Extruded Protein Pieces Texture Control

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Solution Overview

Problem

There is a need for diverse high protein food products that offer enjoyable textures and flavors suitable for various eating occasions, as existing protein products often lack variety and may require substantial hydration or cooking, limiting their versatility.

Innovation Solution

The development of extruded protein pieces with a protein content of 30% to 90% by weight, incorporating a protein matrix disruptive ingredient, oil, and inclusions, which are processed under specific extrusion conditions to create a protein matrix with granules of compacted protein, providing a desirable texture and flexibility for different uses, such as breakfast cereals, meat substitutes, or bacon bit alternatives.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If existing protein products are used, then protein content is provided, but texture and flavor variety is limited and extensive hydration or cooking is required

Engineering Contradiction:

Improveversatility for different eating occasionsVSAvoidpreparation complexity requiring hydration or cooking

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent applies parameter changes by controlling extrusion process variables (temperature, pressure, moisture content, screw speed) to create protein products with varied textures and structures. The extrusion process transforms protein ingredients into ready-to-eat forms with different densities, hardness, and mouthfeel characteristics, eliminating the need for extensive hydration or cooking while maintaining high protein content

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials by combining protein ingredients with other food components during extrusion to create multi-functional products. The composite structure incorporates starches, fibers, and other additives that contribute to diverse textures and flavors, allowing the protein products to serve multiple purposes (breakfast cereals, meat substitutes, bacon bit alternatives) without requiring additional preparation steps

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If protein content is increased to meet consumer demand, then nutritional density is improved, but product diversity and variety are reduced

Engineering Contradiction:

Improveprotein contentVSAvoidproduct diversity for different uses

Core Design Contradiction:

Quantity of substanceVSAdaptability or versatility

Solution Approach 1:

The patent applies local quality by creating products with non-uniform internal structures through controlled extrusion. Different regions of the extruded product have varying protein concentrations, densities, and textures, allowing high overall protein content while providing localized variations in mouthfeel and appearance. This enables diverse product forms (flakes, pellets,-expanded structures) that cater to different consumer preferences and applications

Inventive Principle:

Principle #3Local quality

3Quantity of substance

If extrusion process is optimized for high protein content, then nutritional value is improved, but texture quality and consumer acceptability may be compromised

Engineering Contradiction:

Improveprotein contentVSAvoidtexture quality and consumer acceptability

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent optimizes extrusion parameters (temperature, pressure, moisture, screw speed, die geometry) to achieve the desired balance between high protein content and acceptable texture. By carefully controlling the specific mechanical energy input and residence time, the process creates a protein matrix with appropriate structural integrity and mouthfeel characteristics while maintaining high protein concentration

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite material formulations combining protein ingredients with functional additives that enhance texture and consumer acceptability. These composites include starches that provide structural support, fibers that contribute to chewiness, and other components that improve mouthfeel, allowing the product to maintain high protein content while achieving desirable textural properties

Inventive Principle:

Principle #40Composite materials

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 extruded protein pieces offer a high protein content with a desirable texture and flavor, suitable for various eating occasions, including being used as breakfast cereals, meat substitutes, or bacon bit alternatives, without requiring extensive hydration or cooking, enhancing consumer options for high protein intake.

Implementation Method 1

processed under specific extrusion conditions to create a protein matrix with granules of compacted protein

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentUS11793214B2Extruded protein product and methods of making

Publication Date: 2023.10.24 GENERAL MILLS INC

AI summary

The present disclosure relates to extruded protein products and methods for producing an extruded protein product. In particular, an extruded piece is disclosed having a high protein content and having a desirable texture and flavor. Methods for making an extruded piece include processing, under extrusion conditions, a combination of a powdered protein ingredient, a protein matrix disruptive ingredient, water, and an oil.