Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEM AND METHOD FOR MIXING POLYUNSATURATED FATTY ACIDS
INTO A FLUID FOOD PRODUCT
TECHNICAL FIELD OF THE DISCLOSURE
This invention relates in general to a system and method of producing a fluid
food product, and more particularly to producing a fluid food product with
polyunsaturated fatty acids.
BACKGROUND
Milk is consumed by many Americans from a young age. Consuming milk
may serve as a convenient way for people, kids in particular, to receive
dietary
supplements or vitamins. Certain ingredients, supplements, or vitamins may be
added
to milk to produce milk products having enhanced nutritional qualities.
Certain
polyunsaturated fatty acids, such as docosahexaenoic acid ("DHA"), may provide
health benefits when taken as a supplement. Introducing polyunsaturated fatty
acids to
milk may enhance the milk's nutritional value.
Similarly, introducing
polyunsaturated fatty acids to other types of fluid food products may enhance
the
nutritional value of those fluid food products.
SUMMARY
Particular embodiments described herein include an apparatus for distributing
oil into fluid food product. According to some embodiments, an apparatus for
distributing oil (such as one or more polyunsaturated fatty acids) into fluid
food
product includes a batch tank, a transfer line, a pressure tank, a funnel, an
oil
dispenser, an inline shear mixer, and a flow line. The batch tank holds a
volume of
fluid food product. The transfer line is in fluid connection with the batch
tank. The
pressure tank holds a volume of oil and includes a side inlet and a bottom
fluid
passage. The bottom fluid passage is coupled to the transfer line. The funnel
is
disposed through a top opening in the pressure tank and dispenses oil into the
pressure
tank. A stem portion of the funnel extends at least halfway into an interior
of the
pressure tank. The funnel includes at least one vent allowing gas to escape
the
pressure tank. The oil dispenser is connected to the pressure tank between the
bottom
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fluid passage and the transfer line. The oil dispenser dispenses oil from the
pressure
tank into a flow of fluid food product from the batch tank. The inline shear
mixer
includes an inlet connected to the transfer line downstream from the oil
dispenser. The
inline shear mixer mixes the fluid food product and the oil. The flow line is
connected
to an outlet of the inline shear mixer and flows the fluid food product-and-
oil mixture
to the batch tank.
Particular embodiments described herein include a method for distributing oil
(such as one or more polyunsaturated fatty acids) into fluid food product.
According
to some embodiments, a method of producing a mixture of oil and fluid food
product
includes: placing a funnel in a top opening of a pressure tank, flushing the
pressure
tank with an inert gas such as nitrogen, flowing the oil into the pressure
tank through
the funnel, maintaining a flow of inert gas such as nitrogen into the pressure
tank,
dispensing a flow of fluid food product from the batch tank into a transfer
line,
dispensing oil from a pressure tank into the transfer line, flowing the
dispensed oil
and the flow of fluid food product to an inline shear mixer, dispersing the
dispensed
oil into the flow of fluid food product in the inline shear mixer, flowing the
flow of
fluid food product comprising the micronized oil-in-fluid food product
droplets to the
batch tank, and distributing the flow of fluid food product comprising the
micronized
oil-in-fluid food product droplets in a volume of fluid food product in the
batch tank.
The stem of the funnel extends at least halfway down into the interior of the
pressure
tank. The inert gas such as nitrogen flows through the bottom fluid passage
until the
oxygen level in the pressure tank is 2% or less to flush the pressure tank.
The flow of
inert gas such as nitrogen is maintained through a side inlet of the pressure
tank such
that the oxygen level remains at 2% or less. The oil is added to the flow of
fluid food
product at a pre-determined oil-to-fluid food product ratio. The inline mixer
creates a
plurality of micronized oil-in-fluid food product droplets in the flow of
fluid food
product.
Certain embodiments of the present disclosure may provide one or more
technical advantages. As an example, the pressure tank prevents oxidation of
any
introduced polyunsaturated fatty acids by providing an inert environment using
pumped-in an inert gas such nitrogen gas. Inserting the funnel such that the
stem
extends at least halfway into the interior of the pressure tank ensures that
the oil
transferred to an oxygen-deprived portion of the pressure tank.
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In addition, dispensing oil in line (e.g. via a transfer line) into to a flow
of
fluid food product prevents oil from being exposed to air when being added to
fluid
food product. The in line dispensing of oil prevents oxidation compared to
conventional methods that add oil to a tank of fluid food product via an
opening in the
tank.
As another example, the use of an inline shear mixer to mix the oil and fluid
food product creates micronized droplets of oil in the fluid food product.
Creating
small droplets of the oil enhances its suspension in the fluid food product.
When the
oil is suspended, as opposed to floating at the surface, the droplets remain
separated
from each other and away from oxygen rich environments. Additionally,
micronized
droplets may be more readily distributed in a volume of fluid food product.
Other technical advantages of the present disclosure will be readily apparent
to
one skilled in the art from the following figures, descriptions, and claims.
Moreover,
while specific advantages have been enumerated above, various embodiments can
include all, some, or none of the enumerated advantages.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present disclosure and its
advantages, reference is now made to the following description, taken in
conjunction
with the accompanying drawings, in which:
FIGURE 1 illustrates an example system for mixing oil into fluid food
product, according to some embodiments;
FIGURE 2 illustrates an example funnel disposed through a top opening of an
example pressure tank, according to some embodiments; and
FIGURE 3 illustrates an example mixer capable of dispersing oil into a flow
of fluid food product, according to some embodiments;
FIGURE 4 is a flow diagram illustrating a first example method of mixing oil
into fluid food product;
FIGURE 5 is a flow diagram illustrating a second example method of mixing
oil into fluid food product;
FIGURE 6 is a flow diagram illustrating a third example method of mixing oil
into fluid food product.
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DETAILED DESCRIPTION
Some embodiments are presented in the list of embodiments below. Further
details of such embodiments are also presented in further paragraphs.
Embodiment 1. A system having an apparatus comprising:
- a pressure tank, comprising a bottom fluid passage and a side inlet
capable
operable to receive a gas or liquid, and
- a funnel comprising a top opening, a stem; and one or more vents,
wherein the funnel is disposed through a top opening in the pressure tank, and
the
stem of the funnel extends at least halfway down into the interior of the
pressure tank.
