Aerated Dairy Core with Non-Aerated Shell for Texture Stability
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Solution Overview
Problem
Existing food products with aerated dairy materials, such as cream cheese and ice cream, face challenges in maintaining dimensional stability and texture due to temperature fluctuations, leading to a collapse of the aerated structure, which affects their shelf life and consumer experience.
Innovation Solution
A process involving freezing dairy materials to -2°C or less, aerating them to an overrun of 10-150%, and shaping them before depositing them between or on layers of non-aerated dairy materials with low overrun, ensuring the aerated dairy material maintains a Stevens firmness of 20 or more and a water activity of 0.90 or more at refrigerated temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If aerated dairy material is used to create a light and appealing texture, then consumer appeal is improved, but dimensional stability deteriorates causing the aerated structure to collapse at refrigerated temperatures
Solution Approach 1:
The patent applies parameter changes by controlling the freezing temperature to -2°C or lower during aeration, and maintaining specific overrun (10-150%) and firmness (Stevens firmness ≥20) parameters. This allows the aerated dairy material to achieve both light texture for consumer appeal and dimensional stability through controlled physical state changes at specific temperature parameters
Solution Approach 2:
The patent creates a composite structure combining aerated dairy material (core) with non-aerated dairy material (shell). The aerated core provides light texture and consumer appeal, while the non-aerated shell with overrun ≤7% provides structural support and dimensional stability, preventing collapse at refrigerated temperatures
2Stability of the object's composition
If the aerated dairy material is kept frozen to maintain dimensional stability, then texture stability is improved, but the product becomes edible only within a narrow temperature range
Solution Approach 1:
The patent applies local quality by creating distinct regions with different properties: the inner aerated core maintains a frozen state for texture stability, while the outer non-aerated shell provides a transition zone. This allows the product to be stored frozen for stability but becomes edible across a broader temperature range as the shell melts first, then the core thaws to a consumable state
Solution Approach 2:
The patent applies preliminary action by pre-freezing the dairy material before aeration and shaping. This preliminary freezing creates a stable matrix that maintains the aerated structure during storage, then allows controlled thawing to achieve edibility, effectively preparing the product in advance to bridge the temperature stability-edibility gap
3Ease of manufacture
If the dairy material is aerated to high overrun (10-150%) to create light texture, then consumer appeal is improved, but the firmness and sliceability deteriorate
Solution Approach 1:
The patent applies segmentation by dividing the product into two functional parts: the aerated core (overrun 10-150%) provides light texture and consumer appeal, while the separate non-aerated shell (overrun ≤7%) provides firmness and sliceability. This segmentation allows each component to optimize its properties without compromising the other
Solution Approach 2:
The patent creates a composite material system where the aerated dairy core (high overrun) combines with the non-aerated dairy shell (low overrun). The core delivers light texture for consumer appeal, while the shell reinforces structural integrity and firmness, enabling both high aeration and adequate strength simultaneously
4Stability of the object's composition
If the aerated dairy material is shaped in frozen state, then dimensional stability is improved, but the processing complexity increases
Solution Approach 1:
The patent applies preliminary action by freezing the dairy material before aeration and shaping operations. This preliminary freezing step creates a stable, workable matrix that maintains dimensional stability during subsequent processing. The frozen state provides structural support that prevents collapse during shaping, while the process remains manageable through sequential operation steps
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach creates a multiple texture food product with a stable aerated core and a sliceable shell, maintaining texture and preventing collapse, enhancing the product's shelf life and consumer appeal by ensuring the aerated dairy material remains firm and stable at refrigerated temperatures.
Implementation Method 1
freezing the dairy material by cooling it to a temperature of -2°C or less
Implementation Method 2
aerating the frozen dairy material to an overrun of from 10 to 150%
Data Source
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AI summary
The present invention provides a process for the manufacture of a multiple texture food product comprising the steps of (1) providing a dairy material, freezing the dairy material by cooling it to a temperature of -2°C or less, (3) aerating the frozen dairy material, (4) shaping the aerated, frozen dairy material, (5) depositing the shaped, aerated, frozen dairy material on or between one or more layers of a food material which is not the aerated dairy material, wherein the aerated dairy material has a Stevens firmness of 20 or more at a temperature in the range of from 5 to 10°C and a water activity (aW) of 0.90 or more. The present invention further provides an aerated dairy material as well as a multiple texture food product which comprises a core of the aerated dairy material and a shell of a food material which is not the aerated dairy material.