Continuous Dough Foaming Process for Gluten-Free Baked Goods
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Solution Overview
Problem
Existing methods for producing gluten-free baked goods with high plant protein content and low carbohydrate content struggle to achieve the desired dough handling properties, volume, crumb structure, texture, and flavor, leading to inconsistent and inferior product quality.
Innovation Solution
A continuous process for coupled mixing and dosing of foamed doughs or pastes under increased static pressure, which involves adding a fluid to a dry powder mix in an extruder to create a highly viscous dough or paste, and then controlling the gas solution and dispersion within the dough or paste to achieve a stable foam structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If gluten is removed from the dough composition to produce gluten-free baked goods, then the allergenic potential is eliminated, but the foam structure stability deteriorates leading to oversized gas inclusions and volume loss
Solution Approach 1:
The invention changes the physical-chemical parameters of the dough system by replacing gluten with alternative protein sources and adjusting the composition of plant proteins and polysaccharides. This allows achieving stable foam structure without gluten by modifying the molecular network formation capabilities of the dough components, enabling gas bubble stabilization through alternative mechanisms.
Solution Approach 2:
The invention uses composite material systems combining multiple plant proteins and polysaccharides to replace gluten's functionality. The synergistic interaction between different protein sources and carbohydrate matrices creates a network structure that can trap and stabilize gas bubbles, compensating for the absence of gluten's elastic properties.
2Productivity
If physical foaming methods are used to introduce gas fractions into baked goods, then the foaming process is accelerated, but the foam structure stability deteriorates due to shear stress during transport leading to bubble coalescence
Solution Approach 1:
The invention performs preliminary stabilization of the foam structure during the mixing and dough formation stage, creating a robust protein-polysaccharide network before gas introduction. This pre-established molecular framework provides mechanical strength to withstand subsequent shear stresses during transport and processing, preventing bubble coalescence even under rapid physical foaming conditions.
Solution Approach 2:
The dough composition is specifically formulated with protective agents and optimized protein matrices that act as a cushioning network around gas bubbles. This protective layer absorbs and distributes shear stresses during transport, preventing direct mechanical damage to the foam lamellae and maintaining bubble integrity throughout the production process.
3Quantity of substance
If high plant protein content is used in gluten-free baked goods, then the nutritional value is improved, but the dough handling properties and product quality deteriorate
Solution Approach 1:
The invention applies local quality optimization by distributing different functional components throughout the dough matrix. Specific plant proteins and polysaccharides are positioned and formulated to perform localized functions: some components provide viscosity control for dough handling, while others contribute to gas bubble stabilization and crumb structure formation, enabling high protein content without compromising overall product quality.
Solution Approach 2:
The invention systematically adjusts multiple composition parameters including protein-to-carbohydrate ratios, moisture content, and the specific types and proportions of plant proteins and polysaccharides. By optimizing these parameters, the dough achieves both high nutritional value and desirable rheological properties for consistent manufacturing and excellent baked product quality.
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 process enables the production of gluten-free, protein-rich, low-carbohydrate baked goods with improved dough handling, volume, crumb structure, texture, and flavor, comparable to traditional baked goods, while also reducing production inefficiencies and eliminating the need for yeast.
Implementation Method 1
conveyed by a motor-driven extruder screw in a process chamber
Implementation Method 2
a fluid supply device 1 for adding a fluid 10 to the dry powder mix 6, thereby producing a highly viscous dough or paste
Implementation Method 3
a compressed gas supply device 15 for supplying a gas component under pressure, which is dissolved and/or finely dispersed in the dough or paste fluid phase
Implementation Method 4
a compressed gas supply device 15 for supplying a gas component under pressure, which is dissolved and/or finely dispersed in the dough or paste fluid phase
Implementation Method 5
a measuring device 19 which measures the degree of gas dissolution
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
The invention relates to a method, a control and/or regulating device, a device and products, as well as the use of such products. It demonstrates how gas-foamed products are produced from doughs or pastes in an elongated process chamber, whereby the static pressure required for gas dissolution is maintained in the process chamber up to the outlet opening, and only upon exit from a metering valve device downstream of the process chamber is the foaming in the dough or paste initiated in a controlled manner under predetermined process conditions under pressure reduction.