Embodiment 2. The system of embodiment 1, further having a
transfer
line and a batch tank, wherein the bottom fluid passage is fluidly coupled to
the
transfer line, the transfer line is in fluid connection with a batch tank,
wherein the
batch tank is operable to hold a volume of fluid food product.
Embodiment 3. The system according to embodiment 2, further having
an oil dispenser connected to the pressure tank between the bottom fluid
passage and
the transfer line, the oil dispenser being operable to dispense an oil from
the pressure
tank into a flow of fluid food product from the batch tank.
Embodiment 4. The system according to any of the embodiments 2
to 3,
further comprising an inline shear mixer configured to:
- receive a flow of the dispensed oil from the transfer line;
- mix the fluid food product and the oil to create an oil-in-fluid food
product
mixture;
- discharge the oil-in-fluid food product mixture to the batch tank.
Embodiment 5. The system according to any of the embodiments 2 to 4,
wherein the batch tank comprises agitators operable to mix the volume of fluid
food
product with the oil-in-fluid food product mixture.
Embodiment 6. The system according to any of the embodiments 1
to 5,
further comprising one or more valves between the pressure tank and a an inert
gas,
such as nitrogen, tank operable to control a volume of inert gas in the
pressure tank;
wherein the bottom fluid passage of the pressure tank is operable to receive
the inert gas from the inert gas tank into the pressure tank; and
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wherein the side inlet of the pressure tank is operable to receive the inert
gas
from the inert gas tank into the pressure tank.
Embodiment 7. The
system according to embodiment 6, wherein the
one or more valves are further operable to operate in a purge mode and a
maintenance
5 .. mode, wherein:
- the purge mode allows the inert gas to be dispensed into the pressure
tank
through the bottom fluid passage and optionally through the side inlet of the
pressure
tank; and
- the maintenance mode allows the inert gas to be dispensed into the
pressure
tank through the side inlet without allowing the inert gas through the bottom
fluid
passage.
Embodiment 8. The
system according to any of the embodiments 1 to 7,
wherein the side inlet comprises a spray ball, the spray ball operable to:
- dispense an inert gas such as nitrogen into the pressure tank; and
- dispense fluid food product into the pressure tank.
Embodiment 9. The
system according to any of the embodiments 4 to 8,
further having a flow line connected to an outlet of the inline shear mixer
operable to
flow the fluid food product-and-oil mixture to the batch tank.
Embodiment 10. The
system according to embodiment 9, wherein the oil
dispenser comprises a mass flow meter operable to dispense the oil at a pre-
determined oil-to-fluid food product ratio, wherein the pre-determined oil-to-
fluid
food product ratio is approximately 1 pound of oil per 100 gallons of fluid
food
product.
Embodiment 11. The
system according to any of the embodiments 1 to
10, wherein the funnel further comprises a cap disposed over a top opening of
the
funnel, the cap comprising a vent.
Embodiment 12. The
system according to any of the embodiments 1 to
11, wherein the pressure tank has an oxygen level of 2% or less when oil is
present
within the pressure tank.
Embodiment 13. A method of mixing oil and a fluid food product comprising
using a system according to any of the embodiments 2 to 12, wherein:
- oil is in the pressure tank, and
- the fluid food product is in the batch tank.
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Embodiment 14. The
method according to embodiment 13, comprising:
- placing a funnel into a top opening of a pressure tank such that a stem
of the
funnel extends at least halfway down into the interior of the pressure tank;
- flushing the pressure tank with an inert gas such as nitrogen through a
bottom fluid passage of the pressure tank until the oxygen level in the
pressure tank is
2% or less;
- flowing the oil into the pressure tank through the funnel;
- maintaining a flow of inert gas into the pressure tank through a side
inlet of
the pressure tank such that the oxygen level remains at 2% or less; and
- dispensing the oil from pressure tank into a flow of fluid food product.
Embodiment 15. The method according to any of the embodiments 13 to 14,
wherein the oil is dispensed from the pressure tank into the flow of fluid
food product
at a pre-determined oil-to-fluid food product ratio, wherein the pre-
determined oil-to-
fluid food product ratio is approximately 1 pound of oil per 100 gallons of
fluid food
product.
Embodiment 16. The
method according to any of the embodiments 14 to
15, wherein flushing the pressure tank comprises flowing the inert gas into
the
pressure tank at a rate of 200 cf/h or 400 cf/h.
Embodiment 17. The
method according to any of the embodiments 14 to
16, wherein maintaining a flow of inert gas comprises flowing the inert gas
through
the side inlet at a rate of 20 cf/h.
Embodiment 18. The
method according to any of the embodiments 13 to
17, further comprising:
- rinsing the pressure tank comprising flowing fluid food product through
the
side inlet of the pressure tank; and
- dispensing the rinsing fluid food product from the pressure tank into the
flow
of fluid food product.
Embodiment 19. The
method according to any of the embodiments 13 to
18, comprising:
- dispensing a flow of fluid food product from the batch tank into the
transfer
line;
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- dispensing the oil from the pressure tank into the transfer line such
that the
oil is added to the flow of fluid food product at a pre-determined oil-to-
fluid food
product ratio;
- flowing the dispensed oil and the flow of fluid food product to an inline
shear mixer;
- dispersing the dispensed oil into the flow of the fluid food product in
the
inline shear mixer creating a plurality of micronized oil-in-fluid food
product droplets
in the flow of fluid food product;
- flowing the flow of fluid food product comprising the micronized oil-in-
fluid
food product droplets to the batch tank;
- distributing the flow of fluid food product comprising the micronized oil-
in-
fluid food product droplets in a volume of fluid food product in the batch
tank.
Embodiment 20. The method according to embodiment 19, wherein
dispensing the oil from the pressure tank comprises providing the pressure
tank with
an oxygen level of 2% or less.
Embodiment 21. The method according to any of the embodiments 19
to
20, wherein the pre-determined oil-to-fluid food product ratio is
approximately 1
pound of oil per 100 gallons of fluid food product.
Embodiment 22. The method according to any of the embodiments 19
to
21, further comprising:
- rinsing the pressure tank with the fluid food product;
- dispensing the rinsing fluid food product into the flow of fluid food
product
from the batch tank.
