Nutrient enrichment type instant potato crisp chips and production method thereof

Abstract

The present invention discloses a nutrition fortified instant potato crisp chip and a production method thereof, and relates to the technical field of food processing, the nutrition fortified instant potato crisp chip is prepared from the following raw materials by mass: 60%-85% of a potato matrix, 4%-6% of a nutrition fortified component, 0.5%-2% of a seasoning component, and 15%-20% of a grease component, the nutrient enrichment component is at least one of fish collagen peptide powder, oyster calcium powder, tuna peptide powder, euphausia superba powder, whey protein powder, soybean protein, directed enzyme and natural food-grade plant extract; according to the nutrient enrichment type instant potato crisp chip and the production method thereof, a composite raw material system containing the potato matrix, the nutrient enrichment component in a specific proportion, the seasoning component and the grease component is constructed, and the nutrient enrichment component accounts for 4%-6% of the total mass of the raw materials, so that the product keeps the basic flavor and texture of potatoes, and the nutrient enrichment type instant potato crisp chip has the advantages that the nutrient enrichment type instant potato crisp chip has a good taste; and directional and quantitative strengthening of various nutrients such as protein and calcium is realized, so that healthy snacks with high protein and high calcium are prepared.

Description

Technical Field

[0001] This invention relates to the field of food processing technology, specifically to a nutritionally fortified ready-to-eat potato chips and its production method. Background Technology

[0002] With the rise of healthy eating trends, consumers' demands for snack products are no longer limited to taste and flavor, but also place greater emphasis on their nutritional value and health attributes. In the potato product sector, while traditional potato chips are popular for their crispy texture, their high fat, high calorie content, and limited nutritional profile are becoming increasingly prominent, making it difficult to meet modern consumers' urgent need for healthy snacks. Although food processing technology has continuously advanced in recent years, and attempts to improve the nutritional value of potato chips by improving processes or adding functional ingredients are common, significant technical challenges remain in achieving targeted and quantitative fortification of specific nutrients such as protein and calcium.

[0003] However, the existing technology faces the challenge of precisely targeting and quantitatively fortifying multiple key nutrients such as protein and calcium while maintaining the original good flavor and texture of potato chips. Currently, most nutrient fortification methods tend to focus on adding a single nutrient, while neglecting the interaction between nutrients and their impact on the overall quality of the product. Directly adding protein powder or calcium supplements can increase the nutrient content, but it often leads to a harder texture and altered flavor, affecting consumer acceptance. Therefore, improvements are needed. Summary of the Invention

[0004] The purpose of this invention is to provide a nutritionally fortified ready-to-eat potato chips and its production method, in order to solve the problem in the prior art that it is difficult to accurately achieve targeted and quantitative fortification of multiple key nutrients such as protein and calcium while maintaining the original good flavor and texture characteristics of potato chips.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a nutritionally fortified ready-to-eat potato chip, prepared from the following raw materials in the indicated weight percentages:

[0006] Potato substrate: 60%–85%, fortified components: 4%–6%, flavoring components: 0.5%–2%, oil components: 15%–20%;

[0007] The nutritional fortification components are at least one of the following: fish collagen peptide powder, oyster calcium powder, tuna peptide powder, Antarctic krill powder, whey protein powder, soy protein, targeted enzymes, and natural food-grade plant extracts.

[0008] Furthermore, the potato matrix is ​​at least one of potato flour, potato flake flour, purple sweet potato flour, and sweet potato flour.

[0009] Furthermore, the raw material also includes starch accounting for 5% to 30% of the total mass of the raw material.

[0010] Furthermore, the seasoning components include edible salt and flavoring powder, wherein the edible salt accounts for 0.5% to 0.7% of the total mass of the raw materials, and the flavoring powder is at least one of onion powder, garlic powder, and white pepper powder, and its total amount accounts for 0.1% to 0.5% of the total mass of the raw materials.

[0011] Furthermore, the oil component is at least one of corn oil, olive oil, sunflower seed oil, and palm oil.

[0012] A method for producing nutritionally fortified ready-to-eat potato chips includes the following steps:

[0013] S1. Preparation of mixed powder: Mix the potato matrix, nutrient fortification components and flavoring components evenly to obtain a dry powder mixture;

[0014] S2. Material maturation and shaping: Water and oil components are added to the dry powder mixture, and the mixture is stirred and kneaded into a plastic dough. The dough is then rolled and die-cut to obtain a pre-shaped embryo.

[0015] S3. Curing treatment: The embryo is baked or deep-fried at low temperature, and then cooled to obtain the nutritionally fortified ready-to-eat potato chips.

[0016] Further, in step S2, the water is warm water at 30-40℃, the mass ratio of water to dry powder mixture is (0.25-0.35):1, the oil component is added at least twice, 80% to 90% is added first during kneading, and the remaining part is sprayed onto the surface of the dough before curing.

[0017] Furthermore, in step S2, a twin-screw dough mixer is used for mixing and kneading for 8 to 10 minutes, and the rolling thickness is 1 to 1.5 mm; the surface of the dough is perforated, with 3 to 4 holes per piece.

[0018] Furthermore, in step S3, the baking is carried out using a tunnel-type hot air baking machine or a mesh belt baking machine, with a baking temperature of 170-190℃ and a total duration of 8-10 minutes, during which the food is turned over once.

