Extruded Fish Snack Texture and Shelf Life
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Solution Overview
Problem
Current methods for producing fish-based snacks fail to achieve a product that is both aerated and crunchy, with high fish protein content, while also ensuring a long shelf life without refrigeration and meeting moisture content regulations.
Innovation Solution
A method involving preparing a homogenous paste of fish muscle, surimi, flour, salt, and leavening agent, extruding it into a non-porous casing, applying heat treatment, and then drying to achieve a product with a moisture content between 5% and 18%, resulting in an expanded and crunchy snack with uniform texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If fish-based snacks are prepared using conventional methods (mixing ground fish with flour, steaming, drying, and frying), then the product can be obtained, but it fails to achieve both aerated and crunchy texture simultaneously
Solution Approach 1:
The patent applies parameter changes by controlling the moisture content within a specific range (5-18%) and using a particular extrusion-cooking-expansion process with controlled temperature and pressure parameters. This enables the fish-based product to achieve both aerated and crunchy texture simultaneously, resolving the texture reliability issue in conventional methods
Solution Approach 2:
The patent utilizes phase transitions through the extrusion-cooking-expansion process where the dough undergoes gelatinization during cooking, then rapidly expands upon cooling and drying. This phase transition mechanism creates the desired aerated structure while maintaining crunchy texture, which conventional methods fail to achieve
2Duration of action of stationary object
If the moisture content is reduced to meet snack regulations (≤5% for potato chips), then shelf life is improved, but achieving aerated and crunchy texture becomes more difficult
Solution Approach 1:
The patent applies preliminary action by pre-cooking the extruded dough to gelatinize the starch and set the basic structure before drying. This preliminary cooking step allows the subsequent drying process to achieve low moisture content (5-18%) while preserving the aerated structure and crunchy texture that would otherwise be lost in conventional sequential processing
Solution Approach 2:
The patent controls moisture content within an optimized range (5-18%) rather than simply minimizing it. This parameter optimization, combined with the extrusion-cooking-expansion process, enables the product to achieve both long shelf life and desirable aerated-crunchy texture, resolving the contradiction between moisture reduction and texture quality
3Quantity of substance
If fish protein content is increased to create healthy snacks, then nutritional value is improved, but the product becomes more difficult to process into aerated crunchy form
Solution Approach 1:
The patent uses composite materials by combining fish-based ingredients (surimi or ground fish) with cereal flours or starches in specific ratios. This composite approach allows high fish protein content (≥12%) while the cereal components provide structural support and gas-trapping capabilities during expansion, making the high-protein dough easier to process into aerated crunchy forms
Solution Approach 2:
The patent optimizes the composition parameters of the dough, including the ratio of fish protein to cereal flour/starch, to achieve the right balance between nutritional value and processability. This parameter optimization enables high fish protein content while maintaining the ease of manufacture for aerated crunchy textures through controlled extrusion and expansion
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 a fish-based snack with high fish protein content, low fat, and a uniform texture, meeting moisture content requirements for shelf stability and allowing for direct consumption or use in the food industry without refrigeration.
Implementation Method 1
preparing a homogenous paste comprising: fish muscle and/or fish flesh and/or surimi, flour and/or starch, salt, leavening agent
Implementation Method 2
applying a heat treatment to the stuffed product obtained in step b) until obtaining a gelled stuffed product
Implementation Method 3
applying a heat treatment to the stuffed product obtained in step b) until obtaining a gelled stuffed product
Implementation Method 4
drying the slices obtained in e) until obtaining a product with a final moisture content between 5% and 18%
Implementation Method 5
expanding by heat treatment wherein the fish-based food product is an expanded and crunchy product and has uniform texture
Data Source
Figure 1A~1D
Figure 2
Figure 3A~3B
AI summary
The present invention belongs to the field of food industry, particularly to the production of snacks. The present invention specifically relates to a fish-based food product, to its method of preparation, and to its use.