High Protein Flakes Structural Integrity via Pellet Extrusion

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Solution Overview

Problem

Conventional methods for producing high protein flakes result in products that are fragile and prone to breakage, failing to meet desirable taste and texture parameters when increasing protein content.

Innovation Solution

A method involving the formation of protein pellets with at least 30% protein content, which are then cooked with a food component and processed into high protein flakes with a protein content of 1% to 50% by weight, using extrusion and thermal processing techniques to enhance structural integrity and texture.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional cooking techniques are used to increase protein content in flakes, then protein content is improved, but structural integrity deteriorates resulting in fragile flakes with multiple points of weakness

Engineering Contradiction:

Improveprotein contentVSAvoidstructural integrity

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent applies preliminary action by forming protein pellets with specific structural properties before the cooking process. These pre-formed pellets contain embedded weak points that are strategically positioned to control fracture behavior during subsequent cooking and flaking operations, preventing random breakage while maintaining high protein content.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention implements beforehand cushioning by incorporating energy-absorbing features within the protein pellet structure prior to cooking. These features act as cushions that absorb mechanical stress during processing, preventing catastrophic failure and maintaining structural integrity throughout the manufacturing process despite high protein content.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Quantity of substance

If protein content is increased in conventional flakes, then nutritional value is improved, but taste and mouthfeel parameters deteriorate

Engineering Contradiction:

Improveprotein contentVSAvoidmouthfeel quality

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The patent applies local quality by creating heterogeneous structures within the flakes where protein-rich regions are distributed non-uniformly. This localized arrangement allows high protein content while maintaining regions with desirable sensory properties, preventing the uniform texture degradation that occurs in conventional high-protein products.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention uses composite materials by combining protein pellets with other food components in a structured arrangement. This composite structure allows the protein component to provide nutritional value while the overall composite maintains desirable taste and mouthfeel characteristics through the interaction of different material phases.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If conventional methods are used to produce high protein flakes, then production simplicity is maintained, but product reliability deteriorates due to excessive breakage

Engineering Contradiction:

Improveprocess simplicityVSAvoidflake integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention implements parameter changes by modifying the physical and chemical parameters of the protein material during pellet formation and cooking. By controlling parameters such as moisture content, temperature, and pressure during processing, the method achieves improved structural integrity while maintaining manufacturing feasibility.

Inventive Principle:

Principle #35Parameter changes

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 produces high protein flakes with improved structural integrity, texture, and reduced breakage, maintaining desirable sensorial properties similar to conventional cereal flakes.

Implementation Method 1

forcing the protein extrudate to exit the extruder

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 2

introducing the protein to an extruder to form a protein extrudate; forcing the protein extrudate to exit the extruder

Methodology Applied

Scientific EffectExtrusion: Extrusion

Implementation Method 3

cooking the first pellets and the food component to give a cooked food product

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentEP3376879B1High protein flakes derived from protein pellets

Publication Date: 2020.11.11 KELLANOVA

Figure 1

AI summary

The present invention relates to methods for preparing high protein flakes comprising forming a protein into a protein pellet and introducing the protein pellet and a food component into a cooker. The protein pellet and the food component are cooked in the cooker to give a cooked food product. The food product is then formed into a high protein flake.