[0019] Furthermore, in step S3, the low-temperature frying is carried out using a continuous low-temperature fryer with a frying temperature of 120-140℃ and a total duration of 3-5 minutes. After frying, the oil is removed by an oil remover at a speed of 800-1000 r / min for 30-60 seconds. The cooling is carried out using a continuous cooling conveyor belt with a cooling temperature of 25-30℃ and a cooling time of 3-5 minutes.

[0020] Compared with existing technologies, the present invention provides a nutritionally fortified ready-to-eat potato chips and its production method. By constructing a composite raw material system containing potato matrix, a specific ratio of nutritional fortification components, flavoring components and oil components, and setting the nutritional fortification components to account for 4% to 6% of the total mass of the raw materials, the product achieves targeted and quantitative fortification of multiple nutrients such as protein and calcium while maintaining the basic flavor and texture of potatoes. This achieves the effect of upgrading traditional empty-calorie snacks into healthy snacks fortified with high protein, high calcium or other functional nutrients.

[0021] By employing a material maturation and shaping process that involves adding warm water and oil components in stages, kneading for specific times and intensities, and combining this with calendering, die-cutting, and perforation of the dough, the problems of starch gelatinization and clumping, poor shaping stability, and easy deformation and cracking of products that are common in traditional potato chip processing are effectively solved. This achieves the effect of improving dough plasticity, ensuring the integrity of the dough shape, and producing a final product with uniform and crisp texture and stable quality.

[0022] By providing two curing processes—baking and low-temperature frying—and specifying the corresponding temperature, time, and associated degreasing and cooling parameters, the product's fat content is effectively controlled while offering diverse tastes and flavors. This avoids the generation of harmful substances that may result from high-temperature processing, thus achieving a balance between the product's health attributes and sensory quality, and perfectly adapting it to the requirements of continuous industrial production. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0024] Figure 1 The preparation process flowchart is provided for an embodiment of the present invention. Detailed Implementation

[0025] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0026] As attached Figure 1 As shown:

[0027] Example 1:

[0028] This invention provides a nutritionally fortified ready-to-eat potato chips and its production method, with the production of 100 grams of finished chips as the benchmark target, and details the raw materials and their mass ratios:

[0029] Potato substrate: 35.0 grams of dried potato flour is used. This substrate forms the main structural framework of the product in this embodiment.

[0030] Nutritional fortification ingredients: Food-grade fish collagen peptide powder, 4.5 grams.

[0031] Flavoring components: consist of two parts:

[0032] Salt: Use 0.6 grams for basic seasoning.

[0033] Flavoring powder: Garlic powder, 0.1 gram, used to provide characteristic flavor.

[0034] Oil composition: Refined corn oil, totaling 17.0 grams. This oil will be added in stages during subsequent processes.

[0035] Process water: Use warm water at 30-40℃, with a dosage of 11.0 grams. Warm water helps the materials to mix and mature evenly, and can prevent excessive gelatinization of starch.

[0036] Preparation method:

[0037] Preparation of mixed powder:

[0038] Add the weighed 35.0g potato flour, 4.5g fish collagen peptide powder, 0.6g salt, and 0.1g garlic powder to a spiral mixer. Turn on the mixer, set the speed to 30 rpm, and mix for 5 minutes until all powdery materials are evenly mixed to obtain a dry powder mixture with uniform color and texture.

[0039] Material maturation and shaping:

[0040] Add water and knead: Slowly add 11.0 grams of warm water at 35°C to the above dry powder mixture. At the same time, start the twin-screw dough mixer to initially mix the mixture with the warm water.

[0041] Add the oil in two batches during the kneading process: Add the corn oil in two batches, totaling 17.0 grams.

[0042] First addition of oil: About 2 minutes after kneading begins, add about 85% of the total corn oil (about 14.5 grams) and continue kneading.

[0043] Full kneading: The total kneading time of the twin-screw dough mixer is controlled at 10 minutes. Through this process, the ingredients, water, and oil are fully and evenly kneaded to form a smooth, soft, and non-sticky dough, completing the maturation process of the ingredients.

[0044] Rolling and Die-cutting: The matured dough is transferred to a rolling mill, and by adjusting the gap between the rollers, the dough is rolled into a continuous sheet with a uniform thickness of 1.2 mm. Then, a die-cutting machine is used to cut the sheet into preset rectangular pieces of 3 cm × 5 cm.

[0045] Surface perforation: Perforate the surface of each cut rectangular embryo using a special needle array, ensuring that three holes are evenly pierced on each embryo. This step helps release internal steam during subsequent baking, preventing the embryo from bulging or deforming.

[0046] Curing process:

[0047] The shaped and perforated blanks are evenly spread on the mesh belt of the tunnel-type hot air baking machine.

[0048] Baking: Set the baking zone temperature to 180℃. The total baking time for the dough in the oven is 10 minutes. During this process, at the 5-minute mark, the dough is automatically flipped over to ensure even heating and consistent browning on both sides.

[0049] Cooling: After baking, the crisps immediately enter a continuous cooling conveyor belt. The temperature of the cooling belt is controlled at 25℃. After running on the cooling belt for 3 minutes, the core temperature of the crisps drops to room temperature, thus obtaining basic nutritionally fortified ready-to-eat potato crisps.

[0050] Effect:

[0051] Sensory quality: The finished product is a uniform golden yellow color with a smooth surface, free from burning or a white center. It has an excellent crispness, melts in your mouth, and has a rich roasted potato aroma and a harmonious garlic flavor.

