Ohmic Heating Stages for Edible Inclusion Integrity
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Solution Overview
Problem
Current food processing methods, including ohmic heating, struggle to achieve homogeneous heating and preserve the integrity of edible inclusions like fruits and vegetables in starch-based products, leading to issues like uncooked portions, altered texture, and loss of quality.
Innovation Solution
A method involving two stages of ohmic heating, with holding steps in between, where a composition comprising starch and at least 20% individually distinguishable edible inclusions is heated to specific temperature ranges, ensuring uniform heating and minimal damage to inclusions, performed in a continuous process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional batch processing with scraped steam heated kettles is used, then the food product can be heated, but the heating time is long causing overcooking and damage to edible inclusions
Solution Approach 1:
The patent replaces conventional mechanical heating systems (steam heated kettles with scraped surfaces) with ohmic heating technology that uses electrical current to generate heat directly within the food product. This substitution of heating mechanism enables rapid and uniform heating without the long processing times and mechanical damage associated with conventional batch processing
Solution Approach 2:
The patent introduces a multi-stage ohmic heating process with specific temperature parameters (first stage: 60-95°C, second stage: 75-110°C) and controlled holding times. By precisely controlling temperature parameters and using intermediate holding steps, the process achieves complete cooking without overcooking, resolving the contradiction between heating efficiency and inclusion integrity
2Productivity
If continuous processing with scraped surface heat exchangers is used, then heating speed is faster, but the integrity of food pieces is significantly damaged
Solution Approach 1:
The patent replaces mechanical scraped surface heat exchangers with ohmic heating that uses electrical fields to generate internal heat. This eliminates the mechanical scraping action that damages food pieces while maintaining continuous processing capability and fast heating speed
Solution Approach 2:
The ohmic heating system allows the food product to heat itself through internal generation of heat by electrical current. The composition's own electrical conductivity enables self-heating without mechanical contact, preserving the integrity of edible inclusions while achieving rapid heating in continuous processing
3Temperature
If ohmic heating is used for food products comprising starch and particles, then heating is uniform and faster, but homogeneous distribution of conductivity is not achieved leading to uncooked portions
Solution Approach 1:
The patent divides the ohmic heating process into multiple stages with different temperature targets and holding times. The first stage heats to 60-95°C with holding, followed by a second stage to 75-110°C with additional holding. This segmentation of the heating process ensures progressive and uniform cooking throughout the product, eliminating uncooked portions
Solution Approach 2:
The patent employs periodic heating cycles with intermediate holding steps where ohmic heating is temporarily stopped. This periodic action with heating-holding-heating sequences allows heat to distribute uniformly throughout the composition, ensuring homogeneous cooking while maintaining the advantages of ohmic heating
4Manufacturing precision
If batch processing is used to preserve edible inclusions, then damage to particles is reduced, but processing time is extended and productivity decreases
Solution Approach 1:
The patent replaces mechanical batch processing systems with continuous ohmic heating. This substitution eliminates the long processing times of batch methods while avoiding mechanical damage to inclusions, as ohmic heating uses electrical fields rather than mechanical contact
Solution Approach 2:
The patent implements continuous ohmic heating processing where the food composition continuously flows through the heating system. This continuous process maintains high productivity while the gentle ohmic heating mechanism preserves the integrity of edible inclusions, resolving the contradiction between speed and 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
This method results in a homogeneously heated and cooked composition with excellent texture, taste, and sterility, maintaining a high content of intact edible inclusions, outperforming conventional methods by preventing uncooked portions and conduit blockages.
Implementation Method 1
Ohmic heating (or direct resistance heating) is a process in which food liquids and solids are heated simultaneously by passing an electric current through them
Data Source
AI summary
Methods of heating compositions comprising at least 20% (w/w) individually distinguishable edible inclusions are provided herein. The method of heating as disclosed herein comprises applying a first ohmic heating treatment to the composition, wherein the composition has at the end of the first ohmic heating treatment a temperature from 60° C. to 95° C.; applying a first holding step to the composition, wherein the temperature of the composition is at most 5° C. lower than the temperature of the composition after the first ohmic heating treatment; applying a second ohmic heating treatment to the composition, wherein the composition has at the end of the second ohmic heating treatment a temperature ranging from 75° C. to 110° C.; and applying a second holding step to the composition, wherein the temperature of the composition is at most 5° C. lower than the temperature of the composition after the second ohmic heating treatment, wherein the steps are performed as a continuous process with an initial back pressure of at least 4 bar.