes. Among the various molecules proposed in literature there are monoglycerides, which are dispersed directly in the hot oil and, cooling the system, the formation of an oleogel is obtained, which is not a fat-substitute or fat-imitator compound, for example not comparable to butter or margarine which instead, by definition, contains about 20% water. Furthermore, these systems are not suitable for rolling and for the production of pastry products.

Another way to obtain oleogels described in these known documents is to start from a structured emulsion with polysaccharides and proteins, and to dehydrate it completely. In this case too, a non-rollable anhydrous material is obtained.

Finally, these known documents propose a third method for preparing oleogels. This involves starting from an emulsion that is dehydrated or freeze- dried until the water is completely removed. The method obtains a foam which, immersed in oil, absorbs up to 98% of the oil (emulsion template method). The resultant oleogel is a non-rollable solid.

The document Ashok R. Patel et al.: "Biopolymer-based Structuring of Liquid Oil into Soft Solids and Oleogels Using Water-Continuous Emulsions as Templates", Langmuir, vol. 31, no. 7, 24 February 2015, also describes the production of solid anhydrous oleogels (97% oil) starting from dehydrated or freeze-dried emulsions (emulsion template method). This does not obtain a reliable product with 10-30% of water.

The document Heidi D. Batte et al. "Phase Behavior, Stability and Mesomorphism of Monostearin-oil-water Gels, Springer for Research & Development, 1 March 2007 describes the preparation of a gellified monoglyceride-based emulsion, but it does not provide any dehydration and moreover does not allow to obtain a reliable product. This document describes the ageing of the gellified emulsion during its preservation, in particular as a phenomenon that implies an unwanted re-organization of the system with increased consistency that occurs without loss of water. However, the changes induced in the gellified emulsion do not imply a loss of water induced by dehydration. In practice, therefore, the system proposed in this document is comparable to a viscous cream and contains too much water to be rolled.

Finally, the documents Avi Goldstein et al.: "Monoglyceride Stabilized Oil in Water Emulsion: an Investigation of Structuring and Shear History on Phase Behaviour", Food Biophysics, Kluwer Academic Publishers-Plenum Publishers, NE, vol. 7, no. 3, 15 June 2012, and US-A-2005/249855 describe the preparation of a gellified monoglyceride-based emulsion, but do not mention any dehydration.

There is therefore a need to perfect a method for the production of fat- substitute and/or fat-imitator compounds, in particular a method for the production of a solid emulsion with a limited content of saturated fats and without trans isomers of fatty acids usable, for example in the food sector, as a fat-substitute and/or fat- imitator compound, which can overcome at least one of the disadvantages of the state of the art.

The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.

Other limitations and disadvantages of traditional solutions and technologies will be clear to a person of skill after reading the remaining part of the present description with reference to the drawings and the description of the embodiments that follow, although it is clear that the description of the state of the art connected to the present description must not be considered an admission that what is described here is already known from the state of the prior art.

SUMMARY OF THE INVENTION

The present invention is set forth and characterized in the independent claims, while the dependent claims describe other characteristics of the present invention or variants to the main inventive idea.

According to some embodiments, a method is provided to make Tollable fat- substitute and/or fat- imitator compounds. According to one embodiment the method comprises:

i) preparing a gellified emulsion or hydrogel that includes an aqueous phase a) and a lipid phase b) comprising oil and one or more surfactants comprising nonionic surfactants, in which the nonionic surfactants comprise monoglycerides. ii) partially dehydrating the gellified emulsion to obtain a solid plastic emulsion usable as a fat-substitute and/or fat-imitator compound having a residual water content comprised between 10% and 30% in weight compared with the overall weight of the solid plastic emulsion, so that the solid plastic emulsion is reliable. According to another possible embodiment, the solid plastic emulsion has a reduced content of saturated fatty acids and is without trans isomers.

According to other embodiments, a solid plastic emulsion is provided obtainable using a method as in embodiments described here.

According to other embodiments a solid plastic emulsion is provided obtainable using a method as in embodiments described here, for use in the food sector.

According to other embodiments, a solid plastic emulsion is provided obtainable using a method as in embodiments described here, for use in the cosmetic sector.

According to other embodiments, a solid plastic emulsion is provided obtainable using a method as in embodiments described here, for use in the lubrication sector.

According to other embodiments, a formulation is provided for preparing a product that comprises a solid plastic emulsion obtainable using a method as in embodiments described here.

According to other embodiments, a formulation is provided for preparing a food product that comprises a solid plastic emulsion obtainable using a method as in embodiments described here.

