Fat-Based Confection Coating for Heat Stability and Low Fat
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Solution Overview
Problem
Existing coated food products are not heat-stable, leading to melting issues during warm weather, and they are high in fat, which is necessary due to limitations in prior methods of formation.
Innovation Solution
A method involving the application of a liquid coating composition and particulate material to a food piece, followed by exposure to hot air, to create a heat-stable, lower-fat coated food product with a final coating comprising a homogeneous blend of the two, using a process that includes separate streams for the coating and particulate material, and optimizing temperatures and air flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior art methods are used to form coated food products, then the products have organoleptically pleasing coating, but the fat content is high and the products are not heat-stable
Solution Approach 1:
The patent changes the physical and chemical parameters of the coating process by applying liquid coating composition at controlled temperatures (60-95°F during application, then 100-180°F hot air treatment) and specific time durations (30-90 seconds coating time, 10-15 minutes total process). These parameter changes enable the formation of a heat-stable coating with lower fat content (less than about 10% by weight) while maintaining organoleptic appeal, resolving the contradiction between heat-stability and fat content.
2Ease of operation
If prior art coated products are transported and stored during warm weather, then the products can be distributed, but they melt and form messy conglomerates
Solution Approach 1:
The patent applies preliminary action by forming a heat-stable coating on the food pieces before transport and storage. The coating process includes applying liquid coating composition followed by hot air treatment (100-180°F) to pre-establish a stable protective layer that prevents melting during subsequent warm weather transport and storage, eliminating the need for special handling conditions.
3Quantity of substance
If liquid coating composition is applied for longer time, then more coating is deposited on food pieces, but the process time increases
Solution Approach 1:
The patent employs pneumatic and hydraulic principles by using a finely dispersed spray to apply the liquid coating composition. This spray application method delivers the coating material efficiently and uniformly across the food pieces, achieving adequate coating coverage in a shortened time frame (30-90 seconds) compared to traditional methods, thus resolving the contradiction between coating amount and process time.
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
Results in a coated product with reduced fat content, high melting point, and low moisture, preventing melting and sticking, thus eliminating the need for special storage and handling conditions while maintaining organoleptic appeal.
Implementation Method 1
applying (e.g., delivering via a finely dispersed spray) a liquid coating composition and a particulate material to the outer surface of a food piece to form a final coating layer
Implementation Method 2
the coated food product is preferably exposed to hot air. This air should have a temperature that is at least about 30° F. higher, more preferably at least about 40° F. higher, and even more preferably from about 60-90° F. higher than the temperature at which the application steps were carried out
Implementation Method 3
The fat in the liquid coating composition preferably has a melting point of less than about 104° F., more preferably from about 50-100° F., and even more preferably from about 75-95° F.
Data Source
AI summary
New coated food products are provided. The products comprise a center food piece such as a nutmeat or cereal piece, and a coating surrounding the center food piece. The coating can be flavored with flavorings such as cheese, chocolate, or fruit. The coating comprises a substantially homogeneous mixture of a fat-based composition and a particulate material, which results in a stable coating that can tolerate higher temperatures when compared to prior art products while also having 50% or less of the fat content of prior art coatings.