3d printing technologies for food fabrication
TRANSCRIPT
3-D PRINTING TECHNOLOGIES FOR FOOD FABRICATION
Presented By
Flora-Glad Chizoba Ekezie
May 3, 2023 3D Printing Technologies for Food Fabrication
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KEY HIGHLIGHTS
Introduction
Types of 3D Printing Materials
3D Food Printing
3D Printing Parameters
3-D Printing Technologies
Types of Food Printable Materials
Impacts, Future Outlook and Conclusion
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INTRODUCTIONAccording to ASTM International (2012), 3-D printing is an innovative manufacturing process which involves joining material to make an object from a 3D model data, usually layer-by-layer as opposed to subtractive manufacturing methodologies.
It is also called additive manufacturing technology/ rapid prototyping and defined as a mechanized method of creating a three dimensional object by laying down successive layers of material using a reasonably sized machine, and a computer containing blue prints (package model) of the object, with a variety of printing technologies (Sun et al., 2015).
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INTRODUCTION.......Contd
3-D technologies were developed for the manufacturing industry and initially typically processed plastics, ceramics and metals.
Though recently, there has been an additionally slew of innovation toward using alternative materials like metals of various sorts, organic matter such as food materials etc.
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TYPES OF MATERIALS FOR 3D ADDITIVE MANUFACTURING
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Metallic Materials
Polymeric Materials Ceramic materials
Food
Tool Steel ABS Alumina Sugar
Aluminum Nylon Mullite Chocolates
Titanium Filled Nylon Zircona Fruits
Inconel Polycarbonate Silicon Carbide
Vegetables
Copper Polyphenylsulfonate tricalcium phosphate
Snacks
Stainless steel Polyetheretherketone Sand Gels
Gold/Platinum Aluminum Loaded Polyamide
Plaster
Bhandari and Regina, 20145
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Cotteleer, 2014
SUBTRACTIVE MANUFACTURING VERSUS ADDITIVE MANUFACTURING
Subtractive ManufacturingProducing a part by removing raw material via: boring, drilling, milling, sawing, shaping, planning, reaming etc.
Additive Manufacturing
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Traditional manufacturing processes creates objects by taking away material. additive manufacturing recreates
an object layer-by-layer from scratch by adding materials.
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2D MANUFACTURING VS 3D MANUFACTURING
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HISTORY OF 3D PRINTERS
1984Charles Hull developed the first 3D printer and named the technique stereo-lithography.
Later 1990sStratasys commercialized 3D printing, calls it fused deposition modeling (FDM)
2005Zcorp launched the first high definition colored 3D printer.
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Golding et al., 2011
ADDTIVE MANUFACTURING (3-D PRINTING) AND MARKET SIZE AND FORECAST
The global additive manufacturing sector market reached sales of $3.0 Billion dollars in 2013, an annualized growth of 30% over sales of $2.3 Billion in 2012. AM industry growth
over the last 25 years have been 25.4% and 29% in the last 3 years.
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3D Printing Technologies for Food Fabrication
Market Outlook
Forecasts for growth of the AM market by business analysts range from $7 billion by 2020, to bull market scenarios as high as $21.3 billion by 2020, on 34 percent (Forbes, 2014).
Wohler (2013) predicts the market for AM products and services will reach $10.8 billion worldwide by 2020.
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Wohler, 2013
WORKING PRINCIPLE OF A 3D PRINTER
The AM process begins with a 3D model of the object, usually created by computer aided design (CAD) software or a scan of an existing artifact. Specialized software slices this model into cross-sectional layers, creating a computer file that is sent to AM machine.
The AM then creates the object file that is sent to the AM machine. The AM machine creates the object by adding layers of materials on top of each other until the original work are 3D objects.
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Godoi et al., 2016
3D FOOD PRINTING
Three-dimensional (3D) Food Printing, also known as Food Layered Manufacture is a digitally controlled, robotic construction process which can build up complex 3D food products layer-by-layer (Huang et al., 2013).
The revolutionary food manufacturing technique precisely mix, deposit, and cook layers of ingredients, so that users can easily and rapidly experiment with different material combinations.
With this technology, food can be designed and fabricated to meet individual needs on health condition and physical activities through controlling the amount of printing material and nutrition content.
