Microwave Dehydration of Plant Batter for Expanded Snacks
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Solution Overview
Problem
Current methods for producing expanded snack foods are limited by the need for extrusion and frying, which restrict the use of high moisture substrates like fruits and vegetables, and result in products with compromised nutritional and sensory qualities.
Innovation Solution
A method involving a batter made from a plant-based substrate, emulsifier, and starch, which is dehydrated using microwaves to produce a non-fried, non-extruded expanded snack food product with a desirable texture and flavor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional extrusion and frying methods are used to produce expanded snack foods, then an expanded texture is achieved, but the nutritional and sensory qualities are compromised and high moisture substrates cannot be used
Solution Approach 1:
The patent changes the processing parameters by replacing high-temperature extrusion and frying with microwave dehydration at lower temperatures. This parameter change allows the formation of an expanded structure through controlled water removal, achieving the desired texture while preserving the nutritional and sensory qualities of heat-sensitive substrates like fruits and vegetables
Solution Approach 2:
The patent substitutes the mechanical extrusion system with a microwave-based dehydration system. Instead of using mechanical force to create expansion, the invention uses microwave energy to rapidly evaporate water, creating vacuum pockets that form the expanded structure during drying, thereby avoiding the need for high-temperature mechanical processing
2Reliability
If high moisture substrates like fruits and vegetables are used, then nutritional and sensory qualities are improved, but the forming and dehydration process becomes hindered or economically unfeasible
Solution Approach 1:
The patent replaces traditional thermal dehydration systems with microwave dehydration. This substitution enables efficient water removal from high moisture substrates by directly heating the water molecules, significantly reducing dehydration time and energy consumption, thereby making the process economically feasible while preserving substrate quality
Solution Approach 2:
The microwave dehydration process employs periodic or pulsed microwave energy application, allowing controlled water removal from high moisture substrates. This periodic action prevents overheating and maintains the structural integrity of the substrate while achieving the desired dehydration level
3Ease of manufacture
If plant-based powders are used to manufacture snacks, then the dehydration process is feasible, but heat-labile nutrients are lost and sensory attributes are reduced
Solution Approach 1:
The patent substitutes conventional thermal dehydration with microwave dehydration, which operates at lower temperatures and shorter times. This substitution prevents the degradation of heat-labile nutrients and maintains the sensory properties of plant-based substrates while still achieving feasible dehydration and expanded structure formation
4Shape
If extrusion followed by frying is used, then expanded snack products are produced, but the process is complex and requires multiple steps
Solution Approach 1:
The patent merges the forming and expansion steps into a single microwave dehydration process. Instead of separate extrusion and frying operations, the invention uses microwave energy to simultaneously dehydrate the substrate and create the expanded structure through vacuum pocket formation, thereby simplifying the manufacturing process and reducing equipment complexity
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 allows for the production of expanded snack foods with a crunchy texture and high plant-based content, while maintaining the nutritional and sensory qualities of the substrates, and can be easily scaled for industrial or domestic use.
Implementation Method 1
dehydrated using microwaves to produce a non-fried, non-extruded expanded snack food product
Implementation Method 2
The microwave dehydration step may be carried out using a power density setting of 15-50 kW
Implementation Method 3
The use of a microwave is thought to cause a rapid increase in the temperature of the water within the batter, which increases internal pressure resulting in the formation of bubbles within the batter that give rise to the expanded, textured architecture of the product
Implementation Method 4
The use of a microwave is thought to cause a rapid increase in the temperature of the water within the batter, which increases internal pressure resulting in the formation of bubbles within the batter
Data Source
AI summary
An expanded snack food product comprising a rigid matrix defining a cellular structure, and a batter for making an expanded snack food product comprising a substrate, an emulsifier and starch. A method of manufacture and a kit is also disclosed.