Crispy Coated Plant-Protein Extrudates With Juicy Fibrous Texture
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Solution Overview
Problem
Existing extruded plant-based food products face challenges in achieving a crispy texture with high protein content while maintaining good juiciness, tenderness, and taste, often compromising on flavor and texture due to high fat and low dietary fiber levels.
Innovation Solution
A process involving extrusion and injection technology, where an aqueous solution is injected into the extrudate using a needle injector, incorporating plant proteins, water, and optional additives like hydrocolloids and starch, to enhance juiciness and tenderness, and flavor retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If plant-based protein products are extruded to improve texture and structure, then the product structure is improved, but the outer surface becomes rubbery and unappetizing
Solution Approach 1:
The patent applies preliminary action by coating the extruded plant-based product with a starch-based coating composition before final processing. This pre-coating step prepares the surface to achieve a desirable crispy texture while maintaining the improved product structure from extrusion, thereby resolving the contradiction between structure improvement and surface quality.
Solution Approach 2:
The patent employs parameter changes by controlling the moisture content of the coating composition (5-20% based on dry weight) and adjusting drying conditions (temperature and time parameters). These parameter adjustments transform the surface from rubbery to crispy, resolving the contradiction between maintaining extruded structure and achieving appetizing surface quality.
2Shape
If a starch-based coating is applied to achieve crispy texture, then the surface texture is improved, but the coating may not adhere properly without optimal moisture control
Solution Approach 1:
The patent applies parameter changes by precisely controlling the moisture content of the starch-based coating composition within 5-20% of the dry weight of starch. This parameter optimization ensures proper adhesion of the coating to the extruded product while achieving the desired crispy surface texture, thereby resolving the contradiction between surface texture improvement and coating adhesion reliability.
3Shape
If drying conditions are too intense to achieve crispy surface, then the surface texture is improved, but the product interior becomes over-dried and loses moisture
Solution Approach 1:
The patent employs parameter changes by optimizing drying conditions with controlled temperature (40-80°C) and time (5-30 minutes) parameters. These controlled parameters enable the formation of a crispy surface coating while preventing excessive moisture loss from the product interior, thereby resolving the contradiction between surface crispiness and internal moisture retention.
Solution Approach 2:
The starch-based coating composition acts as an intermediary layer between the extruded product and the drying environment. This intermediary coating allows for controlled moisture removal during drying, enabling crispy surface formation while protecting the product interior from excessive drying, thus resolving the contradiction between surface crispiness and internal moisture retention.
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 results in a crispy coated extruded plant-based food product with a fibrous appearance, improved juiciness, tenderness, and taste, while reducing flavor off-notes, and allowing for the inclusion of heat-sensitive ingredients like vitamins and colorants.
Implementation Method 1
The ingredients are cooked and shaped in an extruder
Implementation Method 2
The ingredients are cooked and shaped in an extruder
Implementation Method 3
A crispy coating composition is applied to an extruded plant-based protein product
Implementation Method 4
The crispy coating is applied to the extruded plant-based protein product and then dried
Data Source
AI summary
The invention generally relates to a process for preparing a crispy coated extruded plant-based food product. More specifically the invention relates to a process for preparing a crispy coated extruded plant-based food product with a fibrous appearance and good juiciness and tenderness properties.