Method for making reconstituted plant material using co-extrusion

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Solution Overview

Problem

There is a need to improve products derived from plant materials for nutraceutical, phytotherapeutical, food supplement, or food use, making them easier to use and more appealing to consumers while enhancing sensory characteristics such as taste, flavor, and aroma.

Innovation Solution

A method involving the extraction of plant substances to obtain fibrous plant residues and plant extracts, followed by separation and extrusion of the residues through die openings to create three-dimensionally shaped products with controlled material densities, allowing for controlled liquid absorption and expansion to achieve desired shapes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If plant materials are processed into conventional forms (pills, capsules, powders), then they provide essential nutrients, but they are difficult to use and handle

Engineering Contradiction:

Improveease of useVSAvoidnutritional value

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The invention changes the physical form parameter of plant materials from conventional powders or capsules to three-dimensional reconstituted structures with controlled porosity and density, making them easier to handle while preserving nutritional content through controlled substance release

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates composite structures by combining fibrous plant residues with plant extracts in a reconstituted matrix, integrating both structural integrity for ease of handling and nutritional functionality for reliable nutrient delivery

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If plant materials are concentrated into extracts, then they provide essential substances, but they lack sensory characteristics (taste, flavor, aroma)

Engineering Contradiction:

Improveconcentration of essential substancesVSAvoidsensory characteristics

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The invention applies local quality by incorporating plant extracts specifically into the porous matrix structure at controlled locations and concentrations, ensuring both high substance concentration and preservation of sensory characteristics through localized impregnation rather than uniform mixing

Inventive Principle:

Principle #3Local quality

3Strength

If fibrous plant residues are used directly, then they maintain structural integrity, but they cannot absorb controlled amounts of liquid at certain locations

Engineering Contradiction:

Improvestructural integrityVSAvoidcontrolled liquid absorption

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The invention transforms fibrous plant residues into a porous reconstituted material with controlled pore size and distribution, enabling the material to maintain structural integrity while absorbing controlled amounts of liquid at specific locations through the engineered porous network

Inventive Principle:

Principle #31Porous materials

4Quantity of substance

If plant materials are processed through extraction, then substances are separated, but the fibrous residues lose their original shape and structure

Engineering Contradiction:

Improveseparation of plant substancesVSAvoidoriginal plant structure

Core Design Contradiction:

Quantity of substanceVSShape

Solution Approach 1:

The invention applies preliminary action by collecting and preserving fibrous plant residues immediately after extraction before they degrade, then rapidly reconstituting them into three-dimensional structures that restore and maintain the original plant shape and structure for subsequent use

Inventive Principle:

Principle #10Preliminary action

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 method enables the production of reconstituted plant products that are easy to use, offer improved sensory characteristics, and provide controlled release of substances, enhancing their nutritional and sensory value.

Implementation Method 1

separately extruding the two or more different fibrous plant residues through die openings of the two or more separate extruder to obtain two or more extrudates

Methodology Applied

Scientific EffectExtrusion: Extrusion

Implementation Method 2

The plants are forced through a die or nozzle in a known extrusion process

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 3

the product has different material densities to be able to absorb controlled amounts of liquid at certain locations such that the product expands in a controlled manner and assumes a desired shape when immersed into a liquid

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentEP3185702B1Method for making reconstituted plant material using co-extrusion

Publication Date: 2025.04.09 SWM LUXEMBOURG

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AI summary

The present invention relates to a method for making products of reconstituted plant material using extrusion and/or molding processes, wherein the reconstituted plant material comprises a fibrous plant product and a plant extract applied thereto. Further, the invention relates to the products obtained by these methods. The plants used may be all plants comprising one or more substances of interest for an edible product.