Co-extruded Food Coating pH Control via Brine Solutions
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Solution Overview
Problem
Existing methods for co-extrusion of food products face challenges in controlling the characteristics of protein-based casing materials, leading to unpredictable and irreversible changes in surface properties, resulting in uncontrolled surface conditions and reduced processability of food products.
Innovation Solution
A set of brine solutions comprising a salt-saturated medium for moisture content reduction and a buffer-salt solution for pH maintenance is used in a method that includes co-extrusion and subsequent processing steps to control the physical state of proteins, maintaining the coating's helical or crystalline form and preventing irreversible changes in surface characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If protein-based casing material is used for co-extrusion, then the coating provides structural strength, but the surface characteristics change irreversibly during subsequent processing
Solution Approach 1:
The patent applies parameter changes by controlling the pH of brine solutions during processing. Specifically, maintaining pH within 4.5-6.5 during coagulation and 5.0-7.0 during precipitation prevents irreversible changes in surface characteristics while preserving casing strength. This pH control mechanism stabilizes the protein structure throughout subsequent processing steps.
Solution Approach 2:
The patent implements preliminary action by pre-coagulating the protein casing material before extrusion and pre-precipitating it in controlled pH conditions. This preliminary treatment establishes a stable protein structure that resists irreversible changes during subsequent processing, thereby maintaining surface characteristics while providing structural strength.
2Adaptability or versatility
If process settings are changed after co-extrusion to modify product characteristics, then product differentiation is achieved, but uncontrolled irreversible changes in surface properties occur
Solution Approach 1:
The patent uses controlled parameter changes through sequential brine treatments with specific pH ranges. The first brine solution (pH 4.5-6.5) enables coagulation for initial structure formation, while the second brine solution (pH 5.0-7.0) provides precipitation for surface stabilization. This controlled parameter progression allows product differentiation without causing uncontrolled surface changes.
Solution Approach 2:
The patent implements feedback control by monitoring and maintaining pH levels within specific ranges during each processing step. This feedback mechanism ensures that process settings can be adjusted for product differentiation while preventing irreversible surface changes, as deviations from the optimal pH range would trigger corrective actions.
3Ease of manufacture
If brine processing is used to enhance product characteristics, then flavor and texture are improved, but pH fluctuations cause coating characteristics to change
Solution Approach 1:
The patent applies parameter changes by using two distinct brine solutions with controlled pH ranges. The first brine (pH 4.5-6.5) provides coagulation for texture enhancement, while the second brine (pH 5.0-7.0) provides precipitation for pH stabilization. This sequential parameter control enhances product characteristics while preventing uncontrolled pH fluctuations in the coating.
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 significantly enhances the processability of co-extruded food products by maintaining the smoothness and stability of the coating, ensuring consistent product quality throughout processing and thermal treatment stages.
Implementation Method 1
a coating moisture content reducing step using the first brine solution, the first brine solution comprising a salt solubilised in an aqueous medium
Implementation Method 2
a coating pH setting step using the second brine solution, the second brine solution comprising a buffer salt solubilised in an aqueous medium
Implementation Method 3
Under the influence of the coagulation solution the protein coagulates and/or precipitates and the casing layer is strengthened
Data Source
AI summary
The present invention relates to a set of brine solutions for use in a method for in-line processing of food products, said method comprises the steps of a) co-extruding a food dough into a flow of co-extruded food products having a coating that comprises a protein, or a hybrid coating of a protein and a polymer, and b) subjecting the flow of co-extruded food products to a food product strengthening step, said food product strengthening step comprises the step of subjecting the flow of food products to a first brine solution comprising a salt solubilised in an aqueous medium, and a second brine solution comprising a buffer salt solubilised in an aqueous medium. The present invention further relates to a method for in-line processing of food products using the set of brine solutions of the present invention and a lactate salt comprising brine solution.