Extruded Cereal Flakes High-Frequency Cutting Texture Control
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Solution Overview
Problem
Current cereal flake manufacturing processes require additional processing steps to achieve specific texture profiles upon reconstitution, as existing methods result in inconsistent texture properties such as soggy or crispy flakes when wetted, due to limitations in cutting frequencies and structural properties of extruded products.
Innovation Solution
A method involving a cooking-extrusion-direct expansion process with a high cutting frequency (1000 Hz to 2800 Hz) to produce flakes with controlled porosity (50-90%) and mean wall thickness (30-90 microns), allowing for direct flaking without a flattening step, which enables efficient rehydration and texture control upon reconstitution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional extrusion process with low cutting frequency is used, then the manufacturing process is simpler, but the flakes have thick walls and low expansion rates resulting in inconsistent texture profiles
Solution Approach 1:
The patent changes the cutting frequency parameter from traditional low frequencies to high frequencies (1000-2800 Hz), which fundamentally alters the flake structure to achieve thin walls (30-90 microns) and high porosity (50-90%), resulting in consistent texture profiles upon reconstitution
Solution Approach 2:
The patent introduces dynamic control of the extrusion and cutting process parameters, including temperature (100°C-180°C), water content (5%-30%), and cutting frequency (1000 Hz-2800 Hz), allowing real-time adjustment to achieve desired flake properties for different applications
2Manufacturing precision
If additional processing steps are added to adjust physical properties, then the texture profile control is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent combines mixing, cooking, extrusion, and cutting operations into a single integrated extrusion process, eliminating the need for separate flattening and toasting steps while achieving precise control over flake texture properties through parameter optimization
Solution Approach 2:
By optimizing parameters within the extrusion process (temperature, pressure, cutting frequency), the patent achieves texture profile control that previously required multiple additional processing steps, thereby reducing manufacturing complexity while maintaining precision
3Speed
If the flakes have high porosity and thin walls, then the rehydration speed is improved, but the structural strength during processing is reduced
Solution Approach 1:
The patent optimizes the balance between porosity (50-90%) and wall thickness (30-90 microns) by controlling extrusion temperature (100°C-180°C) and cutting frequency (1000 Hz-2800 Hz), achieving fast rehydration while maintaining sufficient structural integrity during processing
Solution Approach 2:
The high-frequency cutting action (1000 Hz-2800 Hz) creates periodic structures in the flake walls that provide both porosity for rapid rehydration and periodic reinforcement that maintains structural strength during handling and processing
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 achieves cereal flakes with consistent texture profiles, providing a porridge within three minutes of rehydration and controlled liquid absorption, enhancing the sensory and physical properties of the flakes, such as retaining shape or disintegrating appropriately upon reconstitution.
Implementation Method 1
cooking the dough in the extruder at a temperature comprised between 100°C and 180°C
Implementation Method 2
extruding the dough through an extrusion die; cutting the dough into flakes directly at the outlet of the die
Data Source
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AI summary
A method is provided to manufacture cereal flakes with texture properties. The flakes have a porosity of 50-90%, a mean wall thickness of 30-90 microns, a thickness of 0.5- 2 mm, a length of 2-8 mm and a liquid absorption index of 100-600 g liquid per 100 g flakes. The method involves cooking a dough in an extruder, cutting the extruded dough to obtain flakes and then drying the flakes.