Dehydrated Vegetable Noodles Antimicrobial Treatment
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Solution Overview
Problem
Grain-based noodles are high in carbohydrates, contain gluten, and are processed foods with high levels of sugar, salt, and oil, making them unsuitable for consumers with dietary or health issues, and they lack nutritional value.
Innovation Solution
Dehydrated vegetable noodles are produced by contacting vegetables with antimicrobial agents, cutting them into noodle shapes, spinning to remove excess moisture, and dehydrating to create a shelf-stable, gluten-free, and nutritious alternative that is lower in carbohydrates and calories.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If grain-based noodles are used, then they provide structural integrity and ease of manufacture, but they are high in carbohydrates, gluten, and processed additives with low nutritional value
Solution Approach 1:
The patent changes the fundamental material parameter from grain-based carbohydrates to vegetable-based fibers. By selecting vegetables with appropriate cell wall structures (such as zucchini, spaghetti squash, or other squash varieties) and controlling the dehydration parameters, the noodles achieve structural integrity without relying on grain carbohydrates, thus reducing carb content while maintaining manufacturability
Solution Approach 2:
The patent extracts and removes the problematic components (gluten, processed sugars, salts) from the noodle formulation by using pure vegetable materials. The extraction process involves selecting vegetables naturally free from these additives and employing dehydration techniques that concentrate the vegetable fibers without introducing external processing chemicals, thereby eliminating harmful substances while preserving essential structure
2Quantity of substance
If vegetable noodles are made fresh, then they have high nutritional value and are gluten-free, but they have short shelf life due to moisture content
Solution Approach 1:
The patent utilizes phase transition through dehydration, transforming the moisture state from liquid to vapor removal. By applying controlled heat and air flow during the dehydration process, the vegetable noodles lose their free water content, transitioning from a fresh, perishable state to a dried, stable state. This phase change enables long-term storage while preserving the nutritional integrity of the vegetable fibers
Solution Approach 2:
The patent applies preliminary antimicrobial treatment before dehydration to prevent microbial growth during storage. By treating the vegetable noodles with appropriate preservatives or antimicrobial agents prior to the dehydration process, the patent ensures that the noodles remain safe and stable throughout extended storage periods, thereby extending shelf life without compromising nutritional value
3Duration of action of stationary object
If dehydration is applied to remove moisture, then shelf life is extended, but energy consumption increases
Solution Approach 1:
The patent optimizes dehydration parameters by controlling temperature, air flow rate, and exposure time to achieve efficient moisture removal. By adjusting these parameters, the patent minimizes energy consumption while still achieving sufficient dehydration to extend shelf life. For example, using moderate temperatures with extended air flow time can be more energy-efficient than high-temperature short-duration drying
Solution Approach 2:
The patent employs natural convection and ambient air flow during the dehydration process, reducing the need for high-energy heating systems. The vegetable noodles are arranged to maximize surface area exposure to air, allowing natural evaporation and convection to perform much of the dehydration work, thereby reducing overall energy consumption while maintaining effective moisture removal for shelf life extension
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 food-safe, convenient, and versatile product with increased nutritional value and extended shelf life, suitable for consumers with gluten intolerance or preferences, offering a healthier alternative to traditional grain-based noodles.
Implementation Method 1
spinning the noodle shaped vegetable material, where the spinning removes excess liquid and moisture from the noodle shaped vegetable material
Implementation Method 2
contacting a vegetable with a solution containing a first antimicrobial agent... the first antimicrobial agent comprises hypochlorite solution, ozone, hydrogen peroxide, peroxyacetic acid or combination thereof
Implementation Method 3
incubating the vegetable noodle at a temperature sufficient to kill a microorganism... the second temperature is between about 130° F. and about 160° F.
Data Source
AI summary
The present disclosure features dried vegetable noodles having an increased shelf life and methods of making dehydrated vegetable noodles. The noodles are dry, shelf stable cut vegetable noodles (cut from whole produce, not extruded) and are lower in carbohydrate calories and higher in nutritional value than traditional grain-based noodles. The process results in a food safe, extended shelf stable singularized noodle that is nutritious, convenient and versatile.