It integrates additive manufacturing and digital gastronomy techniques to produce 3D custom-designed food objects without object-specific tooling, molding or human intervention.
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INCEPTION OF 3D FOOD PRINTING
The total history of 3D Food Printing is less than 15 years, although the desire of rapidly fabricating custom-made food was expressed early in the 1960s through the movie, Star Trek.
The idea of creating 3D decoration on the cake surface using hand cream extruder as shown in can be considered as the precursor of 3D Food Printing process.
The latter is an automated version with computerized design pattern for fabrication compared to the previous manual process.
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EDIBLE 3D PRINTER: HOW IT WORKS
The current food printing process starts with designing a virtual 3D model. Slicing software translates this model into individual layers and finally generates machine codes for printing.
After uploading the codes into a printer and choosing a preferred food recipe, the food printing starts.
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From Idea to 3D printed shape
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16Cohen et al., 2009
3D PRINTING PARAMETERS
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Infill It is a value usually represented in percentage that shows how much a solid model should
be filled in with material when printed.
Number of Shells (Outline/Perimeter Shells) It is a value that sets the number of outlines printed on each layer of object, the more shells
the stronger the printed object is.
Layer Height It is the main parameter that affects print quality as it sets the thickness of each layer that is being printed. The lower the number, the thinner each layer is, the better quality you get of
your 3D prints.
TemperatureThe temperature at which the printer needs to be, while printing.
CONTD…..
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Printing Speed The speed at which the printing head moves while extruding the filament to create the physical representation of the 3D model.
Movement Speed (Speed while travelling)
The speed that the printing head moves when its not printing a material. Here the speed can be faster than while travelling and normally up to
twice the speed while printing.
CURRENT 3D PRINTING TECHNOLOGIES
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Bommel, 2014
APPLICABLE 3D PRINTING TECHNOLOGIES FOR FOOD PRINTING
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Selective Laser Sintering
BINDER JETTING INKJET PRINTING
Fused Deposition Modelling
3-D FOOD
PRINTING
APPLICABLE 3D PRINTING TECHNOLOGIES FOR FOOD PRINTING
1. Selective Sintering technology
Sugars and sugar rich powders can be selectively sintered to form complex shapes.
After a layer of fresh powder is spread, a sintering source: hot air in Figure (A) or laser in Figure (B) moves along the axes to fuse powder particles so that they can bind together and form a solid layer.
This process is repeated by continuously covering the fused surface with a new layer of material until the 3D object is completed.
Selective sintering offers more freedom to build complex food items in a short time without post-processing. It is suitable for sugar materials with relatively low melting points (Deackard and Beaman, 2008).
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(A) Selective hot air sintering and (B) Selective laser sintering
CONTD……
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Netherlands Organization for Applied Scientific Research (TNO), TNO’s SLS Printer (Gray et al., 2010) to sinter sugars and Nesquik powders. Similarly, savory snacks were also fabricated
using SLS technique.
Selective Laser Sintering of Nesquik powder
OTHER PRODUCTS OF SLS
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Savoury Snacks made by SLS
Chocolates and sweet cherry by SLS
SLS BY TNO SLS BY CANDYFAB
STEP-BY-STEP SLS-3D PRINTING WITH THE CANDYFAB 4000
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1 2 3
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4 5
CONTD….
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2. FUSED DEPOSITION MODELINGFused deposition modeling (FDM) also called hot-melt extrusion involves melting a semi-solid thermoplastic material and extruded from a movable FDM head and then deposited.
The material is heated slightly above its melting point so that it solidifies almost immediately after extrusion and welds to the previous layers.
In food printing, FDM is applied to create personalized 3D chocolate products (Yang et al., 2001) .
The food printer designed based on FDM has a compact size, and low maintenance cost. The disadvantages such as seam line between layers, long fabrication time, and delamination.
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FUSED DEPOSITION MODELING…Contd
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3D printers that run on FDM Technology build parts layer-by-layer by heating thermoplastic material to a semi-liquid state and extruding it via nozzle (1). The nozzle
lays the material down in layers (2) as a build platform (3) moves according to computer-controlled paths.
Hot Melt Extrusion (FDM)
CONTD…MIT researchers used hot-melt chocolate as a dispensing liquid and developed a functional prototype Bdigital chocolatier (Zoran and Coelho, 2011). In this project, compressed air was applied to push the melt chocolate out of chambers for customized candy and chocolate fabrication.
