Grain Cooking Bag with Headspace for Fluffy Texture

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Solution Overview

Problem

Traditional methods for cooking grains, such as sous vide and 'cook in water' products, result in grains that do not expand properly and can congeal into blocks, leading to post-thermal process contamination issues and requiring additional interventions for shelf life extension.

Innovation Solution

Cooking grains in a sealed, loose package with a brine and water mixture in a bag that has an air and moisture barrier, allowing grains to expand and maintaining a fluffy texture without perforations, using a packaging machine to fill the bag with grains, brine, and air, and cooking methods like submersion in hot water or steam exposure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If grains are cooked in a sealed bag without headspace, then the bag is fully utilized, but the grains cannot expand properly and congeal into blocks

Engineering Contradiction:

Improvebag utilizationVSAvoidgrain expansion

Core Design Contradiction:

Volume of moving objectVSShape

Solution Approach 1:

The invention introduces a third dimension (headspace volume) to the packaging system. By allocating a specific portion of the bag volume (at least 10% headspace) that does not contain grains, the system enables grain expansion in three-dimensional space without compromising overall bag utilization. This dimensional allocation resolves the contradiction between maximizing bag capacity and allowing proper grain expansion.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If grains are cooked in perforated bags, then water can drain after cooking, but the grains experience post thermal process contamination and require additional interventions

Engineering Contradiction:

Improvecooking process simplicityVSAvoidfood safety

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention extracts the drainage function from the bag structure itself (perforations) and replaces it with an external water removal step after cooking. The sealed bag maintains food safety during cooking, and water is removed afterward through decanting or draining, eliminating the need for perforations that compromise containment and food safety.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention applies beforehand cushioning by using a sealed bag that prevents contamination during the thermal process. The seal acts as a protective barrier that maintains food safety throughout cooking, and water removal is handled afterward, preventing contamination issues that would require additional chemical or physical interventions.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Manufacturing precision

If grains are vacuum cooked in a bag, then the cooking is precise and controlled, but the grains cannot expand properly and congeal into blocks

Engineering Contradiction:

Improvecooking controlVSAvoidgrain texture

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

The invention changes the pressure parameter during cooking by cooking in atmospheric pressure rather than vacuum conditions. This parameter change allows grains to expand properly and achieve a fluffy texture while maintaining the controlled cooking environment through the sealed bag system. The headspace volume further facilitates expansion by providing physical space for volume increase.

Inventive Principle:

Principle #35Parameter changes

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 produces loose, fluffy cooked grains with extended refrigerated shelf life without chemical or physical interventions, ensuring food safety and preventing contamination.

Implementation Method 1

cooking the grains in the bag... submerging the bag in hot water

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the grains can absorb moisture and expand during cooking

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 3

providing a head space filled with air in the bag to provide space for the grains to expand during cooking

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20240365822A1Process for cooking grains

Publication Date: 2024.11.07 OSI IND LLC

AI summary

A process for cooking grains in a bag having an air and moisture barrier is provided. The process includes filling a portion of the bag with a type of grain, such as rice, adding brine to the bag and leaving a headspace of air in the bag to enable the grain to expand as it is being cooked. The process further includes sealing the bag and placing the bag in a cooking device. The grain can be cooked in the bag by submerging the bag in hot water. The grain can also be cooked in a cabinet having various heat sources, a rotary drum or a continuous cooking device. The grain cooked by this process comes out loose and fluffy, and is not congealed. The process can be used for rice, oats and other grains.