Integrated Bread Shelf Life Extender Composition
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Solution Overview
Problem
Baked bread products, particularly white bread, have a short shelf life due to physical, chemical, and microbiological changes, leading to staling and economic losses, with existing solutions either extending shelf life but compromising texture or preventing mold without maintaining freshness.
Innovation Solution
An integrated shelf life extender composition comprising 10-80 wt% fat, 1-10 wt% hydrocolloid, 1-5 wt% glyceride, 1-5 wt% dough strengthener, and 1-10 wt% flavor components is added to the dough mix, creating a novel delivery system that maintains texture, moisture, and flavor retention for up to 7 days.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional bread production methods are used, then manufacturing speed and cost efficiency are improved, but shelf life is limited to less than five days due to staling and microbiological changes
Solution Approach 1:
The patent applies preliminary action by incorporating specific ingredients (emulsifiers, stabilizers, antioxidants, and preservatives) into the dough before baking. These ingredients are pre-selected and pre-dosed to prevent staling and microbiological degradation during storage, thereby extending shelf life without compromising the efficiency of modern production methods
Solution Approach 2:
The patent uses composite materials by combining multiple functional ingredients (emulsifiers, stabilizers, antioxidants, and preservatives) in specific ratios within the dough formulation. This composite approach creates synergistic effects that simultaneously address texture maintenance, oxidative stability, and microbial protection, achieving extended shelf life while maintaining production efficiency
2Duration of action of stationary object
If shelf life extenders are added to prevent staling, then duration of action is improved, but texture and moisture quality deteriorate
Solution Approach 1:
The patent applies parameter changes by optimizing the ratios and concentrations of emulsifiers, stabilizers, antioxidants, and preservatives in the dough formulation. By precisely controlling these compositional parameters, the patent achieves extended shelf life while maintaining optimal texture and moisture characteristics throughout the storage period
Solution Approach 2:
The patent applies local quality by assigning specific functional roles to different ingredient components: emulsifiers for texture stability, stabilizers for moisture retention, antioxidants for preventing oxidative rancidity, and preservatives for microbial control. Each component addresses specific local quality aspects, ensuring comprehensive protection without compromising overall bread quality
3Reliability
If individual ingredients are sourced and dosed separately, then ingredient functionality is optimized, but process complexity and measurement precision requirements increase
Solution Approach 1:
The patent applies merging by integrating multiple functional ingredients (emulsifiers, stabilizers, antioxidants, and preservatives) into a single standardized dough formulation or premix. This consolidation maintains the functional benefits of each individual ingredient while significantly simplifying the dosing process, reducing measurement errors, and lowering process complexity for manufacturers
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 integrated composition effectively extends the shelf life of bread by maintaining texture and moisture, reducing staling, and enhancing flavor perception, while ensuring microbiological stability, thus reducing food waste and economic losses.
Implementation Method 1
about 1 wt. % to about 10 wt. % of at least one hydrocolloid adsorbent
Implementation Method 2
about 10 wt. % to about 80 wt. % of at least one fat composition
Implementation Method 3
about 1 wt. % to about 5 wt. % of at least one dough strengthener
Data Source
AI summary
A method of extending the shelf life of a baked bread product containing wheat flour, includes providing for addition to a dough mix containing at least a portion of the wheat flour in the baked bread product recipe, an integrated shelf life extender composition which comprises in weight percent based on the total weight of the shelf life extender composition:a) about 10 wt. % to about 80 wt. % of at least one fat composition;b) about 1 wt. % to about 10 wt. % of at least one hydrocolloid adsorbent;c) about 1 wt. % to about 5 wt. % of at least one glyceride;d) about 1 wt. % to about 5 wt. % of at least one dough strengthener;e) about 1 wt. % to about 10 wt. % of at least one flavour component.The integrated shelf life extender composition is added to the dough mix in an amount of about 0.5 wt. % to about 2 wt. %, based on the total weight of the baked bread product recipe. The dough mix containing the shelf life extender composition is thereafter incorporated into the baked bread product recipe in a particular embodiment, the baked bread product is white bread.