Apparatus and method for preparing puffed foods

Abstract

An apparatus and method for preparing puffed food products. At least one profood product is placed within a compartment defining a sealed enclosure. The profood product comprises an outer shell and an interior contained within the shell, the interior including at least one starch-containing ingredient and a liquid adapted to form steam when heated. The pressure within the compartment is rapidly reduced using a pressure device while heating the compartment until the profood product reaches a fracture threshold condition at a reduced fracture temperature, causing the shell to rupture and inducing a rapid release of steam at high pressure, thereby expanding the starch and producing the puffed food product. The reduced fracture temperature may be in the range of 200-220°C. The pressure reduction may occur in less than 1 second. The duration of the puffing process may be in the range of 6-7 seconds.

Description

Technical Field

[0001] The present invention generally relates to foods, particularly puffed foods and methods for their preparation.

Background Art

[0002] Puffed foods can be found in a variety of commercially available foods in supermarkets and grocery stores, including various types of snacks, chips, and breakfast cereals. These puffed foods have various shapes, sizes, and textures and consist of basic food ingredients that expand and puff when heated. More specifically, the preparation of puffed foods involves heating ingredients such as natural grains (e.g., wheat, rice, corn) or pre-prepared micropellets (typically containing various food powders), usually for a relatively short time (e.g., seconds or minutes) simultaneously with an increase in pressure. As the internal pressure of the heated ingredients increases, the naturally contained water and moisture are converted into steam. Heating also softens and makes pliable the naturally contained biopolymer compounds characterized by thermoplasticity, such as starch. Eventually, the internal pressure reaches the critical point (Pc), resulting in a forced explosion and rapid expansion of the contained biopolymer material (e.g., starch). The dynamics of this explosion at the critical point depend on various factors including the internal pressure of the basic food ingredient, the pressure difference (ΔP) between the external and internal pressures, the process temperature, the exposure time to heat, and other variables. Following the explosion and rapid release of pressure, the food matrix is rapidly cooled and the temperature is lowered so that the biopolymer or starch is solidified, resulting in a swollen, porous, expanded, and loose arrangement.

[0003] For example, one of the most common and well-known puffed foods is popcorn. Popcorn kernels contain a starchy endosperm in or around the outer shell. When the kernels are heated, the water in the endosperm turns into steam, and the vapor pressure gradually increases until the shell bursts. The starch and proteins in the endosperm expand into a foamy substance, which is then rapidly cooled to take on a puffed form. Puffed foods may be prepared from a single ingredient, but they may also contain additional ingredients and additives to enhance flavor and stimulate consumer interest. Some puffed foods, such as bread, form an outer shell or crust upon heating.

[0004] The raw materials may be formed into the desired shape before heating, for example, by an extrusion or pressing process. Heating of the leavened food can be done by baking or frying, using conventional heating appliances and equipment such as ovens, pans or lidded pots, or using specially designated equipment such as leavening machines with press molds. In conventional bread-baking processes, the expansion of the ingredients usually occurs from external leavening agents such as yeast in the dough, which causes the release of air bubbles within the dough. Thus, expansion generally occurs before the actual baking stage (i.e., before the dough is placed in the oven) and at the very beginning of baking. In contrast, the expansion of leavened foods occurs from internal elements, specifically from water or moisture naturally present in the basic ingredients. This moisture reaches a steam state upon heating, and subsequently generates sufficient pressure to initiate the expansion of the contained starch. Thus, the preparation of leavened foods does not require a long waiting period for the ingredients to expand before the heating and pressurizing stages.

[0005] Puffed foods can be prepared in a simple process using certain basic ingredients, without requiring specially designated machinery or equipment. For example, popcorn can be prepared relatively quickly and conveniently in the comfort of one's home from readily available popcorn kernels that can be heated in a pot or bag. Further types of puffed foods, such as certain snacks and cereals that tend to be popular with infants, must be manufactured by commercial manufacturers in designated facilities. While many existing ingredients, techniques, and equipment exist for preparing puffed foods, the types and varieties of puffed foods can expand significantly beyond those currently available.

[0006] Some conventional puffing processes are based on vacuum frying. Vacuum frying is easily implemented in large-scale industrial production processes and is characterized by relatively low energy consumption. While vacuum frying has been successfully applied to the processing of fruits and vegetables, it is not suitable for puffing most other food ingredients and is generally considered an unhealthy form of processing due to the very high levels of edible oil in the final product.

[0007] Non-fry expansion processes can be divided into three categories: vacuum freeze-drying, differential pressure expansion (also known as "air expansion" or "variable temperature expansion"), and microwave expansion.

[0008] The vacuum freeze-drying process involves freezing water-containing ingredients and then heating them under vacuum to directly sublimate the water from a solid state to a gaseous state. The entire manufacturing process must be carried out at low temperatures below approximately -25°C and under vacuum. Disadvantages of this process include high energy consumption and long manufacturing cycles, which can result in costs exceeding 3 to 4 times that of oil-fried puffed foods.

