Low Water Activity Filling Crystallization via Scraped-Surface Heat Exchanger
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Solution Overview
Problem
Existing methods for producing low water activity fillings for sandwich cookies, such as crème-type fillings, often require additional sugar or prolonged cooling processes to achieve the necessary firmness, which increase production time and costs.
Innovation Solution
A process involving heating a fat component above its melting point, mixing with sugar, and passing the slurry through a scraped-surface heat exchanger at controlled temperatures and cooling rates to achieve desired nucleation and crystallization, eliminating the need for additional sugar and cooling tunnels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional sugar is added to increase crystallinity, then the firmness of the filling is improved, but production time and ingredient costs increase
Solution Approach 1:
The patent changes the temperature parameter during processing - specifically heating the fat component to above its melting point before mixing with sugar, then controlling the cooling rate through the heat exchanger. This temperature parameter change enables proper crystallization without additional sugar, resolving the contradiction between firmness and production time/costs
Solution Approach 2:
The patent utilizes phase transitions of the fat component - melting it above its melting point to create a homogeneous mixture, then controlling controlled cooling to achieve desired crystallization. This phase transition approach allows the fat to provide firmness through proper crystal structure formation rather than relying on additional sugar
2Strength
If the filling is passed through a cooling tunnel for several minutes, then the firmness and crystallization rate are improved, but production time and energy usage increase
Solution Approach 1:
The patent performs preliminary heating of the fat component above its melting point before mixing with sugar. This preliminary action ensures complete melting and homogeneous mixing, which sets up the system for rapid controlled crystallization in the heat exchanger, eliminating the need for prolonged cooling tunnel treatment and maintaining high production speed
Solution Approach 2:
The patent changes the cooling rate parameter by using a scraped-surface heat exchanger that provides controlled cooling at rates of about 3.89°C/minute to about 40°C/minute. This controlled cooling rate parameter enables rapid crystallization without requiring extended cooling tunnel time, thus maintaining productivity
3Strength
If additional sugar is added to adjust firmness, then the texture is improved, but ingredient costs increase
Solution Approach 1:
The patent changes the temperature parameter - heating fat above melting point and controlling cooling rate - to achieve proper crystallization and firmness through the existing fat and sugar composition. This parameter change allows the original ingredient formulation to provide desired firmness without requiring additional sugar additions, thus reducing ingredient costs
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
This method produces fillings with optimal firmness and crystallinity suitable for rotary sandwiching machines without the need for cooling tunnels or additional sugar, reducing production time and costs while maintaining desired organoleptic properties.
Implementation Method 1
cooling the slurry in the scraped surface heat exchanger at a cooling rate of about 3.89°C (7°F)/minute to about 40°C (72°F)/minute
Implementation Method 2
achieve desired nucleation and crystallization
Implementation Method 3
heating the fat component to a temperature of 5.56°C (10°F) to 11.11°C (20°F) above the melting point of the fat component
Data Source
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AI summary
A method and system for making a low-water activity filling, such as crème type fillings, is provided. The fillings advantageously can be used with rotary sandwiching machines without the need for a cooling tunnel downstream of the scraped-surface heat exchanger in the production line. The fillings produced herein comprise a fat component and sugar source, and the fat in the filling has the desired crystallinity. The process and system described herein unexpectedly achieve both a desired nucleation and crystallization rate and crystal structure, as well as the resulting increased filling firmness, in the fillings produced therewith.