The Food Industry from a Classical Perspective
The scope of the food industry has historically involved the processing of raw materials, the use of additives, and ultimately, packaging in glass, metal, plastic containers, or combinations of these materials and cellulose. In this context, ensuring the nutritional needs of a growing population while guaranteeing product safety and preventing health risks based on established standards has been defined as the primary goal of this industry.
The Food Industry and New Challenges
In recent decades, scientific and industrial advancements have enabled the processing of large volumes of raw materials using fully automated machinery, reducing production costs and minimizing waste. However, as the challenge of food supply diminishes, consumers in the modern world are increasingly seeking product variety. As a result, competition among manufacturers has driven research to innovate. These efforts have mainly focused on creating new structures, flavors, packaging diversity, and extending the shelf life of products. The second stage of this evolution involves increasing consumer awareness of the quality of food ingredients and the desire to consume healthier foods, such as reducing sugar, fats, and eliminating toxins and synthetic substances, or replacing animal proteins with plant-based ones.
Entering the Digital Age
The collaboration between computer science and mechatronics has led to the development of precise, fast machines that are continuously evolving. One such tool is the 3D printer. A 3D printer creates multiple 2D layers based on 3D data, which ultimately form a 3D structure. The overall structure of these printers includes a material reservoir, a mechanical arm, and a computer controller based on the provided 3D design. The machine melts the material and extrudes it at specified coordinates where the arm is positioned. The extruded material melts a small portion of the underlying layer, creating adhesion. Over time, with the creation of successive layers, a 3D structure is formed.
The Development of Food-Grade Polymers and the Need for 3D Printers
For a long time, 3D printers were used in industries based on plastic polymers to produce prototypes of industrial designs. This limitation arose because the raw materials required for 3D printing must have the ability to melt and solidify quickly after leaving the nozzle, a property common in most petrochemical polymers. However, with advances in the physics and thermodynamics of food materials, edible raw materials with extrusion capabilities and the ability to bond to printed layers have been developed.
Cocoa, Hydrogels, and Emulsions
Initially, the fast-melting properties of chocolate, allowed the creation of previously unattainable 3D structures. However, the development of knowledge regarding hydrogels, oleogels, and emulsions has facilitated the creation of 3D structures with various materials containing colors. It should be noted that many of these techniques are still in the early stages of development and are primarily used to develop customized products in direct-to-consumer outlets like cafes and restaurants.
3D Printing of Meat with Desired Fats and Proteins
One area where 3D printers have shown great potential in the food industry is in the production of plant-based meat. Natural meat is essentially the tissue of animals, composed of a random combination of muscle protein fibers and fat strands, which creates a chewable texture and a pleasant mouthfeel for consumers. 3D printing technology allows the simulation of natural meat texture by combining plant-based protein gels and designed plant fats based on digital patterns of natural meat. This has led to successful results, paving the way for the mass industrial production of plant-based meat.
