Expanded Snack Products Reducing Acrylamide via High Moisture Dough
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Solution Overview
Problem
Current expanded or popped snack products lack sufficient natural fruit and vegetable content and are contaminated with high levels of process contaminants like acrylamide and furan due to the Direct Expansion technology used in their production, failing to provide nutritious options for children.
Innovation Solution
The development of shelf-stable, expanded or popped snack products that incorporate high amounts of natural fruit and vegetable ingredients, such as purees and powders, while minimizing process contaminants through the use of direct expansion, air popping, or compression popping methods, and incorporating processing aids like calcium carbonate and citric acid to reduce contaminant formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If Direct Expansion technology is used to maximize efficiency and minimize moisture in the dough, then productivity and efficiency are improved, but process contaminants such as acrylamide and furan are generated at high levels
Solution Approach 1:
The patent changes the moisture parameter of the dough from minimal (as in conventional DX) to high moisture content (20-40% water). This parameter change allows the use of alternative expansion methods (air popping or compression popping) that do not generate high levels of process contaminants while maintaining efficiency and productivity.
2Productivity
If minimal amount of fruit or vegetable is included in expanded or popped snacks, then the product can be produced efficiently with current technology, but the nutritional value and natural ingredient content are insufficient
Solution Approach 1:
The patent changes the moisture parameter of the dough to high levels (20-40% water), which enables the incorporation of substantial amounts of fruit and vegetable ingredients (at least 10% by weight, preferably 20-40%). This parameter change allows efficient production while maintaining high nutritional value and natural ingredient content.
3Productivity
If high temperatures and pressures are utilized in Direct Expansion processing, then expansion and productivity are improved, but process contaminants are generated at high levels
Solution Approach 1:
The patent replaces the thermal-mechanical Direct Expansion system with alternative expansion methods such as air popping or compression popping. These alternative methods achieve expansion without requiring the high temperatures and pressures that generate process contaminants, while maintaining productivity and expansion efficiency.
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
These snack products offer a nutritious and wholesome option for children, providing at least one serving of fruit or vegetable per serving and significantly reducing acrylamide levels to less than 150 ppm, ensuring safety and nutritional integrity.
Implementation Method 1
subjecting the pellets to a treatment step to form the expanded or popped snack product
Implementation Method 2
incorporating processing aids like calcium carbonate and citric acid to reduce contaminant formation
Data Source
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AI summary
Shelf stable, expanded or popped snack products are disclosed that contain at least one fruit ingredient and/or at least one vegetable ingredient. Also disclosed are methods of producing and using, the snack products.