1. Adjust Equipment Parameters Based on Raw Material Properties: The key parameters of food emulsifier equipment include rotational speed (shear force), mixing time, and feeding ratio. For raw materials with high viscosity (e.g., heavy cream), increasing the rotational speed (to enhance shear force) and extending the mixing time can help break down large fat globules into smaller, uniform particles. For example, in ice cream production, a rotational speed of 3000-4000 rpm and a mixing time of 15-20 minutes are typically used to achieve the desired emulsion fineness. The feeding ratio of oil and water phases is also critical; for oil-in-water emulsions (e.g., milkshakes), the aqueous phase should be added first, followed by the oil phase at a controlled rate, to prevent phase inversion. For water-in-oil emulsions (e.g., butter), the oil phase should be the continuous phase, and the aqueous phase should be added gradually.
2. Pre-Treat Raw Materials to Enhance Emulsification Efficiency: Pre-treatment of raw materials can significantly improve the emulsification effect. For example, oil-soluble ingredients (e.g., vegetable oil, cocoa butter) can be pre-heated to reduce viscosity, making them easier to disperse. Water-soluble ingredients (e.g., sugar, stabilizers) should be fully dissolved in the aqueous phase to avoid agglomeration. For powdered emulsifiers (e.g., soy lecithin), pre-dispersing them in the oil or aqueous phase (depending on their solubility) can prevent clumping and ensure uniform distribution. In addition, removing air from the raw materials (e.g., degassing the aqueous phase) can prevent the formation of bubbles during emulsification, which can affect product stability.
3. Control Process Temperature to Maintain Emulsion Stability: Temperature has a significant impact on emulsion formation and stability. For most food emulsions, the emulsification process should be carried out at a moderate temperature (30-60°C). Higher temperatures reduce the viscosity of the oil phase, enhance molecular mobility, and improve shear efficiency. However, excessive temperatures can damage heat-sensitive ingredients (e.g., proteins in milk, vitamins in beverages) or cause oil oxidation. For example, in the production of yogurt drinks, the emulsification temperature should be controlled at 40-45°C to avoid denaturing the yogurt proteins. After emulsification, rapid cooling of the emulsion (e.g., using a plate heat exchanger) can help lock in the uniform droplet size distribution and prevent phase separation during storage.
4. Use Multi-Stage Emulsification to Improve Emulsion Fineness and Stability: For products that require high emulsion stability (e.g., long-shelf-life sauces, functional beverages), multi-stage emulsification is recommended. This involves using a combination of pre-dispersion and high-shear emulsification. For example, first, use a low-speed mixer to pre-blend the oil and water phases to form a coarse emulsion, then pass the coarse emulsion through a high-shear emulsifier to refine the droplet size. Some advanced systems also include a homogenizer as a third stage, which uses high pressure to further reduce droplet size (to below 1 μm) and improve stability. Multi-stage emulsification ensures that the emulsion is uniformly refined, reducing the risk of phase separation, sedimentation, or floating during storage.
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