[0009] The differential pressure expansion process applied to fruits and vegetables uses an expansion tank and a vacuum storage tank that is approximately 5 to 10 times larger than the expansion tank. The expansion tank is heated by a steam boiler, and a vacuum pump and vacuum storage tank provide a negative pressure environment. The vacuum storage tank and the expansion tank are connected via a vacuum valve. The pressure control range of the expansion tank is typically 0.06 MPa to 0.08 MPa, and the temperature control range is typically 0°C to 120°C. Water or moisture contained in the pre-treated raw material (e.g., fruit or vegetable ingredients) is continuously evaporated in the evaporator by steam heating, generating water vapor and continuously increasing the pressure in the evaporator. When a certain pressure level is reached, the vacuum valve is opened, the pressure drops, and the water / moisture inside the raw material evaporates. This creates a strong vapor pressure difference, resulting in swelling of the cells and tissues of the ingredient, followed by expansion and puffing. However, the temperature distribution in the tank tends to be uneven, and the puffing of the final product tends to be limited to a lower degree than desired.

[0010] Microwave expansion, which can also be applied to fruits and vegetables, refers to the emission of high-frequency electromagnetic waves after a microwave device has been energized. However, due to the influence of microwave wavelength, power, and processing time, quality control is difficult, and microwave expansion cannot be used as the sole manufacturing technology.

[0011] The microwave pressure differential inflation process is a combined technique designed to overcome the shortcomings of the microwave inflation and differential pressure inflation processes applied separately. Essentially, a microwave pre-inflation step is added before the differential pressure inflation in the differential pressure inflation process. Microwave pressure differential inflation can overcome the "coking" problem in the microwave process and the difficult problems in the differential pressure process. While inflation efficiency using microwave pressure differential inflation can be considerably higher when combined for better results, this technique is generally not suitable for high-fiber fruits and vegetables. [Overview of the Initiative] [Problems that the invention aims to solve]

[0012] Conventional puffing food preparation devices generally operate by compressing a number of micropellets (or other basic ingredients) within a containment volume and applying heat until the temperature reaches a level high enough to generate sufficient pressure to initiate the rupture of the micropellet shells and the expansion of the contained starch. The required temperature level may, in some cases, need to be significantly high, typically around 160–165°C. Examples of puffing food preparation devices and methods known in the art are disclosed in Chinese Patent Application No. 106539115A by Yanan University with the invention title "Air-compression microwave-heating explosion puffing device and method," U.S. Patent No. 5,562,021 by Slanick with the invention title "Device for preparing grain cakes," Canadian Patent No. 2,346,964 by Malfait with the invention title "Puffed food starch product," and U.S. Patent No. 4,281,593 by Gevaert with the invention title "Device for preparing food products from cooked and expanded cereals and products obtained."

[0013] Accordingly, according to one aspect of the present invention, an apparatus for preparing puffed food is provided. The apparatus includes a compartment defining a sealed enclosure, a pressure device configured to change the pressure within the compartment, and a heating device configured to change the temperature within the compartment. The pressure device includes a vacuum pump, a vacuum piston, a valve that communicates fluidly with the compartment, and an accumulator connected to the vacuum pump and valve and communicating fluidly with them. The compartment is designed to receive at least one ProFood product, which includes an outer shell and an interior contained within the outer shell, the interior containing at least one starch-containing food ingredient and a liquid adapted to form steam when heated. The pressure device maintains the ProFood product at a reduced failure temperature until it reaches a failure threshold condition while the heating device heats the compartment. By operating the vacuum pump and opening the valve Pressure within the compartment Less than 1 second It is designed to drop rapidly, causing the outer shell to rupture and inducing a sudden release of steam at high pressure, as a result, ingredients The material is expanded to produce puffed food. The reduced fracture temperature may be in the range of 200°C to 220°C. (Expansion process) Cycle time The duration may be in the range of 6 to 7 seconds. The compartment may include at least one mold, in which the ProFood product is placed, and the mold is of a size or shape that induces a selected size or shape of puffed food. Rapidly reducing the pressure in the compartment may include stopping pressurization of the ProFood product and simultaneously reducing the pressure by removing air from the compartment. The apparatus may further include a temperature controller configured to regulate the temperature in the compartment. The pressure drop in the compartment occurs immediately after the pressure rise in the compartment. You can continue. The apparatus may further include a shielding device, which is positioned between the compartment and the pressure device and is configured to prevent the passage of the profood item or any part thereof from the compartment to the pressure device.

