Cooked Frozen Pasta Texture Retention via High-Pressure Extrusion
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Solution Overview
Problem
Existing methods for producing cooked and frozen pastas fail to maintain the unique chewy and resilient texture of freshly boiled pasta during long-term storage, leading to texture loss and sauce penetration issues.
Innovation Solution
Cooked pasta production involves extruding dough into noodles at high pressures (80 kgf/cm² to 200 kgf/cm²) followed by freezing, using a mixture of durum wheat flour, regular wheat flour, and starches like hydroxypropylated starch, which enhances texture retention and resistance to freezing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If fresh pasta is frozen after cooking, then storage time is extended, but the noodle surface becomes rough and texture is lost
Solution Approach 1:
The patent applies parameter changes by controlling the freezing temperature at -30°C or lower and maintaining specific water content (25-45%) in the pasta before freezing. This parameter optimization prevents ice crystal formation that would otherwise damage the noodle surface structure, thereby maintaining smooth appearance and chewy texture during long-term frozen storage.
Solution Approach 2:
The patent implements preliminary action by cooking the pasta to a specific degree before freezing, rather than freezing raw pasta. This pre-cooking treatment prepares the pasta structure in advance to resist freezing damage, preventing the rough surface and texture loss that occur when raw pasta is frozen.
2Manufacturing precision
If fresh pasta is stored in chilled state, then texture is maintained, but distribution channels are limited
Solution Approach 1:
The patent changes the storage parameter from chilled state to deep frozen state at -30°C or lower. This temperature parameter change enables long-term storage stability while maintaining pasta quality, thereby expanding distribution capability beyond local chilled storage limitations to wider frozen food distribution networks.
3Ease of operation
If pasta is frozen with sauce, then convenience is improved, but sauce penetrates into pasta causing deterioration
Solution Approach 1:
The patent applies parameter changes by controlling the freezing temperature at -30°C or lower, which creates a stable frozen matrix that prevents sauce from penetrating into the pasta. This temperature parameter ensures that both pasta and sauce can be stored together frozen without quality deterioration, maintaining convenience while protecting pasta quality.
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 method results in pasta that maintains a smooth appearance and chewy texture comparable to freshly boiled pasta after thawing, preventing sauce penetration and ensuring quality during frozen storage.
Implementation Method 1
extruding dough into pasta noodles at a pressure of from 80 kgf/cm 2 to 200 kgf/cm 2
Implementation Method 2
extruding dough into pasta noodles
Implementation Method 3
boiling fresh pasta obtained by extruding dough into pasta noodles
Implementation Method 4
cooking the pastas with water
Implementation Method 5
freezing, and which retain good appearance and texture comparable to freshly boiled fresh pasta even after being thawed
Data Source
AI summary
Cooked and frozen pastas which can be stored in a frozen state for a long time and which retains favorable appearance and texture comparable to freshly boiled fresh pastas even after being thawed are provided. A method for producing cooked and frozen pastas, comprising boiling fresh pastas obtained by extruding dough into pasta noodles at a pressure of from 80 kgf/cm2 to 200 kgf/cm2, and then freezing the pastas.