A review on customized food fabrication process using Food Layered Manufacturing

Exploring the potential of 3D-printed texture-modified diets for the management of dysphagia

Dysphagia is a swallowing disorder characterized by mild to severe pain during food ingestion. Patients with dysphagia require special care and food that meet the patient's requirements of nutrition and ease of swallowing which can be achieved by texture-modified diets. Texture modification is important for improving swallow safety and control and preventing aspiration, pneumonia, and choking. 3D printing is the leading technology in today's era and is widely used for the texture modification of food for patients with swallowing disorders. 3D printing is fast, reliable, and customizable and has the potential to fabricate unappealing and tasteless food into different colours, textures, and shapes. Our discussion brings to review the present and future of 3D printing in preparing texture-modified diets for dysphagia. The challenges associated with dysphagia diets that can be overcome by 3D printing have also been discussed. The review also focuses on the IDDSI framework for determining the suitability of food for dysphagic patients. The key factors such as the material used, and viscosity have been discussed along with various pre-existing literature. The key challenges with the food industry and future research areas have also been discussed.

Collaborative Heterogeneous Mini-Robotic 3D Printer for Manufacturing Complex Food Structures with Multiple Inks and Curved Deposition Surfaces

The necessity of developing more realistic artificial food requires the aggregation of different biomaterials in an ordered and controlled manner. One of the most advanced methods for this is food printers reproducing additive manufacturing processes. This study presents a fully automatized 3D food printer leveraging collaborative Cartesian and multi-ink robotic systems to create complex food structures, with materials with different rheological settings using a screw conveyor configuration with controlled motion velocity. The developed food printer followed a formal mechatronic design strategy with fully functional instrumentation and automation systems. An adaptive controller was developed and implemented to regulate the coordinated operation of booth robotic devices, which are enforced by the G-code corresponding to the target food structure, leading to the necessary resolution. This device was tested with different commercial food inks to develop structures with complex shapes. The workability of the developed printer was confirmed by examining the food samples obtained using multiple materials, including creating different three-dimensional structures of a single complex food ink and creating simple structures made of different food inks with diverse structures that could yield a synthetic tissue that reproduces synthetic meat.

3D printing: trends and approaches toward achieving long-term sustainability in the food industry

Global food security has recently been under serious threat from the rapid rise in the world's population, the problems brought on by climate change, and the appearance of new pandemics. As a result, the need for novel and innovative solutions to solve the existing problems and improve food sustainability has become crucial. 3D printing is expected to play a significant role in providing tangible contributions to the food industry in achieving sustainable development goals. The 3D food printing holds the potential to produce highly customized food in terms of shape, texture, flavor, structure and nutritional value and enable us to create new unique formulations and edible alternatives. The problem of whether the cost of the printed meal and 3D printing itself can be sustainably produced is becoming more and more important due to global concerns. This review intends to provide a comprehensive overview of 3D printed foods with an overview of the current printing methodologies, illustrating the technology's influencing factors, and its applications in personalized nutrition, packaging, value addition, and valorization aspects to fully integrate sustainability concerns thus exploring the potential of 3D food printing.

Recent advances in 3D food printing: Therapeutic implications, opportunities, potential applications, and challenges in the food industry

3D food printing (3DFP) offers a transformative approach in the food industry, diverging from traditional manufacturing techniques. The integration of food science and nutrition with 3DFP is pioneering personalized, eco-friendly, and nutrient-rich food options, overcoming limitations of traditional manufacturing methods. For the past 10 years, we have been strongly focused on creating innovative, efficient, and functional food products while allowing customization of food based on preferences for nutrition, flavor, texture, mouthfeel, and appearance. Beyond customization, 3DFP demonstrates promise in addressing pressing global challenges including food security, famine, and malnutrition by facilitating the production of fortified, shelf-stable food products suitable for resource- constrained environments. This comprehensive review explores the intersection of 3DFP with food constituents, emphasizing its potential in enhancing customization, sustainability, food safety, and shelf-life extension. Additionally, it discusses the therapeutic potential of 3D printed foods for various diseases, including gastrointestinal disorders, cancer, diabetes, neurodegenerative disorders, and food allergies. Moreover, the review examines potential food applications of 3DFP, such as in space food, food packaging, dairy industry, fruit and vegetable processing, and cereal-based foods. The review also addresses key challenges associated with 3DFP and underscores the importance of four-dimensional food printing (4DFP).