According to other embodiments, a formulation is provided for preparing a cosmetic product that comprises a solid plastic emulsion obtainable using a method as in embodiments described here.

According to other embodiments, a formulation is provided for preparing a lubricant product that comprises a solid plastic emulsion obtainable using a method as in embodiments described here.

Other embodiments concern a reliable solid plastic emulsion comprising an aqueous phase a) and a lipid phase b) comprising oil and one or more surfactants comprising nonionic surfactants, in which said nonionic surfactants comprise monoglycerides, said solid plastic emulsion being dehydrated and having a residual water content comprised between 10% and 30% in weight with respect to the overall weight of the solid plastic emulsion, so that said solid plastic emulsion is reliable.

These and other aspects, characteristics and advantages of the present disclosure will be better understood with reference to the following description and the attached claims.

The various aspects and characteristics described in the present description can be applied individually where possible. These individual aspects, for example aspects and characteristics described in the attached dependent claims, can be the object of divisional applications.

It is understood that any aspect or characteristic that is discovered, during the patenting process, to be already known, shall not be claimed and shall be the object of a disclaimer.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

We shall now refer in detail to the various embodiments of the present invention, of which one or more examples are shown hereafter. Each example is supplied by way of illustration of the invention and shall not be understood as a limitation thereof. For example, the characteristics shown or described insomuch as they are part of one embodiment can be adopted on, or in association with, other embodiments to produce another embodiment. It is understood that the present invention shall include all such modifications and variants.

Before describing these embodiments, we must also clarify that the present description is not limited in its application to details of the construction and disposition of the components as described in the following description using the attached drawings. The present description can provide other embodiments and can be obtained or executed in various other ways. We must also clarify that the phraseology and terminology used here is for the purposes of description only, and cannot be considered as limitative.

Moreover, unless otherwise defined, all the technical and scientific terms used here and hereafter have the same meaning as commonly understood by a person with ordinary experience in the field of the art to which the present invention belongs. Even if methods and materials similar or equivalent to those described here can be used in practice and in the trials of the present invention, the methods and materials are described hereafter as an example. In the event of conflict, the present application shall prevail, including its definitions. The materials, methods and examples have a purely illustrative purpose and shall not be understood restrictively.

All the measurements are made, unless otherwise indicated, at 25 °C and at atmospheric pressure. All the temperatures, unless otherwise indicated, are expressed in degrees Celsius.

All percentages and ratios indicated refer to the weight of the total composition (% w/w), unless otherwise stated.

All the percentage ranges given here are provided with the estimate that the sum with respect to the total composition is 100%, unless otherwise indicated.

All the ranges reported here shall be understood to include the extremes, including those that report an interval "between" two values, unless otherwise indicated.

The present description also includes the ranges that derive from uniting or overlapping two or more ranges described, unless otherwise indicated.

The present description also includes the ranges that can derive from the combination of two or more values taken at different points, unless otherwise indicated.

We must point out that in the present description, the term emulsion refers to a system containing an aqueous phase, oil and an emulsifier. It can be liquid, solid or creamy.

Furthermore, in the present description, the term gellifled emulsion refers to a creamy system containing an aqueous phase, oil and an emulsifier able to create a network that makes the system self-standing.

Moreover, the term solid dehydrated emulsion refers to a solid system containing an aqueous phase, oil and an emulsifier. The latter creates a strong network that incorporates the oil and the water. For example, a solid dehydrated emulsion can have the solid consistency similar to a slab of butter and/or margarine.

Embodiments described here concern a method for the production of fat- substitute and/or fat-imitator compounds. In particular, embodiments described here concern a method for preparing a solid plastic emulsion having a reduced content of saturated fatty acids and free of trans isomers, totally similar to commercial margarines consisting of hydrogenated fats or derivatives of palm oil, and usable as a fat-substitute and/or fat-imitator compound, for example in the food industry.

According to some embodiments, the method provides to structure an oil in the presence of one or more surfactants, such as monoglycerides for example, and possibly other ingredients, to obtain a solid emulsion, followed by a partial dehydration step. The solid emulsion obtained before and/or after partial dehydration can be supplemented with additional ingredients in order to modulate its rheological characteristics and can be used as an alternative to solid fats for the production of foods, such as baked products, pastry products, ice cream and confectionery.

