Enzyme-Treated Biscuit Dough for Fat Reduction Without Texture Loss
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Solution Overview
Problem
The bakery industry faces challenges in reducing fat and sugar content in biscuits and cookies without compromising texture, taste, and shelf life, as conventional methods either increase costs or negatively affect product quality.
Innovation Solution
Incorporating small amounts of lipases and proteases during dough preparation to reduce fats and sugars by up to 25%, using enzymes like Thermomyces lanuginosus lipase and Bacillus amyloliquefaciens protease, which act as emulsifiers to maintain product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If fat content is reduced in the recipe, then calorie content is reduced, but the baked biscuits and cookies become drier, crumblier, and have shorter shelf-life
Solution Approach 1:
The patent introduces an intermediary substance (modified starch or hydrocolloid) that mediates between the reduced fat and the sugar constituents, performing the lubricating and coating function that fat would normally provide. This intermediary maintains shelf-life by preventing air ingress to sugar constituents even when fat content is reduced.
Solution Approach 2:
The patent changes the physical or chemical parameters of the alternative fat substitutes by using modified starch with specific properties (amylose content 20-80%, amylopectin content 20-80%) or hydrocolloids with specific viscosity ranges. These parameter changes enable the substitutes to perform fat-like functions at lower concentrations.
2Quantity of substance
If fat content is reduced in the recipe, then calorie content is reduced, but the texture and mouthfeel of the baked biscuits and cookies deteriorate
Solution Approach 1:
The modified starch or hydrocolloid acts as an intermediary that replicates the textural properties of fat by coating sugar constituents and providing lubrication in the dough, thereby maintaining acceptable texture and mouthfeel despite reduced fat content.
Solution Approach 2:
The patent creates a composite material system combining modified starch or hydrocolloid with sugar constituents, where the composite performs the functional role of fat. This composite approach allows the mixture to exhibit fat-like textural properties even with reduced fat content.
3Quantity of substance
If conventional emulsifiers or modified starch are used in high quantity (3% or more), then fat reduction is achieved, but the cost increases and texture, mouthfeel, and taste are compromised
Solution Approach 1:
The patent optimizes the concentration parameters of modified starch or hydrocolloid to achieve effective fat substitution at lower levels (below 3%). By carefully controlling amylose/amylopectin ratios or hydrocolloid viscosity, the patent reduces the quantity needed while maintaining functionality and avoiding the cost and quality issues of high-concentration alternatives.
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
Enzymes enhance texture, mouthfeel, and flavor while reducing fat and sugar content, achieving up to 25% reduction without adversely affecting the baked products' properties.
Implementation Method 1
one or more lipases or/and one or more proteases, which act as emulsifiers to maintain product quality
Data Source
AI summary
The present invention relates to methods, uses and products for preparing a baked product comprising reduced fat. The method comprises steps of a) preparing a dough with one or more lipases or/and one or more proteases, b) moulding and/or sheeting the dough and c) baking the dough. The baked product is selected from a group consisting of biscuits, cookies, 5 and crackers. The baked product has at least 10-25 wt. % fat reduced when compared to a baked product prepared without the one or more lipases or/and one or more proteases.