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CONTD…
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3D Printed Carrots by FDM
3D Printed Chocolates by FDM
Other products printed by FDM
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PizzaPizza
Burger
3. BINDER JETTINGIn standard binder jetting technology, each powder layer is distributed evenly across the fabrication platform, and liquid binder sprays to bind two consecutive powder layers (Sachs et al., 2009).
The powder material is usually stabilized through water mist to minimize disturbance caused by binder dispensing.
In an edible 3D printing project by Walters et al., 2011, sugars and starch mixtures were used as the powder material and a Z Corporation powder/binder 3D printer as platform to fabricate customized shape with complex structures.
Binder jetting offers advantages such as faster fabrication and low materials cost, but suffers from rough surface finish and high machine cost.
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BINDER JETTING….. CONTD
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Powder Bed Binder Jet
4. INKJET PRINTING
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Brommel, 2014 used pneumatic membrane foodjet to deposit selected material drops onto pizza bases, biscuits and cupcakes.
The ejected stream/droplets fall under gravity, impact on the substrate, and dries. The drops can form a two and half dimensional digital image as decoration or surface fill.
Inkjet food printing dispenses stream/droplet from syringe-type printhead in a drop-on-demand way. 3D edible food products such as cookies, cakes, or pastries are created in a layer structure, which involves pre-patterning food items at multiple
layers of processing.
INKJET PRINTING…… CONTD
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Inkjet Printing
Inkjet 3D Food printer
INKJET PRINTING…… CONTD
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Brommel, 2014
Fused Deposition Modeling
Sintering technology Binder Jetting Inkjet printing
Materials Chocolate
Low melting powder such as sugar, Nesquik, powders e.t.c
Powder such as sugars, starch, corn flour, flavours, e.t.c
Low viscosity materialssuch as paste or puree
Viscosity 103 ~ 105 cP - 1 ~ 10 cP (Binder) 5×102 ~ 5×103 cP
Platform • Motorized stage • Motorized stage • Motorized stage • Motorized stage
• Heating unit• Sintering source (laser or hot air) • Powder bed • Inkjet printhead
• Extrusion device• Powder bed
• Inkjet printhead for binder printing
• Thermal control unit
Printing Resolution
Nozzle diameter: 0.5 ~1.5 mm
Powder size:100 μm
Nozzle diameter ≤ 50 mm Powder particle ≤100 μm
Nozzle diameter ≤ 50 μm
Sun et al., 2015
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FabricatedProducts
Customized chocolates
Food-grade art objects, toffee shapes
Sugar cube in full color
Customized cookies,Bench-top food paste shaping
Pros • Cost effective • Better printing quality • More material choices • Better printing quality
• Fast fabrication • Complex design • Better printing quality
• Full color potential
• Complex design
Cons • Low printing quality • Expensive platform • Slow fabrication • Slow fabrication
• High power consumption • Expensive platform • Expensive printhead
• Limited materials • Expensive platform
• Limited materials
Machine Choc Creator Food Jetting Printer Chefjet Foodjet
Company Choc Edge TNO 3D Systems De Grood Innovations
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Examples of Commercially available Food Printers
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TYPES OF PRINTABLE FOOD MATERIALS
1. Natively Printable Materials
Natively printable materials like hydrogel, cake frosting, cheese, and chocolate can be
extruded smoothly from a 3D printhead (Cohen et al., 2009).
2.Non-printable Traditional Material
Food like rice, meat, fruit and vegetables, largely consumed by people every day, are not printable by nature.
To enable their capability of extrusion, adding hydrocolloids in utilized (Lipton et al., 2010).
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CONTD….
Alternative ingredients extracted from algae, fungi, seaweed, lupine, and insects are novel sources for protein and fiber.
In the BInsects Au Gratin project, insect powders mixed with extrudable icing and soft cheese were used as printing materials to shape food structures and make tasty pieces (Walters et al., 2011).
Residues from the current agricultural and food processing can be transformed to biologically active metabolites, enzymes, and food flavor compounds (Nikitina et al., 2007), as sustainable and eco-friendly printing material sources.