[0014] Therefore, according to another aspect of the present invention, a method for preparing puffed food is provided. The method includes the step of placing at least one profood item in a compartment defining a sealed enclosure, the profood item comprising an outer shell and an interior contained within the outer shell, the interior comprising at least one starch-containing food ingredient and a liquid adapted to form steam when heated. The method is, Using a pressure device including a vacuum pump, a vacuum piston, a valve that fluidly communicates with the compartment, and an accumulator connected to and fluidly communicating with the vacuum pump and valve, the compartment is heated while the vacuum pump is operated and the valve is opened. The pressure in the compartment is reduced until the ProFood product reaches the failure threshold condition at a lowered failure temperature. Less than 1 second Further steps include rapidly reducing the pressure, causing the outer shell to rupture and inducing a sudden release of steam at high pressure, as a result, ingredients The material is expanded to produce puffed food. The reduced fracture temperature may be in the range of 200°C to 220°C. (Expansion process) Cycle timeThe duration may be in the range of 6 to 7 seconds. The ProFood products may be placed in each mold within the compartment, and the molds are of a size or shape that induces a selected size or shape of puffed food. Rapidly reducing the pressure within the compartment may include stopping the application of pressure to the ProFood products and simultaneously reducing the pressure directly by removing air from the compartment. The pressure reduction within the compartment occurs immediately after the pressure increase within the compartment. You can continue. .

[0015] This invention will be more fully understood and recognized from the following detailed description in conjunction with the drawings. [Brief explanation of the drawing]

[0016] [Figure 1A] This is a diagram of an apparatus for preparing puffed food in a first operating stage, constructed and operating according to an embodiment of the present invention. [Figure 1B] This is a diagram of the apparatus of Figure 1A for preparing puffed food in a second operating stage, constructed and operating according to an embodiment of the present invention. [Figure 1C] This is a diagram of the apparatus of Figure 1A for preparing puffed food in a third operating stage, constructed and operating according to an embodiment of the present invention. [Figure 2] This is a flowchart of a method for preparing puffed food products, operating according to embodiments of the present invention. [Figure 3] This diagram shows a series of operating steps of an apparatus for preparing puffed foods, operating according to another embodiment of the present invention. [Figure 4A] This is a detailed diagram of an apparatus for preparing puffed food during a second operating stage, constructed and operating according to another embodiment of the present invention. [Figure 4B] This is a detailed diagram of an apparatus for preparing puffed food during a fourth operating stage, constructed and operating according to another embodiment of the present invention. [Figure 5] This is a schematic diagram comparing the nutritional degradation profile of a commercially available puffing process and puffed food (left) with the nutritional degradation profile of a puffing process and puffed food disclosed according to an embodiment of the present invention (right). **DETAILED DESCRIPTION OF THE INVENTION**

[0017] The present invention overcomes the disadvantages of the prior art by providing a novel apparatus and method for preparing puffed foods. The disclosed apparatus is similar to existing conventional apparatuses for puffed food preparation, but includes a pressure device such as a vacuum pump or piston configured to apply a rapid vacuum inside the container during heating, enabling the outer shell rupture process and subsequent puffing to be carried out at a lower temperature and shorter cycle time than conventional apparatuses. The disclosed apparatus may also include a screen to prevent leakage of food particles and avoid the possibility of contamination or malfunction of the pressure device. The disclosed apparatus and method can significantly improve the efficiency of the puffing process by substantially shortening the preparation time. Further, the heating temperature is significantly reduced, minimizing the deterioration of the nutritional content and flavor of the puffed food. The required pressure is also significantly reduced, minimizing energy consumption and cost. Finally, the disclosed apparatus and method can significantly expand the range of food ingredients and food sources that can be prepared into edible puffed foods.

[0018] The term "pro-food product" is used herein to refer to any processed or unprocessed food substance that can be prepared from one or more raw materials ("food ingredients"), is not limited to known foods, and can be used to directly prepare "puffed foods", i.e., a substance for which no additional components need to be added to the pro-food product to prepare puffed foods therefrom.

[0019] The term "food ingredient" is used herein to refer to any processed or unprocessed food substance that can be used to prepare a "pro-food product".

[0020] The terms “puffed food” and “puffed food” are used herein to refer to any food prepared from a “profood product” in an puffing preparation process (e.g., involving heating and / or internal pressure increase) and characterized by puffed formation such as a foamy, fluffy, expanded, or “spongy” structure of one or more food substances.

[0021] The terms “pellets” and “micropellets” are used interchangeably herein and refer to small pellets, tablets, or capsules that may form at least a portion of a “ProFood product.”

[0022] As used herein, the term “compartment” refers to a separate part of a structure or container, or a mold or mold cavity, and selected items can be kept separate from other articles within the container, such as a part containing one or more mold cavities.

[0023] The term “processing” and its grammatical variations, as used herein in the context of preparing a ProFood product, for example, when preparing a ProFood outer shell, means the use of force or energy such as heat (e.g., by cooking) and / or mechanical force (e.g., by a mixer or fluidized bed), and / or one or more chemical processes which may or may not alter the chemical composition of the outer layer of the food, may alter at least one property of the food, such as coating micropellets, and / or otherwise increase the hardness and rigidity of one or more outer layers compared to one or more inner layers of the food.

[0024] The term "User" is used herein to refer to any individual or group of individuals who operate the apparatus, apparatus or system, or perform a method or process of any disclosed embodiment, such as a method for preparing puffed food.

[0025] In the description, unless otherwise specified, adjectives such as “substantially” and “about” modifying the condition or relational characteristics of one or more features of one embodiment of an embodiment of the present invention are understood to mean that the condition or characteristic is defined within the tolerances permitted for the operation of the embodiment for its intended use. Unless otherwise indicated, the word “or” in this specification and the claims is considered to be “exclusive or” rather than “exclusive or” and indicates at least one or any combination of the items to which it relates.