[0052] Texture characteristics: It has a loose texture, no hard core or lumps, moderate breaking strength, and is easy to package and transport.

[0053] Nutritional indicators: Tests show that the protein content in the finished product has increased from about 8% in pure potato flour to no less than 13% (on a dry basis), achieving effective nutritional fortification.

[0054] Process stability: Throughout the entire production process, the dough has good plasticity, does not stick to the equipment, and the embryo is formed completely without shrinkage or cracking.

[0055] Example 2:

[0056] This embodiment is basically the same as the previous embodiment, except that by combining fish collagen peptides and oyster calcium powder, and introducing corn starch as a molding improver, the positive role of starch components in optimizing product texture and taste is verified, and the flexibility and effectiveness of the formula in achieving compound nutritional fortification are demonstrated.

[0057] Raw materials and proportions:

[0058] This example uses the preparation of 100 grams of finished chips as the baseline target, and lists the raw materials and their mass ratios:

[0059] Potato substrate: 32.0 grams of dried potato flakes are used. This substrate has good water absorption, which helps to create a delicate texture.

[0060] Starch: Food-grade corn starch is used, with a dosage of 8.0 grams. This component is a key additive in this embodiment, designed to enhance the formability of the dough and the crispness of the finished product.

[0061] Nutritional fortification components: include two functional ingredients:

[0062] Fish collagen peptide powder: 2.5 grams is used to provide protein nutrition.

[0063] Oyster Calcium Powder (Food Grade): 2.5 grams per serving, provides easily absorbed calcium.

[0064] Flavoring components: consist of two parts:

[0065] Salt: Use 0.5 grams for basic seasoning.

[0066] Flavoring powder: 0.1g of white pepper powder is used to provide a mild spicy flavor.

[0067] Oil composition: Extra virgin olive oil, totaling 16.0 grams. This oil will be added in stages during subsequent processing, giving the product a unique olive oil aroma.

[0068] Process water: Use warm water at 30-40℃, with a dosage of 13.0 grams. Because the formula contains corn starch with strong water absorption, the amount of water added has been appropriately increased.

[0069] Preparation method:

[0070] The preparation process in this embodiment is strictly performed according to the following steps:

[0071] Preparation of mixed powder:

[0072] Add the weighed 32.0g potato starch, 8.0g corn starch, 2.5g fish collagen peptide powder, 2.5g oyster calcium powder, 0.5g salt, and 0.1g white pepper powder to a spiral mixer. Turn on the mixer, set the speed to 40 rpm, and mix continuously for 6 minutes to ensure that all powdered materials, especially the calcium powders of different colors, are completely and evenly dispersed, resulting in a highly uniform dry powder mixture.

[0073] Material maturation and shaping:

[0074] Add water and knead: Slowly add 13.0 grams of warm water at 35°C to the above dry powder mixture. At the same time, start the twin-screw dough mixer to initially mix the mixture with the warm water.

[0075] Add the oil in two batches during the kneading process: Add the total weight of 16.0 grams of olive oil in two separate batches.

[0076] First addition of oil: About 2 minutes after kneading begins, add about 90% of the total amount of olive oil (about 14.4 grams) and continue kneading.

[0077] Kneading throughout: The total kneading time in the twin-screw dough mixer is controlled at 9 minutes. It can be observed that due to the addition of starch, the dough formation speed is accelerated, and the final dough has a more delicate and smooth texture, moderate elasticity, and excellent plasticity.

[0078] Rolling and Die-cutting: The matured dough is transferred to a rolling mill, and by adjusting the gap between the rollers, the dough is rolled into a continuous sheet with a uniform thickness of 1.1 mm. Then, a die-cutting machine is used to cut the sheet into preset rectangular pieces of 3 cm × 5 cm.

[0079] Surface perforation: Perforate the surface of each cut rectangular dough piece using a special needle array, ensuring that four holes are evenly pierced on each piece. This step is especially important for dough pieces containing starch, as it effectively prevents deformation caused by excessive internal steam pressure during baking.

[0080] Curing process:

[0081] The shaped and perforated blanks are evenly spread on the mesh belt of the tunnel-type hot air baking machine.

[0082] Baking: Set the baking zone temperature to 180℃. The total baking time for the dough in the oven is 10 minutes. During this process, at the 5-minute mark, the dough is automatically flipped over to ensure even heating and consistent browning on both sides.

[0083] Cooling: After baking, the crisps immediately enter a continuous cooling conveyor belt. The temperature of the cooling belt is controlled at 25℃. After running on the cooling belt for 3 minutes, the core temperature of the crisps drops to room temperature, thus obtaining high-calcium protein complex ready-to-eat potato crisps.

[0084] Effect:

[0085] Sensory quality: The finished product is light golden yellow in color with a uniform luster. The texture is more crumbly than that of Example 1, with a distinct melt-in-your-mouth quality, and a harmonious flavor that combines the aroma of potato, milk (derived from calcium powder), a hint of olive oil, and pepper.

[0086] Texture characteristics: The addition of corn starch significantly improves the extensibility and shaping stability of the dough sheets, resulting in almost no breakage during calendering and die-cutting. The finished chips have a denser and more uniform structure with moderate hardness.

[0087] Nutritional indicators: Tests show that the finished product contains no less than 10% protein (on a dry basis) and no less than 80 mg / 100g of calcium. This successfully achieves dual fortification of calcium and protein.

