Our company is engaged mainly in the production of cold pressed oils and vegetable flours. Our main products are grape seed oil and grape seed flour, which are made by utilizing all the by-products of oil production. Our eternal goal is the implementation of the so-called 'zero waste' principle in everyday production. We place great emphasis on protecting our environment. One side of this is the application of zero waste technologym which means that no waste is generated during production.
The Goal of Our Project
Development of a process for creating an emulsion from mustard oil mud
In the production of cold pressed oils, a by-product called oil mud is formed after settling. Oils alone contain a very wide spectrum of the finest active ingredients, but the resudal dense oil mud is significantly more abundant in a wide variety of useful substances: fiber, essential fatty acids, protein, vitamins and minerals. Therefore, our goal in the project was to bring these useful materials to the consumer in a form that is attractive and pleasing both in content and aesthetics.
As the first step we hoped to achieve this by solving the problem of keeping the two liquid phases formed during the pressing of the mustard seed in the emulsion. We have accomplished this by colloid chemistry and by adding natural material. Several types of processes have been tested, with the combined action of mechanical action and natural emulsion forming materials, to produce the desired emulsified state and degree of consistency. In contrast to the traditional pattern-making process, our method allows the product to be finished in less time and with less water.
Technical-professional result
As planned, the oil mud suspension was converted into an oil-water concentraed emulsion using water and acetic acid, stabilized by the mud, the natural emulsifiers and the increased viscosity of the medium. These natural emulsifiers were so effective that no additional supply of air was required, making it unnecessary for emulsion formation. Thus, without aeration, the desired result can be achieves with just mechanical mixing, which allows the product created this way to be realized at a more competitive price. Initially, the rheological properties (creaminess) of the sauces were supposed to be caused by the amount of air blown in, but the mechanical stirring also gives the emulsion a sufficient amount of air, ensuring the creaminess. Thus, there was no need for aeration emulsifier. When generating the emulsions, the dispersion was done by applying heat energy. In order to maintain the stability of the dispersion, natural stabilizers were added throughout the process, which made it easy to stabilize the emulsions. We have been able to find natural emulsion formers that we could use to create a stable colloidal system that retains its stability for more than a year and gives the products a superior taste.
The next step in making emulsions into product was to experiment with a variety of flavors to create a family of mustards sauces that, with its unique taste, makes a delightful novelty to gourmet product consumers. To this end, we made many organoleptic judgments, featured prodct prototypes at several foreign exhibitions, and finally, five mustard sauce variants were selected.
We deiced to introduce mustard sauces with the following flavors:
rosehip,
quince,
walnut,
piquant apricot
In order to realize industrial production, the product technology description (gentle heat treatment process) have been developed, which guarantees the stability of the emulsions after heat treatment and meets the strictes food safety requirements. To this end, a custom-made sterilizer was purchased.
The process
Developing end products (mustard / mustard sauce) using a new, environmentally and consumer friendly process, using by-products from mustard oil production.
oil sedimentation: unfiltered mustard oil sludge is formed at the bottom of the oil, the oil is drained from the upper part and filtered, the sludge is “extracted” from the bottom of the barrel
manufacture of mustard flour: mustard seed pellets mustard flour