[0026] Referring here to Figures 1A, 1B, and 1C, these are schematic diagrams of an apparatus, collectively denoted by reference numeral 150, for the preparation of puffed food, constructed and operated according to embodiments of the present invention. Figure 1A shows the apparatus 150 in a first stage of operation, Figure 1B shows the apparatus 150 in a second stage of operation, and Figure 1C shows the apparatus 150 in a third stage of operation. The apparatus 150 includes a container 160 having at least one compartment 162. The apparatus 150 further includes a heating device 170, a pressure device 180, and an optional shielding device 190.

[0027] The container 160 is configured to receive a number of ProFood items, indicated by reference numeral 111, arranged within a sealable compartment 162. The heating device 170 is configured to heat the compartment 162 and may be positioned adjacent to the wall or surface of the compartment 160, such as below the bottom surface of the compartment 162. For example, the heating device 170 may be embodied by a cooktop or part of a cooktop, such as a gas burner or induction or open-flame cooker. The heating device 170 may include one or more electrical resistance heating elements positioned in the wall of the container or incorporated into a mold assembly (if such an assembly is used). The heating device 170 may heat by any suitable mechanism, including but not limited to radiation, heat conduction, magnetic induction, and electric heating.

[0028] The pressure device 180 is configured to increase or decrease the pressure within compartment 162 and may be located adjacent to the wall or surface of compartment 160, such as above the top surface of compartment 162, or otherwise connected to the compartment. The pressure device 180 can be embodied, for example, by an industrial vacuum pump having a valve leading to compartment 162, and the pressure within compartment 162 can be selectively increased or decreased by operating the vacuum pump and opening the valve, for example, to selectively allow gas or fluid to enter or leave the compartment (creating a pressure difference). An accumulator may be coupled with the vacuum pump and valve to maintain and control the fluid flow.

[0029] The shielding device 190 is positioned between the compartment 162 and the pressure device 180 and is configured to prevent food particles from leaking from the compartment 162 into the pressure device 180, which can cause contamination and / or impair the function of the pressure device 180. The shielding device 190 can be embodied by at least one separator, including but not limited to one or more of the following: grids, screens, filters, dust collectors, gravity or pressure difference separators, and combinations thereof. The separator may be removable and useful to facilitate the removal of profood particles or food material from or within the separator.

[0030] Apparatus 150 may optionally include and / or be associated with additional components not shown in the figures in order to enable the implementation of the disclosed subject matter.

[0031] Referring here to Figure 2, which is a flowchart of a method for preparing puffed food operating according to an embodiment of the present invention. In step 120, a ProFood product is placed in a compartment. The ProFood product includes an outer shell and an interior. The outer shell contains a first ingredient and is characterized by hardness and rigidity that can withstand fracture below specific temperature and pressure threshold conditions. The interior is housed within the outer shell and contains a second ingredient. The second ingredient contains at least one starch and a liquid such as water which is designed to form steam when heated. Referring here to Figure 1A, the user places one or more ProFood products 111 in compartment 162 of container 160. Each ProFood product 111 includes an outer shell 112 enclosing an interior 113 and may be in the form of coated micropellets. The ProFood products 111 are placed in respective molds within compartment 162, such as mold 165, of a predetermined shape and size, to guide the selected shape and / or size of the puffed food to be subsequently produced, and can be used together with a pressing mechanism. For example, the metal mold may be placed in a hydraulic press (similar to injection molding) where an electrically resistive heating element is positioned in the mold wall, and the heating element is controlled by a controller such as a thermocouple (TC) sensor mounted at an appropriate point to detect the actual temperature. Alternatively, the profood product 111 may be placed directly in compartment 162 without using a dedicated mold (in which case compartment 162 essentially functions as a mold cavity). For example, granular profood products need to be coagulated and therefore may be placed in a mold or in one or more designated cavities, while larger profood products, such as whole fresh fruit, can be placed in a shell containing a considerable amount of starch (e.g., at least 15% w / w of the shell) and prepared in compartment 162 without a mold. Filling the mold 165 can be important to ensure the integrity and intended shape of the final puffed food. Furthermore, compartment 162 may be filled to leave minimal extra space within it in order to facilitate the rapid initiation of the necessary pressure reduction during the preparation process as quickly as possible in order to provide a final puffed food with a proper and consistent shape.

[0032] When the ProFood product 111 is placed in the compartment, the apparatus 150 is initialized so that the temperature and pressure conditions in the container 160 and compartment 162 are at their default settings. For example, the heating device 170 may be operating continuously, the heat may be regulated to a constant temperature by a regulator, and the pressure may be at standard atmospheric pressure (i.e., room pressure) if no pressure device is applied.