[0088] Example 3:

[0089] This embodiment is basically the same as the previous embodiment, except that a low-temperature frying solidification path is adopted to verify the feasibility of the process in controlling the oil content while achieving a crispy texture; and by compounding fish collagen peptides and tuna powder, the product is given a prominent marine flavor while achieving protein fortification.

[0090] Raw materials and proportions

[0091] This example uses the preparation of 100 grams of finished chips as the baseline target, and lists the raw materials and their mass ratios:

[0092] Potato matrix: A blend of 30.0g purple sweet potato powder and 5.0g potato flour. The purple sweet potato powder provides a natural purple color and a unique sweet flavor, while the potato flour balances the fibrous texture of the purple sweet potato powder, ensuring good formability.

[0093] Fortified components include two animal protein sources:

[0094] Fish collagen peptide powder: 5.0 grams, used as a core nutritional fortifier.

[0095] Tuna powder (food grade): Used at a dosage of 0.1 grams, it acts as a synergistic enhancer of flavor and nutrition, providing the core ocean flavor.

[0096] Flavoring ingredients:

[0097] Salt: 0.6 grams, used to enhance the overall flavor and highlight the salty and fresh taste of the ocean.

[0098] Oil composition: Refined corn oil, totaling 17.0 grams. This portion of oil will primarily be used in the subsequent low-temperature frying process, with a small amount added during the dough kneading stage.

[0099] Process water: Use warm water at 30-40℃, with a dosage of 12.0 grams.

[0100] Preparation method:

[0101] The preparation process in this embodiment is strictly performed according to the following steps, but the curing process differs from that in the previous embodiment:

[0102] Preparation of mixed powder:

[0103] Add the weighed 30.0g purple sweet potato powder, 5.0g potato flour, 5.0g fish collagen peptide powder, 0.1g tuna powder, and 0.6g salt to a spiral mixer. Turn on the mixer and set the speed to 45 rpm, mixing continuously for 7 minutes. Since the amount of tuna powder is small but its flavor is rich, it is necessary to ensure that it is completely and evenly dispersed with the other powders, especially the darker purple sweet potato powder, to obtain a well-mixed purple dry powder mixture.

[0104] Material maturation and shaping:

[0105] Add water and knead: Slowly add 12.0 grams of warm water at 35°C to the above dry powder mixture. At the same time, start the twin-screw dough mixer to stir the mixture with the warm water.

[0106] Add oil in stages: During the kneading process, add 17.0 grams of corn oil in two stages. Given that this embodiment primarily uses frying for solidification, the oil-adding strategy during the kneading stage focuses on improving dough elasticity rather than flavor.

[0107] First addition of oil: About 2 minutes after kneading begins, add about 15% of the total corn oil (about 2.5 grams). Its main purpose is to lubricate the dough and improve its extensibility.

[0108] Kneading throughout: The total kneading time in the twin-screw dough mixer is controlled at 10 minutes. The final dough is a uniform purplish-gray color, smooth and soft, and has a certain fibrous texture due to the addition of purple sweet potato powder, but its overall plasticity is good.

[0109] Rolling and Die-cutting: The matured dough is transferred to a rolling mill, where the roller gap is adjusted to roll the dough into a continuous sheet with a uniform thickness of 1.2 mm. Then, a die-cutting machine is used to cut the sheet into pre-set circular pieces with a diameter of 4 cm, to distinguish it from rectangles and showcase the diversity of product shapes.

[0110] Surface perforation: Perforation is performed on the surface of each cut circular embryo using a special needle array to ensure that four holes are evenly pierced on each embryo. This step is crucial for the frying process, as it promotes the release of internal steam, prevents the embryo from expanding violently or forming large air bubbles in the high-temperature oil, and also facilitates oil removal after frying.

[0111] Curing process:

[0112] The shaped and perforated embryos are evenly placed onto the conveyor belt of a continuous low-temperature fryer.

[0113] Low-temperature frying: The temperature of the corn oil in the fryer is set to 130℃. The dough is immersed in the oil along with the conveyor belt, and the total frying time is 3.5 minutes. This low-temperature, long-time frying process effectively dehydrates the dough and moderately cooks the starch and protein, forming a crispy structure, while avoiding the formation of harmful substances or excessively dark color due to excessively high temperatures.

[0114] Oil removal: The fried crisps are immediately fed into a centrifugal degreasing machine. The degreasing machine is set to 900 rpm and the degreasing time is 40 seconds. This step effectively removes excess oil adsorbed on the surface of the crisps, controls the overall oil content of the product, and makes it crispy but not greasy.

[0115] Cooling: The deoiled chips are conveyed to a continuous cooling conveyor belt. The temperature of the cooling belt is controlled at 25°C. After running on the cooling belt for 3 minutes, the core temperature of the chips drops to room temperature, resulting in the final product of this embodiment—ocean-flavored, nutritionally fortified ready-to-eat potato chips.

[0116] Effect:

[0117] Sensory Quality: The finished product has an appealing deep purplish-red color with a uniform hue. It has an extremely crispy texture with distinct layers of flavor. The unique flavor perfectly combines the natural sweetness of purple sweet potato with the rich umami of tuna, resulting in a savory and delicious taste with a prominent marine flavor and no fishy odor.

[0118] Texture characteristics: The product has a loose and porous structure, moderate hardness, and is easily broken when chewed. The degreasing process is effective, the product surface is dry, without visible oiliness, and there is no greasy feeling after chewing.