Embodiment 23. The method according to any of the embodiments 19
to
22, further comprising:
- placing a funnel into a top opening of a pressure tank such that a stem
of the
funnel extends at least halfway down into the interior of the pressure tank;
- flushing the pressure tank with an inert gas such as nitrogen through a
bottom fluid passage of the pressure tank until the oxygen level in the
pressure tank is
2% or less;
- flowing the oil into the pressure tank through the funnel;
- maintaining a flow of inert gas into the pressure tank through a side
inlet of
the pressure tank such that the oxygen level remains at 2% or less; and
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- dispensing the oil from pressure tank into a flow of fluid food product.
Embodiment 24. The method according to any of the embodiments 19 to 23,
wherein the plurality of micronized oil-in-fluid food product droplets have an
average
droplet size in the range of between 3 and 5 microns.
Embodiment 25. The method according to any of the embodiments 13 to 24,
wherein the fluid food product is dairy milk and the oil comprises
docosahexaenoic
acid (DHA).
Embodiment 26. The method according to any of the embodiments 13 to 25,
further comprising pasteurizing the volume of fluid food product comprising
micronized oil-in-fluid food product droplets.
Consuming certain fluid food products may serve as a convenient way for
people, kids in particular, to receive dietary supplements or vitamins.
Certain
ingredients, supplements, or vitamins may be added to the fluid food product
to
produce fluid food product products having enhanced nutritional qualities.
Polyunsaturated fatty acids, such as docosahexaenoic acid ("DHA"), may be
added to
fluid food products to provide additional nutritional value. Polyunsaturated
fatty acids
may be suspended in oils in order to transport and mix them into other
substances. For
example, DHA may be carried in sunflower oil, which may be mixed with a milk.
Herein "oil" refers to any compound or composition of matter that is a viscous
liquid at a room temperature and that is not miscible with water at 25 C in a
concentration range of at least from 0.01% to 10.0%, preferably at list from
0.05% to
5.0%. The viscosity is typically of from 5 mPa.s to 200 mPa.s, for example
from 10
mPa.s to 100 mPa.s, for example from 20 mPa.s to 60 mPa.s at 25 C, for example
under a shear of 64 s-1.
The oil can be a nutrient or functional compound, or can comprise a nutrient
or functional compound, solubilized, dispersed or emulsified in the oil.
Examples of oils include vegetal oils, or animal oils such as fish-oil.
Examples
of vegetal oils include: coconut oil, corn oil, cottonseed oil, olive oil,
palm oil, palm
kernel oil, peanut oil, rapeseed oil, including canola oil, safflower oil,
sesame oil,
soybean oil, sunflower oil, hazelnuts oil almond oil, beech nut oil, brazil
nut oil
cashew oil, macadamia oil, mongongo nut oil pecan oil, pine nut oil, pistachio
oil,
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walnut oil, pumpkin seed oil, grapefruit seed oil, lemon oil, orange oil, and
mixture or
associations thereof
Examples of nutrients or functional compound include vitamins, mineral
supplements, enzymes, liquid collagen, fibers, probiotics, liquid antifoaming
agents,
liquid emulsifiers.
In a particular embodiment, the oil is or comprises polyunsaturated fatty
acids,
such as docosahexaenoic acid ("DHA").
In a particular embodiment, the oil and the fluid food product are
substantially
free of additional emulsifier. The method allows processing the oil and the
fluid to oil
droplets of moderate size and good stability without requiring emulsifiers. It
is
mentioned though that some emulsifier can be present or used in the fluid and
or the
oil, or added in steps subsequent to the method.
Several issues arise when attempting to add oils containing polyunsaturated
fatty acids to fluid food products. First, polyunsaturated fatty acids are
subject to
oxidation, which may produce tastes and smells unsuitable for consumption.
DHA, in
particular, oxidizes readily and despite careful handling, may prove difficult
to mix
into the fluid food product. Most kids would not be willing to drink a fluid
food
product, such as a milk, tasting of fish, no matter its nutritional content.
Second, oils often prove difficult to evenly distribute into the target volume
of
fluid food product. Oils mixed in a fluid food product may clump together and
float to
the surface of the fluid food product. Oils may also stick to the side of any
tanks or
vessels containing the fluid food product, preventing effective mixing of the
oils into
the fluid food product. Thus, the system and methods to introduce
polyunsaturated
fatty acids into fluid food product discussed herein take steps to both
prevent
oxidation and enhance distribution of the polyunsaturated fatty acids in the
fluid food
product.
Typical approaches to adding ingredients to fluid food products include
merely adding the supplemental ingredients into a volume of fluid food product
in a
vessel and mixing the ingredients in the vessel to provide for even
distribution. The
typical approach applied to adding polyunsaturated fatty acids results in the
problems
discussed above. What is needed are systems and methods for mixing
polyunsaturated
fatty acids into fluid food product which prevent oxidation and allow for the
even
distribution of the acids in the fluid food product.
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Certain embodiments relate to a fluid food product comprising
polyunsaturated fatty acids. For purposes of example and explanation, certain
embodiments throughout the disclosure refer to DHA, DHA oil, or oil. DHA is
only
one example of a polyunsaturated fatty acid to which this disclosure is
directed. An
5 oil comprising any polyunsaturated fatty acid can be used in each of the
various
embodiments of the systems and methods disclosed herein. In general,
polyunsaturated fatty acids (PUFAs) refer to a family of fatty acids that
naturally
occur in certain fish, leafy green vegetables, and vegetable oils.
Polyunsaturated fatty
acids can include a carbon chain comprising eighteen or more carbon atoms and
two
10 or more double bonds. Examples of polyunsaturated fatty acids include
omega fatty
acids, such as omega-3 fatty acids (e.g., docosahexaenoic acid (DHA),
docosapentaenoic acid (n-3) (DPAn-3), stearidonic acid (SDA), linolenic acid
(LNA),
and alpha linoleic acid (ALA), and eicosapentaenoic acid (EPA)), and omega-6
fatty
acids (e.g., arachidonic acid (ARA), docosapentaenoic acid (n-6) (DPAn-6),
linoleic
acid (LA), gamma linolenic acid (GLA), and dihomo gamma linolenic acid (n-6)).
