Fat-Coated Fibre Ingredient System for Clean-Label Flatbread
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Solution Overview
Problem
The challenge is to produce ambient shelf-stable flatbreads like tortillas without using monoglycerides or mono-diglycerides of fatty acids, while maintaining freshness, flexibility, and preventing stickiness and cracking, especially in recipes that exclude palm-derived fats for sustainability reasons.
Innovation Solution
A system comprising fat-coated vegetable fibre particles combined with an enzyme preparation, optionally including a fat-coated organic acid, which replaces the need for emulsifiers, improving freshness and flexibility while reducing dough stickiness and adhesion over shelf life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If monoglycerides or mono-diglycerides of fatty acids are used, then freshness and flexibility are improved, but the product contains chemically modified ingredients that conflict with clean-label goals
Solution Approach 1:
The patent removes monoglycerides and mono-diglycerides of fatty acids from the ingredient list while maintaining their functional benefits through alternative ingredients (fat-coated vegetable fibre particles and enzymes), achieving clean-label status without sacrificing freshness
Solution Approach 2:
The patent introduces fat-coated vegetable fibre particles as an intermediary substance that performs the emulsifying and freshness-maintaining functions previously achieved by monoglycerides, serving as a natural bridge between clean-label requirements and functional performance
2Stability of the object's composition
If monoglycerides or mono-diglycerides of fatty acids are used, then flexibility and handling are improved, but the ingredient list becomes less sustainable (especially with palm-derived fats)
Solution Approach 1:
The patent changes the source of fats from palm-derived (sustainability concerns) to alternative vegetable oils, and modifies the physical form from pure emulsifiers to fat-coated fibre particles, maintaining flexibility while improving sustainability profile
Solution Approach 2:
The patent creates a composite material system combining vegetable fibres with fat coatings, where the fibre matrix provides structural integrity and the fat layer provides flexibility and plasticity, replacing the need for pure emulsifier additives
3Shape
If traditional chemical raising systems (sodium bicarbonate plus acidulant) are used, then the desired bubble structure is achieved, but the number of food additives increases
Solution Approach 1:
The patent merges the raising function with the pH control function into a single integrated system using fat-coated organic acid particles that provide both the acidulant function and pH regulation, reducing the number of separate additive ingredients
Solution Approach 2:
The fat-coated organic acid particles serve multiple functions simultaneously: as acidulants for the raising reaction, as pH regulators for shelf stability, and as coating materials for controlled release, eliminating the need for separate additive ingredients
4Reliability
If preservatives are added to extend shelf life, then microbiological stability is improved, but the number of food additives and chemical modifications increase
Solution Approach 1:
The patent enables the tortilla system to self-regulate its own preservation through controlled pH reduction via organic acid release, creating an environment that naturally inhibits microbial growth without requiring separate preservative ingredients
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 system effectively maintains tortilla freshness, flexibility, and appearance, allowing for easy handling and storage without damage, with reduced adhesion and improved extensibility, comparable to products containing emulsifiers, while adhering to sustainability standards.
Implementation Method 1
an enzyme preparation containing at least an amylase
Implementation Method 2
fat-coated vegetable fibre particles wherein the fat-coated vegetable fibres comprise a fat with a melting point between 40 and 80 degrees Celsius
Data Source
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AI summary
The present invention is directed to an ingredient system for flatbread products which are essentially free from added mono-diglycerides, comprising an ingredient system containing a fat-coated vegetable fibre particle, a fat-coated organic acid and an enzyme preparation containing at least an amylase; flatbread products which contains the ingredient system and the use of the ingredient system in flatbread products.