Fresh Filled Pasta Kit Preventing Starch Gelatinization
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Solution Overview
Problem
Pre-packaged filled pasta undergoes pre-gelatinization and quality degradation due to pasteurization, leading to a loss of organoleptic qualities and taste, as well as ingredient exchange between pasta and filling, resulting in a product that differs significantly from homemade fresh filled pasta.
Innovation Solution
A method involving unit portions of fresh pasta and pre-dosed filling pralines, where the pasta undergoes vacuum packaging and cold High Pressure Pasteurization to prevent gelatinization, and the filling is pasteurized and frozen, allowing for on-demand preparation that mimics homemade pasta by avoiding mechanical sealing and ingredient exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pasteurization (heating at 80-100°C) is applied to pasta sheets, then sealing quality and microbial safety are improved, but pre-gelatinization of starch occurs causing loss of organoleptic qualities and taste
Solution Approach 1:
The patent applies High Pressure Pasteurization (HPP) at temperatures below 30°C instead of traditional thermal pasteurization at 80-100°C. This parameter change in treatment temperature and method achieves microbial safety and sealing quality without causing pre-gelatinization of starch, thereby preserving the organoleptic qualities and taste of fresh pasta
Solution Approach 2:
The patent replaces the thermal pasteurization system with a high-pressure mechanical system. By using HPP technology, the pasta is treated under high pressure (typically 400-600 MPa) at low temperatures, substituting thermal energy with mechanical pressure to achieve the same pasteurization effect without starch gelatinization
2Ease of operation
If pasta and filling are packaged together, then convenience is improved, but ingredient exchange occurs causing quality degradation
Solution Approach 1:
The patent divides the food kit into separate compartments: one for pasta sheets and another for filling pralines. This segmentation prevents direct contact and ingredient exchange between pasta and filling during storage and transport, while still providing convenience through a unified packaging structure that includes both components
Solution Approach 2:
The patent introduces a barrier layer or separator between the pasta and filling compartments in the packaging. This intermediary structure prevents direct interaction and ingredient exchange while allowing both components to be packaged together in a single convenient unit
3Duration of action of stationary object
If fresh pasta is stored for extended periods, then availability is improved, but structure and flavor degradation occur due to starch gelatinization and diffusion processes
Solution Approach 1:
The patent uses HPP treatment at low temperatures to extend the shelf life of fresh pasta without causing starch gelatinization. This parameter change in preservation method allows extended storage while maintaining the original structure and flavor characteristics of fresh pasta
Solution Approach 2:
The patent packages the pasta in a controlled atmosphere environment (e.g., modified atmosphere packaging with reduced oxygen and increased carbon dioxide) to prevent oxidative degradation and maintain freshness during extended storage, thereby preserving structure and flavor
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 method maintains the structure and flavor of fresh pasta, preventing pre-gelatinization and ingredient exchange, resulting in a product with a silky surface, appropriate firmness, and excellent egg flavor, similar to homemade pasta, while reducing microbial count and energy costs.
Implementation Method 1
cold High Pressure Pasteurization to prevent gelatinization
Implementation Method 2
pre-gelatinization of starches
Implementation Method 3
vacuum packaging
Implementation Method 4
the filling is pasteurized and frozen
Data Source
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AI summary
A method of making a food kit (1) intended for on-demand preparation of fresh filled pasta (P), such as tortelli, ravioli, panzerotti and the like with much the same properties as homemade fresh pasta, the method comprising making first components (4) consisting of unit portions (5) of single or double sheets of fresh pasta having a predetermined flat shape, cooling, vacuum packaging, high-pressure pasteurization and refrigeration of the pasteurized unit portions (5), to maintain their structure and physical-rheological characteristics unaltered, and avoid pre-gelatinization of starches, and making second components (6) consisting of pre-dosed pralines of filling (7), which later undergo pasteurization, packaging and possibly freezing. The components (4, 6) are packaged and collected in a container (10) for fresh or frozen storage, and are ready to be joined together as they are or after thawing, for on-demand preparation of fresh filled pasta (P) before cooking, thereby avoiding exchange of water, salts and other ingredients between the components (4, 6). A food kit (1) obtained with the method and a method of use of the food kit (1).