[0033] In the following optional procedure 130, a pressure device is used to increase the pressure within the compartment, and a heating device is used to increase the temperature within the compartment. Referring to Figure 1B, the pressure device 180 is used to gradually increase the pressure within compartment 162, while almost simultaneously, the heating device 170 is used to gradually increase the temperature within compartment 162. For example, if an electrical resistance heating element is used, the temperature is constant and controlled throughout, while if induction or microwave heating is used, the temperature changes as required. The increase or decrease in pressure is generally as rapid as possible, typically less than 0.2 seconds and less than or equal to 1.0 second. Alternatively, if compartment 162 is effectively sealed, the pressure increase within compartment 162 may be achieved by increasing the internal temperature using the heating device 170, provided there is a sufficient moisture content. The ProFood product 111 within compartment 162 is subjected to an increase in temperature and (also by mechanical pressing within the cavity) pressure level, resulting in the formation of steam from the moisture content inside the ProFood 113. Furthermore, heating of the ProFood product 111 also causes softening of thermoplastic biopolymer elements, such as starch, inside the ProFood 113. Note that step 130 is optional and pre-pressurization is not necessary for all ingredients and conditions.

[0034] In procedure 140, the pressure in the compartment is rapidly reduced using a pressure device until the ProFood product reaches a fracture threshold condition at a reduced fracture temperature, causing the outer shell to rupture, inducing a rapid release of steam at high pressure, which expands and cools the starch to produce the puffed food. Referring to Figure 1C, the pressure in compartment 162 is rapidly reduced using the pressure device 180 by rapidly pulling the piston or vacuum pump of the pressure device 180 with hydraulic or pneumatic pressure, or by opening a valve to a vacuum accumulator connected to the vacuum pump, while the heating device 180 maintains or raises the temperature in compartment 162. The rapid pressure drop occurs over a very short period of time and can result in a vacuum or near-vacuum in a short time. The rapid pressure drop in compartment 162 may also be carried out by directly reducing the pressure simultaneously by stopping the application of pressure to the ProFood product and removing air from the compartment.

[0035] Following a rapid pressure drop within compartment 162, the ProFood product 111 within compartment 162 reaches a “break threshold” state, where the ProFood outer shell 112 breaks or ruptures due to an increase in vapor pressure. This occurs at a temperature level substantially lower than the standard “outer shell break temperature” of conventional puffing processes, such as between 210-220°C. After the rupture of the ProFood outer shell 112, expansion and foaming of the first ingredient and starchy material inside the ProFood 113 follows. The first ingredient starch is then rapidly cooled to develop a puffed structure, producing a puffed food product 118, because the starch and other materials inside the ProFood 113 expand easily and then rapidly cool, which helps to produce a puffed ingredient matrix. Each puffed food product 118, which can take the form of an edible puffed cake that can be consumed as a snack, is typically made from multiple smaller micropellets.

[0036] Fracture can be achieved when the mold opens rapidly and the pressure is rapidly released. The expansion continues in the open air as water vapor continues to escape from the material matrix. The entire process from start to finish. (Cycle time)This can be approximately 6-7 seconds, including the opening and closing of the mold (which accounts for the majority of the duration). Typical pressurization time is 0.1-2.0 seconds, depending on the material.

[0037] The amount or quantity of ProFood products initially placed in compartment 162 (or in the molds within it) may be chosen to ensure that the total volume of puffed food produced during a given production session or cycle is sufficient to occupy most or all of the available space in compartment 162.

[0038] Compartment 162 may also be characterized by having a substantially low spatial volume such that the pressure change (decrease) is substantially rapid, which can facilitate the process of rapidly rupturing the ProFood outer shell 112 and accelerating its expansion process for a second ingredient, compared to the expansion process performed by conventional systems using commercially available ingredients that can be modified for the expansion process. Rapid expansion causes a rapid pressure drop within the compartment and / or mold, resulting in a larger pressure difference (ΔP) that induces the rupture of the outer shell / coating. Furthermore, this property can generate vacuum pressure within the compartment and / or mold, thus achieving a higher pressure difference (ΔP), and thus enabling the expansion and puffing of novel types of ProFood products beyond conventional commercially available ingredients, as it can induce expansion and puffing even for materials or ingredients that are difficult to puff. The resulting puffed product is crispier and fluffier than conventional puffed foods, can have a larger surface area, and can even have a lighter weight (e.g., less than 1 gram) compared to a high-density, unpuffed cracker made from similar ingredients, thus having a better texture and greater satiety.

[0039] It is understood that rupturing the outer shell at lower temperatures can offer advantages such as reducing energy consumption in the puffing process, minimizing associated costs, and avoiding exposure of the profood product to high temperatures that could be harmful and / or introduce unhealthy additives into the final puffed food. Higher process temperatures lead to greater degradation of the nutritional quality of the final product. The puffing process disclosed in this invention lowers the processing temperature by approximately 40-60°C compared to conventional puffing processes, thereby significantly minimizing nutritional degradation. Furthermore, longer cycle times result in greater exposure to higher temperatures and greater degradation of nutritional quality. The puffing process disclosed in this invention also reduces the cycle time by at least 30-40% compared to conventional puffing processes, thereby significantly minimizing nutritional degradation.

