Palm fat has uniquely optimal melting characteristics that are difficult to replace in products such as baked goods and chocolate-based items. This study investigates the efficacy of using Pickering emulsions derived from Swiss plant oils and their micromilled press cakes. Emulsification was carried out at both the lab and pilot scales using sunflower- and rapeseed-based recipes, with and without additional surfactants, for both oil-in-water and water-in-oil emulsions. The resulting emulsions were measured for viscosity and short- and long-term stability and linked to the properties of the raw materials. The results indicated that the contact angle, size, and macronutrient composition of the particles significantly impact emulsion quality, though differences in oil pressing methods might predominate these effects. The combination of particles and surfactants demonstrated a clear advantage with respect to interface stabilisation, with a suggested link between the wax content of the oil and particles and the resulting emulsion quality and stability.

Palm and palm kernel oils are preferred ingredients in industrial food processing for baked goods and chocolate-based desserts due to their unique properties, such as their distinctive melting behaviors. However, ongoing concerns about the social and environmental sustainability of palm oil production, coupled with consumer demands for palm oil-free products, have prompted the industry to seek alternatives which avoid the use of other tropical or hydrogenated fats. This project investigated replacing palm oils with chemically unhardened Swiss sunflower or rapeseed oils. Target applications were cookies and chocolate fillings. These oils were physically modified through emulsification, stabilized with finely ground oil press cake particles and crystallized waxes. Findings indicated that the emulsification of the oils increased viscosity and that the addition of wax was beneficial for long-term stability; however, the extent of this effect depended on the combination of oil and wax types. Furthermore, wax pre-crystallization and low shear during crystallization significantly improved emulsion stability. Despite these improvements, the resulting emulsions did not achieve sufficient stability and exhibited lower viscosity than palm oil. Future experiments should explore higher wax concentrations (1% or more) and develop analytical methods to better understand the wax composition and its role in oleogel formation.

Palm and palm kernel oils are extensively utilised in food processing due to their unique properties, such as their semi-solid consistency at room temperature. However, growing environmental and social concerns regarding palm oil production have prompted the industry to seek sustainable alternatives to tropical or hydrogenated fats. This project investigated the use of plant oils and their emulsified and crystallised forms as potential substitutes for palm fat in light and dark chocolate fillings, with an emphasis on single-origin ingredients to align with clean-label trends. The emulsions were assessed for viscosity, firmness, colour, and key flavour and aroma profiles. Results demonstrated that palm fat alternatives performed effectively in dark chocolate fillings, with non-emulsified recipes achieving firmness comparable to palm fat. In contrast, light chocolate fillings exhibited reduced firmness at higher inclusion rates of alternatives, and emulsified products were prone to flocculation. Notably, pure oil formulations delivered promising outcomes at lower inclusion rates, as the firmness could be raised by 22.0%, likely due to vegetable oil and cocoa butter interactions influencing crystal morphology. Substituting palm oil with sunflower oil, either crystallised or emulsified, did not compromise the overall flavour. Future investigations should determine the maximum feasible level of palm fat substitution and investigate the potential of adding higher amounts of waxes and emulsifiers to enhance crystal formation and firmness.