Amorphous 1-kestose Dough Shaping for Industrial Baking
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Solution Overview
Problem
Existing methods for producing baked confectionery on an industrial scale using crystalline 1-kestose face challenges due to dough becoming glutinous, making it difficult to shape and resulting in poor texture and shape quality.
Innovation Solution
A method involving dough composition with 30-100% crystalline 1-kestose, water-containing oil and fat, and starch ingredients, allowing for industrial-scale production of baked confectionery with improved shaping and texture, using a water-in-oil emulsified oil and fat, and baking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If crystalline 1-kestose is used as an oligosaccharide in dough, then the dough can be shaped and industrial-scale production is enabled, but the dough becomes glutinous and loses its shape retention
Solution Approach 1:
The patent changes the physical state parameter of 1-kestose from crystalline to amorphous form, and adjusts the concentration parameter to 1-10% by weight in the dough composition. This parameter change resolves the contradiction by enabling both shape retention and industrial scalability without the glutinous problem associated with crystalline forms at higher concentrations.
Solution Approach 2:
The patent creates a composite dough system combining flour, water, fat, and amorphous 1-kestose in specific proportions. This composite approach allows the 1-kestose to function as a functional ingredient for industrial production while the overall composition maintains proper dough rheology and shape retention through the synergistic interaction of all components.
2Reliability
If crystalline 1-kestose is used in dough, then physiological functions are maintained, but the dough becomes difficult to shape and lacks mechanical strength
Solution Approach 1:
The patent changes the physical state of 1-kestose from crystalline to amorphous and reduces the concentration to 1-10% by weight. This parameter change maintains the physiological active functions (prebiotic effect, blood sugar control) while eliminating the negative impact on dough mechanical strength and shapeability that occurs with crystalline forms.
Solution Approach 2:
The patent uses amorphous 1-kestose as a functional copy of crystalline 1-kestose, retaining the essential physiological activities while modifying the physical properties to be compatible with industrial dough processing. The amorphous form serves as a functional equivalent that doesn't compromise dough strength.
3Reliability
If crystalline 1-kestose is used in dough, then oligosaccharide functions are preserved, but the dough lacks adhesion and cannot be rolled or cut properly
Solution Approach 1:
The patent changes the physical state of 1-kestose from crystalline to amorphous and adjusts the concentration to 1-10% by weight. This parameter change preserves the physiological functions (bifidobacterium promotion, cholesterol metabolism) while enabling proper dough adhesion, rolling, and cutting operations required for industrial production.
Solution Approach 2:
The patent introduces water and fat as intermediary components that mediate between the amorphous 1-kestose and the dough matrix. These intermediaries ensure proper distribution and interaction of 1-kestose with other dough components, enabling good adhesion and processability while maintaining the functional properties of the oligosaccharide.
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
Enables the production of baked confectionery with excellent physiologically active functions, such as promoting bifidobacterium growth and cholesterol metabolism, while maintaining a crispy texture and shape suitable for commercial products.
Implementation Method 1
the water-containing oil and fat is a water-in-oil emulsified oil and fat
Implementation Method 2
confectionery which is made by preparing the dough by utilizing the gelatinization of starches
Data Source
AI summary
An object of the present invention is to provide baked confectionery that can be made on an industrial scale, and are sufficiently shapable even when using an oligosaccharide having physiological functions, such as decay resistance, the effect of promoting bifidobacterium growth, the effect of improving the metabolism of lipids such as cholesterol, the effect of regulating impunity, and the effect of inhibiting a rise in blood sugar level. According to the present invention, there is provided baked confectionery comprising flour, a saccharide comprising 1-kestose, and an oil and fat comprising a water-containing oil and fat; and a method for producing such baked confectionery.