Cookie Baking Using Superheated Steam Impingement
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Solution Overview
Problem
Traditional methods for producing shortbread-type cookies result in products with poor organoleptic properties when attempting to increase dietary fibre content and reduce lipid and simple sugars, leading to dense, hard, and unpleasant textures.
Innovation Solution
A process involving the exposure of cookie dough to a hot gas mixture of hot air and superheated steam using an impingement system, with specific temperature and steam content controls, to achieve baking in shorter times and maintain nutritional properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional baking methods are used to produce cookies with increased dietary fibre content and reduced lipid and simple sugars, then nutritional properties are improved, but organoleptic properties deteriorate resulting in dense, hard, and unpleasant textures
Solution Approach 1:
The patent applies parameter changes by modifying the baking process parameters: using superheated steam (temperature above 100°C) instead of traditional hot air convection, and implementing impingement delivery method where steam is directed at high velocity onto the cookie surface. These parameter changes enable the formation of an open crumb structure and light texture even in cookies with high dietary fibre and reduced lipid/sugar content, thereby maintaining good organoleptic properties while improving nutritional composition.
2Productivity
If traditional baking methods are used, then production process is simple, but baking time is long and energy consumption is high
Solution Approach 1:
The patent utilizes phase transitions of water by employing superheated steam as the heating medium. The steam condenses on the cooler cookie surface during baking, releasing latent heat of condensation which provides intense and efficient heat transfer. This phase transition mechanism enables faster baking times and reduced energy consumption compared to traditional hot air convection methods, while also contributing to the desired open crumb structure.
Solution Approach 2:
The patent employs pneumatic principles through the impingement delivery system where superheated steam is forced through nozzles at high velocity and directed onto the cookie surface. This high-speed steam impingement creates efficient heat and mass transfer, intensifying the baking process and reducing both baking time and energy consumption while maintaining 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
The process produces cookies with improved organoleptic qualities, increased specific volume, and enhanced nutritional content, including higher dietary fibre and lower lipid and sugar levels, while maintaining the taste and freshness of ingredients.
Implementation Method 1
a step of exposure thereof to a hot gas consisting of hot air and superheated steam, blown directly on such semi-finished products by means of an impingement system
Implementation Method 2
a hot gas consisting of hot air and superheated steam
Data Source
AI summary
A process is described for the production of shortbread-type cookies, characterised in that it comprises the steps of: mixing the ingredients of a cookie dough, forming the cookie dough to form semi-finished products, baking the semi-finished products formed from the dough, thus obtaining the cookies, cooling the cookies obtained and packaging of the cookies; wherein the step of baking the semi-finished products comprises a step of exposure thereof to a hot gas consisting of hot air and superheated steam, blown directly on the semi-finished products by means of an impingement system; a description is also given of a cookie comprising, in weight per total weight, a dietary fibre content comprised between 1 and 25%, a lipids content comprised between 4 and 23% and a simple sugars content comprised between 8 and 26%.