Plant-Based Crumb Production via Enzymatic Hydrolysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing dairy-free alternatives to milk and white chocolate lack consistency and flavor, and face challenges such as undesirable texture and stability due to the use of plant-based milks, which are incompatible with traditional crumb processing methods.
Innovation Solution
A process involving liquefaction and saccharification of plant-based milks to create a crumb suitable for producing dairy-free chocolate products, using enzymes like α-amylase and β-glucanase, followed by crumb formation with controlled moisture content, allowing for improved flavor profiles and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional crumb processing methods are used with plant-based milks, then the process is simple and quick, but the resulting chocolate products have undesirable texture and lack consistency
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of plant-based milks through controlled hydrolysis of proteins and polysaccharides, adjusting pH levels, and controlling moisture content during crumb formation. These parameter modifications enable plant-based milks to behave similarly to dairy milks during processing, achieving consistent crumb texture and product reliability while maintaining processing efficiency.
Solution Approach 2:
The patent introduces intermediary substances including enzymes (proteases, lipases, amylases) and chemical agents that mediate between the plant-based milk components and the desired crumb structure. These intermediaries facilitate the breakdown of complex plant-based ingredients into suitable forms for crumb formation, enabling consistent product texture without requiring changes to the core processing method.
2Adaptability or versatility
If plant-based milks are used to create dairy-free chocolate alternatives, then the product is suitable for dietary restrictions, but the flavor and organoleptic properties are inferior to traditional chocolate
Solution Approach 1:
The patent employs parameter changes by controlling the hydrolysis degree of proteins and polysaccharides, adjusting pH levels, and optimizing moisture content during crumb formation. These controlled modifications enhance the flavor development and organoleptic properties of plant-based chocolate alternatives, making them comparable to traditional chocolate while maintaining dietary compatibility.
Solution Approach 2:
The patent applies preliminary action by pre-treating plant-based milks with enzymes and chemical agents before crumb formation to break down proteins and polysaccharides into more flavorful and texturally suitable components. This preliminary processing step prepares the plant-based milk to produce superior flavor and texture in the final chocolate product while maintaining its dairy-free nature.
3Stability of the object's composition
If high moisture content is maintained in the crumb, then the crumb remains stable and shelf-life is extended, but the Maillard reactions and flavor development are reduced
Solution Approach 1:
The patent applies parameter changes by precisely controlling moisture content within a specific range (3-8%) and optimizing pH levels and temperature during crumb formation. These controlled parameter modifications create optimal conditions for Maillard reactions to occur while maintaining crumb stability and extending shelf-life, achieving both flavor development and product stability simultaneously.
Solution Approach 2:
The patent employs continuity of useful action by maintaining controlled moisture levels and optimizing processing conditions throughout the entire crumb formation process. This continuous control ensures that Maillard reactions proceed effectively while the crumb structure develops properly, achieving both flavor development and stability without requiring abrupt changes in moisture content or processing parameters.
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 process results in dairy-free chocolate products with superior organoleptic properties, offering improved consistency and flavor compared to existing dairy-free alternatives.
Implementation Method 1
liquefaction and saccharification of plant-based milks to create a crumb suitable for producing dairy-free chocolate products, using enzymes like α-amylase and β-glucanase
Implementation Method 2
The liquid mixture is then concentrated (through the removal of water by means of evaporation) and co-dried, to obtain a dry, shelf stable, crystallized mixture
Data Source
AI summary
The present invention relates to processes and ingredient formulations for the preparation of a plant-based chocolate crumb, preferably a dairy-free or vegan crumb, more preferably an allergen-free vegan crumb, for use in the production of confectionery, such as dairy-free alternatives to milk chocolate and white chocolate. The present invention also relates to uses of the plant-based crumb described herein, for example in the production of plant-based (i.e. dairy-free or vegan) chocolate and chocolate products, and to plant-based chocolates and chocolate products produced using the processes and ingredients described herein. A process of the invention comprises the steps of: liquefaction and/or saccharification; and crumb formation, wherein the plant-based milk is heated and dried to a crumb.