Hydrolyzed Whole Grain Flour Agglomeration

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Solution Overview

Problem

Existing methods for preparing hydrolyzed whole grain flours fail to maintain the structural integrity and nutritional value of whole grains during processing, leading to clumping and unappealing mouthfeel, making it difficult to create consumer-acceptable, ready-to-eat products that meet health claims.

Innovation Solution

A method involving enzyme hydrolysis, fine milling, and agglomeration of whole grains to maintain their structure and enhance dispersibility in liquids and semi-solids, using enzymes like alpha amylase to break down starch bonds while maintaining the whole grain status, followed by extrusion and pelletization, and subsequent milling and agglomeration with a sugar binder.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If hydrolyzed whole grain flour is prepared using conventional methods, then the processing is simpler, but the flour clumps and has poor mouthfeel due to loss of structural integrity

Engineering Contradiction:

Improveprocessing simplicityVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies preliminary action by coating whole grains with starch before hydrolysis processing. This pre-coating protects the grain structure during the hydrolysis process, preventing clumping and maintaining structural integrity while allowing the processing to proceed. The starch coating is applied in advance to prevent the harmful effects of structural degradation during processing.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If whole grain structure is maintained during processing, then nutritional value is preserved, but dispersibility in liquid media deteriorates

Engineering Contradiction:

Improvenutritional valueVSAvoiddispersibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent changes physical parameters by controlling particle size through milling. The whole grains are milled to specific particle size ranges (e.g., 40-80 mesh) which optimizes both the maintenance of structural integrity and the dispersibility in liquid media. This parameter adjustment allows the flour to maintain nutritional value while improving its ability to disperse evenly in liquids without clumping.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If whole grain is finely milled to improve dispersibility, then mouthfeel is improved, but structural integrity is lost leading to clumping

Engineering Contradiction:

ImprovemouthfeelVSAvoidstructural integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent applies preliminary action by coating grains with starch before milling. This pre-coating protects the grain structure during the fine milling process, allowing the grains to be milled to fine particle sizes for improved mouthfeel while preventing the structural degradation that would otherwise cause clumping. The protective coating is established before the damaging milling action occurs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent creates a composite structure by combining whole grains with starch coating. This composite material maintains the beneficial structural integrity of whole grains while adding the dispersibility and anti-clumping properties of the starch coating. The composite structure allows fine milling for improved mouthfeel without losing structural integrity.

Inventive Principle:

Principle #40Composite materials

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 resulting hydrolyzed whole grain flour is highly dispersible, maintains nutritional benefits, and improves mouthfeel, allowing for the production of consumer-acceptable, ready-to-eat products that can be easily incorporated into liquid or semi-solid media, such as drinks, while supporting health claims.

Implementation Method 1

an enzyme hydrolyzes the whole grain flour while maintaining the integrity of the whole grain

Methodology Applied

Scientific EffectEnzyme hydrolysis: Enzyme

Implementation Method 2

enzyme hydrolysis, fine milling, and agglomeration of whole grains to maintain their structure

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 3

The grain used for agglomeration may be untreated/native, pre-gelatinized, or hydrolyzed

Methodology Applied

Scientific EffectAgglomeration:

Data Source

PatentUS8586113B2Method of preparing highly dispersible whole grain flour

Publication Date: 2013.11.19 QUAKER OATS CO

AI summary

A method of preparing a highly dispersible whole grain flour by hydrolyzing, milling and agglomerating grain flour. Highly dispersible hydrolyzed whole grain flours made in accordance with the present invention include an enzyme that hydrolyzes the whole grain flour while maintaining the integrity of the whole grain throughout processing. The whole grain flours of the present invention are highly dispersible in liquid and semi-solid media.