Packaged Batter Emulsion Stability via Water Activity Control
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Solution Overview
Problem
Existing pancake and batter products are not microbiologically stable when refrigerated, leading to spoilage and loss of leavening action, and require additional processing steps like pasteurization or freezing to extend shelf life, which increase costs.
Innovation Solution
A ready-to-use packaged batter with a low water activity and low yield point, formulated with ingredients like flour, sugar, oil, and an oxidoreductase enzyme, that maintains stability and flowability for up to 12 weeks without the need for pasteurization or freezing, allowing multiple uses and maintaining cooking performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If batter is prepared from dry ingredients and stored in refrigerator, then convenience is improved, but microbial stability deteriorates and phase separation occurs
Solution Approach 1:
The patent applies parameter changes by reducing water activity (Aw) to 0.93 or below through formulation adjustments. This critical parameter change prevents microbial growth while maintaining batter functionality and cooking performance, resolving the contradiction between convenience and microbial stability
Solution Approach 2:
The patent uses composite material strategies by combining specific ingredients including oxidoreductase enzymes, emulsifiers, and controlled ratios of fats and carbohydrates. This composite formulation creates a stable matrix that prevents both microbial growth and phase separation, enabling refrigerated storage without pasteurization
2Loss of time
If batter is prepared from dry ingredients, then preparation time is reduced, but batter stability deteriorates and leavening action is lost
Solution Approach 1:
The patent applies preliminary action by pre-formulating the batter with optimized ingredient ratios and adding oxidoreductase enzymes before packaging. This preliminary preparation ensures that leavening agents remain stable and functional during refrigerated storage, allowing the batter to maintain its leavening action weeks after preparation
Solution Approach 2:
The patent changes the water activity parameter to 0.93 or below, which slows down chemical reactions and enzymatic activity that would otherwise degrade the batter. This parameter control preserves leavening action and prevents phase separation during extended refrigerated storage
3Reliability
If pasteurization or freezing is applied to extend shelf life, then microbial stability is improved, but processing complexity and cost increase
Solution Approach 1:
The patent employs a simple, low-cost approach by using formulation-based preservation rather than expensive thermal or freezing processing. The oxidoreductase enzyme system and controlled water activity provide microbial stability without requiring complex pasteurization equipment or freezing infrastructure
Solution Approach 2:
The patent achieves microbial stability through parameter changes in formulation (water activity reduction to 0.93 or below) rather than through thermal or mechanical processing. This eliminates the need for pasteurization or freezing steps, reducing processing complexity and cost while maintaining reliability
4Reliability
If water activity is reduced to improve microbial stability, then refrigerated storage is extended, but yield point increases and flowability deteriorates
Solution Approach 1:
The patent uses composite material strategies by incorporating emulsifiers and specific fat types that maintain low yield point even at reduced water activity. This composite formulation ensures the batter remains pourable and flowable while achieving the target water activity of 0.93 or below for microbial stability
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 packaged batter remains fresh and functional for extended refrigerated storage, maintaining flavor, texture, and leavening properties comparable to freshly made batter, without phase separation or microbial growth, and can be easily dispensed due to its low yield point.
Implementation Method 1
packaged batter products, embodiments of which can exhibit refrigerated storage stability after initial preparation... include an oxidoreductase enzyme
Implementation Method 2
The packaged product may be stable during refrigerated storage for many weeks after the packaged batter product is initially prepared
Implementation Method 3
A ready-to-use packaged batter with a low water activity and low yield point, formulated with ingredients like flour, sugar, oil, and an oxidoreductase enzyme, that maintains stability and flowability for up to 12 weeks
Implementation Method 4
The packaged batter remains fresh and functional for extended refrigerated storage, maintaining flavor, texture, and leavening properties comparable to freshly made batter, without phase separation or microbial growth
Data Source
AI summary
Described are flour-based oil-in-water emulsion compositions, packaged emulsion compositions, and related methods, the emulsions being refrigerator stable in a non-pressurized package and optionally containing ingredients that include glucose oxidase, the package optionally being re-sealable.