Enzymatic Legume Dough Modification for Machinable Snack Sheets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Challenges in producing snack products with high legume content include low dough cohesiveness, high stickiness, and poor sheetability, leading to issues such as dry mouthfeel, chalky after-taste, and gritty texture.
Innovation Solution
Incorporating low oxidation transglutaminase into legume dough at specific concentrations and temperatures to crosslink proteins, reducing stickiness, and enhancing sheetability, resulting in machinable and sheetable dough for products like tortilla-style chips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high levels of legumes (60-100 wt.%) are incorporated into dough to enhance nutritional value, then nutrition value and consumer health perception are improved, but dough cohesiveness decreases and stickiness increases
Solution Approach 1:
The patent introduces corn starch as an intermediary component to mediate between legume flour and water in the dough system. This intermediary helps bridge the gap caused by high legume content, providing structural support and reducing stickiness while maintaining the high nutritional value from legumes.
Solution Approach 2:
The patent modifies the dough composition parameters by adding specific amounts of corn starch (5-20 wt.% of total dough weight) and controlling water content (60-80 wt.% of total dough weight). These parameter changes adjust the rheological properties of the dough, improving cohesiveness and reducing stickiness while preserving high legume content for nutritional benefits.
2Quantity of substance
If high levels of legumes are incorporated into dough, then nutrition value is improved, but sheetability deteriorates
Solution Approach 1:
Corn starch serves as a mediating component that facilitates sheeting operations in high-legume doughs. The starch granules provide a lubricating effect and adjust the dough's plasticity, enabling it to be rolled and shaped into thin sheets without excessive stickiness or cracking, thus improving manufacturability while maintaining high nutritional content.
Solution Approach 2:
By adjusting the ratio of corn starch to legume flour and controlling water content within specific ranges, the patent optimizes the dough's rheological parameters for sheeting. This allows the dough to achieve the right balance of softness and elasticity needed for easy sheeting while preserving 60-100 wt.% legume content for nutritional value.
3Quantity of substance
If high levels of legumes are used in snack products, then nutrition value is enhanced, but texture quality deteriorates with dry mouthfeel, chalky after-taste, and gritty texture
Solution Approach 1:
The patent modifies the texture profile by adjusting the water content (60-80 wt.% of total dough weight) and adding corn starch in specific proportions. These parameter changes create a more balanced moisture distribution and softer matrix structure in the final snack product, reducing the dry mouthfeel, chalky after-taste, and gritty texture associated with high-legume products while maintaining their nutritional benefits.
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 method produces snack products with improved cohesiveness and sheetability, reducing oil uptake and enhancing the texture and taste, while maintaining nutritional benefits of legumes.
Implementation Method 1
low oxidation transglutaminase is described. The dough may be used to make a snack product... The transglutaminase may crosslink the protein present in legumes
Data Source
AI summary
A snack product includes legume, deactivated transglutaminase (TG) oil, moisture, and/or seasonings. The legume dough used to make the snack product is modified to include transglutaminase (TG) to increase its sheetability. The legume dough may include from about 60 wt. % to about 100 wt. % legumes. An exemplary method of making the modified legume dough includes adding about 0.5 wt. % to about 5 wt. % TG, incubating the modified legume dough at about 100° F. to about 130° F. for between about 5 minutes to about 120 minutes.