Hydrolyzed Pulse Flour via Enzyme Extrusion
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Solution Overview
Problem
Food products made from grains and pulses often have undesirable mouthfeel characteristics such as viscosity and grittiness, and may lack certain nutritional benefits due to processing methods that modify their fiber content.
Innovation Solution
A method involving combining pulse and enzyme mixtures, heating them to initiate starch hydrolysis, and extruding to gelatinize and cook the mixture, resulting in soluble, highly dispersible whole grain flours that maintain their nutritional integrity and standard of identity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If grain and pulse products are processed to improve mouthfeel, then texture quality improves, but nutritional content and fiber benefits are lost
Solution Approach 1:
The patent applies parameter changes by controlling extrusion temperature and residence time to achieve partial starch gelatinization rather than complete gelatinization. This partial gelatinization modifies the texture and mouthfeel of the product while preserving the fibrous structure and nutritional components that would otherwise be lost in conventional high-temperature processing. The key is adjusting processing parameters to stop at the optimal point where mouthfeel improves but nutritional integrity is maintained.
2Ease of manufacture
If conventional processing methods are used to cook grains and pulses, then cooking is achieved, but viscosity and grittiness increase
Solution Approach 1:
The patent replaces conventional thermal cooking mechanisms with extrusion cooking that combines mechanical shear force, pressure, and controlled thermal energy. The extrusion process uses mechanical energy from the screw conveyor to cook and gelatinize starch while simultaneously improving texture. This mechanical substitution allows for shorter processing times and better control over the gelatinization degree, avoiding the excessive viscosity and grittiness associated with traditional cooking methods.
3Ease of operation
If high-temperature hydration is used to process whole grain flours, then dispersibility improves, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple processing functions into a single extrusion step. The extruder simultaneously performs cooking, gelatinization, starch modification, and texture development that would otherwise require separate high-temperature hydration and mechanical processing steps. This consolidation achieves improved dispersibility while reducing manufacturing complexity by eliminating the need for separate high-temperature hydration equipment and subsequent mechanical processing equipment.
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 process produces soluble whole grain flours that are highly dispersible, maintain nutritional benefits, and can be used in various food products without the need for high-temperature hydration or mechanical processes, improving manufacturing efficiency and consumer acceptance.
Implementation Method 1
heating the enzyme-pulse starting mixture to between about 48.89° C. and about 93.33° C. to begin to hydrolyze the starch
Implementation Method 2
extruding the heated pulse mixture to continue hydrolyzing the starch and further to gelatinize and cook the heated pulse mixture
Data Source
AI summary
A method and composition comprising hydrolyzed starch. In a first aspect, the method comprises several steps. A first step comprises combining at least a portion of pulse and a suitable enzyme to form an enzyme-pulse starting mixture. The enzyme-pulse starting mixture comprises starch. A second step comprises heating the enzyme-pulse starting mixture to between about 48.89° C. and about 93.33° C. to begin to hydrolyze the starch, thereby providing a heated pulse mixture. A third step comprises extruding the heated pulse mixture to continue hydrolyzing the starch and further to gelatinize and cook the heated pulse mixture thereby providing a pulse product comprising gelatinized, hydrolyzed starch. In a second aspect, the invention provides a composition comprising at least a portion of pulse, and the at least a portion of pulse comprises gelatinized, hydrolyzed starch.