Extruded Flour with Reduced Water Content for Stability
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Solution Overview
Problem
Existing flour production methods face challenges in storage preservation, flavor stabilization, and nutrient retention due to high water content, which leads to microbial and fungal concerns, flavor alterations, and nutrient loss.
Innovation Solution
The method involves extruding whole or milled grains in a low water, high pressure, and low heat dynamic before flour milling, resulting in a functionally enhanced flour with improved cold water starch solubility, reduced fiber content, and stabilized nutrient and flavor profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flour is stored with typical water content (12-14%), then it maintains good functionality for food preparation, but microbial and fungal growth occurs rapidly leading to spoilage
Solution Approach 1:
The patent applies parameter changes by reducing the water content of flour from the typical 12-14% to below 10%, and in some embodiments to 5-8%. This parameter change fundamentally alters the storage stability of the flour, creating an environment that is inhospitable to microbial and fungal growth while preserving the functional properties needed for food preparation.
2Reliability
If heat treatment is applied to reduce water content and extend shelf life, then storage stability improves, but flavor and nutritional quality deteriorate
Solution Approach 1:
The patent applies preliminary action by reducing the water content of the flour to below 10% before storage, rather than using heat treatment during or after storage. This preliminary reduction in water content creates stable conditions that prevent microbial growth and eliminate the need for subsequent heat treatment, thereby preserving flavor and nutritional quality throughout storage.
3Ease of manufacture
If twin screw extrusion with high water content and applied heat is used to process starch, then gelatinization point is reduced, but excessive water and heat cause nutrient degradation and flavor alteration
Solution Approach 1:
The patent applies parameter changes by processing starch at reduced water content (below 10%) and lower temperatures compared to conventional twin screw extrusion. This parameter modification allows sufficient gelatinization to occur while preventing the excessive heat and water conditions that cause nutrient degradation and flavor alteration in traditional processes.
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 enhances the functionality of flours by improving cold water solubility, reducing microbial and fungal growth, and maintaining flavor and nutrient stability, thereby extending shelf life and improving food product quality.
Implementation Method 1
the extruding step is carried out without thermal input beyond heat generated from a changing pressure of extrudate
Data Source
AI summary
A functionally enhanced flour provided by a manufacturing process that subjects a grain precursor to extrusion under low water, high pressure, and low heat dynamic conditions, and methods of using the resulting flour as an ingredient in food products for human and animal consumption.