Aqueous dispersions of tripalmitin particles (with a minimum size of 130 nm) were produced, via a hot sonication method, with and without the addition of food-grade emulsifiers. Depending on their relative size and chemistry, the emulsifiers altered the properties of the fat particles (e.g. crystal form, dispersion state and surface properties) by two proposed mechanisms. Firstly, emulsifiers modify the rate and/or extent of polymorphic transitions, resulting in the formation of fat crystals with a range of polarities. Secondly, the adsorption of emulsifiers at the particle interface modifies crystal surface properties. Such emulsifier-modified fat particles were then used to stabilise emulsions. As the behaviour of these particles was predisposed by the kind of emulsifier employed for their manufacture, the resulting particles showed different preferences to which of the emulsion phases (oil or water) became the continuous one. The polarity of the fat particles decreased as follows: Whey Protein Isolate > Soy Lecithin > Soy Lecithin + Tween 20 > Tween 20 > Polyglycerol Polyricinoleate > no emulsifier. Consequently, particles stabilised with WPI formed oil-in-water emulsions (O/W); particles stabilised solely with lecithin produced a highly unstable W/O emulsion; and particles stabilised with a mixture of lecithin and Tween 20 gave a stable W/O emulsion with drop size up to 30 μm. Coalescence stable, oil-continuous emulsions (W/O) with drop sizes between 5 and 15 μm were produced when the tripalmitin particles were stabilised with solely with Tween 20, solely with polyglycerol polyricinoleate, or with no emulsifier at all. It is proposed that the stability of the latter three emulsions was additionally enhanced by sintering of fat particles at the oil-water interface, providing a mechanical barrier against coalescence.
Modern emulsion processing technology is strongly influenced by the market demands for products that are microstructure-driven and possess precisely controlled properties. Novel cost-effective processing techniques, such as membrane emulsification, have been explored and customised in the search for better control over the microstructure, and subsequently the quality of the final product. Part A of this review reports on the state of the art in membrane emulsification techniques, focusing on novel membrane materials and proof of concept experimental set-ups. Engineering advantages and limitations of a range of membrane techniques are critically discussed and linked to a variety of simple and complex structures (e.g. foams, particulates, liposomes etc.) produced specifically using those techniques.
Membrane emulsification is a promising process for formulating emulsions and particulates. It offers many advantages over conventional 'high-shear' processes with narrower size distribution products, higher batch repeatability and lower energy consumption commonly demonstrated at a small scale. Since the process was first introduced around 25 years ago, understanding of the underlying mechanisms involved during microstructure formation has advanced significantly leading to the development of modelling approaches that predict processing output; e.g. emulsion droplet size and throughput. The accuracy and ease of application of these models is important to allow for the development of design equations which can potentially facilitate scale-up of the process and meet the manufacturer's specific requirements. Part B of this review considers the advantages and disadvantages of a variety of models developed to predict droplet size, flow behaviour and other phenomena (namely droplet-droplet interactions), with presentation of the appropriate formulae where necessary. Furthermore, the advancement of the process towards an industrial scale is also highlighted with additional recommendations by the authors for future work.
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