Co-encapsulation of hydrophilic and hydrophobic bioactives stabilized in nanostarch-assisted emulsion for inner core gel of coaxial 3D printing

3D printing technology, especially coaxial 3D mode of multiple-component shaping, has great potential in the manufacture of personalized nutritional foods. However, integrating and stabilizing functional objectives of different natures remains a challenge for 3D customized foods. Here, we used starch nanoparticle (SNP) to assisted soy protein (SPI) emulsion to load hydrophilic and hydrophobic bioactives (anthocyanin, AC, and curcumin, Cur). The addition of SNP significantly improved the storage stability of the emulsion. Xanthan gum (XG) was also added to the SNP/SPI system to enhance its rheology and form an emulsion gel as inner core of coaxial 3D printing. Low field nuclear magnetic resonance and emulsification analyses showed that AC/Cur@SNP/SPI/XG functional inner core had a strong water binding state and good stability. After printing with outer layer, the SNP/SPI coaxial sample had the lowest deviation rate of 0.8 %. Also, SNP/SPI coaxial sample showed higher AC (90.2 %) and Cur (90.8 %) retention compared to pure starch (S), pure SNP, pure SPI, and S/SPI samples as well as SNP/SPI sample printed without outer layer. In summary, this study provides a new perspective for the manufacture of customized products as multifunctional foods, feeds and even potential delivery of drugs.

Recent advances in gellan gum production and modification for enhanced applicability in food printing and bioactive delivery applications

The importance of Gellan gum has been increasing gradually and its unique characteristics are suitable for various advanced food technologies. This review outlines recent developments in gellan gum production, modification, and newer applications focusing on food printing and bioactive delivery applications, in the last three years. The yield and production condition of gellan gum is a major factor that affects the cost and its applications. Moreover, modified Gellan gum has been shown to have superior characteristics and functionality as compared to native one. The viscosifying, thermosensitive, gelling etc. characteristics of gellan gum makes it an crucial ingredient in case of preparation of 3D printing ink. Further, gellan gum is also found to be important wall material in case of bioactive delivery application through encapsulation. Optimized methods of production, sustainable feedstock, and stress conditions are critical for the desired functionality and yield of the Gellan gum.

Lutein encapsulation into dual-layered starch/zein gels using 3D food printing: Improved storage stability and in vitro bioaccessibility

The ability of 3D printing to encapsulate, protect, and enhance lutein bioaccessibility was investigated under various printing conditions. A spiral-cube-shaped geometry was used to investigate the effects of printing parameters, namely zein concentration (Z; 20, 40, and 60 %) and printing speed (PS; 4, 8, 14, and 20 mm/s). Coaxial extrusion 3D printing was used with lutein-loaded zein as the internal flow material, and corn starch paste as the external flow material. The viscosities of the inks, microstructural properties, storage stability, and bioaccessibility of encapsulated lutein were determined. The sample printed with a zein concentration of 40 % at a printing speed of 14 mm/s (Z-40/PS-14) exhibited the best shape integrity. When lutein was entrapped in starch/zein gels (Z-40/PS-14), only 39 % of lutein degraded after 21 days at 25 °C, whereas 78 % degraded at the same time when crude lutein was studied. Similar improvements were also observed after storing at 50 °C for 21 days. Furthermore, after simulated digestion, the bioaccessibility of encapsulated lutein (9.8 %) was substantially higher than that of crude lutein (1.5 %). As a result, the developed delivery system using 3D printing could be an effective strategy for enhancing the chemical stability and bioaccessibility of bioactive compounds (BCs).

Designing future foods: Harnessing 3D food printing technology to encapsulate bioactive compounds

Bioactive compounds (BCs) provide numerous health benefits by interacting with one or more components of living tissues and systems. However, despite their potential health benefits, most of the BCs have low bioaccessibility and bioavailability, hindering their potential health-promoting activities. The conventional encapsulation techniques are time-consuming and have major limitations in their food applications, including the use of non-food grade chemicals, undesired sensory attributes, and storage stability issues. A cutting-edge, new technique based on 3D printing can assist in resolving the problems associated with conventional encapsulation technologies. 3D food printing can help protect BCs by incorporating them precisely into three-dimensional matrices, which can provide (i) protection during storage, (ii) enhanced bioavailability, and (iii) effective delivery and controlled release of BCs. Recently, various 3D printing techniques and inks have been investigated in order to create delivery systems with different compositions and geometries, as well as diverse release patterns. This review emphasizes the advances in 3D printing-based encapsulation approaches, leading to enhanced delivery systems and customized food formulations.

Fermentation for Designing Innovative Plant-Based Meat and Dairy Alternatives

Fermentation was traditionally used all over the world, having the preservation of plant and animal foods as a primary role. Owing to the rise of dairy and meat alternatives, fermentation is booming as an effective technology to improve the sensory, nutritional, and functional profiles of the new generation of plant-based products. This article intends to review the market landscape of fermented plant-based products with a focus on dairy and meat alternatives. Fermentation contributes to improving the organoleptic properties and nutritional profile of dairy and meat alternatives. Precision fermentation provides more opportunities for plant-based meat and dairy manufacturers to deliver a meat/dairy-like experience. Seizing the opportunities that the progress of digitalization is offering would boost the production of high-value ingredients such as enzymes, fats, proteins, and vitamins. Innovative technologies such as 3D printing could be an effective post-processing solution following fermentation in order to mimic the structure and texture of conventional products.