Co-extruded Food Casing with Barrier Layer
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Solution Overview
Problem
Existing food casing compositions, particularly those using collagen and alginate, face issues with calcium cation migration and myoglobin migration, leading to slimy skin and discoloration, which affect the appearance and cooking properties of fresh food products when refrigerated or frozen.
Innovation Solution
A method involving co-extrusion with a three-layer extruder to create a food product with a barrier layer between the edible filler and the casing layer, preventing calcium cation and myoglobin migration, using a combination of collagen, polysaccharides, and metal salts to maintain the strength and appearance of the casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a collagen and alginate casing mass is used in co-extrusion, then the casing strength is improved, but calcium cation migration occurs leading to slimy skin and impaired cooking properties
Solution Approach 1:
The casing structure is segmented into multiple functional layers: an inner barrier layer composed of collagen and polysaccharides that prevents calcium cation migration, and an outer casing layer that provides structural strength and gelation properties. This segmentation allows each layer to perform its specific function optimally without compromising the other.
Solution Approach 2:
The barrier layer acts as an intermediary between the food product interior and the outer casing layer. It specifically targets and blocks calcium cation migration while maintaining the integrity and strength of the overall casing structure through its collagen and polysaccharide composition.
2Strength
If the casing mass is subjected to shear forces during extrusion, then the casing strength is improved, but myoglobin migrates to the surface causing discoloration
Solution Approach 1:
The casing is divided into an inner barrier layer and an outer casing layer. The barrier layer specifically addresses myoglobin migration and discoloration issues, while the outer layer maintains structural integrity. This segmentation prevents myoglobin from reaching the surface even when shear forces are applied during extrusion.
Solution Approach 2:
The barrier layer serves as an intermediary protective layer between the meat mass and the outer casing. It prevents myoglobin migration to the surface, thereby avoiding discoloration, while still allowing the outer layer to be strengthened through controlled shear forces during extrusion.
3Duration of action of stationary object
If the food product is refrigerated for an extended period, then storage time is improved, but the casing appears discolorated and slimy due to calcium and myoglobin migration
Solution Approach 1:
The barrier layer is incorporated into the casing structure during the extrusion process, providing preliminary protection against calcium cation and myoglobin migration. This preliminary action prevents the development of discoloration and slimy coatings during subsequent refrigeration storage, allowing extended storage without appearance deterioration.
Solution Approach 2:
The barrier layer acts as a continuous intermediary protective barrier throughout the refrigeration storage period. It specifically blocks calcium cations and myoglobin from migrating to the surface, maintaining the casing appearance and preventing slimy coating formation during extended refrigeration.
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 results in a food product with a durable casing that retains strength and appearance for an extended period, preventing discoloration and sliminess during refrigeration or freezing, allowing for longer storage without deterioration.
Implementation Method 1
the barrier layer acts to prevent or delay the migration of both calcium cations and myoglobin in the co-extruded food product
Implementation Method 2
the barrier layer acts to prevent or delay the migration of both calcium cations and myoglobin in the co-extruded food product
Implementation Method 3
The co-extruded food product is then described as being brought into contact with a calcium salt solution. This treatment results in the casing (also referred to herein as covering or skin) gelating which increases the strength of the casing
Data Source
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AI summary
The invention relates to a method for preparing a food product by means of co-extrusion, wherein a casing composition (3a) and a barrier composition (4a) are co-extruded as layers upon an edible filler (5a), such that the edible filler is provided with a casing layer (3) and a barrier layer (4). After co-extrusion, said barrier layer is present between the edible filler and the casing layer. Advantageously, the casing composition comprises collagen, a polysaccharide and water. In embodiments, the casing composition may comprise collagen in an amount of between 2 and 7 wt.%, preferably between 3 and 6 wt. %; and, the casing composition may comprise a polysaccharide in an amount of between 1 and 5 wt.%, preferably between 2 and 4 wt.%. Further, the invention relates to a food product. The food product, for instance a sausage, comprises an edible filler, a casing layer, and a barrier layer, wherein the edible filler is covered by the barrier layer at least partly, and wherein the barrier composition is coverer by the casing layer at least partly.