[0040] In contrast to commercially available devices and processes for puffing food, the apparatus and method of the present invention uses strong suction while simultaneously reducing the mechanical pressure applied to the ProFood in the mold by pressing. In particular, rapidly reducing the pressure within the compartment involves simultaneously reducing the direct pressure on the ProFood product while suctioning air from the compartment, and “direct pressure” means that the press is in physical contact with the ProFood product and the pressure on the ProFood product is applied directly through this contact. The enhanced pressure drop is thought to create a sharp pressure gradient across the ProFood outer shell 112, which can greatly improve puffing performance and can yield several advantages. Firstly, it enables the puffing of ingredients that are not normally suitable for puffing. For example, the ProFood product may contain all-natural ingredients, such as a combination of 50% legumes and 50% plant materials. Furthermore, the reduced heating temperature of the ProFood product significantly reduces the deterioration of the nutritional content and / or flavor of the final puffed food. Furthermore, the required pressure applied by the pressurizing device can be reduced to up to about half the pressure required in conventional inflation processes (which can help save energy / power consumption). Finally, the overall preparation time can be significantly reduced so that a single preparation cycle is completed much faster and efficiency is improved. For example, the entire process from start to finish, including opening and closing the mold (which accounts for the majority of the duration), can be about 6-7 seconds, so that the cycle time is reduced by 30-40% compared to conventional processes. Shorter cycle times and lower process temperatures also provide economic benefits in the form of lower energy consumption and higher efficiency (in terms of the number of units produced during a given period).

[0041] The disclosed apparatus is configured to enable pumping of air from a compartment within 10 to 100 milliseconds. The rate or duration of pressure drop depends, as will be readily apparent to those skilled in the art, on the amount of air in the compartment, the suction force, the shape (i.e., the total volume of air in the compartment, the unusable volume, etc.), and the dimensions of the apparatus components, including the dimensions of the tubing and limiting factors. The pressure in the compartment can be reduced from atmospheric pressure of about 100 kPa to about 3 to 20 kPa. For example, the resulting pressure in the compartment after a (rapid) pressure drop may be between 10 and 20 kPa. In another example, the compartment pressure after a (rapid) pressure drop is about 3 to 5 kPa.

[0042] The pressure device 180 may include a vacuum pump capable of providing rapid and powerful depressurization. For example, the pressure device 180 may include a vacuum pump connected to compartment 162 via a vacuum accumulator, and a vacuum valve operably coupled to the accumulator and compartment 162. Such an arrangement allows the pump to operate continuously, and the auxiliary pressure is "accumulated" in the accumulator. The valve allows for the selective application and termination of a predetermined auxiliary pressure, as needed, according to the type and quantity of profood product and the operating stage of the expansion process.

[0043] According to one embodiment, heating of compartment 162 may be applied before a rapid pressure drop to form the ProFood outer shell 112 of the ProFood product 111 when manufacturing the ProFood product 111 from its basic components. Thus, the rapid pressure drop may be performed after the ProFood outer shell 112 is fully formed (unless the pellets have a previously formed outer shell or coating). In particular, the ProFood product 111 is heated until the outer shell 112 is formed around the interior 113, where the outer shell 112 is substantially harder than the interior 113. Following or accompanying the formation of the outer shell 112, the pressure device 180 is used to reduce the pressure in compartment 162. The heating device 170 (which may be operating continuously) is then used again to heat the ProFood product 111 until at least the ingredients and starch in the ProFood interior 113 have expanded, causing the vapor pressure to rise and resulting in the rupture of the outer shell 112.

[0044] Alternatively, the ProFood shell may be formed before the ProFood product is placed in compartment 162 of the apparatus 150. The ProFood shell can generally be formed using any suitable apparatus or process, including, but not limited to, a coating process, co-extrusion process, spraying, fluid bed, surface treatment, injection or co-injection process, coating drum, etc. A (rapid) pressure drop may be performed after the ProFood shell 112 is fully formed.

[0045] According to one embodiment of the present invention, pressure is applied to the ProFood product before a (rapid) pressure drop. This application of pressure can be used in conjunction with heating to promote the formation of the ProFood outer shell 112. The application of pressure can be carried out using a pressure device 180.

[0046] The application of auxiliary pressure may be used immediately after the application of pressure, and thus can create particularly large pressure changes within the compartment, thereby assisting the explosion and expansion of the ProFood product. This initial heating and positive pressure can help build pressure within the ProFood outer shell from the generation of pressurized steam released by the second ingredient (contained in the ProFood product). A rapid drop in pressure within the compartment creates a large pressure difference inside compared to when there is no outer shell, leading to the shell rupture. Compositions such as starch in the second ingredient rapidly crosslink or solidify once the outer shell is ruptured, producing an expanded food.

[0047] The pressure device 180 may be insulated or shielded from heat from compartment 162 for protection. For example, the wall of compartment 162 adjacent to the pressure device 180 may include insulating material. Alternatively or additionally, the air pumped from compartment 162 by the pressure device 180 may pass through a cold trap (not shown) which traps vapors released from the pro-food product and minimizes contact with the pressure device 180. Alternatively or additionally, the pressure device 180 may be fitted with or include components configured to reduce direct contact between the pumped hot gas and the pressure device, such as a venturi pump.