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3. Alternative Ingredients
MODIFICATION AND COMPARISON OF DIFFERENT PRINTING MATERIALS
AIM: To present a rigorous proof-of-concept investigation of hydrocolloids for food-SFF. A two-dimensional mouthfeel rating system was created (stiffness vs. granularity) and various hydrocolloid mixtures were characterized via an expert panel of taste testers.
METHOD : In order to rigorously describe the mouthfeel of each resultant material, two-dimensional mouthfeel rating system was devised in which the material was rated: 1) weak to firm, and 2) smooth to granular. created (stiffness vs. granularity) and various hydrocolloid mixtures (xanthum gum and gelatine) were characterized via an expert panel of taste testers
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( Cohen et al., 2009)
MODIFICATION AND COMPARISON OF DIFFERENT PRINTING MATERIALS
Mos
t fir
mW
eake
st
Mouthfeel matrix with common foods placed as reference items ( Cohen et al., 2009)
Smoothest Most Granular
Mos
t fir
mW
eake
st
Smoothest Most GranularMouthfeel matrix of hydrocolloid mixture showing the formulations in the appropriate
locations relative to common foods with the closest common foods are listed below the hydrocolloid concentrations
( Cohen et al., 2009)
Formulation of 3D Foods from Alternative Ingredients
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CRUST
MICRORGANISM
EDIBLE MATRIX
Alternative protein
Carbohydrate (Bread, pasta)
Seeds and SproutsYeastBacteria
NutsDried Vegetables or fruitsAlternative proteinAgarWalters et al., 2011
Food Printing Versus Robotics-based Food Manufacturing
3D Food Printing Robotics Based Food Manufacturing
Aims at placing users’ creativity and control at the center of the process by allowing the users to manipulate food forms and materials directly.
Reduces human involvement and workload by automating various manual processes.
Food printing is a digital food fabrication process integrating 3D printing and digital gastronomy technique to manufacture food pieces. It allows users to design and fabricate food with customized color, shape, flavor, texture, and even nutrition.
Robotics-based technologies have been designed to replace labor-intensive operations, to automate individual steps or replace manual operations but had very little relevance to nutrition control and customized fabrication
Engaging consumers is also emphasized in food printer design, i.e., a convenient and friendly interaction between consumers and machines.
Do not engage consumers.
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Comparison of recipes in Food printing and robotic-based manufacturing
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Food printing Robotics-based food manufacturing
Cookies Printable sugar cookies Flour, powdered sugar, egg yolk, and unsalted butter (Lipton et al., 2010)
Snowflake-shaped sugar cookies All-purpose flour, granulated sugar, unsalted butter, egg and egg yolk, salt, and vanilla extract (Bosker, 2013)
Afghan biscuits Flour, sugar, butter, cocoa powder, cornflakes (Bollini et al., 2011) Quick ’N Easy Sugar
Cookies All-purpose flour, sugar, eggs, vegetable oil, vanilla, granulated baking powder, and salt (Bollini et al. 2011)
Chocolate Cadbury milk chocolate (Hao et al., 2010) Cocoa and cocoa butter, full-cream milk, sugar, special flavoring, and emulsifier (Gunstone and Fred, 1997)
Sugar Cubes Sugar, sweet and sour flavored candies, and milk chocolates (3D System, 2013)
Sugar, food colorings, aromatic herbs, and spices (La Bau, 2014)
Potential Technologies Applicable to Food Printing
1. Electrospinning
Fibers provide structure and texture to food products which contributes to a pleasant taste experience.
Examples: Muscle fibers in meat, cellulose fibers in vegetables, …
Challenge: Producing well-defined fibers of various food materials in order to create desired textures and structures in food products
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Electrospinning is capable of producing thin, solid polymer strands ranging from 10 to
1000 nm in diameter. It can generate antimicrobial nanofibers with more desirable sensory properties (Fernandez et al., 2009)
.
Sun et al., 2015
Electrospinning…Contd.
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Contd….. Controlled Fiber Production and Deposition
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Potential applications:
Structuring / texturizing
Thickening / gelating
Encapsulation / controlled release
Making fibers out of alternative food
materials
Meat replacement
Organized structureFiber mat Directionality
Electrospinning….…Contd.
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An integration of electrospinning and food printing may offer a possible all-in-one solution to fabricate food products with personalized nutrition, i.e. extracting
fibers out of materials, encapsulating nutrients, controlling their dispensing volume, and constructing food structures with a controlled release of the
nutrients (Gray, 2010).