For purposes of example and explanation, certain embodiments throughout the
disclosure describe adding an oil, such as an oil comprising DHA and/or other
PUFA(s), to milk. Milk is only one example of a fluid food product to which
this
disclosure is directed. In each of the various embodiments of the systems and
methods
disclosed herein, any fluid food product that may be pumped or flowed through
a
system using piping or other fluid flow equipment can be used in addition to
or as an
alternative to milk. For example, fluid food product may refer to beverages
(e.g.,
milks, juices, teas, coffees, waters, combinations of the preceding, etc.),
creamers,
sauces, toppings, mixtures of edible ingredients, etc. After flowing through
the system
that adds oil to the fluid food product, the fluid food product may either
remain in
fluid form or may be further processed into a final food product having a non-
fluid
form. Furthermore, references to "milk" are not meant to be limiting to any
particular
type of milk. For example, "milk" may refer to non-animal-sourced beverages,
such
as soy milk or almond milk. "Milk" may refer to dairy milk, including full
fat, 2%, or
skimmed milk. The term "milk" should be given meaning to encompass any type of
fluid food product that may be considered milk or derived from a milk.
Similarly,
"teas," "juices," "coffees," and "creamers," encompass any type of fluid food
product
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which may be considered of that type as understood by a person having skill in
the
art.
In an embodiment the amount of oil introduced in the fluid food product is of
from 0.01% to 10.0% by weight, for example from 0.05% to 5.0%, for example
from
0.05% to 0.5%.
In an embodiment the amount of oil introduced in the fluid food product is of
from 0.001 pound per gallon to 10.0 pound per gallon, for example from 0.005
to 5.0,
for example from 0.05 to 0.5.
In an embodiment the amount of nutrient of functional compound introduced
in the fluid food product is of from 0.01% to 10.0% by weight, for example
from
0.05% to 5.0%, for example from 0.05% to 0.5%.
In an embodiment the amount of nutrient of functional compound introduced
in the fluid food product is of from 0.001 pound per gallon to 10.0 pound per
gallon,
for example from 0.005 to 5.0, for example from 0.05 to 0.5.
In certain embodiments, the problem of oxidation is addressed by providing an
oxygen deprived environment for the DHA throughout the mixing process. An
operator may receive non-oxidized DHA in a can. The operator pours the DHA
from
a sealed container into a pressure tank having an oxygen deprived environment.
The
pressure tank uses a dispenser to dispense the DHA oil into a flow of fluid
food
product which is then sent to a mixer. The mixer applies shearing forces which
create
small droplets of DHA oil which are easily suspended in the fluid food
product.
Because they are suspended in the fluid food product, they are less likely to
float to
the surface of a volume of fluid food product where it may be exposed to
oxygen.
In certain embodiments, the problem of non-uniform distribution may be
addressed by suspending the droplets of DHA oil in the fluid food product and
mixing
that mixture into a large volume of fluid food product. The mixer creates
small
droplets of the DHA oil that are suspended in the flow of fluid food product.
That
flow, including the droplets, may flow back to a larger vessel containing the
target
volume of fluid food product. Since only a portion of the large volume of
fluid food
product would flow into the mixer, the vessel containing the large volume of
fluid
food product may be configured to mix the incoming flow with the volume of
fluid
food product in the vessel. Since the oil droplets are suspended in the
introduced flow
of fluid food product, the oil is prevented from clumping together or floating
to the
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surface of the volume of fluid food product. Thus, the oil may be prevented
from
sticking to the sides of the vessel and the suspended droplets may be evenly
distributed.
Methods and systems addressing these problems will be described in more
detail using FIGURES 1 through 6. FIGURE 1 illustrates an example system for
mixing oil into a fluid food product. FIGURE 2 illustrates an example funnel
disposed
through an example pressure tank. FIGURE 3 illustrates an example mixer
capable of
dispersing oil into a flow of fluid food product. FIGURE 4-6 illustrate
various
examples of methods of mixing oil into a fluid food product. Embodiments of
the
present invention and its advantages are best understood by referring to
FIGURES 1-6
of the drawings, like numerals being used for like and corresponding parts of
the
various drawings.
FIGURE 1 illustrates an example system for mixing oil into fluid food
product, according to some embodiments. System 100 includes a batch tank 101,
a
pressure tank 102, an oil dispenser 103, a mixer 104, a transfer line 105, and
a flow
line 106. Milk, used as an example fluid food product throughout, may flow
from
batch tank 101 towards mixer 104 in transfer line 105. Oil may flow from
pressure
tank 102 to oil dispenser 103. Oil dispenser 103 may dispense oil into
transfer line
105 into a flow the milk. Both the oil and milk flow into mixer 104. After
mixing, the
oil and milk enter flow line 106 and flow to batch tank 101.
Batch tank 101 may be any suitable vessel capable of holding a volume of
milk. For example, batch tank 101 may be a 20,000 gallon stainless-steel tank.
Batch
tank 101 may include a number of inlets and outlets in order to receive or
discharge a
flow of milk. Batch tank 101 have may be in fluid connection with transfer
line 105.
For example, batch tank 101 may include an outlet coupled to transfer line 105
directly. Alternatively, batch tank 101 and transfer line 105 are coupled
indirectly
through tubing or piping, for example.
A portion of the volume of milk in batch tank 101 may be discharged as a flow
of milk into transfer line 105. During the process of adding oil into the
milk, not all of
the volume of milk in batch tank 101 needs to be discharged. In some cases,
only a
small fraction of the volume of milk is discharged. For example, in the case
of a
20,000 gallon batch tank 101, discharging only 5,000 gallons of milk from
batch tank
101 may allow for suitable mixing with the oil. In this example, the oil is
dispensed
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and mixed into those 5,000 gallons as they circulate in system 100. The oil is
then
received and mixed into the volume of milk in batch tank 101 (e.g. the
remaining
15,000 gallons) when those 5,000 gallons return. The flow of milk to and from
batch
tank 101 may be a continuous process or may occur in stages.
