Plant-Based Granules for Low-Temperature Waffle Injection Molding
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Solution Overview
Problem
Conventional waffle and cookie production is energy-intensive, emits greenhouse gases, and requires long production cycles, making them less sustainable than they appear, and there is a need for biodegradable and compostable alternatives.
Innovation Solution
Development of plant-based granules composed of vegetable starch, flour, and fat, with optional additives, processed by injection molding to create biodegradable and compostable waffles and pastries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional baking process is used to produce waffles and cookies, then the products are biodegradable and edible, but the energy consumption and greenhouse gas emissions are high
Solution Approach 1:
The patent changes the fundamental processing parameters from thermal baking to injection molding. The granules are molded at lower temperatures (around 60-80°C) compared to conventional baking (typically 180-220°C), significantly reducing energy consumption and greenhouse gas emissions while maintaining the biodegradable and edible properties of the products
Solution Approach 2:
The patent replaces the thermal/chemical baking process with a mechanical injection molding process. Instead of using heat and raising agents to expand the dough, the granules are mechanically compressed and molded into the desired shapes, eliminating the need for high-temperature ovens and associated emissions
2Loss of time
If conventional baking process is used, then the products achieve desired consistency, but the production time is long and throughput is low
Solution Approach 1:
The granules are pre-prepared with optimal moisture content (10-50%) and composition before molding. This preliminary preparation allows the injection molding process to proceed rapidly without requiring lengthy drying or conditioning steps that would extend the production cycle
Solution Approach 2:
The injection molding process enables continuous production where granules are fed, molded, and ejected in an uninterrupted sequence. Multiple cavities in the mold can be filled simultaneously, and the cycle time is minimized by optimizing the molding parameters, allowing for high throughput compared to batch-based conventional baking
3Productivity
If injection molding is used with plant-based granules, then energy efficiency is improved and production speed increases, but the material composition and ratios must be precisely controlled
Solution Approach 1:
The patent specifies precise parameter ranges for the granule composition (starch 20-65 wt%, flour 10-55 wt%, fat/oil 0.5-7 wt%, moisture 10-50%) and ratios (starch to flour 1:1.6-1:5 or 1.6:1-5:1). These controlled parameters ensure the material has the right flowability, compressibility, and structural properties for successful injection molding while maintaining product quality
Solution Approach 2:
The patent uses a composite material system combining multiple plant-based components (starch, flour, fat/oil) in specific proportions. This composite approach allows the material to exhibit synergistic properties that enable both high productivity in injection molding and the desired final product characteristics, while the precise ratio control ensures reproducible results
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 is energy-efficient, reduces greenhouse gas emissions, and allows for rapid production of customizable shapes, including edible disposable tableware with composting times under 50 days.
Implementation Method 1
processed by injection molding
Implementation Method 2
injection molding process
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The present invention relates to the provision of granules consisting of natural, preferably purely plant-based, components. These granules can be processed by injection molding without the addition of any further components. Therefore, the invention also relates to the use of the granules in injection molding, as well as to products manufactured by processing the granules by injection molding, such as wafers in the form of food and dip carriers, and baked goods such as cookies. The present invention also relates to a method for manufacturing wafers and baked goods by injection molding.