Micro-scale fibers can provide structure and texture to food products with a pleasant taste experience, such as muscle fibers in meat and cellulose fibers in
vegetables.
From a technical perspective, the current challenge is to integrate and manipulate electrospinning process in food printing platform.
2. Microencapsulation
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Microencapsulation….Contd.
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Microencapsulation….Contd.
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Microencapsulation…ContdIntegrating such technology into food printing can be achieved by using a multi-printhead system, where at least one print-head generates and dispenses microcapsules in the fabricated food products (Xu et al., 2013).
This would help fragile and sensitive materials survive in processing and packaging conditions, stabilize the shelf life of active ingredients, and create appealing aroma release, taste, odor, and color masking.
This method simplifies the current functional food manufacturing process, enhances functional ingredient stability (e.g., probiotics and bioactive ingredients), and actualize controlled release of flavorings and nutrients (Dunn, 2004).
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Impact of 3D Food Printing on the Food Industry
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Food printer provides a platform for consumer experimentation with various food forms and flavours (Yang et al., 2015).
Previously, this customization process involves specifically hand-made skills with low production rate and high cost.
Food printing technologies could potentially overcome these barriers by offering more freedom in food customization design on shapes, colors and flavours for home users.
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CUSTOMIZED FOOD DESIGN
CUSTOMIZED FOOD DESIGN
Multi-material Food Printing With Complex Internal Structure Suitable For Conventional Post-processing ( Jeffrey et al., 2015)
(A) Multi-material food design (B) Fabricated food samples
from multi-printheadsGreen arrow extends fully
through the heart.
Frosting material breaks away easily…
Customized chocolate bars.
Surface printed crackers
Frosting material breaks away easily…
CONTD….
Personalized Nutrition
Food printing can enable a precise control of people’s diet, and ensure fresh and healthy dishes that exactly meet the needs and preferences of individuals.
It would significantly improve population wellbeing. In this case, food ingredients even with well-known material properties must be tailored to specific formulations under each fabrication.
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3D printed soft chicken
Targeted at patients with Dysfunctional Masticatory Muscles
CONTD…..
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Smooth food meals served to patients with mastication problems in a German Nursing
home.
SIMPLIFYING CUSTOMIZED FOODS SUPPLY CHAIN
Food printers will facilitate the implementation of a build-to-order strategy with low overriding cost.
It is economical to locate production facilities near the end customers. This can help to reconfigure the customized food supply chain and bring products to consumers within a shorter time, acceptable price while utilizing fewer resources.
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Innovative Food Products
Buddhist cuisine applies soy-based or gluten-based materials for cooking meat analogue or mock meat dishes for vegetarians and Buddhists, which taste very similar to meat.
The research from Lipton et al., 2011 also proved the concept of creating a wider range of textures and tastes by mixing small group of hydrocolloids and flavor additives.
In other words, it is feasible to create a wide range of food items with very similar taste and shape by using a limited number of raw materials/ingredients. If such knowledge is embedded into the food printing process, more innovative food products and unique dining experiences can be created.
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Incorporation of Alternative Ingredients
According to Food designers (Soares and Forkes, 2014), insects can be used to make food products with the help of 3D printing to serve as an alternative source of protein intake.
When compared with conventional meat products, the protein concentration inside insects is slightly higher and 3D food printing can greatly contribute to making unpleasant aesthetics and cultural background of insects become more “digestible” to consumers.
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Edible Growth
MODIFICATION OF TRADITIONAL RECIPES
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Some 3D printed foods are not suitable for baking, boilin and frying. Lipton et al., 2010 modified some traditional snacks recipe of Austria (Weihnachtsbaeckerei) made from turkey or scallop with celery by using transglutaminase which enhances their ability to be slow cooked or deep-fried after printing.
Test geometrics of scallops were printed. Both shapes were cooked & deep fried but
retained most of their shape. Only thin regions were deformed.
Enormously deformed during deep frying without addition of transglutamanase
Inncreasing transglutaminase concentration beyond 0.5% by weight
seems to have little effect on the shape stability of 3D printed meats.