In some embodiments, batch tank 101 includes means to distribute the oil
from a flow of oil and milk from flow line 106 into the volume of milk in
batch tank
101. This is necessary if only a portion of the volume of milk in batch tank
101 is
discharged and mixed with oil in mixer 104. Any suitable means to mix fluids
or
distribute an emulsion of a substance in a fluid may be used, including
agitators
disposed in batch tank 101. Mixing using agitators may be finely tuned by
varying the
impeller number, impeller design, placement, and rotational velocity. For
example,
rotational velocity is selected to ensure uniformity of distribution of the
oil in the
milk, but is also adjusted to prevent vortex formation that could entrain air,
prevent
coalescing of droplets, as well as, maintain oil droplets in suspension.
Pressure tank 102 may be operable to hold a volume of the oil before it is
mixed with the volume of milk in the batch tank 101. A portion of pressure
tank 102
may be coupled to transfer line 105. There may be intermediary components or
areas
through which the oil passes before flowing to transfer line 105. For example,
oil may
flow from the pressure tank 102 to oil dispenser 103 before entering transfer
line 105
into a flow of milk. Further details regarding pressure tank 102 may be found
below
in reference to FIGURE 2.
Oil dispenser 103 may be connected to the pressure tank 102. Oil dispenser
103 controls the flow of oil dispensed from pressure tank 102 into transfer
line 105.
Oil dispenser 103 may dispense the oil continuously into a flow of milk in
transfer
line 105. In some embodiments, oil is dispensed from the pressure tank 102
through
dispenser 103 into the flow of milk at a predetermined oil-to-milk ratio. For
example,
the predetermined oil-to-milk ratio may be a weight (e.g. pounds) of the oil
to volume
(e.g. gallons) of milk ratio.
In particular embodiments, oil dispenser 103 includes a mass flow meter
operable to control the flow of oil from pressure tank 102 into transfer line
105. The
mass flow meter may control a metering valve that allows the oil to move from
pressure tank 102 at a specific weight to volume ratio. In some embodiments,
the
mass flow meter controls the flow of oil to dispense one pound of oil per one
hundred
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gallons of milk. The weight to volume ratio may be adjusted to maintain
optimal
mixing of oil into the milk. For example, different weight to volume ratios
may affect
the droplet size of the oil after mixing in mixer 104. Additionally, different
ratios may
change the amount of time system 100 must operate to add a volume of oil to
the
milk.
After the oil is dispensed into a flow of milk, transfer line 105 may direct
the
oil and milk into mixer 104. The mixer 104 may mix the oil into the milk and
transfer
the oil-in-milk mixture to the batch tank 101 through flow line 106. Further
details
regarding mixer 104 may be found below in reference to FIGURE 3.
Modifications, additions, or omissions can be made to system 100 without
departing from the scope of the invention. The components of system 100 can be
integrated or separated. Moreover, the operations of system 100 can be
performed by
more, fewer, or other components.
FIGURE 2 illustrates an example funnel disposed through an example
pressure tank, according to some embodiments. Pressure tank 102 includes a
side inlet
201 and a bottom fluid passage 202. Bottom fluid passage 202 is coupled to
transfer
line 105.
Nitrogen and/or any other inert gas or gasses, may flow into pressure tank 102
through side inlet 201 and/or bottom fluid passage 202. The inert gas
displaces
oxygen in a space, thereby preventing the oxidation of any oil disposed within
that
space. For example, inert gas may flow into pressure tank 102 to provide an
oxygen
level in pressure tank 102 of 2% or less. By reducing the oxygen level to this
level, oil
dispensed in pressure tank 102 may not be oxidized.
In particular embodiments, system 100 further includes a nitrogen tank in
fluid
connection with pressure tank 102 through bottom fluid passage 202 and side
inlet
201. The nitrogen tank may be any suitable pressurized vessel containing a
volume of
nitrogen which may flow into pressure tank 102 to provide an inert
environment. One
or more valves between the nitrogen tank and pressure tank 102 may control the
volume of nitrogen into pressure tank 102. For example, a flow meter may be
placed
between the nitrogen tank and pressure tank 102, the flow meter controlling
the rate
of flow of nitrogen into pressure tank 102 from the nitrogen tank.
The flow of nitrogen to pressure tank 102 may modulate depending on the
stage of the process. Additionally, the flow of nitrogen may take different
paths into
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pressure tank 102 depending on the stage of the process. For example, the one
or
more valves may be operable to operate in a purge mode and a maintenance mode.
The purge mode allows the nitrogen to be dispensed through bottom fluid
passage 202
and optionally through side inlet 201 of pressure tank 102. Before entering
the purge
5 mode, pressure tank 102 may be substantially empty except for outside
air, including
oxygen. The purge mode may allow nitrogen to flow into pressure tank 102
through
bottom fluid passage 202 at a high rate in order to quickly lower the oxygen
levels in
pressure tank 102.
The maintenance mode allows nitrogen to be dispensed through side inlet 201
10 without allowing nitrogen through bottom fluid passage 202. After
dispensing the
desired volume of oil in pressure tank 102, system 100 may enter the
maintenance
mode. In this mode, the rate of flow of nitrogen may decrease, but still
maintained at a
rate sufficient to maintain a low oxygen level, preferably below 2%. Nitrogen
may not
flow in through bottom fluid passage 202 in this mode because it may interfere
with
15 the dispensing of oil into the flow of milk. Oil will leave pressure
tank 102 through
the same bottom fluid passage 202. If gas flows into pressure tank through the
same
passage at the same time, then it may disrupt the flow of oil and potentially
cause
undesired bubbling or oxidation.
Before any oil is dispensed in pressure tank 102, oxygen is purged from
pressure tank 102 by dispensing nitrogen into pressure tank 102 to displace
the
oxygen. Nitrogen gas may be dispensed at a high rate of cubic feet per hour
("cf/h")
when purging the oxygen in order to quickly lower the oxygen levels in
pressure tank
102. For example, the nitrogen may flow into pressure tank 102 at a rate of
200 cf/h
400 cf/h. After pressure tank 102 is flushed with nitrogen, the oxygen level
in
pressure tank 102 is 2% or less. Put another way, pressure tank 102 has an
oxygen
level of 2% or less when oil is present within pressure tank 102.
Funnel 203 may be disposed through a top opening of the pressure tank 102.