[0119] Nutritional indicators: Tests show that the protein content in the finished product is no less than 14% (on a dry basis), achieving high-protein nutritional fortification. At the same time, the total fat content is controlled below 20%, which is superior to traditional high-temperature fried potato chips.

[0120] Example 4:

[0121] This embodiment is basically the same as the previous embodiment, except that it is based on a total batch size of 100 kg (i.e., "100 portions") of finished crispy raw materials, and the production scale is expanded accordingly. The raw materials and their mass ratios are listed below:

[0122] Potato substrate: 35.0 kg of dried potato flour is used.

[0123] Fortified components: Utilizing a compound formulation to enrich nutritional content.

[0124] Fish collagen peptide powder: dosage is 4.5 kg.

[0125] Oyster calcium powder (food grade): Dosage is 0.5 kg.

[0126] Flavoring ingredients:

[0127] Table salt: 0.6 kg.

[0128] Flavoring powder: Onion powder is used, with a dosage of 0.2 kg.

[0129] Oil composition: Refined corn oil, totaling 17.0 kg. This portion of the oil will be added in strict accordance with the process requirements of being added in stages.

[0130] Process water: Warm water with precise temperature control via a heat exchanger is used, with a usage of 35.0 kg. The water temperature is stably controlled at 35℃±2℃.

[0131] Preparation method:

[0132] The preparation process in this embodiment is carried out on a standard industrial food production line. The specific steps and equipment parameters are as follows:

[0133] Preparation of mixed powder:

[0134] Equipment: Stainless steel vertical spiral mixer (working volume 200L).

[0135] Procedure: Add 35.0 kg of potato flour, 4.5 kg of fish collagen peptide powder, 0.5 kg of oyster calcium powder, 0.6 kg of edible salt, and 0.2 kg of onion powder into the mixer in the order of addition.

[0136] Parameters: Close the feed inlet, start the mixer, set the spindle speed to 35 rpm, and the mixing time to 7 minutes. After mixing, discharge the uniformly mixed dry powder mixture into the temporary storage hopper below through the pneumatic discharge valve, ready for the next process.

[0137] Material maturation and shaping:

[0138] Equipment: A twin-screw continuous dough kneading machine is used.

[0139] Adding water and oil: Start the dough mixer and feed the dry powder mixture in the temporary hopper into the dough mixer inlet at a uniform speed through the screw feeder. At the same time, use a precision liquid pump to spray 35.0 kg of 35°C warm water and the first stage corn oil (accounting for 85% of the total, i.e., 14.45 kg) into the powder mixture simultaneously and evenly.

[0140] Kneading parameters: The twin-screw dough mixer is set to a speed that allows the material to remain in the chamber for 9 minutes (i.e., kneading time). Through the sight glass, it can be seen that the material quickly forms uniform, moist particles, and eventually coalesces into a continuous, smooth, and well-extensible dough strip.

[0141] Calendering and Die Cutting:

[0142] Equipment: Combined calendering and die-cutting unit (including a three-roll calender and a roller die-cutting machine).

[0143] Operation: The dough extruded from the twin-screw dough mixer is directly fed into the feed inlet of the roll mill. By adjusting the gap between the three rollers, the dough is precisely rolled into a continuous, uniform sheet with a thickness of 1.3 mm.

[0144] Forming: The calendered dough sheet then enters a roller die-cutting machine. A 3cm x 5cm rectangular mold is engraved on the die-cutting roller, continuously cutting the dough sheet into pre-set shapes. Scrap materials are automatically collected by a recycling device and sent back to the front of the calender for reuse.

[0145] Surface perforation: Before the die-cut blanks enter the baking mesh belt, each blank is perforated by a roller device that runs synchronously above it, ensuring that each blank has 3 holes precisely perforated.

[0146] Curing process:

[0147] Equipment: Fully automatic tunnel-type hot air baking machine (mesh belt width 1.2 meters, length 25 meters).

[0148] Baking parameters: The shaped and perforated dough pieces are evenly spread on the Teflon mesh belt of the baking machine at a density of 4.5 kg / m². The baking machine is set to three temperature zones: Zone 1 170℃ (preheating and shaping), Zone 2 185℃ (main dehydration), and Zone 3 175℃ (browning and crisping). The total baking time for the dough pieces is 9.5 minutes. At the 5-minute mark, the mesh belt system automatically flips the dough pieces once to ensure even heating on both sides.

[0149] Secondary grease coating: After the dough exits the oven and before entering the cooling zone, the remaining 15% corn oil (2.55 kg) is evenly sprayed onto the surface of the chips using a fine atomizing spraying device. This step aims to further improve the taste and color of the finished product.

[0150] cool down:

[0151] Equipment: Multi-layer belt cooling conveyor.

[0152] Parameters: The coated flakes are placed in the cooling zone and cooled for 5 minutes at room temperature (25°C) to completely reduce the core temperature of the product to room temperature.

[0153] Effect:

[0154] Production efficiency: The entire production line operates smoothly and stably with a high degree of automation. It can process approximately 110 kg of raw materials per hour, and the finished product yield is as high as 98.5% (based on the amount of powdered material fed in).

[0155] Product consistency: Randomly sampled cooled finished products were tested, and their color, shape, and thickness were uniform. There was no difference in crispness within batches, and the flavor was stable.

[0156] Quality indicators: According to laboratory sampling tests, the finished product has a moisture content of ≤3%, a protein content of ≥12%, and a calcium content of ≥50mg / 100g.

