Fruit Snack Viscosity Control via Hydratable Thickeners
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing intermediate moisture food products, such as dried fruit snacks, require additional drying steps that increase production costs and can lead to degradation of heat-sensitive vitamins and scaling issues with mineral fortification, particularly with calcium.
Innovation Solution
A method involving the formation of a hot sweetened intermediate moisture flowable fruit or confectionary composition with extended cooking and agitation to create a viscous slurry that can be directly formed into shaped products without additional drying, using a combination of nutritive carbohydrate sweeteners, bulking agents, and hydratable thickeners, reducing the need for capital and operating costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If additional drying steps are used to produce intermediate moisture food products, then the moisture content is reduced to desired levels, but production costs increase and heat-sensitive vitamins degrade
Solution Approach 1:
The patent changes the formulation parameters by incorporating specific thickening agents and adjusting the initial moisture content of the fruit puree mixture. This allows the product to achieve desired intermediate moisture levels (approximately 20-40% moisture content) through controlled cooking and thickening rather than extensive drying, thereby reducing production costs and preserving heat-sensitive nutrients
Solution Approach 2:
The patent performs preliminary thickening and moisture reduction during the cooking phase before forming. By pre-adjusting the moisture content and viscosity through controlled cooking with thickening agents, the need for additional post-forming drying steps is eliminated, reducing both cost and vitamin degradation
2Quantity of substance
If additional drying steps are used to produce intermediate moisture food products, then the moisture content is reduced to desired levels, but processing time increases
Solution Approach 1:
The patent modifies the rheological parameters of the mixture by adding thickening agents during cooking, which accelerates moisture evaporation rate and achieves desired moisture content faster. This eliminates the need for prolonged drying cycles after forming, thereby reducing total processing time
Solution Approach 2:
The patent integrates moisture reduction and thickening into the continuous cooking process rather than separating them into distinct drying stages. The continuous agitation and controlled evaporation during cooking efficiently reduces moisture content while the process flows directly into forming, eliminating idle time between operations
3Quantity of substance
If mineral fortification is added to fruit snacks, then nutritional value is enhanced, but scaling issues occur during processing
Solution Approach 1:
The patent uses thickening agents and controlled moisture content as intermediaries to prevent mineral scaling. The specific formulation of thickened fruit puree creates a matrix that holds mineral fortificants in suspension during cooking and forming, preventing them from precipitating and scaling on equipment surfaces
Solution Approach 2:
The patent adjusts the pH, moisture content, and viscosity parameters of the fruit puree mixture to optimize mineral stability. By controlling these parameters during cooking and forming, the patent prevents mineral fortificants from crystallizing and scaling on processing equipment while maintaining their nutritional value
4Shape
If extended cooking with agitation is used to create viscous slurry, then the product achieves desired consistency without additional drying, but energy consumption increases
Solution Approach 1:
The patent maintains continuous agitation during the cooking process to ensure uniform thickening and prevent burning, while the extended cooking time at controlled temperature efficiently develops the desired viscous consistency. This continuous action achieves the target consistency in a single integrated step, avoiding the energy waste of multiple intermittent processing stages
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 allows for the production of low-moisture, high-solids content fruit products with reduced processing time and minimal finish drying, maintaining nutritional value and preventing vitamin degradation, while also simplifying equipment requirements and reducing operational expenses.
Implementation Method 1
hydratable thickeners
Implementation Method 2
extended cooking with agitation at final moisture levels
Data Source
AI summary
The present invention resides in methods of preparing low moisture sweetened fruit product base. The methods comprise the steps in sequence of forming a hot sweetened intermediate moisture flowable fruit or confectionary composition or slurry by extended cooking with agitation at final moisture levels and a solids content ranging from about 85 to 92° Brix; and without intervening drying, forming the hot slurry into sized and shaped individual pieces.