According to some embodiments, the method for preparing the solid emulsion according to the present description can include two operational steps:

i) preparing a gellified emulsion, or hydrogel, comprising an aqueous phase a) and a lipid phase b) comprising oil and one or more surfactants;

ii) partial dehydration of said gellified emulsion, to obtain a solid plastic emulsion usable as a fat-substitute and/or fat-imitator compound.

According to possible embodiments, the solid plastic emulsion obtained from the partial dehydration has a residual water content comprised between 10% and 30% in weight compared with the overall weight of the solid plastic emulsion.

Consequently, an advantageous aspect of the embodiments described here consists in the combination of two steps - that is, the preparation of the gellified emulsion and its subsequent partial dehydration, for example advantageously until a water concentration comprised between 10% and 30% in weight is reached, so as to obtain a solid dehydrated emulsion - in order to obtain a fat- substitute and/or fat-imitator, such as for example butter or margarine (which normally contain about 20% in weight of water), advantageously with a low content of saturated fats, also suitable for rolling.

In possible implementations, the ratio of the aqueous phase a) and the lipid phase b) in the gellified emulsion, or hydrogel, of preparation step i) can vary from 4: 1 to 2:3. For example, the aqueous phase a) in the gellified emulsion of preparation step i) can be present between 45% and 55%, in particular between 47% and 50% in weight, with respect to the overall weight of the gellified emulsion or hydrogel. According to a possible example embodiment, the ratio between the aqueous phase a) and the lipid phase b) can be 1 :1.

In possible implementations, the gellified emulsion of preparation step i) can consist of aqueous phase a) and lipid phase b).

In possible implementations, the concentration of the surfactants in the lipid phase b) before partial dehydration can range from 3% to 25% in weight, in particular from 4% to 22%, more particularly from 5% to 21% in weight, compared to the weight of the lipid phase b). The remaining portion of the lipid phase b) can be represented by the aforesaid oil, taking care to choose the values so that the sum is 100%.

In possible implementations, the one or more surfactants can have a melting temperature higher than the melting temperature of the oil in the lipid phase b).

In possible implementations, the one or more surfactants used can comprise non-ionic surfactants. In variant embodiments, the one or more surfactants used can consist of non-ionic surfactants.

In possible implementations, the concentration of surfactants in the gellified emulsion or hydrogel can range from 3% to 15% in weight, in particular from 5% to 12%, more particularly from 7% to 10% in weight, compared with the weight of the gellified emulsion.

In possible implementations, the one or more surfactants can include monoglycerides. Monoglycerides or (monoacylglycerols) are a class of glycerides whose molecule is made up of a fatty acid chain added by esterification to a glycerol molecule. Monoglycerides are non-ionic surfactants.

According to possible implementations, the monoglycerides used have a melting point higher than 65°C.

According to possible implementations, the monoglycerides used have a length of the carboxylic chain greater than 16 carbon atoms.

Embodiments described here allow to prepare a solid emulsion in which the lipid fraction mainly consists of liquid oil and hence with a content of saturated fatty acids lower than that of traditional palm oil derivatives. The solid structure of this fatty matrix is advantageously obtained and guaranteed by the presence of lamellar lipid structures of partly dehydrated monoglycerides.

In possible implementations, the concentration of oil in the lipid phase b), before partial dehydration, can range from 65% to 95%, in particular from 70% to 92% in weight, with respect to the weight of the lipid phase b). The remaining portion of the lipid phase b) can be represented by the aforesaid one or more surfactants, taking care to choose the values so that the sum is 100%.

In possible implementations, the oil in the lipid phase (b) can include one oil or a mixture of oils. The oil usable in association with the embodiments described here can be of any nature.

For example, vegetable oil can be used. The vegetable oil used can be a vegetable oil for food use, that is, a vegetable fat for foodstuffs made, for example, from nuts and oilseeds or from other parts of a plant, such as flowering tops, flowers, leaves, fruits, roots and rhizomes. In possible implementations, the vegetable oil can be chosen from a group that comprises: hemp seed oil, safflower oil, rapeseed oil, Copaiba oil, jatropha oil, jojoba oil, flax oil, macadamia oil, walnut oil, argan oil, hypericum oil, olive oil, castor oil, rice oil, peanut oil, sunflower oil, corn seed oil, sesame seed oil, oil of soybeans, grape seed oil, black currant seed oil, or mixtures of two or more of them.

One or more preferred oils can be, for example, sunflower oil, peanut oil, flaxseed oil, olive oil.

Or, according to another example, oil of animal origin, such as fish oil, can be used.

In possible implementations, the aqueous phase a) and the lipid phase b) in step i) of gellified emulsion preparation are heated separately.

