Shelf-Stable Cake Truffle via Water Activity Control
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Solution Overview
Problem
Commercial cake pop and truffle products have a short shelf life due to texture deterioration and microbial growth, especially yeast and mold, which can lead to mold formation in less than 7 days when stored at ambient conditions.
Innovation Solution
A modified cake formula and baking process that reduces water activity to less than 0.71, using ingredients like glycerine, mono- and di-saccharide sugar, modified starch, and micro crystalline cellulose, combined with a binding agent and a fat-based confectionary coating, to create a shelf-stable cake truffle product with a core, crème layer, and outer shell, maintaining moistness and preventing microbial growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a conventional cake formula and baking process are used, then the product has good texture and moistness, but the shelf life is short due to microbial growth and texture deterioration
Solution Approach 1:
The patent applies parameter changes by modifying the water activity (Aw) of the cake crumbs through formulation adjustments. Specifically, the cake formula is modified to achieve a water activity of less than 0.71, which creates an environment unfavorable for microbial growth while maintaining acceptable texture and moistness. This parameter change directly addresses the contradiction by making the product shelf-stable without sacrificing sensory quality.
Solution Approach 2:
The patent uses composite materials by combining cake crumbs with a binding agent to form a matrix structure. This composite approach allows the binding agent to interact with water molecules and control moisture distribution, thereby reducing water activity and preventing microbial growth while maintaining the desired texture and structural integrity of the cake truffle product.
2Reliability
If the water activity is reduced to prevent microbial growth, then the shelf life is extended, but the moistness and texture of the cake may deteriorate
Solution Approach 1:
The patent optimizes the water activity parameter to a specific range (less than 0.71) that simultaneously achieves microbial safety and maintains acceptable texture and moistness. This precise parameter control resolves the contradiction by identifying the optimal Aw level where both microbial inhibition and sensory quality are satisfied.
Solution Approach 2:
The patent applies local quality by creating a heterogeneous distribution of moisture within the cake crumb matrix. The binding agent creates regions with different moisture contents, allowing areas with lower water activity to prevent microbial growth while maintaining overall product moistness and texture through the matrix structure.
3Ease of operation
If the product is stored at ambient conditions, then the convenience of storage is improved, but the product may mold in less than 7 days
Solution Approach 1:
The patent modifies the water activity parameter of the cake crumbs to less than 0.71, which creates conditions that prevent mold and yeast growth at ambient storage temperatures. This parameter modification allows the product to be stored conveniently at room temperature without refrigeration while maintaining microbial safety for extended periods.
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 shelf-stable cake truffle product extends shelf life to over 1 month, with minimal microbial growth, maintaining a desirable texture and moisture, outperforming commercial benchmarks in sensory analysis.
Implementation Method 1
a shelf-stable, especially micro-safe cake with water activity (Aw) less than about 0.71, less than about 0.7 or ideally less than about 0.65
Implementation Method 2
modified starch, such as RemyGel® 663, a fine cross-linked acetylated distarch phosphate, a modified potato starch, a modified tapioca starch or other similar modified starches or other similar hydrocolloids, such as polysaccharides or proteins to increase viscosity of the dough and retain moisture of the final product
Implementation Method 3
The baked cake is then ground into fine crumbs and blended with a binding agent such as a syrup, fat-based crème or frosting to make a cake truffle
Implementation Method 4
an outer shell surrounding the core and/or the optional crème layer. The outer shell is a fat-based confectionary coating
Data Source
AI summary
A modified cake formula and baking process to have a shelf-stable food product, especially micro-safe cake with water activity (Aw) less than about 0.71, less than about 0.7 or ideally less than about 0.65. The process involves grinding the baked cake fine crumbs, and blending the resulting crumbs with a binding agent to make a cake truffle, wherein the cake truffle has a water into activity less than around 0.7, and optionally covering the cake truffle with a confectionary coating, or with milk chocolate.