Impact of technology and whipping conditions on dairy topping fabricationThe continuous manufacturing of dairy toppings has been studied using first the conventional industrial technology, the axial rotor-stator mixer. The influence of process parameters including operating pressure, residence time and rotational speed has been investigated in terms of overrun, bubble size distribution, as well as foam texture and stability using a model dairy emulsion. The performance of the rotor-stator mixer has then been confronted to that of alternative technologies, such as narrow gap annular columns and scraped surface heat exchangers. Experimental results have highlighted the significant role of operating pressure, the ambiguous role of high residence times that make easier the achievement of desired overrun values, but provide larger bubble sizes, and also the negative interaction between high rotational speed and high residence times. Scale effects have been quantified using a generalized Reynolds number that takes into account the shearthinning behaviour of the emulsion, the increase in viscosity due to the gas phase and all the geometrical characteristics of a rotor-stator unit. The results have also shown that scraped surface heat exchangers constitute an attractive alternative to other foaming devices: they behave globally as a rotor-stator unit with long residence time, but provide foams with smaller bubble sizes than other types of units.
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