The lipid phase b) is heated to a temperature above the melting temperature of the one or more surfactants present therein, to obtain the fusion of the entire lipid phase b). In fact, as we said, the one or more surfactants present have a melting temperature higher than that of the oil.

In possible implementations, the aqueous phase a) and the lipid phase b) can then be vigorously mixed together to form an oil/surfactant/water system. Mixing can be performed using a turbo-emulsor. In possible implementations, the oil/surfactant/water system thus obtained is cooled to room temperature until a gel li tied emulsion is formed.

In possible implementations, the aqueous phase (a) can include deionized water supplemented with one or more bases, weak or strong as needed, in order to obtain an alkaline pH. The aqueous phase (a) can contain other additive ingredients such as proteins, carbohydrates, gums, dyes, or other water-soluble food ingredients. These other additive ingredients can be present, in the final solid emulsion, up to 15% in weight, for example from 3% to 15%, in particular from 5% to 13% in weight.

In possible implementations, the one or more surfactants of the lipid phase can include one or more additional ionic surfactants, or co-surfactants. Examples of ionic surfactants or co-surfactants can be saturated fatty acids of any nature. The use of these additional ionic surfactants or co-surfactants can be useful to modulate the properties of the nonionic surfactants used in the lipid phase b), particularly monoglycerides for example, as these are not normally obtainable in pure form but, in particular for industrial use, are obtainable in formulations containing monoglycerides, and also diglycerides and fatty acids.

For example, the additional surfactants, or co-surfactants, such as saturated fatty acids, can be added to the oil in the lipid phase b).

In possible implementations, these additional surfactants or co-surfactants such as saturated fatty acids can be added to the oil in the lipid phase b) in variable percentages, for example up to 15% in weight with respect to the weight of the oil.

For example, saturated fatty acids can be selected with a carboxylic chain with a number of fatty acids greater than 14.

In possible implementations, in the lipid phase b) the concentration of ionic surfactants can range from 0.2% to 1.5% in weight, compared to the weight of the lipid phase (b). Typically, as we said, industrial monoglycerides can also contain variable proportions of diglycerides and fatty acids.

The gellified emulsions obtained from step i) can have values of the elastic modulus G' less than lxl 0 ^J Pa. We must point out here that mixtures of monoglycerides with structuring action are currently admitted as additives (E471) by European EC Regulation 1333/2008 with no limits on the concentration of use - quantum satis.

In possible implementations, the partial dehydration step ii) of the gellified emulsion can provide to subject the gellified emulsion prepared in step i) to partial dehydration until the desired lipid content is reached.

For example, the desired lipid content in the final solid emulsion after partial dehydration can range from 65% to 85%, in particular from 70% to 83% in weight. The remaining content of the final solid emulsion can be water, or water and one or more of the aforesaid further additive ingredients. For example, in certain embodiments, the water in the final solid emulsion after partial dehydration can range, as described above, from 10% to 30%, in particular from 15% to 25%, more particularly from 15% to 22% in weight. Possible examples are 18%, 19%, 20%, 21% in weight.

Advantageously, the partial dehydration can be carried out at a low temperature.

In possible implementations, the partial dehydration can be carried out at a temperature not higher than 60°C, in particular between 25°C and 45°C, more particularly between 30°C and 40°C.

In possible implementations, the partial dehydration can be carried out at atmospheric pressure or reduced pressure, that is, lower pressure than atmospheric pressure.

In possible implementations, the partial dehydration can be carried out in a ventilation mode, for example with a speed of the dehydrating air flow of less than 5 m/s, more particularly less than 4 m/s, even more particularly less than 3 m/s, even more particularly less than 2 m/s, even more particularly less than 1 m/s, even more particularly less than 0.5 m/s, even more particularly less than 0.4 m/s, for example between 0.1 m/s and 0.4 m/s.

In possible implementations, the thickness of the gellified emulsion before the partial dehydration step ii) can be between 0.5 mm and 6 mm, in particular between 1 mm and 5 mm. An example of gellified emulsion thickness can be 5 mm. Another example of gellified emulsion thickness can be 3.5 mm. Another example of gellified emulsion thickness can be 2.5 mm. An additional example of gellified emulsion thickness can be 1 mm. In possible implementations, in the partial dehydration step ii), the water is partly removed, obtaining the desired quantities of residual water in the final solid emulsion, for example as described above. The oil remains incorporated in the lamellar structure of the surfactants. In this way we obtain the advantageous technical effect of preventing the separation of the oil, thanks to the fact that it remains trapped in the lamellar structure of the surfactants, and the structure of the final solid emulsion is advantageously maintained.

