Heating Bran and Germ to Volatilize Wheaty Flavor
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Solution Overview
Problem
Current methods for producing whole grain flours result in baked goods with a dry, grainy texture and a 'wheaty' or 'hay' taste due to the presence of volatile wheaty flavor components and excessive gelatinization, which affects gluten network development and dough machinability.
Innovation Solution
A process involving heating ground bran and germ components with controlled moisture content and temperature in a conveying and mixing device to volatilize volatile flavor components, reducing moisture and achieving a buttery, nutty, caramelized flavor while minimizing starch gelatinization, thereby improving texture and flavor without compromising gluten stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If whole grains are heated to inactivate enzymes, then enzyme inactivation is achieved, but excessive gelatinization of starch occurs and gluten network development is adversely affected
Solution Approach 1:
The patent applies parameter changes by precisely controlling heating temperature (285°F to 410°F), moisture content (5% to 25%), and heating time to achieve enzyme inactivation while preventing excessive starch gelatinization. This optimized parameter combination resolves the contradiction between complete enzyme inactivation and maintaining starch structure stability.
Solution Approach 2:
The patent employs preliminary action by adjusting moisture content to optimal levels before heating, and by using a conveying and mixing device that prepares the bran and germ component for uniform heat distribution. This preliminary preparation ensures that subsequent heating achieves enzyme inactivation without causing excessive gelatinization.
2Object-generated harmful factors
If volatile wheaty flavor components are removed through heating, then wheaty taste is reduced, but texture and flavor quality may deteriorate
Solution Approach 1:
The patent uses parameter changes by controlling heating temperature (285°F to 410°F) and moisture content (5% to 25%) to selectively volatilize unwanted wheaty flavor components while preserving desirable texture and flavor qualities. The specific parameter range achieves flavor improvement without quality deterioration.
Solution Approach 2:
The patent applies the extraction principle by selectively removing volatile wheaty flavor components through controlled heating and moisture reduction, while retaining the beneficial structural and sensory properties of the bran and germ component.
3Object-generated harmful factors
If moisture content is reduced during heating, then wheaty flavor is eliminated, but energy consumption increases
Solution Approach 1:
The patent optimizes energy efficiency by establishing specific moisture content ranges (5% to 25%) and heating temperature ranges (285°F to 410°F) that achieve wheaty flavor elimination with minimal energy consumption. The conveying and mixing device further enhances energy efficiency through continuous processing and uniform heat distribution.
Solution Approach 2:
The patent employs continuous processing through a conveying and mixing device that maintains continuous heat treatment and moisture removal, improving energy efficiency compared to batch processing by eliminating heating cycles and maintaining optimal processing conditions throughout.
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 process produces whole grain flours with a non-gritty texture and enhanced flavor, reduced lipase activity, and improved baking functionality, resulting in baked goods with a buttery, nutty, caramelized taste and improved sensory attributes.
Implementation Method 1
The heating, such as by direct or indirect steam injection, may be conducted to heat the bran and germ component or fraction to a temperature of from about 285° F. to about 410° F. to volatilize volatile wheaty flavor components and moisture in the ground bran and germ component
Data Source
AI summary
The flavor and texture of a ground bran and germ component or fraction is improved by subjecting the ground bran and germ component to heating while conveying and mixing the ground bran and germ component in a conveying and mixing device. The heating may be conducted to heat the bran and germ component or fraction to a temperature of from about 285° F. to about 410° F. to volatilize volatile wheaty flavor components and moisture in the ground bran and germ component and to develop a buttery, nutty, caramelized flavor in the bran component. The wheaty flavor components and moisture are removed from the mixing and conveying device during the heat treatment. The use of substantial moisture reduction with high temperature heating at a low moisture content provides flavor development while reducing wheatiness, graininess, or rawness, and also achieves lipase inhibition and stabilization against rancidity from free-fatty acid production.