Low Moisture Cheese Coating for Popcorn Preservation

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Solution Overview

Problem

Existing popcorn and cheese-based snacks require lyophilization for preservation, are not mechanically stable, and consume high energy due to high moisture content and lack of cohesion, making them prone to mold growth and crumbly texture.

Innovation Solution

A popcorn and cheese-based food with entire grains coated in a low moisture content cheese, either before or after cooking, which maintains a moisture level below 8% without lyophilization, using a method that involves melting and cooking the cheese at medium to high temperatures to form a stable, crispy layer that protects the popcorn from degradation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high moisture content cheese is used in popcorn snacks, then the cheese provides good melting and coating properties, but the snack requires lyophilization for preservation and consumes high energy

Engineering Contradiction:

Improvepreservation stabilityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent changes the moisture content parameter of the cheese from high (>35%) to low (<35%) to eliminate the need for lyophilization. This parameter change allows the snack to be preserved at ambient temperature without energy-intensive freezing and drying processes, while still achieving acceptable preservation stability through the low moisture content cheese coating.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If high moisture content cheese is used, then the cheese melts well, but the snack is prone to mold growth and requires refrigeration

Engineering Contradiction:

Improvecheese melting propertyVSAvoidmold growth risk

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the moisture content parameter of the cheese to below 35%, which fundamentally alters the snack's susceptibility to mold growth. The low moisture content creates an environment unfavorable for microbial development, eliminating the need for refrigeration while still allowing the cheese to provide adequate coating and binding functions.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If the snack structure is made with multiple layers of cheese and popcorn, then cohesion between layers is improved, but the snack becomes mechanically unstable and crumbles easily

Engineering Contradiction:

Improvelayer cohesionVSAvoidmechanical stability

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies different qualities to different parts of the snack structure. The cheese coating is specifically formulated with low moisture content to provide a protective, stable outer layer, while the popcorn interior maintains its natural structure. This local differentiation of properties allows the coating to provide mechanical stability without compromising the overall snack structure.

Inventive Principle:

Principle #3Local quality

4Duration of action of stationary object

If lyophilization is used for preservation, then the snack can be stored long-term, but the process consumes high energy and time

Engineering Contradiction:

Improvestorage durationVSAvoidlyophilization energy

Core Design Contradiction:

Duration of action of stationary objectVSUse of energy by stationary object

Solution Approach 1:

The patent changes the moisture content parameter of the cheese to below 35% before snack formation, which fundamentally alters the preservation requirements. This initial parameter setting allows the snack to achieve long-term storage stability at ambient temperature without undergoing energy-intensive lyophilization, thereby eliminating both time and energy costs associated with the drying process.

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 solution allows for long-term preservation without refrigeration, reduces energy consumption, and maintains organoleptic characteristics, providing a mechanically stable snack with minimal moisture absorption that prevents mold growth and crumbliness.

Implementation Method 1

melting and cooking the cheese at medium to high temperatures to form a stable, crispy layer

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

melting and cooking the cheese at medium to high temperatures to form a stable, crispy layer that protects the popcorn from degradation

Methodology Applied

Scientific EffectCooking: Heating

Data Source

PatentUS10798956B2Food based on popcorn and cheese, and respective production method

Publication Date: 2020.10.13 SLB SRL

AI summary

A method is provided for producing at least one popcorn grain substantially entire and coated, completely or partially, with at least a first layer of a first melted cheese directly in contact with the popcorn grain. The first melted cheese has an initial moisture content of less than 35%, or alternatively, the first melted cheese is cooked too and its moisture after cooking is lower than 8%. A second layer of a second cheese may be applied to the food product.