Fresh Leavened Flaky Pastry Cold Solidification Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing processes for preparing fresh leavened flaky pastry result in a brioche-like texture instead of a flaky texture after baking, and fail to maintain optimal organoleptic qualities and long-term storage capabilities.
Innovation Solution
A process involving mixing, batter preparation, fat inclusion, layer-rolling, cutting into quadrilaterals, shaping, refrigeration, and cold solidification at a negative temperature above the pastry's crystallization temperature, followed by oiling and/or vacuum packing to ensure stability and retention of flakiness, with the use of stabilizers like xanthan gum and preserving agents to enhance shelf life and baking quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pastry is stored at refrigeration temperature below 8°C without freezing, then it maintains fresh status and avoids freezing damage, but it develops a brioche-like texture instead of flaky texture after baking
Solution Approach 1:
The patent applies preliminary action by performing cold solidification at negative temperatures (step j) before final refrigeration storage (step h). This pre-treatment at controlled negative temperatures above crystallization point prepares the pastry structure in advance, ensuring flaky texture development during baking while maintaining fresh status. The preliminary cold solidification step creates the necessary structural conditions that prevent brioche-like texture formation during subsequent refrigeration storage.
2Duration of action of stationary object
If the pastry is stored at refrigeration temperature for long-term storage, then shelf life is extended, but organoleptic qualities deteriorate over time
Solution Approach 1:
The patent applies parameter changes by implementing a two-stage temperature regimen: first cold solidification at negative temperatures above crystallization point (step j), then refrigeration at controlled positive temperatures between 0-8°C (step h). This parameter change strategy extends shelf life to over 30 days while preserving organoleptic qualities. The initial negative temperature treatment stabilizes the pastry structure, enabling long-term storage without quality deterioration.
Solution Approach 2:
The patent utilizes phase transitions by controlling the pastry through cold solidification at negative temperatures (step j) where partial solidification occurs above the crystallization point, then transitioning to refrigeration storage (step h). This controlled phase transition approach maintains the pastry in a stable state that preserves organoleptic qualities during long-term storage while extending shelf life beyond 30 days.
3Stability of the object's composition
If vacuum packing is applied to maintain pastry quality, then storage stability is improved, but packaging complexity increases
Solution Approach 1:
The patent applies inert atmosphere principle by using vacuum packing (step k) to create an oxygen-free environment for the pastry. This eliminates oxidative degradation and maintains storage stability for over 30 days. The vacuum packing, combined with the cold solidification treatment, provides a simple yet effective solution that achieves high storage stability without requiring complex active preservation systems.
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 process achieves a fresh leavened flaky pastry with superior organoleptic qualities and extended shelf life exceeding 30 days, maintaining the characteristic flaky texture and quality comparable to hand-crafted products, with pre-rolled or pre-filled individual pastry products.
Implementation Method 1
cold solidification at a negative temperature above the crystallization temperature of the pastry
Implementation Method 2
storage at the refrigeration temperature
Data Source
AI summary
A process for preparing fresh leavened flaky pastry includes the steps of; a mixing the basic products; b) preparing the batter; c) rolling; d) inclusion of fat; e) layer-rolling; f) cutting the pastry into quadrilaterals; g) shaping the pastry quadrilateral; h) bringing to the refrigeration temperature; and i) storage at the refrigeration temperature. Between steps g) and h), additional steps are included for j) cold solidification at a negative temperature above the crystallization temperature of the pastry; and k) oiling and/or vacuum packing of the pastry.