At the beginning of the process of mixing oil into milk, an operator may
dispense a
volume of oil into pressure tank 102 through funnel 203. The funnel 203 may
comprise a stem 204 and a vent 206. When so disposed, stem 204 of the funnel
203
extends at least halfway into an interior 205 of the pressure tank 102. Funnel
203
delivers the poured oil into a bottom portion of the interior of pressure tank
102. This
bottom portion may be oxygen-deprived, preventing the oxidation of the oil
after it is
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poured in. For example, pressure tank 102 may be pumped with nitrogen gas such
that
a layer of nitrogen fills the bottom of pressure tank 102. Stem 204 of funnel
203
extends into this layer and delivers the oil into the layer of nitrogen.
On the other hand, stem 204 of funnel 203 may not extend all the way to the
bottom of pressure tank 102. Backsplash is prevented by keeping some space
between
the bottom of pressure tank 102 and the end of funnel 203. Backsplash may
interfere
with the delivery of the oil into pressure tank 102. For example, backsplash
can mix
oxygen into pressure tank 102 causing oxidation of the oil within pressure
tank 102.
One or more vents 206 of funnel 203 may aid in delivering oil into pressure
tank 102. As mentioned above, disturbing the flow of oil into pressure tank
102 may
mix oxygen into pressure tank 102, which is detrimental to the oil. Vent 206
allows
gas to escape from pressure tank 102 as oil displaces it when dispensed into
pressure
tank 102. Venting the gas prevents pressure buildup and other disturbing
forces within
pressure tank 102 that may disrupt the flow of oil and mix outside air into
pressure
tank 102.
In particular embodiments, funnel 203 further comprises a cap disposed over a
top opening of funnel 203. The cap comprises a vent. After the desired volume
of oil
is dispensed to pressure tank 102, an operator installs a cap onto the top of
funnel 203
to prevent oxygen from entering pressure tank 102. Thus, when funnel 203 is
not
currently used to dispense oil, the cap placed over the top opening of funnel
203
prevents the entry of outside air containing oxygen. The cap includes a vent
in order
to prevent gas pressure build up within pressure tank 102. For example, as a
nitrogen
flow is maintained to pressure tank 102, excess gas may be vented through at
least
one vent, including a vent on the cap on funnel 203.
After the oil is dispensed into pressure tank 102, nitrogen may now flow
through side inlet 201 in order to maintain the low oxygen level. Since
pressure tank
102 had already been flushed, the flow of nitrogen through side inlet 201 may
flow at
a lower rate. For example, the nitrogen may flow through side inlet 201 at a
rate of 20
cf/h.
In particular embodiments, side inlet 201 of pressure tank 102 comprises a
spray ball. A spray ball extends into pressure tank 102 such that any gas or
fluid
flowing through side inlet 201 into pressure tank 102 flows through the spray
ball
before entering pressure tank 102. The spray ball may enhance the dispersion
of the
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gas or fluid within pressure tank 102. For example, the spray ball may direct
the flow
of nitrogen towards all areas inside pressure tank 102, preventing uneven
distribution.
In addition, the spray ball may enhance the rinsing of pressure tank 102 after
oil is
dispensed. For example, after the volume of oil is dispensed from pressure
tank 102, a
residue of oil may remain on the sides and bottom of the interior of pressure
tank 102.
The residue oil may be mixed into milk by rinsing pressure tank 102 with milk
through side inlet 102. The spray ball helps the rinsing process by spraying
milk onto
all the interior surfaces of pressure tank 102. The milk and rinsed off oil
may flow
through bottom passage 202 and be dispensed at the same rate as the oil was
into a
flow of milk.
In particular embodiments, side inlet 201 of pressure tank 102 may be an
entrance point for cleaning solutions, which may be used to clean the interior
of
pressure tank 102. For example, side inlet 201 may allow cleaning solutions
comprising hot alkaline and acid solutions to flow into pressure tank 102. The
cleaning solutions may clean the interior of pressure tank 102, rendering the
system
sanitary and suitable for food use. In particular embodiments, a central
Cleaning in
Place ("CIP") system is coupled to one or more components of system 100,
including
batch tank 101, pressure tank 102, dispenser 103, mixer 104, transfer line
105, and/or
flow line 106. In some embodiments, pressure tank 102 is coupled to a central
CIP
system through side inlet 201, such that a cleaning solution may flow from the
central
CIP into pressure tank 102 through at least side inlet 201.
FIGURE 3 illustrates an example mixer capable of dispersing oil into a flow
of fluid food product, according to some embodiments. Mixer 104 receives a
flow of
milk 302 with dispensed oil 301. Mixer 104 then mixes the flow of milk 302 and
dispensed oil 301 to create micronized oil-in-milk droplets 303. The
micronized oil-
in-milk droplets 303 then flow from mixer 104 to batch tank 101 through flow
line
106.
In particular embodiments, mixer 104 is an inline shear mixer. Disposing
mixer 104 inline allows mixing without the introduction of outside air. Inline
mixing
prevents aeration and oxidation of the oil within the flow of milk.
Additionally, inline
mixing allows for the mixing to be a continuous process, mixing a continuous
flow of
oil and milk.
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Normally oil and milk do not mix. As discussed above, one problem with
mixing oil and milk is that oil normally coagulates and floats to the surface
of the
milk. Shear mixing solves this issue by creating an emulsion of the oil in the
milk. For
example, a motor may rotate an impellor or high-speed rotor which provides a
shear
force on the oil in the flow of milk in mixer 104. The shear force creates
smaller
droplets of oil. Smaller droplets of oil are more easily suspended in the milk
and
distributed among a volume of milk.
In particular embodiments, mixer 104 may create a micronized oil-in-milk
mixture having an average droplet size in the range of between 3 and 5
microns. At
this size, the droplets are less likely to coagulate and more likely to remain
suspended
in the milk. Thus, even after flowing in flow line 106 and being mixed with
the
volume of milk in batch tank 101, the droplets may remain separate. As a
result, the
oil may be distributed substantially uniformly throughout the volume of milk
in batch
tank 101, successfully mixing the oil into the target volume of milk.