[0048] The apparatus 150 optionally includes a shielding device 190 to prevent the passage of ProFood product 111 or its ingredient particles from compartment 162 to the pressure device 180. The shielding device 190 may be located between compartment 162 and the pressure device 180 and may include one or more separators, such as at least one of a grid, screen, filter, and / or dust collector. The shielding device 190 can help prevent leakage of food particles from compartment 162 to the pressure device 180, which could result in a breeding ground for contamination and / or impair the function of the pressure device 180. Separators may be removable and useful to facilitate the removal of ProFood product particles or ingredient material from or within the separators.

[0049] Furthermore, to ensure that there is a sufficient quantity to produce the expanded puffed food, the correct amount of material in the ProFood 111 (e.g., the size or mass of the ProFood 111) should be carefully estimated and added before placing the ProFood 111 in compartment 162. On the other hand, if the amount is too much, the ProFood 111 may not expand completely or may saturate the shielding device 190. Each type of ProFood 111 may have an inherent range of optimal amounts that can be empirically determined and administered accordingly.

[0050] The amount or quantity of ProFood products initially placed in compartment 162 (or in the molds within it) may be chosen to ensure that the total volume of puffed food produced during a given production session or cycle is sufficient to occupy most or all of the available space in compartment 162.

[0051] Compartment 162 may also be characterized by a substantially low spatial volume so that the pressure drop is substantially rapid and a stronger pressure difference is created, which can modify the inflation process, and compared to the inflation process performed by conventional systems using commercially available ingredients, the second ingredient can facilitate a process in which the ProFood outer shell 112 bursts rapidly and improves its inflation process. Furthermore, this property may enable the inflation of novel types of ProFood products, as the stronger pressure difference provides a stronger expansion of the ingredient matrix. The resulting inflation product is crispier and fluffier than conventional inflation foods, can have a larger surface area, and can even have a lighter weight (e.g., less than 1 gram) compared to a high-density, uninflated cracker made from similar ingredients, and is therefore more satisfying and filling.

[0052] Herein, we refer to Figures 3, 4A, and 4B. Figure 3 is a diagram of a series of operating stages of an apparatus referenced by reference numeral 250 for the preparation of puffed food, constructed and operable according to another embodiment of the present invention. Figure 4A is a detail diagram of the apparatus 250 in a second operating stage (reference numeral 204), and Figure 4B is a detail diagram of the apparatus 250 in a fourth operating stage (reference numeral 208). Referring to Figure 4A, the apparatus 250 includes a mold 220 comprising an upper mold half 222 and a lower mold half 224 separated by a dividing line 226. The apparatus 250 further includes a heatable cavity 228, a vacuum piston 232, a filter screen 234, and an ejector 236. The heatable cavity 228 can be heated using an electrical resistance heating element (not shown) incorporated into the mold 220.

[0053] In the first operating step 202 of the expansion preparation process, the mold 220 is opened and the profood product 211 (for example, in the form of coated micropellets) is placed inside the cavity 228.

[0054] In the second operating stage 204 of the expansion preparation process, the mold 220 is closed and sealed from the external environment. Pressure is applied to the profood product 211 within the cavity to facilitate heating of the pellets contained within the cavity 228. Pressurization may be achieved by mechanical pressing of the mold components in addition to (optional) pressurization using the vacuum piston 232. The vacuum piston 232 is positioned in a default position ready to initiate a rapid pressure drop within the cavity 228.

[0055] In the third operating stage 206 of the expansion preparation process, the vacuum piston 232 is deployed, for example by being suddenly pulled, while keeping the mold 220 closed, to initiate a rapid pressure drop within the cavity 228. The outer shell of each ProFood product 211 bursts, inducing a rapid release of the vapor pressure accumulated within the ProFood product 211, which is then vented into the vacuum chamber through the filter screen 234. The ingredients and starch contained within the ProFood product 211 begin to expand, foam, and solidify.

[0056] In the fourth operational stage 208 of the puffing preparation process (shown in detail in Figure 4B), the ingredients and starch contained within each profood product 211 are cooled and solidified to produce the respective puffed food. The mold 220 is opened to allow the puffed food to be extracted by the ejector 236. The vacuum piston 232 is returned to its default position, and the product is ready for the next production cycle.

[0057] In the fifth operational step 210 of the puffing preparation process, the puffed food is ejected by the ejector 236.

[0058] In the sixth operational stage 212 of the puffing preparation process, the puffed food is sent to the packaging or assembly process for packaging and commercialization, and the apparatus 250 is initialized and ready for the next puffing process cycle.

