The future of food. Creating high added value ingredients with innovative processing technologies. October 2, 2010.

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1 The future of food Creating high added value ingredients with innovative processing technologies Kjeld van Bommel

2 Global food industry issues Increasing global population results in growing demand for food CO 2 Food production/processing inefficient - high costs - high carbon and water footprint - especially meat and dairy Faster product innovation required, however, current processes not flexible 2

3 Global food industry challenges Increase food production and processing efficiency Produce cheaper food products Use alternative food sources (algae, fungi, seaweed, lupine) Develop flexible processes without loosing taste and quality!!! Food sector is of great importance to the Netherlands: turnover of 47 B /y = 10% of GNP; responsible for 20% of total exports (#1 exporter of food in Europe); employs FTE Task & opportunity for TNO to develop new technologies for food processing 3

4 Outline Printing powder Encapsulation printing Production of fibers The future of food 4

5 Rapid manufacturing Layer-wise building of a structure directly from 3D CAD data. Initially Rapid Prototyping: slow, single objects, no functionalities Later Rapid Manufacturing: fast production of functional parts/ production of small series 5

6 TNO inkjet technology for Rapid Manufacturing Drop formation Viscosity: up to 500 mpa s Drop size: 20 to 180 m Frequency: up to 140 khz Temperature: up to 350ºC 6

7 Conventional spray drying Most widely used drying / powder production process in food industry Applications: milk powder, starch, coffee, spices, Disadvantages Broad size distribution of powder particles Drying protocol based on the largest particles High shear rate can affect sensitive ingredients Fines are produced, resulting in product loss, downtime, risk of dust explosions 7

8 Printing powder printing monodisperse drops drying monodisperse powders 8

9 From single nozzle to multinozzle print head < 10 cm 1 nozzle ~ 3 ml/min ~ 0,2 L/h 500 nozzle 500 x 3 ml/min ~ 100 L/h 9

10 Drying results Conventional process (swirl flow nozzle) Printing powder process (Rayleigh break-up nozzle) Polydisperse size and shape Monodisperse size and shape High density, spherical 10

11 Advantages Material, energy and water efficiency start from high solid content water + energy optimal drying conditions due to monodisperse drops energy monodisperse particles (no fines ) material + energy Product properties monodisperse powders of tunable size uniform behavior high density powders possible Additional wide range of materials can be processed flexibility mild process (very low shear) allow use of sensitive products 11

12 Outline Printing powder Encapsulation printing Production of fibers The future of food 12

13 Encapsulation (Micro)encapsulation is widely used in the food industry many techniques in use core-shell encapsulate (microcapsule) shell material core material Applications: taste masking, stability enhancement, controlled release, Materials: omega-3 fatty acids, metal salts, antioxidants, flavors, Challenges: complete encapsulation, tunable microcapsule properties, use of wide range of materials, Continuing need for improved, material independent processes exists 13

14 TNO encapsulation printer core liquid film core-shell 14

15 Core-shell particles mint syrup molten stearic acid no release in cold water fast release in hot water (flavor burst) well defined 200 µm encapsulates 15

16 Printed core shell particles continued linseed oil hot carrageenan solution well defined 280 µm encapsulates thin (homogeneous) shells 85 v% core mechanically triggered release 16 shell = ~ 7

17 Advantages Material and energy efficiency 100% encapsulation (optimal drying conditions due to monodisperse drops) Product properties monodisperse capsules of tunable size / shell uniform behavior Additional converts liquids into powders flexibility wide range of materials can be processed flexibility separated core and shell flows wider process window multilayer shells possible 17

18 Outline Printing powder Encapsulation printing Production of fibers The future of food 18

19 Fibers in food Fibers provide structure and texture to food products which contributes to a pleasant taste experience Examples: muscle fibers in meat, cellulose fibers in vegetables, But also: citrus fibers in low fat full taste mayonnaise (Unilever) Challenge: produce well-defined fibers of various food materials in order to create desired textures and structures in food products No commercially relevant technology exists (yet) 19

20 Electrospinning technology 20

21 Fibers of food polymers carbohydrate (dextran) protein (zein) 21

22 Controlled fiber production and deposition fiber mat directionality directionality discrete fibers Potential applications: organized structure Structuring / texturizing Thickening / gelating Encapsulation / controlled release Making fibers out of alternative food materials Meat replacement 22

23 Outline Printing powder Encapsulation printing Production of fibers The future of food rapid screening of food structures 3D food products 23

24 Rapid screening faster product innovation 24

25 Outline Printing powder Encapsulation printing Production of discrete fibers The future of food rapid screening of food structures 3D food products 25

26 Production of 3D objects 26

27 Production of 3D multimaterial objects 3 materials + gradients 27

28 The future: food fabrication sources ingredients structures tissues food biotechnology (algae, fungi, ) waste (food agriculture) alternative crops: lupine, alternative sources: seaweed, non-food plants, insects, carbohydrates polysaccharide fiber protein fiber fat globule flavor capsule micronutrient capsule flavors micronutrients proteins water fats 28

29 Selective laser sintering of Nesquik Powder bed of Nesquik Laser sintering of pattern 29 Multiple layers 250 µm each Finished object mm

30 Freeform food products Cups: 25 4 mm (2 mm deep) Open pyramid: base mm 30 Grid: mm Chain links: mm

31 Towards 3D food products food printer / food replicator capsules ingredients / raw materials fibers 31

32 For more information please contact: Dr. ir. Kjeld van Bommel TNO Science & Industry De Rondom 1 PO Box HE Eindhoven The Netherlands kjeld.vanbommel@tno.nl office +31 (0) mobile +31 (0)