Crumpet structures: experimental and modelling studies

Crumpets are made by heating fermented batter on a hot plate at around 230°C. The characteristic structure dominated by vertical pores develops rapidly: structure has developed throughout around 75% of the product height within 30s, which is far faster than might be expected from transient heat conduction through the batter. Cooking is complete within around 3 min. Image analysis based on results from X-ray tomography shows that the voidage fraction is approximately constant and that there is continual coalescence between the larger pores throughout the product although there is also a steady level of small bubbles trapped within the solidified batter. We report here experimental studies which shed light on some of the mechanisms responsible for this structure, together with some models of key phenomena.Three aspects are discussed here: the role of gas (carbon dioxide and nitrogen) nuclei in initiating structure development; convective heat transfer inside the developing pores; and the kinetics of setting the batter into an elastic solid structure. It is shown conclusively that the small bubbles of carbon dioxide resulting from the fermentation stage play a crucial role as nuclei for pore development: without these nuclei, the result is not a porous structure, but rather a solid, elastic, inedible, gelatinized product. These nuclei are also responsible for the tiny bubbles which are set in the final product. The nuclei form the source of the dominant pore structure which is largely driven by the, initially explosive, release of water vapour from the batter together with the desorption of dissolved carbon dioxide. It is argued that the rapid evaporation, transport and condensation of steam within the growing pores provides an important mechanism, as in a heat pipe, for rapid heat transfer, and models for this process are developed and tested. The setting of the continuous batter phase is essential for final product quality: studies using differential scanning calorimetry and on the kinetics of change in the visco-elastic properties of the batter suggest that this process is driven by the kinetics of gelatinization. Unlike many thermally driven food processes the rates of heating are such that gelatinization kinetics cannot be neglected. The implications of these results for modelling and for the development of novel structures are discussed.

Modelling oil absorption during post-frying cooling - II: solution of the mathematical model, model testing and simulations

The mathematical models that describe the immersion-frying period and the post-frying cooling period of an infinite slab or an infinite cylinder were solved and tested. Results were successfully compared with those found in the literature or obtained experimentally, and were discussed in terms of the hypotheses and simplifications made. The models were used as the basis of a sensitivity analysis. Simulations showed that a decrease in slab thickness and core heat capacity resulted in faster crust development. On the other hand, an increase in oil temperature and boiling heat transfer coefficient between the oil and the surface of the food accelerated crust formation. The model for oil absorption during cooling was analysed using the tested post-frying cooling equation to determine the moment in which a positive pressure driving force, allowing oil suction within the pore, originated. It was found that as crust layer thickness, pore radius and ambient temperature decreased so did the time needed to start the absorption. On the other hand, as the effective convective heat transfer coefficient between the air and the surface of the slab increased the required cooling time decreased. In addition, it was found that the time needed to allow oil absorption during cooling was extremely sensitive to pore radius, indicating the importance of an accurate pore size determination in future studies.

Colloidal gas aphrons based separation process for the purification and fractionation of natural phenolic extracts

Following previous studies, the aim of this work is to further investigate the application of colloidal gas aphrons (CGA) to the recovery of polyphenols from a grape marc ethanolic extract with particular focus on exploring the use of a non-ionic food grade surfactant (Tween 20) as an alternative to the more toxic cationic surfactant CTAB. Different batch separation trials in a flotation column were carried out to evaluate the influence of surfactant type and concentration and processing parameters (such as pH, drainage time, CGA/extract volumetric and molar ratio) on the recovery of total and specific phenolic compounds. The possibility of achieving selective separation and concentration of different classes of phenolic compounds and non-phenolic compounds was also assessed, together with the influence of the process on the antioxidant capacity of the recovered compounds. The process led to good recovery, limited loss of antioxidant capacity, but low selectivity under the tested conditions. Results showed the possibility of using Tween 20 with a separation mechanism mainly driven by hydrophobic interactions. Volumetric ratio rather than the molar ratio was the key operating parameter in the recovery of polyphenols by CGA.

Critical flux in ultrafiltration of skimmed milk

he best operating conditions, using the critical flux concept during ultrafiltration of skimmed milk, were evaluated for tubular membranes. It was found that irreversible fouling was greatly reduced by operating at or below the critical flux, but was not totally eliminated. The critical flux of skimmed milk was found to be the weak form. The critical flux at cross flow velocity 3.4 in s(-1) for MWCO 200 kDa membrane was 56.9 kg m(-2) h(-1) while for MWCO 25 kDa membranes it was 45 kg m(2) h(-1) suggesting that membrane pore size influenced the flux. The critical flux increased with increasing wall shear stress and decreased with increasing protein concentration. Empirical equations, for predicting the critical flux (J(crit)) for skimmed milk with a protein concentration (c(b)) in the range 3-7% w/w and wall shear stress (tau(w)) in the range 7-60 Pa for MWCO 200 kDa and 25 kDa membranes were J(crit) = 5.1 (tau(w)/c(b)) and J(crit) = 4.0 (tau(w)/c(b)) respectively. In general, the rejections of protein and lactose at the critical flux were not affected by protein concentration, wall shear stress and membrane used, and they were similar to those found when operating at the limiting flux.

