Techno-economic analysis and scalability of oleogel-based fat replacements
A comprehensive analysis and modeling framework for integrating oleogel-based fat replacements in food systems, focusing on scalability, cost-effectiveness, and sensory performance. Utilizes widely available oleogelators for improved formulation strategies in confectionery and fat-based products.
Overview
Re-Du Company presents a solution centered on the integration of oleogel-based fat replacements into commercial food manufacturing, specifically targeting confectionery and fat-based products. This initiative addresses key barriers such as scalability, cost, and sensory performance by providing a techno-economic analysis (TEA) and process feasibility evaluation. The objective is to create a decision-ready framework for selecting oleogel formulations that are scalable, cost-effective, and have favorable sensory and nutritional profiles.
Technical specifications
Our methodology involves modeling oleogel-based formulations using sunflower wax, lecithin, and pectin, which are widely available oleogelators. The process includes simulating conditions such as thermal processing, mixing, and crystallization to evaluate scalability and texture performance. A techno-economic analysis compares these formulations to conventional fats and cocoa butter equivalents (CBEs), estimating operational and capital expenditures with ±30% accuracy. We also assess oxidation stability and shelf life to ensure compatibility with existing fat systems.
Technology readiness level
Currently at a Technology Readiness Level (TRL) of 6, this project is in the validation phase. The proposed 16-week, four-phase project plan includes formulation identification, process simulation, techno-economic analysis, and the delivery of a final report recommending oleogel formulations, process requirements, and TEA results, with a potential path to pilot or commercial validation.
About Re-Du Company
RE-DU is a recycling technology company that has developed a patented process for the chemical deconstruction of mixed plastic waste. By breaking down diverse plastic types—such as PET, PC, PU, and PA—into monomers, the company enables the transformation of previously difficult-to-recycle materials into commercially valuable chemical products. This technology eliminates the need for costly sorting of mixed waste streams and offers an efficient, cost-effective alternative to traditional plastic management systems, which often rely on outdated processes that fail to address the majority of global plastic waste.
By providing a scalable solution for chemical recycling, RE-DU aims to reduce reliance on fossil fuels and minimize the environmental impact of plastic pollution in landfills. The company serves as a partner for industries seeking sustainable chemical feedstocks and is contributing to the development of a circular economy. Supported by initiatives like the Innovation Crossroads Award and research collaboration with Oak Ridge National Laboratory, RE-DU is positioned to help transition toward a net-zero carbon society by proving that mixed plastic waste can be successfully converted into high-quality, reusable resources.
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