[0157] Stability: After 8 hours of continuous production, the equipment operating parameters remain stable, and the product quality fluctuation range is less than 3%.

[0158] Example 5:

[0159] This embodiment is essentially the same as the previous embodiment, except that soy protein is introduced as the core nutritional component, and a targeted enzyme (specifically a neutral protease) is used to perform controlled enzymatic hydrolysis of the protein. This embodiment will verify that this combination can not only achieve nutritional fortification, but also generate flavor precursors through enzymatic hydrolysis, significantly enhancing the natural umami and rich taste of the product, while improving the processing characteristics of the dough, demonstrating the application potential of biotechnology in functional foods.

[0160] Raw materials and proportions:

[0161] This example uses the preparation of 100 grams of finished chips as the baseline target, and lists the raw materials and their mass ratios:

[0162] Potato substrate: 33.0 grams of dried potato flour.

[0163] Nutritional fortification components:

[0164] Soy protein (purity ≥80%): 4.0 g. This component serves as the primary protein source in this embodiment and is also the substrate for the enzymatic hydrolysis reaction.

[0165] Targeted enzyme: Food-grade neutral protease (enzyme activity 50,000 U / g) is used, with a dosage of 0.05 g.

[0166] Flavoring ingredients:

[0167] Salt: 0.6 grams.

[0168] Oil composition: Refined corn oil is used, with a total amount of 17.0 grams.

[0169] Process water: Use warm water at 30-40℃, with a dosage of 11.0 grams. This temperature range is also conducive to the neutral protease exerting its optimal activity.

[0170] Preparation method:

[0171] The preparation process in this embodiment introduces an enzymatic hydrolysis step into the basic process, as detailed below:

[0172] Preparation of mixed powder:

[0173] Add the weighed 33.0g potato flour, 4.0g soy protein, and 0.6g salt to a screw mixer. Turn on the mixer, set the speed to 40 rpm, and mix for 6 minutes to ensure the soy protein is thoroughly and evenly mixed with the other powders.

[0174] Material maturation, enzymatic hydrolysis and molding:

[0175] Adding water and enzyme: Slowly add 11.0 g of warm water at 37°C to the above dry powder mixture. At the same time, dissolve 0.05 g of neutral protease powder evenly in a small amount of warm water and add it along with the water.

[0176] Enzymatic kneading: Start the twin-screw dough mixer. This stage of kneading is not only a physical mixing process, but also a gentle enzymatic process.

[0177] First oil addition: About 2 minutes after kneading begins, add approximately 85% of the total corn oil volume (about 14.5 grams). The addition of oil helps with lubrication but does not significantly affect the action of the protease.

[0178] Enzymatic hydrolysis parameter control: The total kneading time is extended to 12 minutes. During this period, the temperature inside the dough mixer cavity is maintained at 35-40℃, providing a suitable environment for the neutral protease to function. The protease specifically cleaves the peptide bonds of soy protein, generating small peptides and amino acids.

[0179] Termination of Enzyme Activity and Shaping: After kneading, the dough has completed the enzymatic hydrolysis process. The dough is then transferred to a rolling mill. The rolling process itself, along with the subsequent high-temperature baking, will completely inactivate the protease, thus terminating the enzymatic hydrolysis reaction. The dough is rolled into a continuous sheet with a thickness of 1.0 mm, and then die-cut into rectangular embryos of 3 cm × 5 cm.

[0180] Surface perforation: The embryo is perforated, with four holes evenly perforated in each piece.

[0181] Curing process:

[0182] The shaped preforms are evenly spread on the mesh belt of the tunnel-type hot air baking machine.

[0183] Baking: Set the baking temperature to 175℃. The total baking time for the dough is 11 minutes, with the dough being flipped at the 5-minute mark.

[0184] Cooling: The baked chips enter a continuous cooling conveyor belt and are cooled at 25°C for 4 minutes to obtain the final product.

[0185] Effect:

[0186] Sensory quality: The finished product has a uniform light yellow color. Its most prominent feature is the enhanced flavor. Compared with products that directly add soy protein, the product in this example presents a richer and softer natural umami flavor and a slight mellowness, masking the beany taste, and has a crisp and delicate texture.

[0187] Texture characteristics: Due to enzymatic hydrolysis, some proteins are degraded, improving the dough's extensibility and making it less prone to shrinkage during rolling. The finished crisps have a more uniform structure, increased crispness, and a certain layered texture.

[0188] Nutritional and biochemical indicators: The protein content in the finished product was found to be no less than 13% (on a dry basis). Amino acid analysis showed that the total free amino acid content in the product was approximately 30% higher than that of the untreated control group, directly demonstrating the occurrence of enzymatic hydrolysis and its contribution to flavor enhancement.

[0189] Example 6:

[0190] This embodiment is basically the same as the previous embodiment, except that natural food-grade plant extracts (specifically, Sichuan pepper extract and chili extract) are introduced to achieve basic nutritional fortification while giving the product a spicy flavor derived from natural plants and potential health functional attributes.

[0191] Raw materials and proportions:

[0192] This example uses the preparation of 100 grams of finished crisps as the baseline target, and lists in detail the raw materials and their mass ratios:

[0193] Potato substrate: Made from sweet potato flour, 35.0 grams. This substrate has a natural sweetness and color, which creates a unique contrast with the spicy flavor.

[0194] Nutritional fortification component: Fish collagen peptide powder, 4.5 grams.

