3D food printing: A Disruptive Food Manufacturing Technology

Transcription

1 VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD 3D food printing: A Disruptive Food Manufacturing Technology 3D Food Printing Conference, 28 June 2017, Venlo Nesli Sözer (PhD), Principal Scientist

2 What is Additive Manufacturing or 3D printing? 2

3 Additive manufacturing (AM) The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies ASTM F42 Committee Statistics 2016 application areas (Wohlers report 2016) It is forecasted that the global 3D printing products and services will reach 10 billion by 2021 (Wohlers report)

4 AM Technologies which could be applied for food printing Binder jetting / Powder bed Material Jetting: Paste extrusion &inkjet Indirect - mold 4

5 Binder Jetting Powder Bed Fusion A liquid bonding agent is selectively deposited to join powder materials Might result in weak structures (good for design purposes) Thermal energy selectively fuses regions of a powder bed Support structures are needed + many post processing phases 5

6 Material Jetting Paste extrusion Inkjet Medium to high viscosity No support needed Solidification upon cooling or gel forming before or during printing Low viscosity Support needed Godoi et al.,

7 Material Jetting (inkjet & syringe) Droplets of build material are selectively deposited Support structures are needed Godoi et al., 2016 Where are we with 3D food through printing? a nozzle or orifice Material/paste is selectively dispensed No need for support structure 7

8 Need for 3D food printing Active participation Eating experience Design Food (healthy, nutritious, balanced) Cooking experience Playfulness Personalized Affordable Pleasure 3D Printing

9 Benefit Food ingredient industry benefits: Development of new added value ingredients and mixes Food and retail industry benefits: Customization/ Co-creation Nutrition Flavor/color Texture On-demand and on-the-go production Economy at low volume production Flexibility New product design Novel mouthfeel experience Multi-layer printing of various textures Use of novel alternative sources (i.e. algae, side-streams insects) 04/07/2017 9

10 History of 3D Food Printing 2006 Paste extrusion by f.ex. frostings, Nutella, chocolate (Cornell Univ.) CandyFab, Sugar printing (EvilMad Scientist Lab) FP7-PERFORMANCE, easy to chew and swallow senior food printing from pastes (Biozoon). 2013, printing of advanced shapes by sugar (sugar sculptures) (3D Systems) 2013, in vitro meat by bioprinter (Modern Meadow) 2014, printing of chocolate, (Hershey s & 3D Systems) 2015, printed pasta, (Barilla & TNO) 04/07/

11 Use of 3D printing techniques applied for food design Food product Materials AM Technology Reference Cakes Cake batter, icing Extrusion (single head) Yang et al., 2001 Toffee Sugar granules Granular bed sintering The CandyFab Project, 2009 Chocolate Seeded chocolate Extrusion (single head) Causer, 2009 Hydrogel based food structures Xanthan and gelatin Extrusion (twin head) Cohen et al., D structures by Sugar, Nesquick Laser bed sintering Gray, 2010 fused powders Chocolate with filling Chocolate solids and pumpable fillings 3D images embedded in solid foods Edible 3D prints Edible 3D insect structures Food-ink pastes and gels Mashed potato, sugar, chocolate, icing Insect powders with firming agents and flavours Hot-melt extrusion Zoran and Coelho, 2011 Extrusion (single head) Golding et al., 2011 Extrusion (single head) Southerland et al., 2011 Extrusion (single head) Soares et al., 2011 Cereal based snack Wheat flour Extrusion (single head) Severini et al.,

12 Key Patents Title: Brief Content (Patent number), owner Multifunctional Food Printer: Multifunctional 3D food printer with high efficiency and high precision. (CN U, 2013) Zengcgeng Lego Foods, CN Additive manufacturing for producing edible compositions: 3D Food printing system that allows customization of nutritional content, flavour and taste (WO 2014/ A1, ) Systems and Materials Res Corp., USA Manufacturing food using 3D printing technology: 3D Printing System with a heating device to control rheology (WO 2014/ A1) Natural Machines LLC, ES Extrusion Device of 3D: Extrusion device of a 3D printer for food, applicable for a wide range of raw materials (CN U, 2015) Pingliang Ruije Technology Co, CN Multi-material food 3D printing device: 3D printing device including a cooking system. (CN U, 2015) Xi An Elite Robotics Technology Co. Ltd, CN Method for the production of an edible object by powder bed (3D) printing and food products obtainable therewith: Production of an edible object from edible powders and at least one 04/07/2017 edible liquid. (WO 2015/ A1) TNO, NL 12 Frost and Sullivan, 2015

