Baked Goods Shelf Life via Pressure-Controlled Sterilization
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Solution Overview
Problem
Existing methods for producing baked goods with extended shelf life often result in sensory changes, such as reduced moisture and a sweet taste, which are perceived negatively by consumers.
Innovation Solution
A method involving baking a mixture in a closed aluminum foil pan under controlled pressure and temperature conditions, using inert gases to maintain internal pressure corresponding to external pressure, allowing for simultaneous baking and sterilization without additional sugar additions, preserving the texture and moisture of baked goods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If baked goods are preserved using traditional methods (pasteurization, water activity reduction, inert gas packaging), then shelf life is extended to several months, but sensory properties are altered (lower moisture, sweet taste, texture changes)
Solution Approach 1:
The patent combines baking and sterilization into a single integrated process. The baking pan serves dual functions as both the baking container and the sterilization chamber, eliminating the need for separate packaging and post-baking sterilization steps. This merging allows the product to achieve long shelf life while preserving natural sensory properties without requiring additional sugar or moisture reduction.
Solution Approach 2:
The baking pan is designed with multi-functionality, serving as both the baking mold and the sterilization vessel. The pan is subjected to steam sterilization after baking, and the same pan is used for storage and reheating. This universal design eliminates the need for separate packaging materials and preserves the original sensory characteristics of the baked goods.
2Duration of action of stationary object
If water activity is reduced by adding soluble substances (sugar, salt, glycerine), then shelf life is extended from days to months, but the product develops a sweet taste and altered texture
Solution Approach 1:
The patent converts the harmful effect of microorganisms into a benefit by using steam sterilization during the baking process. The steam not only cooks the batter but also sterilizes the entire system including the baking pan, creating a microbiologically stable environment without requiring sugar or chemical preservatives. This approach preserves the natural flavor and texture while achieving long shelf life.
3Reliability
If baked goods are pasteurized in packaging film, then microbiological stability is achieved, but moisture content decreases and taste becomes sweeter
Solution Approach 1:
The patent performs sterilization as a preliminary action during the baking process itself, before the product is packaged for storage. The steam sterilization occurs while the product is still in the baking pan, creating a microbiologically stable environment early in the process. This preliminary sterilization preserves moisture content and prevents the need for post-baking moisture reduction that occurs with traditional pasteurization methods.
4Duration of action of stationary object
If baked goods are stored in closed containers with inert gas atmosphere, then oxidative and microbiological processes are throttled, but the product undergoes sensory changes during storage
Solution Approach 1:
The patent uses steam sterilization to convert the baking process into a dual-purpose operation that simultaneously cooks and sterilizes the product. The steam creates a microbiologically stable environment that prevents spoilage during storage without requiring inert gas packaging. This approach maintains texture stability and prevents the sensory changes that occur with traditional inert gas storage methods.
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
The method produces baked goods with a shelf life of over 12 months without sensory changes, maintaining a soft, crust-free structure and high moisture content, perceived as pleasant and microbiologically stable.
Implementation Method 1
at least one inert gas and/or air is applied to the baking mass, the density of the baking mass being between 0.4 and 0.8 g/cm³ after exposure to the inert gas and/or air
Implementation Method 2
baking the at least one closed baking mold in at least one reactor, wherein in a first phase (phase 1) the reactor pressure is built up to values between 120 kPa and 400 kPa over a period of 3 to 30 min takes place at a reactor temperature between 80°C and 300°C
Implementation Method 3
the flexible baking mold deforms as a result of a pressure difference between the reactor interior and exterior
Implementation Method 4
a steam atmosphere is introduced into the reactor or the reactor is filled with heated gas
Data Source
Figure 1
AI summary
The present invention relates to a method for producing baked goods having a long shelf life, in particular in a closed baking mould, comprising the steps a) producing a baking mix, in particular cake mix, and exposing the baking mix to at least one inert gas and/or air, b) charging the baking mix into at least one baking mould and closing the at least one baking mould, c) baking the baking mix in the at least one closed baking mould in at least one reactor, wherein, in a first phase (phase 1), a reactor pressure and a reactor temperature build up, wherein the reactor pressure at any time point corresponds to an internal pressure in the closed baking mould, in a second phase (phase 2), the reactor pressure and reactor temperature set in the first phase (phase 1) are maintained over a period in which the baking mass is baked, and in a third phase (phase 3), the reactor pressure and the reactor temperature are lowered stepwise, wherein the reactor pressure at any time point corresponds to the internal pressure in the closed baking mould, and d) removing the closed baking mould containing the baked good from the reactor.