Baked Good Coating with Perforated Fat Barrier
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Solution Overview
Problem
The challenge lies in creating a baked good that combines a pastry with a liquid-containing core mass and a coating, where the two components have different properties, without altering the sensory qualities of either, while ensuring stability and preventing uncontrolled liquid transport, which is often compromised by thermal expansion and fat bloom formation.
Innovation Solution
A method involving a one-shot process where a liquid-containing core mass is injected into a casing mixture, with mechanical shearing and ultrasound applied during injection to create a stable, impermeable coating that prevents liquid diffusion, and controlled cooling to manage thermal stresses and texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the contact surfaces are melted to connect the attachment and pastry, then the connection strength is improved, but cracks may occur in thin coatings due to thermal expansion differences
Solution Approach 1:
A connection layer made of pastry cream or similar adhesive material is introduced between the attachment and pastry. This intermediary substance provides strong adhesion without requiring high-temperature melting that would cause thermal expansion differences and cracking in the coating.
Solution Approach 2:
Instead of using high temperature to achieve connection, the invention changes the parameter to use room temperature or lower temperature adhesive materials. This avoids the thermal stress problem while still achieving strong bonding between components.
2Quantity of substance
If the coating is made thinner to increase filling proportion, then the taste and texture intensity of filling is improved, but the coating becomes more susceptible to cracking under thermal stress
Solution Approach 1:
The connection layer acts as a buffer that absorbs thermal expansion stresses, allowing the coating to be made thinner without increasing crack risk. The adhesive layer compensates for the reduced structural support that a thinner coating provides.
Solution Approach 2:
The invention creates a composite structure with multiple layers (coating, connection layer, pastry cream, filling) where each layer has optimized thickness and properties. This composite approach allows the coating to be thin while the overall structure remains stable through the combined strength of all layers.
3Object-affected harmful factors
If mechanical shearing is applied to fragment fat crystals during injection, then fat bloom formation is reduced, but the process complexity increases
Solution Approach 1:
Ultrasonic vibration is applied during the injection process to fragment fat crystals in the pastry cream. This mechanical vibration effect reduces fat bloom formation by creating finer crystal structures, while being integrated into the existing injection mechanism rather than requiring separate processing steps.
Solution Approach 2:
The invention replaces complex mechanical shearing devices with a simpler ultrasonic vibration system. The ultrasonic transducer can be integrated into the injection needle, providing crystal fragmentation through high-frequency vibrations rather than requiring complex mechanical cutting or grinding mechanisms.
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 produces a baked good with a pleasing taste and texture, maintaining product properties over time, preventing soggy or dry issues, and reducing fat bloom formation, while ensuring a strong, long-lasting bond between the core mass and pastry.
Implementation Method 1
the nozzle is assigned an ultrasound source for applying ultrasound to the starting material of the filling
Implementation Method 2
Mechanical shearing, in particular, is provided as a method for such a fragmentation of the starting material for a covering and/or a filling
Implementation Method 3
a coating that is impermeable to the liquid of the liquid-containing core mass, preferably fat-based
Data Source
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AI summary
The invention relates to a method for producing a baked good (10) from at least one pastry (11) and at least one topper (12) made of at least one liquid-containing core mass (13) with at least one coating (14) that is impermeable or partially permeable to the liquid. The method particularly includes producing the at least one topper (12) in a one-shot process and applying the at least one topper (12) to the at least one pastry (11). Furthermore, the invention relates to a baked good (10) with at least one pastry (11) and at least one topper (12) connected to the at least one pastry (11), wherein the at least one topper (12) comprises at least one liquid-containing, preferably gel-like, core mass (13) and a coating (14) for the liquid-containing core mass (13) that is impermeable to the liquid of the liquid-containing core mass, preferably fat-based.Furthermore, the casing (14) has a number of perforations (15) at a contact surface with at least one pastry (11) for controlled moistening of the pastry (11) from the liquid-containing core mass (13). The invention also relates to a device (20) for producing an attachment (12) for a baked good (10), wherein the device (20) has a number of side walls and a base surface, and a number of elements (21) are attached to the base surface, which are designed to create perforations (15) in a casing (14) of the attachment (12).