The efficient production of nanoemulsions, with oil droplet sizes of less than 100nm would facilitate the inclusion of oil soluble bio-active agents into a range of water based foods. Small droplet sizes lead to transparent emulsions so that product appearance is not altered by the addition of an oil phase. In this paper, we demonstrate that it is possible to create remarkably small transparent O/W nanoemulsions with average diameters as low as 40nm from sunflower oil. This is achieved using ultrasound or high shear homogenization and a surfactant/co-surfactant/oil system that is well optimised. The minimum droplet size of 40nm, was only obtained when both droplet deformability (surfactant design) and the applied shear (equipment geometry) were optimal. The time required to achieve the minimum droplet size was also clearly affected by the equipment configuration. Results at atmospheric pressure fitted an expected exponential relationship with the total energy density. However, we found that this relationship changes when an overpressure of up to 400kPa is applied to the sonication vessel, leading to more efficient emulsion production. Oil stability is unaffected by the sonication process.

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This review details recent developments in nondestructive ultrasound separation techniques that can be used to separate, trap, or fractionate particles or emulsified droplets from bulk phase liquids. Whereas most previous reviews have focused on small scales or specific applications, this review groups different aspects of the acoustic separation technique and directs it at an audience with interests in separation technologies. The process has potential as an attractive alternative to common separation processes such as centrifugation, membrane filtration, sedimentation, or fluorescence activated cell sorting (FACS). The technology can achieve precise, gentle, and label-free separation in a system that involves no moving parts. The fundamental concepts are presented in detail and previous studies covering a range of different applications are reviewed. The challenges and opportunities for addressing large-scale industrial applications are evaluated.

The separation of milk fat from natural whole milk has been achieved by applying ultrasonic standing waves (1 MHz and/or 2 MHz) in a litre-scale (5L capacity) batch system. Various design parameters were tested such as power input level, process time, specific energy, transducer-reflector distance and the use of single and dual transducer set-ups. It was found that the efficacy of the treatment depended on the specific energy density input into the system. In this case, a plateau in fat concentration of ∼20% w/v was achieved in the creamed top layer after applying a minimum specific energy of 200 kJ/kg. In addition, the fat separation was enhanced by reducing the transducer reflector distance in the vessel, operating two transducers in a parallel set-up, or by increasing the duration of insonation, resulting in skimmed milk with a fat concentration as low as 1.7% (w/v) using raw milk after 20 min insonation. Dual mode operation with both transducers in parallel as close as 30 mm apart resulted in the fastest creaming and skimming in this study at ∼1.6 g fat/min.

Ultrasonic processing can suit a number of potential applications in the dairy industry. However, the impact of ultrasound treatment on milk stability during storage has not been fully explored under wider ranges of frequencies, specific energies and temperature applications. The effect of ultrasonication on lipid oxidation was investigated in various types of milk. Four batches of raw milk (up to 2L) were sonicated at various frequencies (20, 400, 1000, 1600 and 2000kHz), using different temperatures (4, 20, 45 and 63°C), sonication times and ultrasound energy inputs up to 409kJ/kg. Pasteurized skim milk was also sonicated at low and high frequency for comparison. In selected experiments, non-sonicated and sonicated samples were stored at 4°C and were drawn periodically up to 14days for SPME-GCMS analysis. The cavitational yield, characterized in all systems in water, was highest between 400kHz and 1000kHz. Volatile compounds from milk lipid oxidation were detected and exceeded their odor threshold values at 400kHz and 1000kHz at specific energies greater than 271kJ/kg in raw milk. However, no oxidative volatile compounds were detected below 230kJ/kg in batch systems at the tested frequencies under refrigerated conditions. Skim milk showed a lower energy threshold for oxidative volatile formation. The same oxidative volatiles were detected after various passes of milk through a 0.3L flow cell enclosing a 20kHz horn and operating above 90kJ/kg. This study showed that lipid oxidation in milk can be controlled by decreasing the sonication time and the temperature in the system depending on the fat content in the sample among other factors.