Layered Cookie Dough Processability and Slowly Digestible Starch
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Solution Overview
Problem
Existing layered cookies face challenges in maintaining a high slowly digestible starch content due to gelatinization during baking, which affects their energy supply duration and nutritional profile, and the addition of fat and sugar impacts dough processability and organoleptic properties.
Innovation Solution
A method for producing layered cookies with a dough comprising refined cereal flour, limited added water, and specific fat and sugar content, which includes forming a biscuit dough with 21% refined cereal flour and up to 8% added water, baking, and assembling with a filling to achieve a slowly-digestible-starch-over-total-available-starch ratio of at least 31%, while maintaining processability and nutritional benefits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the starch content is increased in the dough composition to provide long-lasting energy, then the slowly digestible starch content increases, but the amount of water required increases leading to increased gelatinisation and reduced slowly digestible starch content
Solution Approach 1:
The patent changes the physical-chemical parameters of the starch by using native starch with specific properties (low gelatinisation temperature, high amylose content) and controlling the water activity and pH during processing to prevent excessive gelatinisation while maintaining high starch content
Solution Approach 2:
The patent uses composite starch systems combining native starch from specific sources (potato, corn, tapioca) with particular amylose-amylopectin ratios to achieve both high starch content and resistance to gelatinisation, creating a composite material with optimized nutritional and processing properties
2Quantity of substance
If fat and sugar content is decreased in the biscuit part to improve nutritional profile, then the nutritional quality improves, but the dough processability deteriorates
Solution Approach 1:
The patent introduces intermediary substances such as emulsifiers (lecithin, monoglycerides) and hydrocolloids (xanthan gum, guar gum) that mediate between the reduced fat-sugar matrix and the dough structure, providing plasticization and processability without adding excessive calories or compromising nutritional quality
Solution Approach 2:
The patent modifies the physical parameters of the dough by controlling water activity, pH, and using enzymatic treatments to alter the rheological properties, enabling good processability with reduced fat and sugar through parameter optimization rather than relying solely on fat-sugar plasticization
3Quantity of substance
If native starch is added to the filling composition to increase slowly digestible starch content, then the energy supply duration increases, but the organoleptic properties deteriorate due to disagreeable mouth feeling
Solution Approach 1:
The patent applies local quality by using different starch types in different layers - the biscuit part contains native starch for slow digestion, while the filling uses modified starch or starch from sources with better mouthfeel properties, allowing each layer to optimize its function without compromising overall product quality
Solution Approach 2:
The patent changes the physical parameters of the starch in the filling by using pre-gelatinized starch, starch with specific particle size distributions, or starch modified through physical/chemical means to reduce viscosity and improve mouthfeel while maintaining the slow-digesting functionality
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 results in layered cookies providing long-lasting energy with a high slowly digestible starch content, improved processability, and a healthier nutritional profile, while maintaining a good sensory impact and industrial production feasibility.
Implementation Method 1
The gelatinisation occurs owing to the presence of water in the dough mixture. Gelatinisation refers to the partial melting of the crystalline domains of starch, resulting in increased digestibility. During the heat treatment of moist dough the starch granules first swell, then progressively loose their crystalline structure until they burst, resulting in the leaching out of the polysaccharides contained in the granules (amylose and amylopectin).
Data Source
AI summary
The disclosure concerns a method for producing a layered cookie comprising at least one biscuit and a filling, the layered cookie containing 10 wt % to 25 wt % fat and 15 wt % to 40 wt % sugar, wherein the slowly-digestible-starch-over-total-available-starch ratio of the layered cookie is at least 31 wt %, the method including: forming a dough comprising a cereal flour, fat, sugar and at most 8 wt % added water relative to the total weight of the dough; molding the dough into the shape of a biscuit; baking the biscuit; and assembling the biscuit with a filling to form a layered cookie; wherein the cereal flour comprises refined cereal flour, in an amount of at least 21 wt % over the total weight of the dough, with a water absorption under 55% as measured by Brabender® Farinograph®.