Extruded Vegetable Flour Coated Carriers for High Surface-Active Substance Powders
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Solution Overview
Problem
Current methods for producing free-flowing powders with surface-active substances, such as emulsifiers, are limited by high production costs, low carrier capacity, and unwanted off-tastes or discolorations, particularly when using starch as a carrier, and struggle to achieve high concentrations of surface-active substances while maintaining free-flowing characteristics.
Innovation Solution
The method involves extruding a mixture of surface-active substances with vegetable flours or brans, optionally with inorganic salts and water, to create coated carriers that can contain higher amounts of surface-active substances, improving carrier potential and nutritional value, and using rice flour or cake flour as carriers to achieve cost-efficiency and better functional properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If starch is used as a carrier, then the powder product achieves high carrier potential, fine free-flowing characteristics, white color, and bland taste, but the production cost increases due to laborious production methods and chemical dependencies
Solution Approach 1:
The patent replaces expensive purified starch with cheaper vegetable flours (wheat, rice, corn, potato) that can be easily obtained and processed. These alternative carriers achieve sufficient carrier potential without requiring the laborious chemical purification processes needed for starch, thereby reducing production costs while maintaining functional performance
Solution Approach 2:
The patent modifies the carrier material parameters by using vegetable flours with different compositional characteristics (protein content, starch content, fiber content) compared to purified starch. By adjusting these parameters and combining multiple flour types, the invention achieves cost reduction while maintaining the essential carrier potential and flow characteristics
2Ease of manufacture
If vegetable flours are used as carriers, then production cost decreases and nutritional value improves, but carrier capacity and free-flowing characteristics deteriorate
Solution Approach 1:
The patent creates composite carrier systems by combining multiple vegetable flours (e.g., wheat flour, rice flour, corn flour, potato flour) in specific ratios. This composite approach leverages the complementary properties of each flour type - the high carrier capacity of some flours compensates for the lower flow characteristics of others, achieving both cost reduction and maintained functional performance
Solution Approach 2:
The patent applies different vegetable flours to different functional requirements within the carrier system. Specific flours are selected and proportioned to provide particular local functions - some flours optimized for carrier capacity, others for flow characteristics, with the overall mixture achieving balanced performance
3Quantity of substance
If surface-active substance concentration is increased above 35% by weight, then carrier capacity improves, but the product becomes greasy and undesirable characteristics appear
Solution Approach 1:
The patent uses vegetable flours as intermediary carrier materials that can accommodate high concentrations of surface-active substances without direct contact between the substance and the final product formulation. The flour matrix absorbs and distributes the surface-active substance, preventing greasy appearance while enabling high functional concentrations
Solution Approach 2:
The patent employs vegetable flours as disposable carrier materials that can be easily discarded or degraded during the baking process. These flours serve their purpose of carrying and distributing surface-active substances during processing, then break down or remain as inert residue, avoiding the persistence of greasy characteristics in the final product
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
This approach results in cost-effective, high-quality, free-flowing powders with improved functional properties, enhanced nutritional value, and compatibility with food products, allowing for higher surface-active substance concentrations without compromising flow characteristics.
Implementation Method 1
extruding the mixture through one or more orifices
Data Source
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AI summary
The present invention relates to substantially free flowing powder products as well as preparation thereof. The powder product comprises coated carriers with excellent functional properties. The powder products can be produced in a simple and cost efficient way.