Advantageously, the partial dehydration can be carried out slowly, that is, for a prolonged time. This can have the advantage, together with the low temperature at which the partial dehydration is carried out, of maintaining the desired structure of the final solid emulsion, at the same time removing the desired quantity of water.

In possible implementations, the partial dehydration has a duration that can vary from 2 hours to 48 hours, in particular from 10 hours to 40 hours, more particularly from 15 hours to 36 hours. For example, the time required for obtaining the solid emulsion by partial dehydration can depend on the initial thickness of the gellified emulsion before the partial dehydration step ii), temperature, pressure and ventilation.

According to the present description, the solid emulsion obtained as a final product at the end of the partial dehydration step ii) is a solid which can have physical characteristics and microbiological stability similar to a vegetable margarine.

In possible variant embodiments, as well as the above additive ingredients, substances with an antimicrobial, antioxidant, flavoring and coloring action or other substances can be added to the formulation at step i), or downstream of step ii), according to needs.

The rheological properties of the final solid emulsion can advantageously be modulated as a function of the initial formulation, the level of partial dehydration to be obtained, and of the possible addition of any other ingredients after partial dehydration.

For example, the values of the elastic modulus G' of the solid emulsion obtainable according to embodiments of the method described here can vary from 10 ⁴ to 10 ⁶ Pa at 15°C (typical processing temperature of margarines). These elastic modulus G' values and rheological properties make the solid emulsion described here suitable for various uses as alternative healthy fat, replacing traditional solid fats.

The solid emulsion is therefore usable as a solid plastic food fat and can be applied in any food where palm oil derivatives or hydrogenated fats are traditionally or normally used.

Advantageously, the final solid plastic emulsion according to the present description can be successfully used to make bakery products in general, both bakery products that are not pastry or rolled, such as short-crust pastry products, biscuits, pies, battered doughs, or suchlike, and also for making bakery products in pastry, that is, obtained by rolling. Furthermore, the final solid plastic emulsion according to the present description can be successfully used for making creams and confectionery, such as candy. Moreover, the solid emulsion can be used for breadsticks, coating fats, ice cream, sweet and savory cereal products in general.

According to possible variants, embodiments described here can also provide to use the solid emulsion obtainable according to some embodiments of the method described here outside the food industry, for example in cosmetic and/or lubricating products.

EXAMPLES

Example 1

Example 1 describes a first formulation of a solid emulsion developed according to example embodiments of the present description. The composition of the product comprises sunflower oil, surfactants (monoglycerides and free fatty acids) and an alkaline aqueous solution. The partial dehydration of the gellified emulsion was carried out at 35°C for 24 hours under ventilated conditions (0.3 m/s). As seen in Table 1 below, the solid emulsion after partial dehydration contained about 17% in weight of water and 83% in weight of lipid phase, understood as the sum of oil and surfactants. The elastic modulus G' after partial dehydration increased by about one order of magnitude.

Table 1

Gellified Dehydrated solid emulsion emulsion Sunflower oil (% w/w) 47.6 75.2

Surfactants (% w/w) 4.8 7.6

Aqueous phase (% w/w) 47.6 17.2

Elastic modulus G' (Pa) a 15 8.7xl0 ³ 7.3xl0 ⁴

°C

Example 2

Example 2 describes a second formulation of a solid emulsion developed according to example embodiments of the present description. The composition of the product comprises sunflower oil, surfactants (monoglycerides and free fatty acids) and an alkaline aqueous solution. The partial dehydration was performed at 40°C for 15 hours in ventilated conditions (0.1 m/s). As seen in Table 2 below, the solid emulsion after partial dehydration contained approximately 21.3% in weight of water and about 78.7% in weight of lipid phase, understood as the sum of oil and surfactants. The elastic modulus G' after partial dehydration increased by almost two orders of magnitude.

Table 2

Gellified Dehydrated solid emulsion emulsion

Sunflower oil (% w/w) 41.6 62.5

Surfactants (% w/w) 10.8 16.2

Aqueous phase (% w/w) 47.6 21.3

Elastic modulus G' (Pa) a 15 1.2xl0 ⁴ 7.3xl0 ⁵

°C

Example 3

Example 3 describes a third formulation of a solid emulsion developed according to example embodiments of the present description. The composition of the product comprises sunflower oil, vegetable fat (unhydrogenated and not from palm plants), surfactants (monoglycerides and free fatty acids) and an alkaline aqueous solution. The partial dehydration was performed at 30°C for 36 hours in ventilated conditions (0.2 m/s). As can be seen in Table 3 below, the solid emulsion after partial dehydration contained about 17.4% water and about 82.6% lipid phase, understood as the sum of oil, vegetable fat and surfactants. The elastic module after partial dehydration increased by nearly two orders of magnitude.

