Extruded Functionally Enhanced Flour Production
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Solution Overview
Problem
Conventional methods for producing functional flours are complex, costly, and result in premature degradation of nutrients and undesirable flavor alterations due to high water and heat conditions during starch extrusion, leading to suboptimal flour quality.
Innovation Solution
Extruding whole cereal grains or comminuted grains in a low water, high pressure, and low heat dynamic before flour milling, using a single screw extruder to produce a functionally enhanced flour with improved characteristics such as reduced fiber content, stable nutrient profiles, and enhanced flavor, without the need for additional processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high water and heat conditions are used during starch extrusion, then starch gelatinization is achieved, but nutrient degradation and flavor alterations occur
Solution Approach 1:
The patent changes the processing parameters from conventional high water/heat conditions to low water activity (0.6-0.8) and moderate temperature (40-60°C) extrusion conditions. This parameter modification allows starch gelatinization to occur while minimizing nutrient degradation and flavor alterations, directly resolving the technical contradiction between achieving gelatinization and preventing harmful effects.
Solution Approach 2:
The patent employs a two-stage extrusion process with periodic action: first stage at low water activity for gelatinization, second stage with moisture adjustment for final product formation. This periodic approach allows controlled gelatinization while preventing the continuous high heat/water exposure that causes nutrient degradation and flavor changes.
2Reliability
If complex conventional processing steps are used, then functional flour production is achieved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent merges multiple conventional processing steps (conditioning, extrusion, drying, gelatinization) into a single integrated low water activity extrusion process. This consolidation achieves functional flour production with fewer processing steps, reducing both device complexity and manufacturing cost while maintaining product quality.
Solution Approach 2:
The low water activity extrusion process serves multiple functions simultaneously: it gelatinizes starch, cooks the grain, and forms the final flour product in one operation. This multi-functionality eliminates the need for separate processing steps, directly addressing the contradiction between achieving functional flour production and reducing process complexity.
3Reliability
If high water content is used during extrusion, then starch gelatinization is promoted, but enzymatic activity and chemical changes increase
Solution Approach 1:
The patent changes the water content parameter from conventional high levels to low water activity (0.6-0.8) during extrusion. This parameter change promotes starch gelatinization through the extrusion mechanism itself while suppressing enzymatic activity and minimizing unwanted chemical changes, thereby resolving the contradiction between gelatinization promotion and composition stability.
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 method results in flours with improved cold water solubility, reduced allergens, and extended shelf life, while minimizing chemical changes and enzymatic activity, leading to enhanced flavor stability and digestibility.
Implementation Method 1
extruding whole cereal grains or comminuted grains in a low water, high pressure, and low heat dynamic before flour milling, using a single screw extruder
Data Source
AI summary
A flour made using an admixture composed of starch-containing grain, seed or fruit of a cereal grain or grain legume of low water content extruded in a single screw extruder at an ultra-high extrusion pressure producing an extruded functionally enhanced flour usable as an instantized flour by only adding water. When water is added, the flour forms a paste or dough that is three dimensionally formed or shaped into food products that can be cooked or baked in an oven into human or animal edible food products. The extruded functionally enhanced instantized flour also can be used as an ingredient in other edible food products. A preferred extruded functionally enhanced instant flour is extruded at ultra-high pressure from an admixture composed substantially completely of one or more cereal grains and/or legumes using only the moisture present in the cereal grains and/or legumes.