Shelf-Stable Plant-Based Fermented Dairy Analogue Texture Control
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Solution Overview
Problem
Existing plant-based fermented dairy analogues face challenges in achieving a stable, satisfactory texture suitable for consumption from flexible containers, while also addressing issues of protein content, shelf-life, and compatibility with high-temperature treatments.
Innovation Solution
A process involving a plant-based food composition with plant proteins, cereal flour, and hydrophilic liquid, heated, homogenized, and fermented to create a shelf-stable plant-based fermented dairy analogue with a controlled texture, suitable for packaging in flexible containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If high-temperature treatment is applied after fermentation to ensure extended shelf-life, then shelf-life is improved, but texture is deteriorated (loss of texture, protein aggregation, grainy texture, unsatisfactory liquid texture)
Solution Approach 1:
The patent applies preliminary action by conducting fermentation before heat treatment to establish a stable microbial ecosystem and produce natural thickeners (exopolysaccharides) that protect the product structure during subsequent high-temperature processing. The fermentation step is performed at controlled temperatures (30-45°C) for 4-24 hours before the heat treatment at 85-125°C, allowing the microbial culture to prepare the matrix that will withstand the thermal process.
Solution Approach 2:
The patent employs parameter changes by optimizing the heat treatment parameters (temperature range of 85-125°C, time range of 5-30 minutes) to achieve shelf-stability while minimizing texture degradation. The process also controls pH during fermentation (targeting 3.5-4.5) and uses specific cooling rates after heat treatment to prevent protein aggregation and maintain smooth texture.
2Manufacturing precision
If plant-based ingredients (cereal flour, fibers) are used to increase viscosity, then texture thickness is improved, but upon successive heat-treatments the texture becomes unsatisfactorily thick and grainy
Solution Approach 1:
The patent uses parameter changes by controlling the viscosity of the plant-based composition within a specific range (50-500 cP at 20°C) before fermentation, and adjusting the water activity (aw) to 0.90-0.95 after processing. These parameter optimizations ensure the texture remains satisfactorily thick without becoming excessively grainy or unstable during successive heat treatments and storage.
Solution Approach 2:
The patent applies composite materials by combining plant proteins (pea, fava bean, lentil) with cereal flours and fibers in specific ratios, creating a composite matrix that provides both thickness and stability. The fermentation process further complexifies this matrix through microbial metabolism, producing exopolysaccharides that enhance texture stability without requiring excessive thickening agents.
3Ease of operation
If the texture is made too thick for satisfactory consumption from flexible container, then comfort is improved, but flowing properties are worsened (product blocked in container)
Solution Approach 1:
The patent optimizes the viscosity parameter to a balanced range (50-500 cP at 20°C) that provides sufficient thickness for comfort while maintaining adequate flowing properties for dispensing from flexible containers. The water activity is controlled at 0.90-0.95 to ensure the product remains pourable yet thick enough for satisfactory mouthfeel and consumption experience.
4Speed
If the texture is made too liquid for satisfactory consumption from flexible container, then flowing properties are improved, but discharge control is worsened (uncontrolled discharge, waste, dirtiness)
Solution Approach 1:
The patent controls the viscosity parameter (50-500 cP at 20°C) and water activity (0.90-0.95) to achieve a texture that flows adequately for easy dispensing from flexible containers while maintaining sufficient thickness to prevent uncontrolled discharge. This balanced parameter optimization ensures consumers can control the flow rate by manual pressure without experiencing waste or mess.
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 a shelf-stable plant-based fermented dairy analogue with a stable, smooth texture that is neither too thick nor too liquid, allowing easy consumption from flexible containers while maintaining nutritional quality and extended shelf-life.
Implementation Method 1
heating the plant-based food composition at 55° C. to 80° C. for 5 to 15 minutes to obtain a gelatinized plant-based food composition
Implementation Method 2
homogenizing the gelatinized plant-based food composition at a pressure above 50 bar
Implementation Method 3
fermenting the inoculated plant-based food composition until reaching a pH of 3.0 to 5.0
Implementation Method 4
heat-treating the plant-based fermented dairy analogue at a temperature from 75° C. to 125° C. for 3 seconds to 15 minutes to obtain a shelf-stable fermented dairy analogue
Data Source
AI summary
The present invention relates to a process for preparing a packaged food product consisting of a shelf-stable plant-based fermented dairy analogue contained in a flexible container is disclosed. In particular, the shelf-stable plant-based fermented dairy analogue has a satisfactory and stable texture, including a texture suitable for consumption with a flexible container, such as flexible pouch. It also relates to resulting packaged food product consisting of a shelf-stable plant-based fermented dairy analogue contained in a flexible.