Co-extruded Food Casing Stabilization via Multiphase Thermal Treatment
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Solution Overview
Problem
Existing methods for co-extrusion of food products with protein or protein-based casings face unpredictable and irreversible changes in casing material characteristics, leading to uncontrolled surface conditions and reduced processability, resulting in discarded products.
Innovation Solution
A method involving co-extrusion followed by a multiphase thermal treating process that controls the physical state of the protein casing, maintaining it in the helical or crystalline form to prevent unwanted changes, ensuring a smooth and stable surface, and incorporating a surface treating step and optional post-thermal treatments like chilling, cooking, or packing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If co-extrusion of food dough with protein casing is performed, then a flow of co-extruded food products is produced, but the casing material characteristics change unpredictably and irreversibly during manufacturing
Solution Approach 1:
The patent applies parameter changes by controlling the physical state of the protein casing through specific temperature and humidity parameters during processing. By maintaining the protein in a helical or crystalline form through controlled thermal treatment, the casing characteristics remain stable and predictable throughout manufacturing, resolving the unreliability issue while maintaining productivity
Solution Approach 2:
The patent utilizes phase transitions by preventing unwanted phase changes in the protein casing. By controlling processing conditions to maintain the protein in stable helical or crystalline phases and avoiding transitions to random coil structures, the casing maintains consistent characteristics during co-extrusion and subsequent processing steps
2Ease of manufacture
If process settings are changed after co-extrusion in subsequent processing steps, then the food product can be further processed, but the surface characteristics of the casing material change uncontrolled into undesired conditions
Solution Approach 1:
The patent applies preliminary action by pre-treating the co-extruded food products with a specific thermal process before subsequent processing steps. This preliminary thermal treatment stabilizes the protein casing structure in advance, preventing uncontrolled surface changes during later processing operations like brining, smoking, or cooking, thus maintaining manufacturing precision while ensuring ease of manufacture
Solution Approach 2:
The patent applies preliminary anti-action by implementing a surface treating step that prevents unwanted surface changes before they can occur. By applying this protective treatment early in the processing sequence, the casing surface is protected from developing sticky, inconsistent, or smudgy conditions during subsequent processing, resolving the contradiction between ease of manufacture and manufacturing precision
3Productivity
If the protein casing is not stabilized, then processing can proceed, but uncontrolled shrinkage and surface irregularities occur leading to discarded products
Solution Approach 1:
The patent applies parameter changes by establishing specific temperature and humidity parameters for thermal treatment that stabilize the protein casing. By controlling these parameters to maintain the protein in stable physical states, the harmful effects of uncontrolled shrinkage and surface irregularities are eliminated, allowing continuous processing without product discard and maintaining high productivity
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
This approach stabilizes the casing characteristics, preventing uncontrolled shrinkage and surface irregularities, allowing for better control over the texture and appearance of the final product, enhancing processability and maintaining product quality throughout processing.
Implementation Method 1
a multiphase thermal treating process that controls the physical state of the protein casing
Implementation Method 2
maintaining it in the helical or crystalline form to prevent unwanted changes
Implementation Method 3
the protein coagulates and/or precipitates and the casing layer is strengthened
Implementation Method 4
the protein coagulates and/or precipitates and the casing layer is strengthened
Data Source
AI summary
The present invention relates to a method and production line for in-line processing of food products. The method comprises the step of co-extruding a food dough into a flow of co-extruded food products having a casing that comprises a protein, or a hybrid casing of a protein and a polymer, wherein the method subsequently comprises the successive steps of: a) subjecting the flow of co-extruded food products to a surface treating step, b) subjecting the flow of food products to a thermal treating step, and c) optionally, subjecting the thermally treated flow of food products to a post-thermal treating step, wherein in step b) the flow of food products is at least subsequently subjected to a first thermal treating step, and a second thermal treating step.