Chocolate Nugget Casting with Microalgae Coating
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Solution Overview
Problem
Existing chocolate manufacturing processes struggle to produce solid chocolate nuggets with microalgae that are less than 10 mm in diameter due to viscosity issues, and they fail to prevent color diffusion of microalgae during cooking.
Innovation Solution
A process involving precise temperature control and an overpressure step during chocolate pouring, combined with the use of a coating agent, to create chocolate nuggets with microalgae that maintain their color and size consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional chocolate manufacturing processes are used, then chocolate can be produced, but chocolate nuggets with microalgae less than 10 mm in diameter cannot be produced due to viscosity issues
Solution Approach 1:
The patent applies parameter changes by precisely controlling the temperature of the chocolate-microalgae mixture at 33°C during the casting process. This specific temperature parameter optimization reduces the viscosity of the mixture, enabling it to be properly cast into small nugget forms less than 10 mm in diameter that were previously unachievable with conventional processes
Solution Approach 2:
The patent uses an overpressure step during the casting process to facilitate the flow and proper formation of the chocolate-microalgane mixture into small nuggets. The applied pressure overcomes the viscosity resistance and enables successful casting of small-diameter chocolate chips containing microalgae
2Productivity
If chocolate chips with microalgae are produced using conventional processes, then chocolate chips can be manufactured, but the color of microalgae diffuses from the chocolate chip to the rest of the matrix during cooking
Solution Approach 1:
The patent introduces a coating agent as an intermediary layer between the microalgae-containing chocolate core and the surrounding cooking matrix. This coating layer acts as a barrier that prevents the diffusion of microalgae color and compounds into the surrounding food matrix during cooking, while still allowing the chocolate chips to be manufactured using conventional processes
3Length of moving object
If precise temperature control and overpressure step are applied, then small chocolate chips with microalgae can be cast, but the process complexity increases
Solution Approach 1:
The patent optimizes specific parameters (temperature at 33°C and applied pressure) to achieve the desired outcome of casting small chocolate chips. By precisely setting and maintaining these parameter values, the process becomes more controllable and reproducible, justifying the increased device complexity through consistent production of small-diameter chocolate chips with microalgae
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 effectively produces chocolate nuggets with microalgae that are less than 10 mm in diameter, preventing color diffusion during cooking and ensuring uniformity in food preparations.
Implementation Method 1
Heat the chocolate to a temperature between 45°C and 50°C
Implementation Method 2
Allow the mixture obtained in step iii. to drop to a temperature of exactly 33°C
Implementation Method 3
Apply a pressure of between 500 mbar and 2 bar to the product obtained in step b.
Implementation Method 4
Allow the chips obtained in step d. to cool to a temperature of between 4°C and 20°C
Data Source
AI summary
The present patent application relates to a method for manufacturing chocolate chips comprising microalgae, the chocolate chips and the use of said chocolate chips. The method enables perfect incorporation of the microalgae through the use of a precise temperature and the pouring of small-sized chocolate chips by means of a pressure boosting step at the time of pouring. A coating agent is also introduced in order to solve the problem of microalgae colour diffusion. These chocolate chips are ideal for use in food preparations, for example in cookies, cereal bars, toppings, or mueslis.