3 d food printing conference nesli sozer

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 Investigator

2

What is Additive

Manufacturing or 3D

printing ?

323.8.2017 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 bedMaterial Jetting:

Paste extrusion &inkjetIndirect

- mold

chocolate printing.wmv

5

Binder Jetting Powder Bed Fusion

http://www.custompartnet.com/wu/images/rapid-prototyping/sls.png

Thermal energy selectively

fuses regions of a powder bed

Support structures are needed +

many post processing phases

A liquid bonding agent is selectively

deposited to join powder materials

Might result in weak structures (good for

design purposes)

http://blog.nus.edu.sg/u0804594/common-rp-techniques/d-3dp/

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., 2016

7

Material Jetting (inkjet & syringe)

Material/paste is selectively dispensed

through a nozzle or orifice

No need for support structure

Droplets of build material are

selectively deposited

Support structures are needed

Godoi et al., 2016

Where are we with 3D

food printing?

823.8.2017 8

Need for 3D food printing

Active

participation

Design

Pleasure

Eating

experience

Cooking

experience

Playfulness

Personalized

Food (healthy, nutritious, balanced)

Affordable

3D Printing

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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)

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History of 3D Food Printing

2006 Fab@Home

Paste extrusion by f.ex. frostings, Nutella,

chocolate (Cornell Univ.)

2006-2009 CandyFab, Sugar printing

(EvilMad Scientist Lab)

2012-2015 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)

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., 2009

3D structures by

fused powders

Sugar, Nesquick® Laser bed sintering Gray, 2010

Chocolate with filling Chocolate solids and

pumpable fillings

Hot-melt extrusion Zoran and Coelho,

2011

3D images embedded

in solid foods

Food-ink pastes and

gels

Extrusion (single head) Golding et al., 2011

Edible 3D prints Mashed potato, sugar,

chocolate, icing

Extrusion (single head) Southerland et al., 2011

Edible 3D insect

structures

Insect powders with

firming agents and

flavours

Extrusion (single head) Soares et al., 2011

Cereal based snack Wheat flour Extrusion (single head) Severini et al., 2016

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Key Patents

Title: Brief Content (Patent number), owner

Multifunctional Food Printer: Multifunctional 3D food printer with high efficiency and high

precision. (CN 203136994 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 2014/190217 A1, ) Systems and

Materials Res Corp., USA

Manufacturing food using 3D printing technology: 3D Printing System with a heating

device to control rheology (WO 2014/190168 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 204249369 U , 2015) Pingliang Ruije Technology Co, CN

Multi-material food 3D printing device: 3D printing device including a cooking system.

(CN 204070482 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 edible liquid. (WO 2015/115897 A1) TNO, NLFrost and Sullivan, 2015

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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)

VTT approach

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Aim

Evaluate the applicability of various

protein, starch and fiber-rich food

ingredients and their mixtures in 3D

printed healthy customized snacks.

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Materials

Materials Composition

Rye bran (micronized)

(VTT)

13 % prot,44 % starch,27 % DF,2% fat

Oat protein conc (OPC)

(VTT)

48 % prot,37 % starch,7 % DF,4 % fat

Faba bean protein

(FPC) (VTT)

62 % prot, 1 % starch, 11 % DF, 3.5 %

fat

Starch (Ultra-Sperse,

Ingredion)

cold water swelling modified food starch

derived from waxy maize starch

Skimmed milk powder

(SMP) (Valio)

35 % prot, 53 % lactose, 0.6 % fat

Semi-skimmed milk

powder (SSMP) (Valio)

37 % prot, 38 % carbohy (lactose free),

15 % fat

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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.

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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: 22-600 kPa depending on

the paste material.

Post processing: Oven drying at 100 oC 15-30 min or freeze drying.

Material extrusion type of device used for

3D printing of food materials

Results

Printability of pastes prepared from starch

and/or milk powder

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Printability of pastes prepared from rye bran or

plant protein concentrates

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Oscillatory stress sweeps for selected pastes

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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.

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Dry matter content and hardness of selected 3D

printed samples after oven- or freeze-drying

SampleDry matter

content (%)Hardness (N)

Oven-

dried

Freeze-

dried

Oven-

dried

Freeze-

dried

60% SSMP 85.2 ± 0.9 89.4 ± 0.3 42.6 ± 3.1 36.7 ± 5.7

35% OPC 79.8 ± 1.9 95.6 ± 0.1 13.0 ± 2.0 2.2*

45% FBPC 63.1 ± 1.7 95.9 ± 0.1 2.9 ± 0.9 59.8 ± 16.3

*sample very fragile, only one sample could be measured

2523/08/2017 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.

Multilayer food textures by advanced manufacturing

technologies 3DSURPRISE project

(Sept 2016- 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€

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VTT Team

in

3D Food

Printing

Sini Metsä-Kortelainen

Senior Scientist, VTT

Expertise

• 3D printing technologies

• Material science

Pasi Puukko

Research Team Leader, VTT

Expertise


Antti Vaajoki

Research Scientist, VTT

Expertise


• Material technologies

Alejandro Revuelta


Expertise

• Engineering, design

• Auxiliary in-machine operations

Martina Lille


Expertise

• Food rheology and material

characterization

Nesli Sözer

Principal Investigator, VTT

Expertise

• Food ingredient technology

• Food structure design

Kyösti Pennanen


Expertise

• Consumer research

Jaakko Paasi

Principal Scientist, VTT

Expertise

• Business and innovation

research

TECHNOLOGY FOR BUSINESS

Further information

please contact

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