As shown above, certain embodiments of system 100 prevent oxidation of the
oil and create a uniform distribution of the oil in milk. Oxidation is
prevented by
maintaining the oil in oxygen deprived environments from its time in pressure
tank
102 to mixer 104 and in batch tank 101. Uniform distribution is enhanced by
using
mixer 104 which creates micronized oil-in-milk droplets. The droplets may
easily be
distributed within the milk without coagulation and sticking to the sides of
batch tank
101.
FIGURE 4 is a flow diagram illustrating a first example method of mixing oil
into fluid food product. While particular embodiments will be described
wherein
components of system 100 perform certain steps of method 400, any suitable
component or combination of components of system 100 may perform one or more
steps of the method.
In step 402, an operator places funnel 203 into a top opening of pressure tank
102. Funnel 203 is disposed such that stem 204 of funnel 203 extends at least
halfway
down into the interior of pressure tank 102. As discussed earlier, the stem
204
extending down into pressure tank 102 allows the oil dispensed into pressure
tank 102
to be dispensed into an oxygen-deprived portion of pressure tank 102.
After funnel 203 is positioned, the operator may provide an oxygen-deprived
environment inside pressure tank 102. At step 404, pressure tank 102 is
flushed with
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nitrogen through bottom fluid passage 202. As nitrogen flows into pressure
tank 102,
the air is displaced through a vent and is removed from pressure tank 102. The
flushing of pressure tank 102 continues until the oxygen level in pressure
tank 102
reaches 2% or less. In particular embodiments, the flushing of pressure tank
102
includes flowing nitrogen into pressure tank 102 at a rate 200 cf/h or 400
cf/h.
After a suitable environment is provided, oil may flow into pressure tank 102.
At step 406, an operator may pour oil into pressure tank 102 through funnel
203. The
oil is dispensed at a bottom portion of pressure tank 102 where stem 204 of
funnel
203 ends. Since pressure tank 102 was flushed with nitrogen, the oil may be
dispensed
into a layer of nitrogen, a space having a low oxygen level.
The oxygen-deprived environment is maintained even after the oil is dispensed
into pressure tank 102. At step 408, a flow of nitrogen is maintained into
pressure
tank 102 through side inlet 201. This maintenance flow ensures that the oxygen
level
within pressure tank 102 remains at 2% or less. During the process of mixing
oil and
milk, nitrogen may flow out of pressure tank 102 and be replaced by outside
air. In
order to prevent the mixing of oxygen and the oil, nitrogen may continue to
flow into
pressure tank 102 through side inlet 201. In particular embodiments, the
maintenance
flow includes flowing nitrogen through side inlet 201 at a rate of 20 cf/h.
By flowing the nitrogen through side inlet 201 of pressure tank 102,
disruption
of the dispensing of the oil through bottom fluid passage 202 is minimized. In
particular embodiments, side inlet 201 includes a spray ball which enhances
the flow
of nitrogen into pressure tank 102. The spray ball more evenly distributes the
gas or
fluid flowing through side inlet 201 into pressure tank 102.
At step 410, the oil is dispensed from pressure tank 102 into a flow of milk.
In
particular embodiments, the oil is dispensed from the pressure tank into the
flow of
milk at a pre-determined oil-to-milk ratio, wherein the pre-determined oil-to-
milk
ratio is approximately one pound of oil per one hundred gallons of milk. Each
step
helps ensures that the oil dispensed into the flow of milk has not been
oxidized. Thus,
when added to the flow of milk, the oil may be effectively mixed into the
milk.
In particular embodiments, method 400 may further comprise the steps of
rinsing the pressure tank with milk and dispensing the rinsing milk from
pressure tank
102 into the flow of milk. After the oil is dispensed from pressure tank 102,
a portion
of the oil may remain in pressure tank 102 stuck to its interior. In order to
remove the
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residue oil, milk may flow through side inlet 201 in order to rinse pressure
tank 102.
The milk and rinsed-off residue oil may then be dispensed. The rinsing milk
may be
dispensed from pressure tank 102 in the same manner that the oil had been
dispensed.
Particularly, the rinsing milk may flow through bottom fluid passage 202 to
dispenser
5 103. Dispenser 103 may dispense the rinsing milk at the same weight to
volume ratio
as the oil.
Modifications, additions, or omissions may be made to method 400 depicted
in FIGURE 4. Method 400 may include more, fewer, or other steps. For example,
steps may be performed in parallel or in any suitable order. While discussed
as
10 various components of system 100 performing the steps, any suitable
component or
combination of components of system 100 may perform one or more steps of the
method.
FIGURE 5 is a flow diagram illustrating a second example method of mixing
oil into fluid food product. While particular embodiments will be described
wherein
15 components of system 100 of performing the steps of method 500, any
suitable
component or combination of components of system 100 may perform one or more
steps of the method.
Oil is mixed into a target volume of milk in method 500. At step 502, an
operator dispenses a flow of milk from batch tank 101 into transfer line 105.
Batch
20 tank 101 holds the target volume of milk into which the oil is mixed.
Only a portion
of the volume, however, is dispensed into transfer line 105. In this manner,
an amount
of oil may be mixed into a volume of milk without having to flow the entire
volume
of milk through different components of the system.
At step 504, oil is dispensed from pressure tank 102 into transfer line 105.
The
oil is added to the flow of milk at a pre-determined oil-to-milk ratio. For
example,
pressure tank 102 may be coupled to transfer line 105 such that a line from
dispenser
103 and the line from batch tank 101 form a T-junction, into which both the
oil and
flow of milk flow and mix together. In particular embodiments, the oil-to-milk
ratio is
approximately one pound of oil per one hundred gallons of milk. In particular
embodiments, pressure tank 102 is provided an oxygen level of 2% or less while
the
oil is present. In this manner, the oil dispensed into the flow of milk has
not been
oxidized.
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After the oil is dispensed, at step 506, the flow of milk and dispensed oil
flow
to mixer 104. For example, the flow of milk and dispensed oil may flow to an
inlet of
an inline shear mixer. Once at mixer 104, at step 508, the oil may be
dispersed into
the flow of milk. Mixer 104 creates a plurality of micronized oil-in-milk
droplets in
the milk. For example, an inline shear mixer may create oil-in-milk droplets
having an
average, for example an average by weight or by number, droplet size ranging
from 3
to 5 microns. The emulsion created helps maintain the droplets suspended in
the milk
and aids in their distribution into the larger volume of milk in batch tank
101.
