Frozen Confection Protein Agglomeration and Delayed Sugar Addition
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Solution Overview
Problem
Existing methods for producing frozen confections, especially non-stabilized or minimally stabilized high-fat formulations, face challenges in achieving nutritional balance, desirable taste, and texture while avoiding off-tastes and heat shock instability, which leads to icy products.
Innovation Solution
A method involving the separation of sucrose addition in the frozen confection manufacturing process, where an ingredient mix with a pH of 6.1-6.4, comprising 3-17% fat and 1-10% protein, is homogenized and pasteurized to form agglomerated proteins, with sugar added after pasteurization to prevent acid aftertaste and promote controlled agglomeration, allowing for improved texture and mouthfeel without additional stabilizers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If acidification is used to adjust pH for protein agglomeration, then texture and mouthfeel are improved, but sour aftertaste occurs in high fat non-stabilized formulations
Solution Approach 1:
The process is segmented into two distinct stages: first, acidification and protein agglomeration occur during homogenization at pH 5.8-6.3; second, sugar is added after pasteurization rather than before. This segmentation allows the acidification to occur without sugar present, preventing the sugar from interfering with protein aggregation while still achieving the desired texture, and the sour aftertaste is eliminated through the subsequent sugar addition.
Solution Approach 2:
Protein agglomeration is performed as a preliminary action before sugar addition. By acidifying the mix and allowing proteins to agglomerate during homogenization before pasteurization, the textural benefits are achieved in advance. The sugar is then added after pasteurization, ensuring that the protein structure is already formed and the sour aftertaste issue is resolved.
2Ease of manufacture
If non-stabilized or minimally stabilized formulations are used, then clean label and reduced additives are achieved, but heat shock instability occurs leading to icy products
Solution Approach 1:
The invention changes the pH parameter to 5.8-6.3 during homogenization, which is optimal for protein agglomeration. This specific pH range allows proteins to aggregate and form a stabilizing network without requiring additional stabilizing agents. The parameter change enables clean label formulations while maintaining heat shock stability through the protein-based stabilization mechanism.
Solution Approach 2:
The invention creates a composite protein system through controlled agglomeration of multiple protein types (casein, whey proteins) during acidification. This composite protein structure provides stabilization properties that replace the need for commercial stabilizers, achieving clean label status while maintaining reliability against heat shock and preventing ice crystal formation.
3Ease of operation
If sugar is added before pasteurization, then homogeneous mixing is achieved, but protein agglomeration is inhibited and sour aftertaste occurs
Solution Approach 1:
Protein agglomeration is performed as a preliminary action before sugar addition. The mix is acidified and homogenized to allow proteins to aggregate, then pasteurized to lock in the protein structure. Sugar is added after pasteurization, ensuring that protein agglomeration occurs without sugar interference while still achieving homogeneous distribution of sugar in the final product.
Solution Approach 2:
The mixing process is segmented into two phases: first, acidification and protein agglomeration during homogenization without sugar; second, sugar addition after pasteurization. This segmentation resolves the conflict between homogeneous mixing and protein agglomeration by performing each function in the optimal sequence.
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 approach results in frozen confections with enhanced textural and sensorial properties, reduced fat content, and stability against heat shock, eliminating the need for additional stabilizers or hydrocolloids, while maintaining a desirable mouthfeel and preventing grittiness.
Implementation Method 1
providing an ingredient mix free from added sugar or comprises below 0.2 wt. % sugar, the ingredient mix comprising 3 - 17 wt. % fat, 3 - 17 wt. % milk solids non-fat, and 1 - 10 wt. % protein comprising casein and whey, the ingredient mix having a pH of 6.1 - 6.4 homogenising the ingredient mix and subsequently pasteurizing the ingredient mix at a temperature of 80°-100°C for a period of 0.5 - 3 min to form agglomerated protein comprising casein and whey
Data Source
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AI summary
The invention relates to a method of producing a frozen confection product, the method comprising the steps of: providing an ingredient mix free from added sugar or comprises below 0.2 % wt, the composition comprising 3 - 17 wt. % fat, 3 - 17 wt. % milk solids non-fat, and 1 - 10 wt. % protein comprising casein and whey, the ingredient mix having a pH of 6.1 – 6.4; homogenising the ingredient mix and subsequently pasteurizing the composition at a temperature of 80°- 100°C for a period of 0.5 – 3 min to form agglomerated protein comprising casein and whey, adding 3 – 25 wt. % of sugar to the ingredient mix; and freezing while optionally aerating the ingredient mix, to form a frozen confection product. The invention also relates to a product obtained with the method.