Fry-Dried Instant Meat Product with Pregelatinized Starch
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Solution Overview
Problem
Existing methods for producing instant processed meat products, such as freeze-drying (FD) and hot air drying (AD), face challenges in achieving high reconstitutability in hot water while maintaining cost-effectiveness and production efficiency.
Innovation Solution
A fry-drying method is employed, specifically atmospheric fry-drying, which involves drying the instant processed meat product in heated oil and fat, combined with the addition of gelatinized starch to enhance water absorption and maintain shape during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If freeze-drying (FD) method is used, then reconstitutability in hot water is improved, but production time is increased and cost is increased
Solution Approach 1:
The invention changes the drying parameters by using fry-drying at temperatures of 100-200°C under reduced pressure (0.01-0.5 MPa), which is a different thermal regime from conventional FD. This parameter change achieves rapid drying while maintaining porous structure formation, resolving the contradiction between drying time and reconstitutability
Solution Approach 2:
The invention utilizes phase transition of water during fry-drying under reduced pressure, where water rapidly evaporates from liquid to vapor phase, creating porous cavities in the meat product. This phase transition mechanism enables both rapid drying and porous structure formation, simultaneously addressing drying time and reconstitutability requirements
2Productivity
If hot air drying (AD) method is used, then production efficiency is improved and cost is reduced, but reconstitutability in hot water deteriorates
Solution Approach 1:
The invention changes the drying environment from atmospheric hot air to reduced pressure fry-drying conditions. This parameter change enables faster drying than AD while creating superior porous structure for reconstitution, resolving the contradiction between production efficiency and reconstitutability
Solution Approach 2:
The invention intentionally creates a porous internal structure with numerous cavities through fry-drying under reduced pressure. This porous material structure is key to achieving both rapid drying (improving productivity) and excellent reconstitutability (improving reliability), thus resolving the contradiction between AD's efficiency and poor reconstitution
3Loss of time
If atmospheric fry-drying is used, then drying time is reduced, but reconstitutability in hot water deteriorates due to dense internal structure
Solution Approach 1:
The invention uses periodic or staged fry-drying process under reduced pressure, controlling the drying rate to allow progressive formation of porous cavities. This periodic action enables rapid drying while preventing dense structure formation, resolving the contradiction between drying time and reconstitutability
Solution Approach 2:
The reduced pressure condition facilitates rapid phase transition of water to vapor, creating expanding vapor bubbles that form porous cavities during the frying process. This mechanism achieves both short drying time and good reconstitutability by simultaneously creating the necessary porous structure
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 an instant processed meat product with superior reconstitutability in hot water, comparable to FD methods, while significantly reducing drying time and production costs.
Implementation Method 1
addition of gelatinized starch to enhance water absorption
Implementation Method 2
addition of gelatinized starch to enhance water absorption and maintain shape during molding
Implementation Method 3
drying the instant processed meat product in heated oil and fat
Implementation Method 4
drying is carried out in heated oil and fat... it includes atmospheric fry-drying and vacuum fry-drying methods
Implementation Method 5
vacuum fry-drying is a drying method in which the drying is carried out in oil and fat under reduced pressure
Data Source
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AI summary
Provided at low cost are: an instant processed meat product having extremely excellent reconstitution properties in hot water; and a method for producing the instant processed meat product having excellent production efficiency. Disclosed are: a fried and dried instant processed meat product containing pregelatinized starch; and a method for producing the fried and dried instant processed meat product. The method includes: preparing a material for the instant processed meat product, pregelatinized starch, and water; kneading the material for the instant processed meat product, the pregelatinized starch, and the water to obtain a kneaded product; shaping the kneaded product; and frying and drying the shaped kneaded product to obtain a fried and dried product.