Durum Wheat Scraps Mixture for Dough Quality and Waste Reduction
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Solution Overview
Problem
The challenge lies in effectively reusing scraps from durum wheat-based baked products to reduce waste and enhance the quality of dough for sweet and savory baked goods, while maintaining desirable organoleptic and digestibility characteristics.
Innovation Solution
A process involving the extraction and reprocessing of gluten and starch from scraps to create a mixture in paste or freeze-dried form, which can be added to doughs, utilizing specific yeast and lactobacilli strains for fermentation and gelatinization, thereby forming a stronger gluten mesh and improving digestibility and rising properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If scraps from durum wheat-based baked products are discarded, then waste management is simplified, but resource waste occurs and environmental sustainability deteriorates
Solution Approach 1:
The patent applies the discarding and recovering principle by collecting scraps from durum wheat-based baked products (pasta-making waste, bread trimmings, bakery rejects) and reprocessing them through a multi-step procedure involving cooking, cooling, mixing with soft wheat flour, and freezing to create a reusable ingredient mixture. This transforms discarded materials into valuable resources that can be incorporated into new dough formulations, thereby reducing waste while managing processing complexity through a systematic approach
Solution Approach 2:
The patent uses an intermediary approach by introducing a intermediate processing stage where scraps are cooked, cooled, and mixed with soft wheat flour before being incorporated into final dough formulations. This intermediary treatment (creating a pre-processed mixture that is then frozen and stored) serves as a bridge between the raw scrap material and the final usable ingredient, making the integration of durum wheat scraps into bakery products more manageable and less complex
2Productivity
If durum wheat scraps are reprocessed into dough additives, then resource utilization improves, but processing time and complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-cooking the durum wheat scraps, pre-mixing them with soft wheat flour, and pre-freezing the mixture before it is needed for final dough formulation. This pre-processing creates a ready-to-use ingredient that can be directly incorporated into new dough batches without requiring additional processing time during production, thereby improving resource utilization while minimizing the time cost during actual manufacturing
Solution Approach 2:
The patent implements continuity of useful action by creating a continuous cycle where scraps from production are continuously collected, processed through the standardized procedure (cooking, cooling, mixing, freezing), and stored as a reusable ingredient. This continuous process ensures that the reprocessing operation runs efficiently and consistently, improving overall productivity while managing time through standardized, repeatable steps rather than ad-hoc processing
3Manufacturing precision
If gluten and starch are extracted from scraps, then product quality improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies the extraction principle by selectively removing and isolating the gluten and starch components from the durum wheat scraps through the cooking and mixing process. By extracting these specific functional components (gluten for structure, starch for texture) and concentrating them in the pre-processed mixture, the patent improves product quality while managing complexity through a focused extraction approach rather than attempting to process the entire scrap material
4Reliability
If scraps are reused in dough formulations, then environmental sustainability improves, but control over final product characteristics becomes more difficult
Solution Approach 1:
The patent applies parameter changes by systematically controlling key parameters throughout the reprocessing procedure: cooking temperature and time, cooling temperature, mixing ratios with soft wheat flour, and freezing temperature. By standardizing these parameters, the patent maintains consistency in the reprocessed ingredient's properties, making it reliable and predictable when incorporated into final dough formulations, thereby preserving sustainability benefits while ensuring process control
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 solution allows for the reuse of waste materials, enhancing the quality of baked goods by improving homogeneity, rising, and digestibility, while reducing waste and extending the product's shelf life, with a lower glycaemic index and increased antioxidant properties.
Implementation Method 1
the starch granules are taken to a high temperature, in an aqueous environment, in order to become digestible. In these conditions, they are hydrated, lose their orderly structure and assume a disorderly structure, with the characteristics of a gel. This is the process of gelatinisation of the starches
Implementation Method 2
utilizing specific yeast and lactobacilli strains for fermentation and gelatinization
Data Source
AI summary
Process for preparing a mixture in paste or freeze-dried to be added to doughs for sweet or savoury products, comprising the phases of: grinding basic products in a grinder to obtain a ground material; where said basic products comprise durum wheat semolina pasta and/or bread and/or baked goods; cooking said ground product to obtain a precooked product; cooling said precooked product to obtain a cooled precooked product; mixing said cooled precooked product with a mixture of malt, yeasts and lactobacilli, where said yeasts comprise Kluyveromyces.