Extruded Starch Composition for Shape-Stable Matte Heat Cooking
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Solution Overview
Problem
Conventional compositions for heat cooking disintegrate during cooking and lack a matte appearance, with existing anti-disintegration agents affecting flavor and texture.
Innovation Solution
A method using an extruder to process a composition with specific starch, insoluble dietary fiber, protein, and moisture content, involving heating, kneading, depressurization, and cooling to create a strong starch matrix structure, maintaining shape and matte texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a sugar composition containing 35 mass % or more of maltotriose is used as an anti-disintegration agent during stewing, then vegetable tissues resist collapsing and losing shape, but the composition lacks a matte texture and has an inferior appearance
Solution Approach 1:
The invention changes the physical and chemical parameters of the starch by controlling gelatinization degree (30-80 mass%) and moisture content (20-40 mass%), transforming the starch structure to achieve both disintegration resistance and matte texture without requiring high sugar content
Solution Approach 2:
The invention creates a composite structure within the starch itself, forming an aged starch layer on the surface while maintaining a strong starch matrix inside, combining different functional zones in one material to achieve both protective and aesthetic properties
2Ease of manufacture
If conventional starch compositions are used for heat cooking, then the processing is simple, but the composition disintegrates during cooking and lacks a matte texture
Solution Approach 1:
The invention performs preliminary gelatinization and aging of the starch before the actual cooking process, pre-establishing a strong matrix structure and matte surface layer that prevents disintegration during subsequent heat cooking without complicating the overall manufacturing process
Solution Approach 2:
By controlling specific parameters (gelatinization degree, moisture content, temperature-time conditions), the invention transforms ordinary starch into a structurally enhanced composition that maintains shape stability during cooking while keeping the processing method relatively simple
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 a starch-containing composition that maintains shape and achieves a highly matte texture during heat cooking, addressing disintegration issues and appearance concerns.
Implementation Method 1
heating the composition prepared at step (i) along a course from the first flight section to the kneading section so as to reach a temperature of 100° C. or more but 200° C. or less at the kneading section
Implementation Method 2
disintegration the starch grains in the raw material and then to form an aged starch layer on the surface of the composition while creating a strong starch matrix structure inside the composition
Implementation Method 3
heating the composition prepared at step (i) along a course from the first flight section to the kneading section so as to reach a temperature of 100° C. or more but 200° C. or less at the kneading section under pressurized conditions
Implementation Method 4
depressurizing the composition kneaded at step (ii), from the pressurized state at the kneading section to atmospheric pressure or less at the vent section
Implementation Method 5
lowering the degree of gelatinization in the composition kneaded at step (ii) by 6 mass % or more at the kneading section and onward
Data Source
AI summary
A manufacturing method for a starch-containing composition that is not prone to collapsing shape in a liquid during heat cooking, is highly lusterless, and has excellent appearance which utilizes an extruder including a feeder for loading a food material and a die for discharging the food material after kneading and shaping. The screw has a first flight, a kneading, and a second flight section, and the barrel has a bend section at the first-half of the second flight section of the screw. A composition containing at least 3.0 mass % insoluble dietary fiber, at least 10.0 mass % starch, at least 3.0 mass % protein, and a dry-basis water content of at least 25 mass % is prepared.; The composition is then heated under pressure, kneaded, and depressurized until the degree of gelatinization is lowered by at least 6 mass %.