An engineering model of the human colon

The development and performance of a three-stage tubular model of the large human intestine is outlined. Each stage comprises a membrane fermenter where flow of an aqueous polyethylene glycol solution on the outside of the tubular membrane is used to control the removal of water and metabolites (principally short chain fatty acids) from, and thus the pH of, the flowing contents on the fermenter side. The three stage system gave a fair representation of conditions in the human gut. Numbers of the main bacterial groups were consistently higher than in an existing three-chemostat gut model system, suggesting the advantages of the new design in providing an environment for bacterial growth to represent the actual colonic microflora. Concentrations of short chain fatty acids and Ph levels throughout the system were similar to those associated with corresponding sections of the human colon. The model was able to achieve considerable water transfer across the membrane, although the values were not as high as those in the colon. The model thus goes some way towards a realistic simulation of the colon, although it makes no pretence to simulate the pulsating nature of the real flow. The flow conditions in each section are characterized by low Reynolds numbers: mixing due to Taylor dispersion is significant, and the implications of Taylor mixing and biofilm development for the stability, that is the ability to operate without washout, of the system are briefly analysed and discussed. It is concluded that both phenomena are important for stabilizing the model and the human colon.

Modelling oil absorption during post-frying cooling - I: model development

Several studies have highlighted the importance of the cooling period in oil absorption in deep-fat fried products. Specifically, it has been established that the largest proportion of oil which ends up into the food, is sucked into the porous crust region after the fried product is removed from the oil bath, stressing the importance of this time interval. The main objective of this paper was to develop a predictive mechanistic model that can be used to understand the principles behind post-frying cooling oil absorption kinetics, which can also help identifying the key parameters that affect the final oil intake by the fried product. The model was developed for two different geometries, an infinite slab and an infinite cylinder, and was divided into two main sub-models, one describing the immersion frying period itself and the other describing the post-frying cooling period. The immersion frying period was described by a transient moving-front model that considered the movement of the crust/core interface, whereas post-frying cooling oil absorption was considered to be a pressure driven flow mediated by capillary forces. A key element in the model was the hypothesis that oil suction would only begin once a positive pressure driving force had developed. The mechanistic model was based on measurable physical and thermal properties, and process parameters with no need of empirical data fitting, and can be used to study oil absorption in any deep-fat fried product that satisfies the assumptions made.

A possible reconceptualization of food engineering discipline

Food industry is critical to any nation’s health and well-being; it is also critical to the economic health of a nation, since it can typically constitute over a fifth of the nation’s manufacturing GDP. Food Engineering is a discipline that ought to be at the heart of the food industry. Unfortunately, this discipline is not playing its rightful role today: engineering has been relegated to play the role of a service provider to the food industry, instead of it being a strategic driver for the very growth of the industry. This paper hypothesises that food engineering discipline, today, seems to be continuing the way it was in the last century, and has not risen to the challenges that it really faces. This paper therefore categorises the challenges as those being posed by: 1. Business dynamics, 2. Market forces, 3. Manufacturing environment and 4. Environmental Considerations, and finds the current scope and subject-knowledge competencies of food engineering to be inadequate in meeting these challenges. The paper identifies: a) health, b) environment and c) security as the three key drivers of the discipline, and proposes a new definition of food engineering. This definition requires food engineering to have a broader science base which includes biophysical, biochemical and health sciences, in addition to engineering sciences. This definition, in turn, leads to the discipline acquiring a new set of subject-knowledge competencies that is fit-for-purpose for this day and age, and hopefully for the foreseeable future. The possibility of this approach leading to the development of a higher education program in food engineering is demonstrated by adopting a theme based curriculum development with five core themes, supplemented by appropriate enabling and knowledge integrating courses. At the heart of this theme based approach is an attempt to combine engineering of process and product in a purposeful way, termed here as Food Product Realisation Engineering. Finally, the paper also recommends future development of two possible niche specialisation programs in Nutrition and Functional Food Engineering and Gastronomic Engineering. It is hoped that this reconceptualization of the discipline will not only make it more purposeful for the food industry, but it will also make the subject more intellectually challenging and attract bright young minds to the discipline.