13 Challenges in 3D printing of food Material science: Shape stability Additive and recipe control (need for: thickeners, enzymes, crosslinking agents with shape memory) Replicate traditional foods Compatible printing material with traditional cooking, i.e. baking, frying Rheology of food materials vary by time Stable print materials needed Manufacturing technology: Safety Easy to clean surfaces, cartridges Throughput High throughput or large reservoir needed for vast printing Speed Either fast or cheap enough to operate thousands (applies particularly for food industry) 04/07/

14 VTT approach

15 Aim Evaluate the applicability of various protein, starch and fiber-rich food ingredients and their mixtures in 3D printed healthy customized snacks. 04/07/

16 Materials Materials Rye bran (micronized) (VTT) Oat protein conc (OPC) (VTT) Faba bean protein (FPC) (VTT) Starch (Ultra-Sperse, Ingredion) Skimmed milk powder (SMP) (Valio) Semi-skimmed milk powder (SSMP) (Valio) Composition 13 % prot,44 % starch,27 % DF,2% fat 48 % prot,37 % starch,7 % DF,4 % fat 62 % prot, 1 % starch, 11 % DF, 3.5 % fat cold water swelling modified food starch derived from waxy maize starch 35 % prot, 53 % lactose, 0.6 % fat 37 % prot, 38 % carbohy (lactose free), 15 % fat 04/07/

17 Preparation of Samples for Printing The pastes consisting of starch or milk powder alone were prepared by mixing the starch or milk powder into deionized water followed by homogenization. The plant protein concentrates (OPC, FBPC) and rye bran were suspended in deionized water and heated in a boiling water bath for 10 min under regular mixing. The suspension was allowed to cool to room temperature and homogenized. 04/07/

18 3D Printing Process 3D printing of the pastes were performed by nscrypt printer (nscrypt, Inc, Orlando, Florida) 25 mm x 25 mm squares filled with diamond-like structures were 3D printed at room temperature # of layers and thickness: 10, 0.3 mm printing speed: 2mm/s diameter of the tip: 0.41 air pressure: kpa depending on the paste material. Post processing: Oven drying at 100 o C min or freeze drying. Material extrusion type of device used for 3D printing of food materials 04/07/

19 Results

20 Printability of pastes prepared from starch and/or milk powder

21 Printability of pastes prepared from rye bran or plant protein concentrates 04/07/

22 Oscillatory stress sweeps for selected pastes 04/07/

23 The effect of post processing on selected samples Sample list: 1) 1.5% CNF + 5% starch, 2) 15% starch, 3) 30% rye bran, 4) 35% OPC, 5) 45% FBPC, 6) 0.8% CNF + 50 % SSMP and 7) 60% SSMP. 04/07/

24 Dry matter content and hardness of selected 3D printed samples after oven- or freeze-drying Sample Dry matter content (%) Hardness (N) Ovendried Freezedried Ovendried Freezedried 60% SSMP 85.2 ± ± ± ± % OPC 79.8 ± ± ± * 45% FBPC 63.1 ± ± ± ± 16.3 *sample very fragile, only one sample could be measured 04/07/

25 Conclusions The applicability of additive manufacturing technologies is strongly dependent on the material properties and the associated binding properties. We have optimized various mixes for 3D food printing, which is a starting point for future development of healthy, customized 3D printed foods. Additive manufacturing in line with the ideology of prosumerism will in the next 5 years enter the mainstream to facilitate the new industrial food production chain to meet the increased consumer demand for customization. 04/07/

26 Multilayer food textures by advanced manufacturing technologies 3DSURPRISE project (Sept June 2019) Aim: to develop new applications of advanced manufacturing technologies for 3D printing of multi-textural food structures in a techno-economically feasible and sustainable way. Res. Partners: VTT(coord), Aalto Univ. Ind. Partners: Valio, Polttimo, Ravintolakolmio, Selecta, 3DTech, DeskArtes Main funding agency: TEKES (Finnish Funding Agency for Innovation) Total budget: 690 k

27 Martina Lille Senior Scientist, VTT Expertise Food rheology and material characterization Nesli Sözer Principal Scientist, VTT Expertise Food ingredient technology Food structure design Pasi Puukko Research Team Leader, VTT Expertise 3D printing technologies Sini Metsä-Kortelainen Senior Scientist, VTT Expertise 3D printing technologies Material science VTT Team in 3D Food Printing Jaakko Paasi Principal Scientist, VTT Expertise Business and innovation research Antti Vaajoki Research Scientist, VTT Expertise 3D printing technologies Material technologies Kyösti Pennanen Senior Scientist, VTT Expertise Consumer research Alejandro Revuelta Senior Scientist, VTT Expertise Engineering, design Auxiliary in-machine operations 04/07/

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