Buckwheat Hull Particle Size Control in Snack Chip Sheeting
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Solution Overview
Problem
Conventional methods for producing whole grain sheeted snack foods, such as those containing buckwheat hulls, face challenges with dough sticking to sheeter rollers and the reduction of bran or pericarp particles during the sheeting process, leading to inconsistent removal and reduced visibility of whole grains in the final product.
Innovation Solution
A method involving a moist dough with added ground buckwheat hulls of specific particle size, between 99% passing through a 20-mesh U.S. standard screen and less than 20% through a 60-mesh screen, is used to create a visible whole grain snack without excessive accumulation on sheeter wires, ensuring minimal particle size reduction during sheeting and maintaining product visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If whole grain buckwheat flour containing hulls is used in conventional dough sheeting, then the product contains visible whole grains, but the bran or pericarp accumulates on the sheeter wire or scraper blade resulting in inconsistent removal of dough
Solution Approach 1:
The patent changes the particle size parameter of buckwheat hulls by grinding them to a specific size range (99% passing through 20-mesh screen, less than 20% through 60-mesh screen). This parameter modification allows the hulls to remain visible in the final product while being small enough to prevent accumulation on sheeter wires and scraper blades, thereby resolving the contradiction between whole grain content and dough removal consistency
Solution Approach 2:
The patent uses ground buckwheat hulls as an intermediary form between whole hulls and completely ground flour. This intermediate particle size serves as a mediator that maintains the visual indication of whole grains while eliminating the harmful accumulation effect on sheeting equipment
2Illumination intensity
If large pieces of bran or pericarp are included in the dough, then whole grain visibility is improved, but the particles are reduced in size by physical forces during sheeting process
Solution Approach 1:
The patent applies preliminary action by pre-grinding the buckwheat hulls to the desired particle size range before incorporating them into the dough. This pre-processing step ensures that the hulls are already at the optimal size for both visibility and preventing excessive reduction during sheeting, thereby maintaining particle size control throughout the manufacturing process
3Ease of manufacture
If buckwheat hull particles are made visible in the final product, then consumer identification of whole grain content is improved, but excessive accumulation occurs on the sheeting wire or scraper blade
Solution Approach 1:
The patent modifies the particle size parameter of buckwheat hulls to a specific range that balances two competing requirements: large enough to remain visible in the final product for consumer identification, but small enough to prevent excessive accumulation on sheeting equipment that would cause production interruptions
Data Source
AI summary
A multi-grain chip having buckwheat hull inclusion of a specific particle size. The buckwheat hull component of the chip provides a visual indication of the multi-grain characteristics of the chip. The particle size of the buckwheat hulls is specified in order to compliment production of the chip on existing corn chip lines and to enhance product visual attributes.