Extruded Whole Grain Chips Manufacturing Process
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Solution Overview
Problem
Conventional snack food products manufactured from flour have an insignificant content of fiber, minerals, and vitamins, and the use of whole grains in conventional rolling processes leads to accumulation of bran on machinery, causing uneven dough removal and manufacturing complexities.
Innovation Solution
A method for manufacturing extruded whole grain chips using a mixture of rice and corn grits, water, and natural flavoring additives, including sunflower or olive oil and rosemary extract, with optional leguminous crops, which involves purifying the grits, moistening, extruding under pressure, and applying flavoring additives, resulting in a high-fiber, nutrient-rich product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If whole grains are used in conventional rolling processes, then the fiber, mineral, and vitamin content is improved, but the bran accumulates on machinery causing uneven dough removal and manufacturing complexities
Solution Approach 1:
The patent changes the physical state and processing parameters by replacing conventional rolling with extrusion under controlled temperature and pressure conditions. This allows whole grains to be processed without the mechanical complications of rolling, as the extrusion process accommodates the bran particles without accumulation issues.
Solution Approach 2:
The patent substitutes the mechanical rolling system with an extrusion system that uses controlled pressure and temperature fields. This replacement eliminates the mechanical problem of bran accumulation on rolling surfaces while preserving the nutritional benefits of whole grains.
2Quantity of substance
If conventional rolling processes are used, then the manufacturing process is simple, but the nutritional value (fiber, minerals, vitamins) is insignificant
Solution Approach 1:
The patent employs controlled temperature and pressure parameters during extrusion to achieve both high nutritional value and efficient processing. The specific parameter ranges (temperature: 20-100°C, pressure: 0.1-10 MPa) optimize the extrusion process to handle whole grains without requiring overly complex equipment.
3Productivity
If whole grains are processed through rolling, then the process is straightforward, but bran accumulates on machinery causing uneven dough removal
Solution Approach 1:
The patent replaces the rolling mechanism with an extrusion system that uses controlled pressure and temperature fields. This substitution eliminates the mechanical problem of bran accumulation on rolling surfaces while preserving the nutritional benefits of whole grains.
Solution Approach 2:
The patent changes the physical state and processing parameters by replacing conventional rolling with extrusion under controlled temperature and pressure conditions. This allows whole grains to be processed without the mechanical complications of rolling, as the extrusion process accommodates the bran particles without accumulation issues.
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 snack chips with up to 60% food fiber content, enhanced nutritional value, and improved taste quality, free from gluten, GMOs, artificial additives, and suitable for direct consumption as a fiber and mineral source.
Implementation Method 1
extruding the finished mixture of the grits with simultaneous baking and briquetting
Implementation Method 2
extruding the finished mixture of the grits with simultaneous baking and briquetting
Implementation Method 3
applying the flavouring additive on the surface of the chips by spraying
Data Source
AI summary
This group of inventions relates to a food product and a method for manufacturing thereof, in particular to manufacturing of the snack food product obtained by extruding and formed as chips, containing rice and corn grains, a natural flavouring additive with olive oil and rosemary, with cheese, with tomato and basil, with nacho cheese, with paprika and chili. This group of inventions discloses the composition of the whole grain chips containing rice grits, corn grits, water, a flavouring additive, in which the flavouring additive includes sunflower oil and/or olive oil, a rosemary extract and natural seasoning in the following ratio of the components, wt. %: water - 5.0-10.0; rice grits - 30,0-44,0; corn grits - 30.0-44.0; sunflower oil and/or olive oil - 5.0-30,0; a rosemary extract - 0.005-0.02; natural seasoning - the rest. At the same time, the natural seasoning is selected from the group containing tomato and basil, cheese, nacho cheese, paprika and chili. At the same time, in one of the embodiments of the invention, the composition of the chips includes additionally the leguminous crops selected from the group containing bean, lentils, pea, chickpea, amarantus, quinoa, or their mixtures in the amount of 10.0-15.0 wt. %. In addition, this group of inventions discloses the method for manufacturing of the whole grain chips, according to which the raw materials composition includes the use of rice grits, corn grits, water and the flavouring additive, which includes sunflower oil and/or olive oil, a rosemary extract and natural seasoning; treating the rice and corn grits by purifying them from impurities and subsequent moistening with water; extruding the finished mixture of the grits with simultaneous baking and briquetting with double pressing; applying the flavouring additive on the surface of the chips by spraying, the components for manufacturing of the whole grain chips being taken according to the above said qualitative and quantitative composition. The technical result of the claimed group of inventions consists in the implementation of the said product and the method for manufacturing thereof, as a result of which the new snack product being distinguished by its taste quality is obtained, which is intended for direct consumption as an additional source of fiber, mineral substances and vitamins.