3D Printing Technologies for Food Fabrication

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).

May 3, 20233D Printing Technologies for Food

Fabrication3

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


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


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


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.


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.


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


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…..


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


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


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


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


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.


Comparison of recipes in Food printing and robotic-based manufacturing


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


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.


Contd….. Controlled Fiber Production and Deposition


Potential applications:

Structuring / texturizing

Thickening / gelating

Encapsulation / controlled release

Making fibers out of alternative food

materials

Meat replacement

Organized structureFiber mat Directionality

Electrospinning….…Contd.


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


Microencapsulation….Contd.


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…..


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.


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.


Fabrication66

OTHER PRINTED EDIBLE PRODUCTS


Fabrication67

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


Fabrication68

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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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


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


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.


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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