Bonito Extract Low-Temperature Vacuum Extraction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for preparing bonito extracts using hot water extraction result in products with off-flavor, bitter taste, and fishy odor, necessitating the use of chemical additives to mask these flaws.

Innovation Solution

A method involving the extraction of katsuobushi under low temperature and reduced pressure conditions to produce a bonito extract with reduced off-flavor and bitter taste and increased flavor and umami taste, without the need for chemical additives.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If hot water extraction method is used to maximize extraction of flavor components, then extraction efficiency is improved, but off-flavor, bitter taste, and fishy odor increase

Engineering Contradiction:

Improveextraction efficiencyVSAvoidoff-flavor and bitter taste

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the extraction parameters from high temperature to low temperature (40-60°C) and from atmospheric pressure to reduced pressure (50-150 mmHg). This parameter change allows efficient extraction of umami components while preventing the extraction of bitter taste components and off-flavor substances that are extracted at high temperatures.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal extraction mechanism (hot water extraction) with a pressure-driven extraction mechanism (reduced pressure extraction). By using vacuum or reduced pressure conditions, the extraction process occurs at low temperatures, fundamentally changing the extraction mechanism to avoid thermal degradation and unwanted compound extraction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Quantity of substance

If hot water extraction is used, then flavor components are extracted, but chemical additives are required to mask bitter taste and off-flavor

Engineering Contradiction:

Improveflavor componentsVSAvoidneed for chemical additives

Core Design Contradiction:

Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent converts the limitation of low temperature extraction (slower extraction kinetics) into a benefit by using reduced pressure conditions. The reduced pressure lowers the boiling point of water and enhances mass transfer, compensating for the slower extraction rate at low temperatures. This combination allows efficient extraction of desirable flavor components without extracting bitter and off-flavor compounds, eliminating the need for chemical additives to mask defects.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Quantity of substance

If extraction time is extended to maximize flavor extraction, then umami taste increases, but bitter taste and off-flavor also increase

Engineering Contradiction:

Improveumami taste componentsVSAvoidbitter taste and off-flavor

Core Design Contradiction:

Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent changes the temperature parameter to low temperature (40-60°C), which creates a selective extraction environment. At this temperature range, umami components are extracted efficiently while bitter taste components and off-flavor substances remain largely unextracted. The reduced pressure condition further enhances this selectivity by facilitating the extraction of volatile umami compounds while preventing the extraction of non-volatile bitter and off-flavor compounds.

Inventive Principle:

Principle #35Parameter changes

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 low temperature and reduced pressure extraction method effectively reduces off-flavor and bitter taste components while enhancing the umami taste and overall sensory characteristics of the bonito extract, allowing for the production of high-quality tuna fish sauce without chemical additives.

Implementation Method 1

a method for preparing a bonito extract by extracting katsuobushi under low temperature and reduced pressure

Methodology Applied

Scientific EffectExtraction: Liquid-Liquid Extraction

Data Source

PatentUS20250098719A1Skipjack tuna extract having increased flavor and umami, and method for producing same

Publication Date: 2025.03.27 CJ CHEILJEDANG CORP

AI summary

The present disclosure relates to a method for preparing a bonito extract by extracting katsuobushi under low temperature and reduced pressure; a bonito extract which is prepared by extraction under low temperature and reduced pressure, and has reduced off-flavor and bitter taste and increased flavor and umami taste; a method for preparing a tuna fish sauce, comprising a processing step of mixing and sterilizing the bonito extract and seasoning ingredients; and a tuna fish sauce.