Table 3

Gellified Dehydrated solid emulsion emulsion

Sunflower oil (% w/w) 37.6 59.1

Surfactants (% w/w) 10.8 17.3

Fat (% w/w) 4.0 6.2

Aqueous phase ( % w/w) 47.6 17.4

Elastic modulus G' (Pa) a 15 1.4xl0 ⁴ l.lxlO ⁶

°C

Example 4

Example 4 describes a fourth formulation of a solid emulsion developed according to example embodiments of the present description. The composition of the product comprises sunflower oil, vegetable fat (unhydrogenated and not from palm plants), surfactants (monoglycerides and free fatty acids), an alkaline aqueous solution and carbohydrates. The partial dehydration was performed at 30°C for 36 hours in ventilated conditions (0.2 m/s). Carbohydrates were added to the dehydrated solid emulsion. As seen in Table 4 below, the finished solid emulsion contained about 15.2% water and about 71.8% lipid phase, understood as the sum of oil, vegetable fat and surfactants. The elastic module after partial dehydration increased by nearly two orders of magnitude.

Table 4

Gellified Dehydrated solid emulsion emulsion

Sunflower oil (% w/w) 37.6 51.4

Surfactants (% w/w) 10.8 15.0

Fat (% w/w) 4.0 5.4

Aqueous phase (% w/w) 47.6 15.2

Carbohydrates (% w/w) . 13.0

Elastic modulus G' (Pa) a 15 1.5xl0 ⁴ 1.7xl0 ⁶

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Example 5 Example 5 describes the use of the solid emulsion shown in example 1, for preparing biscuits.

The formulation of the recipe for the biscuit mix in weight (% w/w) was: 50% plain flour, 21% solid emulsion prepared as in example 1, 16.5% sugar, 1 1.4% water, 0.34% salt (NaCl), 0.76% yeast powder. The ingredients were mixed and round biscuits were formed with 3.5 cm diameter and 0.4 cm height. Samples were baked in the oven at 200°C for 10 minutes. As a control, similar biscuits were prepared containing palm oil for biscuits instead of the solid emulsion. After baking, the biscuits had a moisture content of 3%. The samples were comparable in color, consistency and sensory characteristics.

Example 6

Example 6 describes the use of the solid emulsion shown in example 1 for preparing pastry creams. The formulation of the cream, in weight (% w/w), was as follows: 41.0% solid emulsion prepared as in example 1, 32.2% icing sugar, 13.5% skimmed-milk powder and 13.3% water. The system was homogenized until a homogeneous compound was obtained. As a control, a similar cream was prepared containing palm oil instead of the solid emulsion. The samples were comparable in color and sensory characteristics.

Example 7

Example 7 describes the use of the solid emulsion shown in example 2 for preparing toffee type candies. In particular, the granulated sugar was caramelized at 150°C for 3 mins and cooled. The solid emulsion prepared as in example 2 was then added (16% in weight). The system was mixed until a homogeneous compound was obtained, and deposited on silicone molds. As a control, similar samples were prepared with hydrogenated coconut oil instead of the solid emulsion. The samples were comparable in color, consistency and sensory characteristics.

Example 8

Example 8 describes the use of the solid emulsion shown in example 3 for preparing puff pastry, that is, a rolled bakery product. The formulation of the puff pastry, in weight (% w/w), was as follows: 32% plain flour, 47% solid emulsion prepared as in example 3, 20% water, 1% salt. Flour, water and salt were mixed and the dough was left to rest for 1 hour. The dough on which the solid emulsion was deposited according to the present description was then rolled (5x3), waiting 1 hour between one rolling and the other. The dough was cooked at 200°C for 10 mins. As a control, a similar puff pastry was prepared containing palm oil margarine for puff pastry instead of the solid emulsion. After cooking the samples were comparable in color, moistness and sensory characteristics.

It is clear that modifications and/or additions of parts and/or operative steps may be made to the method for making fat-substitute and/or fat-imitator compounds as described heretofore, without departing from the field and scope of the present invention.

It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art shall certainly be able to achieve many other equivalent forms of method for making fat-substitute and/or fat-imitator compounds, having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby.