Low Moisture Breadcrumb via Rotary Drying
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional breadcrumb becomes soggy upon immersion in water due to high water content, making it unsuitable for use in moist environments, particularly for coating microwaveable products, and existing drying methods like fluid bed dryers create airborne dust issues.
Innovation Solution
A method involving extruding a dough composition with a gelling agent, followed by drying in a rotary dryer with a countercurrent hot air stream to achieve a crumb with a water content of 0.1-1.5% by weight, which is more water-resistant and free from significant energy input or heat-induced defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional breadcrumb is used, then it is easy to manufacture, but it becomes soggy immediately upon immersion into water
Solution Approach 1:
The patent changes the water content parameter from conventional levels (4-12%) to a significantly reduced level (0.1-1.5%) through a two-stage drying process. This parameter change transforms the crumb's water resistance properties, enabling it to maintain crispness in moist environments while remaining manufacturable through the described drying process
2Quantity of substance
If fluid bed dryer is used to dry crumb, then water content can be reduced, but a large amount of airborne dust is created
Solution Approach 1:
The patent extracts the harmful fluidization process from the drying system and replaces it with a conveyor belt dryer. This removes the source of airborne dust generation while maintaining the ability to reduce water content to the required 0.1-1.5% level through controlled drying
3Reliability
If crumb is dried to very low moisture content, then water resistance is improved, but heat induced defects may occur
Solution Approach 1:
The patent applies preliminary action by adding a hydrocolloid coating to the crumb before the drying process. This coating protects the crumb particles during drying, preventing heat-induced defects while enabling the crumb to be dried to the very low moisture content (0.1-1.5%) required for water resistance
Solution Approach 2:
The hydrocolloid coating serves as a protective cushion during the drying process, shielding the crumb from direct heat exposure that could cause defects. This beforehand protection allows aggressive drying to achieve low moisture content without compromising product quality
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 crumb is extremely water-resistant, maintaining crispness during cooking or reheating and reducing oil pick-up during frying, while avoiding the dust issues associated with fluid bed dryers.
Implementation Method 1
drying the extruded composition in a rotary dryer to form a dried composition, wherein the water content of the dried composition is from about 0.1% to about 1.5% by weight
Implementation Method 2
drying in a rotary dryer with a countercurrent hot air stream
Implementation Method 3
a method of manufacture of a crumb comprises: extruding a dough composition comprising flour, a gelling agent, optional further ingredients and water
Data Source
AI summary
A method of manufacture of a breadcrumb coating for a food product provides a crumb with an extremely low moisture content without the need for substantial energy input. The method achieves such very low moisture content without significant adverse effect on product quality.