Practical scale modification of oleogels by ultrasonic standing waves

Lipid-based materials, such as substitutes for saturated fats (oleogels) structurally modified with ultrasonic standing waves (USW), have been developed by our group. To enable their potential application in food products, pharmaceuticals, and cosmetics, practical and economical production methods are needed. Here, we report scale-up of our procedure of structurally modifying oleogels via the use of USW by a factor of 200 compared to our previous microfluidic chamber. To this end, we compared three different USW chamber prototypes through finite element simulations (FEM) and experimental work. Imaging of the internal structure of USW-treated oleogels was used as feedback for successful development of chambers, i.e., the formation of band-like structures was the guiding factor in chamber development. We then studied the bulk mechanical properties by a uniaxial compression test of the sonicated oleogels obtained with the most promising USW chamber, and sampled local mechanical properties using scanning acoustic microscopy. The results were interpreted using a hyperelastic foam model. The stability of the sonicated oleogels was compared to control samples using automated image analysis oil-release tests. This work enabled the effective mechanical-structural manipulation of oleogels in volumes of 10–100 mL, thus paving the way for USW treatments of large-scale lipid-based materials.