[0195] Natural food-grade plant extracts:

[0196] Sichuan pepper extract: 0.05 grams.

[0197] Capsicum extract: 0.05 g.

[0198] Flavoring ingredients:

[0199] Salt: 0.6 grams.

[0200] Oil composition: Sunflower seed oil, totaling 17.0 grams. Sunflower seed oil has a mild aroma and does not easily mask the characteristic flavor of the plant extracts.

[0201] Process water: Use warm water at 30-40℃, with a dosage of 11.0 grams.

[0202] Preparation method:

[0203] In this embodiment, special attention was paid to the method of adding plant extracts to ensure their uniform dispersion:

[0204] Preparation of mixed powder:

[0205] Pretreatment: To avoid uneven mixing due to small amounts of plant extract, it is first manually mixed with 5.0 grams of fish collagen peptide powder in a small container to prepare a premix.

[0206] Main mixing: Add the above premix, the remaining 35.0g of sweet potato flour and 0.6g of salt into the spiral mixer.

[0207] Mixing parameters: Turn on the mixer, set the speed to 50 rpm, and mix continuously for 8 minutes. This slightly higher speed and longer mixing time are designed to ensure that trace amounts of plant extracts are completely and evenly dispersed throughout the powder system, resulting in a uniformly colored dry powder mixture.

[0208] Material maturation and shaping:

[0209] Add water and knead: Slowly add 11.0 grams of warm water at 35°C to the dry powder mixture. At the same time, start the twin-screw dough mixer.

[0210] Add the oil in stages:

[0211] First addition of oil: About 2 minutes after kneading begins, add about 85% of the total sunflower seed oil (about 14.5 grams) and continue kneading.

[0212] Kneading throughout: The total kneading time in the twin-screw dough mixer is controlled at 10 minutes. The final dough is smooth and has good plasticity, emitting a faint spicy aroma.

[0213] Rolling and die-cutting: The matured dough is transferred to a rolling mill and rolled into a continuous sheet with a thickness of 1.2 mm. It is then die-cut into round blanks with a diameter of 4 cm.

[0214] Surface perforation: The embryo is perforated, with four holes evenly perforated in each piece.

[0215] Curing process:

[0216] The shaped preforms are evenly spread on the mesh belt of the tunnel-type hot air baking machine.

[0217] Baking: Set the baking zone temperature to 170℃. The total baking time for the dough is 10 minutes, with the dough being flipped over at the 5-minute mark.

[0218] Cooling: The baked chips enter a continuous cooling conveyor belt and are cooled at 25°C for 4 minutes to obtain the final product.

[0219] Effect:

[0220] Sensory quality: The finished product has a uniform color. It has a unique and harmonious flavor of numbing spiciness and aroma, which, combined with the slight sweetness of sweet potato, creates a rich and layered taste, and the texture is crispy.

[0221] Texture characteristics: The product has a uniform structure and good crispness.

[0222] Nutritional and functional indicators: The protein content of the finished product is no less than 13% (on a dry basis) according to testing. In addition, the product contains extracts of Sichuan pepper and chili pepper, giving it unique flavor properties and potential bioactivity.

[0223] Comparative example:

[0224] Traditional potato chip production process, raw materials and proportions:

[0225] Ingredients: Fresh potatoes (peeled and sliced), 100% of the ingredients.

[0226] Seasoning component: edible salt, usually sprinkled on powder after frying for seasoning, the amount used is about 1% to 2% of the finished product weight.

[0227] Oils and fats: Frying oils (such as palm oil, soybean oil, etc.) are used for deep frying at high temperatures, and a large amount of oil will be absorbed into the product.

[0228] Preparation method:

[0229] Raw material pretreatment: Wash and peel fresh potatoes.

[0230] Slicing: Use a slicer or by hand to slice potatoes into thin slices of varying thickness, typically between 1.0 and 2.5 mm.

[0231] Rinsing: Rinse the sliced ​​potatoes with clean water to remove free starch from the surface. This step can lead to the loss of water-soluble vitamins and other nutrients.

[0232] Deep frying: Put the rinsed wet potato chips directly into a hot oil pan (usually 160-180℃) for frying for about 2 to 4 minutes, until the potato chips become crispy and golden in color.

[0233] Oil removal and seasoning: After frying, drain the potato chips or remove the oil by simple centrifugation, and then sprinkle with salt or other seasoning powder while they are still hot.

[0234] Product Features:

[0235] Sensory quality: Golden in color but may be uneven, crispy in texture, with a noticeable oily feel, and the flavor mainly depends on the seasonings added later.

[0236] Nutritional indicators: The product's nutrition is almost entirely derived from the potatoes themselves, with significant nutrient loss during rinsing and high-temperature frying. Protein content is low (approximately ≤5%), and there is no targeted nutritional fortification. Total fat content is typically as high as 30%–40%.

[0237] Texture and stability: The texture is relatively hard and brittle. Due to the lack of homogenization and molding processes, the product shape, thickness, and size are inconsistent. It has a short shelf life and is prone to developing a rancid odor due to oil oxidation.