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Turkey with transglutaminase was printed into a truncated hemisphere (a) and cooked sous-vide (b). The overall shape survived cooking, Celery fluid gel (green fluid in c) was printed into a turkey cube (d)
Lipton et al., 2010
3D Printed traditional Austria cookies maderetained their geometry after baking with slight
skump in exterior
CONTD…..
Rapid Prototyping Tool for New Product Development
To improve the communications between food scientists, food engineers, marketing people, distributors, and consumers during the product development stage, food producers need to explore ingredient combination and fabricate new design samples.
A promising solution is to further develop the food printer as a prototyping tool to conduct small batch production in a cost-effective and time-efficient way.
It can help to fully understand comprehensive technical requirements, explore ingredient combination, taste, and mouthfeel prior to starting mass production. The fabricated food products may be used to verify consumer interest in a proposed design and ingredient stability of specific designs.
This could also help filter out a large number of design candidates that do not meet the requirements in a short time at acceptable cost.
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OTHER PRINTED EDIBLE PRODUCTS
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Dovetailed - 3D Fruit Printer
Printed Raspberries
Book made of chocolate from the Chocolate Museum in Barcellona Pasta Letters Printed Kiwi Fruit
HOW PICTURES ARE PRINTED ON CAKES
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A4 paper made from frosting Edible Ink
CartridgeInsert papers
into the printer
Allow to printTrimming
Final edible picture of any
kind
APPLICATION IN OTHER MANUFACTURING SECTORS
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KEY PLAYERS IN EDIBLE FOOD PRINTING MARKET
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Fabrication
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PROS AND CONS OF ADDITIVE MANUFACTURING
Product Evolution
Customization to customer preferences.Zero cost of increased complexity.Faster product. development.Less wastage.Elimination of tooling or molding.
Mass customizationManufacturing at point of use.Supply chain disintermediation.Customer empowerment and co-creation.Store and distribute designs electronically. Print on demand thus reducing inventoryAdvertising
Business Model Evolution
Supply chain Evolution
Manufacturing closer to point of useResponsiveness and flexibility.Print on demand
ConsUnexpected pre-and post-processing requirements, high cost of machine, lack of industry standards, low speed thus not suitable for mass production, limited number of materials
etc
POTENTIAL REGULATORY CHALLENGES
Ensuring the machines, processes and finished products meet FDA safety standards may not be advancing as quickly as the machine.
Example 1: Most 3D Foods are made with paste like ingredients that need to have an adhesive-quality so as stick layers and dry or cook quickly enough to finish the product. FDA will require safety evaluation of these ingredients and how firms expect to meet this standard is unclear.
Possible solutions may include
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a) Filing a notification that 3D printing ingredients are GRAS
b) The other option for establishing safety could be through a food additive petition which can take years thus stall the advancement of 3D food printing
CONTD….
Example 2: Another potential regulatory challenge will be how to oversee the safety of 3D printed foods, draft GMPs and what the agency will deem as complaint.
Possible solutions
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a) The Food Industry may demand separate requirements for 3D food printing so that expectations are clear and tailored to the technology.
Other regulatory challenges will be adulteration and education which can be tackled using the conventional quality control + analysis and supply chain management.
3D Players in the industry might have to consider IP rights protection as a lot of confusion among manufacturers will potentially arise regarding printing technology, recipe and ingredients.
FUTURE WORK
1. Designing methods for integrating data about the individuals, and establishing algorithmic representations of traditional recipes. These algorithms would need to map the input space of the dish (crispiness, tenderness, flakiness, etc.) to the process parameters of the recipe.
2. Researchers and industry will also need to develop more stable print materials.
3. Safe certified printers will need to be developed.
4. Added precision in the crafting of food shapes and the ability to replicate full 3D designs will allow for new presentations of food.
5. Higher throughput and larger reservoir food printers will be needed.
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CONCLUSION
The prospects food printing technologies in food fabrication is enormous. Both natively printable materials and non-printable traditional food materials are used.
Although quite a number of food printing technologies are available, there is still a long way to further develop them for commercial usage.
Food printing may exert a significant influence on various types of food processing, which allow food designers/users to manipulate forms and materials with enhanced and unprecedented capability.
This versatility, applied to food manufacturing, can improve efficiency to deliver high quality, freshly-prepared food items to consumers, personalized nutrition and enable users to develop new flavors, textures and shapes to create entirely new eating experiences.
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What would you like to print?
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