Nut-Based Pellet Extrusion for Shelf-Stable Snacks
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Solution Overview
Problem
Existing processes fail to produce shelf-stable, expandable nut-based pellets and desirable chip-like snacks with improved shape, texture, and flavor, while providing reduced fat, higher protein, and fiber content, as they struggle to incorporate high nut content effectively.
Innovation Solution
A process involving nut flour admixtures with pre-gelatinized or native starches and optional minor ingredients, extruded into pellets, then pressure-cooked in a popper to produce crispy snack chips with reduced fat content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high nut content is incorporated into extruded pellets, then nutritional profile (protein and fiber) is improved, but manufacturability and storability deteriorate
Solution Approach 1:
The patent changes the moisture content parameter of the nut-based pellets to a specific range (10-15% by weight) after extrusion and before packaging. This parameter optimization enables the pellets to be shelf-stable while maintaining high nut content, resolving the contradiction between nutritional quality and storability
Solution Approach 2:
The patent creates a composite material system combining nut flour with selected starches (potato, tapioca, corn, or rice starch) and optional binders. This composite formulation achieves the right balance between high nut content for nutrition and starch/binder components that provide structural stability and storability during shelf life
2Quantity of substance
If high nut content is incorporated into extruded pellets, then nutritional profile (protein and fiber) is improved, but pellet shape and texture quality deteriorate
Solution Approach 1:
The patent optimizes extrusion parameters including temperature, pressure, and moisture content to produce pellets with consistent shape and texture despite high nut content. The controlled moisture range (10-15%) and extrusion conditions enable high nut content pellets to maintain desirable manufacturing precision
Solution Approach 2:
The composite formulation of nut flour with starches and binders creates a material that extrudes well and maintains shape. The starch and binder components provide structural support that enables high nut content pellets to achieve good shape and texture quality during extrusion and drying
3Ease of manufacture
If traditional corn or potato-based products are used, then ease of manufacture is maintained, but nutritional profile (fat content) worsens
Solution Approach 1:
The patent uses the same extrusion process parameters and equipment for nut-based pellets as traditional corn or potato-based products, maintaining ease of manufacture. The process parameters (moisture, temperature, pressure) are optimized but the fundamental manufacturing approach remains simple and scalable
Solution Approach 2:
The patent replaces traditional frying with pressure cooking to cook the nut-based pellets. This substitution reduces fat content significantly (to less than 5 grams per 28-gram serving) while maintaining the same manufacturing equipment and process simplicity, achieving both ease of manufacture and improved nutrition
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 process generates shelf-stable nut-based pellets that can be stored for months and transformed into crispy snack chips with enhanced nutritional and flavor profiles, offering a healthier snack option with less than 5 grams of fat per 28-gram serving.
Implementation Method 1
The extruder mechanically mixes, shears and cooks the nut dough before passing it through a die to form an extrudate
Implementation Method 2
the pellet mixture is introduced into a pressure popper
Implementation Method 3
the pellet mixture is introduced into a pressure popper... producing an expanded cake
Data Source
AI summary
A method is disclosed for producing an intermediary product in the form of a nut-based pellet that is capable of being stored for up to about six months. To form the nut pellets, a nut dough is passed through an extruder. The extrudate produced is then cut into pellets and dried. Starch pellets can then optionally be mixed with the nut pellets or small nut pieces and cooked to form a snack chip. The snack chip is formed by compressing and cooking the pellet mixture, expanding the pellet mixture, and compressing the pellet mixture again.