Ovenable Crumb-Coated Snack Barrier Layer
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Solution Overview
Problem
Oven-heated crumb-coated snacks often experience cracks and 'blow outs' due to pressure build-up, as they lack the crispy texture achieved through deep frying, which is not replicable with conventional oven baking methods.
Innovation Solution
A pre-baked crumb-coated snack with a barrier layer comprising 15-75 wt.% oligosaccharides, 2-45 wt.% protein, and 0-50 wt.% starch, which forms a cohesive dehydrated layer preventing cracks and moisture leakage, combined with a crumb layer for a crispy outer coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional oven baking methods are used for crumb-coated snacks, then the cooking process is simpler and requires less oil, but the snacks lack crispy texture and experience cracks and blow outs due to pressure build-up
Solution Approach 1:
The patent changes the chemical composition parameters of the barrier layer by incorporating specific oligosaccharides (DP 4-20), proteins, and starches in defined ratios. This compositional parameter change enables the barrier layer to withstand oven baking temperatures without cracking or blowing out, while still allowing the filling to cook properly through controlled moisture and heat transfer.
Solution Approach 2:
The patent creates a composite barrier layer material combining oligosaccharides, proteins, and starches. This composite structure provides both the structural integrity needed to prevent cracks and blow outs during oven baking, and the functional properties to allow proper cooking of the filling, resolving the contradiction between structural reliability and cooking effectiveness.
2Strength
If deep frying is used to cook crumb-coated snacks, then crispy texture and golden brown appearance are achieved, but the process requires more oil and higher temperatures
Solution Approach 1:
The patent modifies the barrier layer's chemical composition to include oligosaccharides, proteins, and starches in specific proportions. These compositional changes enable the barrier layer to undergo gelatinization and dehydration during oven baking, creating a crispy texture similar to deep frying but with lower oil consumption and energy input.
Solution Approach 2:
The patent substitutes the deep frying mechanical system (immersion in hot oil) with an oven baking thermal system. The engineered barrier layer undergoes phase changes and chemical transformations during oven baking that replicate the crispy texture formation of deep frying, thereby achieving the same sensory outcome with a different, more efficient cooking method.
3Loss of substance
If the barrier layer is made thinner to reduce material usage, then production cost decreases, but the barrier layer becomes less effective at preventing cracks and pressure build-up
Solution Approach 1:
The patent optimizes the compositional parameters of the barrier layer by incorporating oligosaccharides with specific degree of polymerisation (DP 4-20), proteins, and starches in defined ratios. This compositional optimization enhances the barrier layer's structural performance per unit thickness, allowing thinner applications to maintain adequate protection against cracks and blow outs during oven baking.
Solution Approach 2:
The patent develops a composite barrier layer material where oligosaccharides, proteins, and starches work synergistically. This composite structure provides enhanced structural integrity and crack resistance per unit thickness compared to conventional single-material coatings, enabling reduced material usage while maintaining reliability.
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 solution effectively prevents cracks and maintains a crispy texture during oven baking, allowing for the production of a ready-to-eat snack with a cohesive outer coating, similar to deep-fried snacks.
Implementation Method 1
the combination of the oligosaccharides, protein and starch constitutes at least 50 wt.% of the dry matter of the barrier layer
Implementation Method 2
During frying, the starch in the batter gelatinizes and water is removed from both the batter and crumb particles
Implementation Method 3
water is removed from both the batter and crumb particles. Together, these changes contribute to the formation of a crunchy outer layer
Implementation Method 4
the heat transfer rate during baking is much lower than during deep frying
Data Source
AI summary
The invention relates to an ovenable pre-baked crumb-coated snack comprising: (a) a filling having a water content of 30-90 wt.%; (b) a barrier layer surrounding the filling, said barrier layer containing - 15-75 wt.%, calculated by weight of dry matter, of oligosaccharides having a degree of polymerisation (DP) in the range of 4-20; - 2-45 wt.%, calculated by weight of dry matter, of protein; - 0-50 wt.%, calculated by weight of dry matter, of starch; wherein the combination of the oligosaccharides, protein and starch constitutes at least 50 wt.% of the dry matter of the barrier layer; and (c) a layer of crumb particles deposited onto the surrounding barrier layer. The pre-baked crumb-coated snack can be heated in an oven to prepare a ready-to-eat snack without the occurrence of blow outs.