At step 510, the flow of milk comprising the micronized oil-in-milk droplets
flows to batch tank 101. The flow may be received by an inlet of batch tank
101.
After flowing back to batch tank 101, the oil within the flow may be
distributed
within the target volume of milk. At step 512, the flow of milk comprising the
micronized oil-in-milk droplets is distributed in the volume of milk in batch
tank 101.
The distribution of the oil-in-milk droplets may occur by any suitable means,
including, for example, impellers in batch tank 101 agitating the volume of
milk.
Since the droplets are suspended in the flow of milk, they may be easily
distributed
into the volume of milk in batch tank 101. As a result, even though only a
portion of
the target volume of milk flowed out of batch tank 101, the oil may be
distributed
across the entire volume of milk in batch tank 101.
Modifications, additions, or omissions may be made to method 500 depicted
in FIGURE 5. Method 500 may include more, fewer, or other steps. For example,
steps may be performed in parallel or in any suitable order. While discussed
as
various components of system 100 performing the steps, any suitable component
or
combination of components of system 100 may perform one or more steps of the
method.
FIGURE 6 is a flow diagram illustrating a third example method of mixing oil
into fluid food product. While particular embodiments will be described
wherein
components of system 100 of performing the steps of method 600, any suitable
component or combination of components of system 100 may perform one or more
steps of the method. Method 600 may comprise one or more steps from each of
method 400 and method 500.
At step 602, funnel 203 is placed into a top opening of pressure tank 102 such
that stem 204 of funnel 203 extends at least halfway down into the interior of
pressure
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tank 102. As described above, this step helps prevent oxidation and aids with
the
delivery of the oil into pressure tank.
At step 604, pressure tank 102 is flushed with nitrogen through bottom fluid
passage 202 of the pressure tank 102. Flushing continues until the oxygen
level in
pressure tank 102 reaches 2% or less.
At step 606, oil flows into pressure tank 102 through funnel 203.
At step 608, a flow of nitrogen is maintained into pressure tank 102 through
side inlet 201 of pressure tank 102. This ensures that such that the oxygen
level
remains at 2% or less.
At step 610, a flow of milk is dispensed from batch tank 101 into transfer
line
105. At step 612, oil is dispensed pressure tank 102 into transfer line 105
such that the
oil is added to the flow of milk at a pre-determined oil-to-milk ratio. For
example, the
oil may be dispensed at a weight to volume ratio of one pound of oil for every
one
hundred gallons of milk.
After the oil is dispensed into the flow of milk in transfer line 105, at step
614,
the dispensed oil and the flow of milk flow to mixer 104. Mixer 104 may
comprise an
inline shear mixer, which uses shear forces to disperse the oil in the milk.
At step 616, the dispensed oil is dispersed into the flow of the milk in the
inline shear mixer creating a plurality of micronized oil-in-milk droplets in
the flow of
milk. For example, the micronized oil-in-milk droplets may be sufficiently
small to
remain in suspension throughout the mixing process.
The droplets of oil must then be distributed into the target volume of milk.
At
step 618, the flow of milk comprising the micronized oil-in-milk droplets
flows back
to batch tank 101. After entering batch tank 101, at step 620, the flow of
milk
comprising the micronized oil-in-milk droplets is distributed in a volume of
milk in
batch tank 101. For example, batch tank 101 may comprise agitators, such as a
plurality of impellors, which mix and distribute the flow comprising the
droplets
within the volume of milk. Because the droplets are small, they remain
suspended and
may be uniformly distributed in the target volume of milk.
In particular embodiments, method 600 further comprises steps of rinsing
pressure tank 102 with milk and dispensing the rinsing milk into the flow of
milk
from batch tank 101. For example, after the dispensing the oil from pressure
tank 102,
residue oil may remain inside pressure tank 102. Milk may flow from batch tank
101,
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or any other source, into pressure tank 102 through side inlet 201. After
being used to
rinse pressure tank 102, the milk may be dispensed into transfer line 105 and
flow
back to batch tank 101.
In particular embodiments, method 600 further comprises the step of
pasteurizing the volume of milk comprising micronized oil-in-milk droplets.
After oil
is mixed into the target volume of milk, the resulting enhanced milk may still
need
further processing to create a safe-to-consume beverage. Subjecting the volume
of
milk to pasteurization kills harmful microbes, thereby producing a consumable
product.
Modifications, additions, or omissions may be made to method 400 depicted
in FIGURE 6. Method 600 may include more, fewer, or other steps. For example,
steps may be performed in parallel or in any suitable order. While discussed
as
various components of system 100 performing the steps, any suitable component
or
combination of components of system 100 may perform one or more steps of the
method.
The systems and methods described herein may include one or more technical
advantages. For example, using pressure tank 102 prevents oxidation of any
introduced polyunsaturated fatty acids by providing an inert environment using
pumped-in nitrogen gas. By first flushing the vessel holding the oil during
the process
and maintaining a flow of nitrogen, low oxygen levels are maintained, limiting
oxidation. Inserting the funnel such that the stem extends at least halfway
into the
interior of the pressure tank ensures that the oil transferred to an oxygen-
deprived
portion of the pressure tank, e.g. into a layer of nitrogen.
In addition, dispensing oil in line (e.g. via a transfer line) into to a flow
of
fluid food product prevents oil from being exposed to air when being added to
fluid
food product. The in line dispensing of oil prevents oxidation compared to
conventional methods that add oil to a tank of fluid food product via an
opening in the
tank.
As another example, the use of an inline shear mixer to mix the oil and fluid
food product creates micronized droplets of oil in the fluid food product.
Using an
inline mixer prevents the introduction of outside air into the mixing process.
Using
shear forces to create small droplets of the oil enhances its suspension in
the fluid
food product. When the oil is suspended, as opposed to floating at the
surface, the
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droplets remain separated from each other and away from oxygen rich
environments.
Additionally, micronized droplets may be more readily distributed in a volume
of
fluid food product.
Although the present disclosure has been described with several embodiments,
numerous changes, variations, alterations, transformations, and modifications
can be
suggested to one skilled in the art, and it is intended that the present
disclosure
encompass such changes, variations, alterations, transformations, and
modifications as
fall within the scope of the appended claims.
