Melt emulsification—Is there a chance to produce particles without additives?

Melt emulsification is a well known process. Milk is thus homogenized for over 100 years. In the melt emulsification process, the future disperse phase is melted and dispersed into droplets, the size of which is controlled by an emulsification process. After emulsification, the droplets are cooled down and solid particles of spherical shape are formed. In order to realize melt emulsification processes, we developed the new SHM (Simultaneous Homogenizing and Mixing) nozzle, which enables us to mix separate phases directly into the droplet forming zone of homogenization nozzles. This molten milk fat globule can be homogenized at elevated fat content (up to 42 vol% instead of max. 17 vol%) and elevated temperatures (up to 150 °C instead of max. 70 °C) without loosing product quality as for conventional homogenization processes. In addition, more than 80% of the energy costs can be saved and additional mixing units can be spared. This is realized by a controlled and quick dilution and cooling down of molten fat globules directly after their disruption in the nozzle itself. SHM-technology also allows for the dispersing of molten waxes. Instant cooling down after adjusting particle sizes also allows us to work without emulsifiers or other additives as absolutely required in conventional melt emulsification processes where molten droplets will coalesce upon their collisions in the homogenization nozzle. SHM-melt emulsification is thus an alternative to conventional milling processes, which are often limited by the stickiness of these products.

Graphical abstractSHM homogenization of waxes with different melting points. With simultaneous homogenizing and mixing (SHM) nozzle, molten milk fat globules can be homogenized at elevated fat content and elevated temperatures, saving more than 80% of the energy costs. Instant cooling after adjusting particle sizes allows us to work without emulsifiers or other additives.Figure optionsDownload full-size imageDownload as PowerPoint slide