Flour Tortilla Fat Composition for Rolling and Shelf-Life Stability
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Solution Overview
Problem
Existing flour tortillas, particularly those with reduced fat content, face challenges such as inferior rolling properties, non-uniform shape and size, increased stickiness, and reduced shelf-life stability, which are exacerbated by the use of vegetable oils and enzymes, leading to issues like zippering and stack height problems.
Innovation Solution
Incorporating a specific fat component, predominantly composed of triglycerides of saturated fatty acids with 8-22 carbon atoms, into the tortilla dough to enhance properties like rolling, folding, and shelf-life stability without the need for emulsifiers or other non-triglyceride dough conditioners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If vegetable oils or enzymes are used to reduce fat content in tortillas, then health benefits are improved, but rolling properties and shelf-life stability deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the fat component by specifying triglycerides of saturated fatty acids with 8-22 carbon atoms in specific proportions (lauric acid 10-14%, palmitic acid 35-45%, stearic acid 20-35%). This parameter optimization resolves the contradiction by achieving both reduced health concerns and improved reliability in rolling properties and shelf-life stability
Solution Approach 2:
The patent creates a composite fat structure combining multiple saturated fatty acid triglycerides in specific ratios. This composite approach (lauric + palmitic + stearic acid triglycerides) provides synergistic effects that simultaneously address health concerns while maintaining superior rolling characteristics and shelf-life stability compared to single fat sources
2Object-affected harmful factors
If fat content is reduced in tortillas, then health benefits are improved, but stickiness and uniformity of shape and size worsen
Solution Approach 1:
The patent optimizes the fat composition parameters by specifying precise ranges for different saturated fatty acid triglycerides. This parameter control enables reduced fat content while maintaining manufacturing precision and uniformity of tortilla shape and size during production
Solution Approach 2:
The specific combination of saturated fatty acid triglycerides acts as an intermediary substance that enables reduced fat content while preventing the stickiness and uniformity problems that normally occur with fat reduction. This intermediary fat composition mediates between health benefits and manufacturing quality
3Ease of operation
If regular fat content is used in tortillas, then rolling and folding properties are improved, but calorific density and health concerns worsen
Solution Approach 1:
The patent changes the fat composition parameters to use primarily saturated fatty acid triglycerides (lauric, palmitic, stearic acids) in specific proportions. This parameter change maintains excellent rolling and folding properties while reducing overall fat content and calorific density compared to traditional tortillas
Solution Approach 2:
The patent applies local quality by optimizing specific portions of the fat composition (different fatty acid types in specific ratios) to provide the necessary functional properties for rolling and folding, while the overall fat content remains reduced. This localized optimization of fat structure achieves both operational ease and health benefits
Data Source
AI summary
The invention relates to a method for preparing a flour tortilla, comprising -preparing a tortilla dough from cereal flour and fat particles, which fat particles at least substantially consist of triglycerides of saturated fatty acids having8-22 carbon atoms; - shaping the tortilla dough into a tortilla shape; and -heating the shaped tortilla dough, thereby obtaining the flour tortilla. The invention further relates to a flour tortilla dough, comprising fat particles dispersed therein, which fat particles at least substantially consist of triglycerides of saturated fatty acids having8-22 carbon atoms, and to a flour tortilla that can be obtained by a method according to the invention or made from dough according to the invention.