[0238] The above comparative examples are compared side-by-side with Example 1 of the present invention (basic nutritional fortified version):

[0239] Comparison Dimensions Comparative example (traditional fried potato chips) Example 1 (Basic Nutritionally Fortified Version) Technological advancements brought about by this invention Raw material system The nutritional composition is fixed, made from a single ingredient (fresh potatoes). Compound formula: potato flour + nutritional fortifier (fish collagen peptide) + flavoring agent. Nutritional designability: Precise and targeted nutritional fortification (such as high protein) can be achieved through formulation. Integrated flavor: Flavor is integrated during the raw material mixing stage, resulting in a more uniform flavor profile. Nutritional components Low protein content (≤5%). Vitamins and other nutrients are easily lost during washing and at high temperatures. High fat content (30%–40%). Protein content is significantly increased (≥13%), achieving nutritional fortification. Nutrients are added during the mixing stage with minimal loss. Fat content is controllable (≤20%). This represents a qualitative leap from "empty-calorie snacks" to "functional nutritional snacks," meeting the modern consumer demand for healthy foods. Processing technology It relies on fresh ingredients and is highly seasonal. Washing leads to nutrient loss and environmental burden. High-temperature deep frying can easily produce harmful substances (such as acrylamide). The raw material is a dry powder, so it is not limited by season. There is no washing step that results in nutrient loss. The main processing method is baking, or low-temperature frying followed by degreasing, making it safer. The process is more stable and environmentally friendly. It avoids the health risks of high-temperature frying, resulting in safer products. Product Consistency The slices are uneven in thickness and shape, resulting in large fluctuations in the quality of the finished product. Through calendering and die-cutting, the product shape, thickness, size, and height are uniform. It is perfectly adapted to continuous industrial production, ensuring the stability and standardization of product quality, which is conducive to brand building. core technology Simply slice and fry. A holistic solution combining water / oil synergistic curing, homogenization molding, nutrient fortification, and gentle curing. It is not a simple process improvement, but rather a completely new and systematic product design approach and production paradigm.

[0240] Conclusion: The above comparison clearly shows that the technical solution provided by this invention is significantly superior to the traditional potato chip production process in multiple core dimensions such as nutrition, health, advanced technology, and product consistency.

[0241] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A nutritionally fortified ready-to-eat potato chip, characterized in that, It is prepared from the following raw materials in the following weight percentages: Potato substrate: 60%–85%, fortified components: 4%–6%, flavoring components: 0.5%–2%, oil components: 15%–20%; The nutritional fortification components are at least one of the following: fish collagen peptide powder, oyster calcium powder, tuna peptide powder, Antarctic krill powder, whey protein powder, soy protein, targeted enzymes, and natural food-grade plant extracts.

2. The nutritionally fortified ready-to-eat potato chips according to claim 1, characterized in that, The potato substrate is at least one of potato flour, potato flake flour, purple sweet potato flour, and sweet potato flour.

3. The nutritionally fortified ready-to-eat potato chips according to claim 1, characterized in that, The raw materials also include starch, which accounts for 5% to 30% of the total mass of the raw materials.

4. The nutritionally fortified ready-to-eat potato chips according to claim 1, characterized in that, The seasoning components include edible salt and flavoring powder. The edible salt accounts for 0.5% to 0.7% of the total mass of the raw materials, and the flavoring powder is at least one of onion powder, garlic powder, and white pepper powder, with a total amount accounting for 0.1% to 0.5% of the total mass of the raw materials.

5. The nutritionally fortified ready-to-eat potato chips according to claim 1, characterized in that, The oil component is at least one of corn oil, olive oil, sunflower seed oil, and palm oil.

6. A method for producing a nutritionally fortified ready-to-eat potato chip, applicable to the nutritionally fortified ready-to-eat potato chip as described in any one of claims 1 to 5, characterized in that, Includes the following steps: S1. Preparation of mixed powder: Mix the potato matrix, nutrient fortification components and flavoring components evenly to obtain a dry powder mixture; S2. Material maturation and shaping: Water and oil components are added to the dry powder mixture, and the mixture is stirred and kneaded into a plastic dough. The dough is then rolled and die-cut to obtain a pre-shaped embryo. S3. Curing treatment: The embryo is baked or deep-fried at low temperature, and then cooled to obtain the nutritionally fortified ready-to-eat potato chips.

7. The method for producing a nutritionally fortified ready-to-eat potato chips according to claim 6, characterized in that, In step S2, the water is warm water at 30-40℃, and the mass ratio of water to dry powder mixture is (0.25-0.35):

1. The oil component is added at least twice, with 80% to 90% added during kneading and the remaining portion sprayed onto the surface of the dough before curing.

8. A method for producing a nutritionally fortified ready-to-eat potato chips according to claim 6, characterized in that, In step S2, a twin-screw dough mixer is used for mixing and kneading for 8 to 10 minutes, and the rolling thickness is 1 to 1.5 mm; the surface of the dough is perforated, with 3 to 4 holes per piece.

9. A method for producing a nutritionally fortified ready-to-eat potato chips according to claim 6, characterized in that, In step S3, the baking is carried out using a tunnel-type hot air baking machine or a mesh belt baking machine, with a baking temperature of 170-190℃ and a total duration of 8-10 minutes, during which the food is turned over once.

10. A method for producing a nutritionally fortified ready-to-eat potato chips according to claim 6, characterized in that, In step S3, the low-temperature frying is carried out using a continuous low-temperature fryer with a frying temperature of 120-140℃ and a total duration of 3-5 minutes. After frying, the oil is removed by an oil remover at a speed of 800-1000 r / min for 30-60 seconds. The cooling is carried out using a continuous cooling conveyor belt with a cooling temperature of 25-30℃ and a cooling time of 3-5 minutes.

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