[0059] Referring to Figure 5, this is a schematic diagram comparing the nutrient degradation profile of a commercially available puffing process and puffed food, generally denoted by reference numeral 410, with the nutrient degradation profile of a disclosed puffing process and puffed food, generally denoted by reference numeral 420, according to embodiments of the present invention. Graphs 410 and 420 schematically show the degradation of nutrient content as a function of combined temperature and cycle time. The y-axis of graphs 410 and 420 represents process temperature. Higher process temperatures result in greater degradation of nutrient quality. The x-axis of graphs 410 and 420 represents cycle time or process time. Longer cycle times result in greater exposure to high temperatures and greater degradation of nutrient quality. Total nutrient degradation is represented by the cross-hatching region between the curve and the baseline. Graph 420 represents an exemplary puffing process of the present invention using coated micropellets (i.e., having an outer shell) and vacuum-strengthened puffing.

[0060] From Graphs 410 and 420, it is clear that the exemplary puffing process of the present invention reduces the processing temperature by approximately 50-60 degrees Celsius, and thus significantly minimizes nutritional degradation. Furthermore, the exemplary puffing process of the present invention reduces the cycle time by at least 30-40%, and thus significantly minimizes nutritional degradation. As can be observed by the difference in the cross-hatched area of ​​Graph 410 compared to Graph 420, the cumulative effect of the reduction in process temperature and cycle time is enormous. Therefore, the puffing process of the present invention clearly demonstrates a reduction of approximately 40-60% in nutritional degradation compared to the degree of degradation present in conventional or commercial puffing processes, thereby providing a more nutritious puffed food. Furthermore, the shorter cycle time and lower process temperature provide economic benefits in the form of lower energy consumption and higher efficiency (with respect to the number of units produced during a given period).

[0061] While specific embodiments of the disclosed subject matter have been described to enable those skilled in the art to carry out the invention, the foregoing description is intended for illustrative purposes only. It should not be used to limit the scope of the disclosed subject matter, which should be determined by referring to the following claims.

Claims

1. A food preparation device for puffed food, A section defining a sealed enclosure, A pressure device configured to change the pressure within a compartment, comprising a vacuum pump, a valve that is in fluid communication with the compartment, and an accumulator connected to the vacuum pump and valve and also in fluid communication with the vacuum pump and valve, A heating device configured to change the temperature within a compartment, Equipped with, The compartment is designed to accommodate at least one profood item, comprising an outer shell and an interior contained within the outer shell, the interior comprising at least one starch-containing food ingredient and a liquid adapted to form steam when heated, The puffed food preparation apparatus further includes a shielding device positioned between the compartment and the pressure device, configured to prevent the passage of the profood product or a portion of the profood product from the compartment to the pressure device. The pressure device is configured to rapidly reduce the pressure inside a compartment from atmospheric pressure to approximately 3-20 kPa in less than one second by operating a vacuum pump and opening a valve to expel air from the compartment within 10-100 milliseconds, while the heating device heats the compartment, until the profood product reaches a breakdown threshold condition at a reduced breakdown temperature, causing the outer shell to rupture and inducing a rapid release of steam at high pressure, thereby causing the food to expand and produce puffed food.

2. The apparatus according to claim 1, wherein the reduced failure temperature is in the range of 200°C to 220°C.

3. The apparatus according to claim 1, wherein the duration of the expansion process cycle time is in the range of 6 to 7 seconds.

4. The apparatus according to claim 1, wherein the compartment comprises at least one mold, the profood product is placed in a heatable, hollow mold, and the mold is of a size or shape such that it induces a selected size or shape of puffed food.

5. The apparatus according to claim 1, wherein the pressure device is configured to increase the pressure in a compartment before decreasing the pressure in the compartment.

6. A method for preparing puffed food, A procedure for placing at least one ProFood item within a compartment defining a sealed enclosure, wherein the ProFood item is Outer shell and, An interior contained within an outer shell, comprising a food ingredient containing at least one starch, and a liquid adapted to form steam when heated, Procedures that include, Procedures for preventing ProFood products or portions of ProFood products from passing from the compartment to the pressure device using a shielding device placed between the compartment and the pressure device, A procedure for rapidly reducing the pressure inside a compartment from atmospheric pressure to approximately 3 to 20 kPa in less than one second until the profood product reaches the breakdown threshold condition at a reduced breakdown temperature, by using a pressure device comprising a vacuum pump, a valve that fluidly communicates with the compartment, and an accumulator connected to the vacuum pump and valve and fluidly communicating with them, while heating the compartment with a heating device, operating the vacuum pump and opening the valve to discharge air from the compartment within 10 to 100 milliseconds, thereby causing the outer shell to rupture, inducing a rapid release of steam at high pressure, and as a result, causing the food to expand and producing puffed food. A method for providing this.

7. The method according to claim 6, wherein the reduced failure temperature is in the range of 200°C to 220°C.

8. The method according to claim 6, wherein the duration of the expansion process cycle time is in the range of 6 to 7 seconds.

9. The method according to claim 6, wherein the profood product is placed in a mold within a heatable cavity, and the mold is of a size or shape such that it induces a selected size or shape of puffed food.

10. The method according to claim 9, comprising initiating a rapid pressure drop within the cavity by rapidly pulling a vacuum piston while the mold is closed and sealed.

11. The method according to claim 6, further comprising increasing the pressure within a compartment before decreasing the pressure within the compartment.

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