Nut Paste Preparation Using Surface-Treated Shells
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Solution Overview
Problem
Conventional methods for producing nut-based pastes or butter-like spreads face challenges in achieving favorable organoleptic properties, texture, and high yields of nutritionally favorable components without extensive processing, expensive equipment, or high production costs.
Innovation Solution
A method involving surface treatment of nutshells and/or non-shelled nuts, followed by grinding with drupe endocarp or other fat-containing food products, to produce an edible fat-containing food product with enhanced bioactive material extraction and storage stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional methods are used to prepare nut-based paste, then processing steps and equipment complexity increase, but organoleptic properties and texture improvement are achieved
Solution Approach 1:
The patent combines nut kernels, nut shells, and drupe endocarp into a single mixture that is ground together in one processing step. This merging of materials and operations eliminates the need for separate processing steps for each component, thereby simplifying the overall process while achieving the desired organoleptic properties through the synergistic combination of ingredients.
Solution Approach 2:
The invention uses a single grinding device to process multiple components (nut kernels, shells, and endocarp) simultaneously, making the equipment multi-functional. This universal approach allows one device to perform what would traditionally require multiple specialized devices and processing stages, reducing device complexity while maintaining product quality.
2Ease of manufacture
If nut shells and drupe endocarp are discarded as waste, then production costs decrease, but economic value and environmental impact are lost
Solution Approach 1:
Instead of discarding nut shells and drupe endocarp as waste, the invention recovers and incorporates these materials into the final nut-based paste product. By recovering these previously discarded components and utilizing their nutritional and functional properties, the process simultaneously reduces production costs through reduced waste management and captures economic value from previously unused materials.
Solution Approach 2:
The invention converts the previously harmful or wasted status of nut shells and endocarp into beneficial ingredients. These materials, which were formerly discarded as waste products, are now recognized as valuable sources of fiber, antioxidants, and other nutrients that enhance the final product's health benefits and market value.
3Ease of operation
If edible oils are added to facilitate mechanical processing, then texture and fluidity improve, but rancidity and shelf stability deteriorate
Solution Approach 1:
The invention allows the nut mixture to be processed without requiring the addition of external edible oils. The natural fats present in the nut kernels, combined with the mechanical action of the grinder, provide sufficient lubrication and fluidity for processing. This self-service approach eliminates the need for added oils that would compromise shelf stability, thereby maintaining both ease of processing and product reliability.
4Quantity of substance
If water is added during processing, then low calorie and low fat content are achieved, but susceptibility to mold, fungus and bacterial growth increases
Solution Approach 1:
The invention replaces aqueous-based processing with a dry mechanical grinding system. Instead of using water to control fat content and facilitate processing, the method employs mechanical force and friction within a closed grinding chamber to achieve the desired texture and fat reduction. This substitution of mechanical action for aqueous processing eliminates the moisture that would promote microbial growth, thereby achieving low fat content without compromising against mold, fungus, and bacterial contamination.
Data Source
AI summary
Described is a method for preparing a nut paste, comprising the steps of: a) treating the surface of nutshells and/or non-shelled nuts to remove surface contaminants from the shell material; b) preparing a mixture comprising: b1) surface-treated non-shelled nuts, b2) shelled culinary nuts and surface-treated nutshells, and/or b3) shelled culinary nuts and surface-treated non-shelled nuts; and c) grinding the mixture to an average particle size of 500 μm or less to provide a nut paste; wherein the mixture contains at least 0.05 wt.-% of surface-treated nutshell material based on the total weight of solids, and wherein the mixture does not contain added water. The method enables optimized extraction and yield of nutritionally beneficial components of both nut kernels and nut shells while enabling fast and inexpensive processing. In addition, a nut paste obtainable by the aforementioned method and the use of surface-treated nut shells and/or surface-treated non-shelled nuts in ground form as filler material in the preparation of food is described.