Milk Caramel Production Using Pressure Dissolving and Maillard Reaction
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Solution Overview
Problem
Current methods for producing milk caramel are energy-intensive, as they typically involve boiling the entire mass, leading to high energy consumption and inefficiency.
Innovation Solution
An automated device and method that utilize a pressure dissolver to create a master solution from a base mixture of glucose syrup and sugar or water under superatmospheric pressure below the boiling point, followed by the addition of a milk product in a caramelizing device where the Maillard reaction occurs, reducing energy requirements through controlled temperature and pressure management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the entire mass is boiled in traditional methods, then the Maillard reaction is achieved, but energy consumption is high
Solution Approach 1:
The production process is divided into two separate stages: (1) preparing a base solution by heating glucose syrup and water below boiling point, and (2) adding milk product in a caramelizing device where the Maillard reaction occurs. This segmentation allows energy-intensive boiling to be eliminated while maintaining reaction effectiveness.
Solution Approach 2:
The base solution of glucose syrup and water is prepared in advance by heating below boiling point, creating optimal conditions for the subsequent Maillard reaction when milk product is added. This preliminary preparation reduces the energy needed during the actual caramelization stage.
2Use of energy by moving object
If the base mixture is heated below boiling point, then energy savings are achieved, but the Maillard reaction efficiency may be reduced
Solution Approach 1:
The process utilizes parameter changes by heating the base solution to a controlled temperature below boiling point (e.g., 100-150°C), then adding milk product which triggers the Maillard reaction. The reaction efficiency is maintained through optimized temperature, pressure, and residence time parameters in the caramelizing device.
Solution Approach 2:
The process exploits phase transitions including evaporation of water from the base solution and the chemical phase changes during the Maillard reaction. Controlled evaporation concentrates the base solution to enhance reaction efficiency without requiring full boiling.
3Temperature
If superatmospheric pressure is used, then temperature control below boiling point is achieved, but device complexity increases
Solution Approach 1:
The process employs pneumatic principles by using superatmospheric pressure in the pressure dissolver to enable temperature control below the boiling point. The pressure control system, while adding complexity, allows precise thermal management and facilitates the separation of heating and caramelization stages.
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
This approach results in significant energy savings of 30 to 70% compared to traditional methods, achieved by heating the base mixture below its boiling point and allowing spontaneous flash evaporation, which reduces the dry matter content and optimizes the Maillard reaction for milk caramel production.
Implementation Method 1
heating the masterbatch below the boiling point of the masterbatch
Implementation Method 2
allowing spontaneous flash evaporation, which reduces the dry matter content
Implementation Method 3
milk caramel production by using the Maillard reaction. The Maillard reaction is understood to be a comparatively complex set of several chemical reactions that lead to a large number of reaction products
Data Source
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AI summary
A device (1) and a method are used for the automated production of milk caramel. The device (1) has a pressure dissolving container (5) for receiving a base mixture with glucose syrup and sugar or with water and a sugar substitute. The pressure-dissolving container (5) is opposite the atmospheric pressure under pressure. The pressure-dissolving container (5) serves to generate a base solution fromthe base mixture by heating the base mixture below the boiling point of the base solution. The device (1) has a supply line (17) for feeding a milk product into the basic solution. The supply line (17) is arranged downstream of the pressure-dissolving container (5). The device (1) has a caramelizing device (23) for producing milk caramel from the milk product. The caramelizer (23) is located downstream of the pressure-dissolving container (5).