Puffed Dairy Protein Snack via Two-Stage Extrusion

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Solution Overview

Problem

Existing methods fail to produce a shelf-stable, protein-based pellet suitable for making a puffed dairy snack with a light and crispy texture due to browning issues when incorporating dairy proteins, which reduces protein quality and introduces off-flavors.

Innovation Solution

A two-stage extrusion process is used to create a starch and milk protein derivative pellet with similar hydration profiles and particle sizes, employing calcium caseinate, whey protein isolate, or milk protein isolate, to minimize browning and ensure gel formation, resulting in a puffed dairy-based snack with high protein and calcium content.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If dairy protein (lactose) is incorporated into puffed food products, then protein content is improved, but browning reactions occur causing off-flavors and reduced protein quality

Engineering Contradiction:

Improveprotein contentVSAvoidbrowning reactions

Core Design Contradiction:

Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent modifies the chemical parameters of the dairy protein by using acid-treated casein instead of regular casein or lactose. This parameter change (acid treatment) alters the reactivity of the protein, specifically reducing its tendency to undergo Maillard browning reactions while maintaining the protein content and nutritional value.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a temporary protective coating or modifier that prevents browning during the puffing process. This could be a temporary chemical modifier or coating that is applied to the dairy protein, prevents harmful reactions during processing, and is then removed or degraded, leaving the desired protein-rich final product without browning.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Ease of operation

If conventional grain cakes are made from rice and cereal grains, then crispy texture and convenience are achieved, but protein content remains insufficient

Engineering Contradiction:

ImproveconvenienceVSAvoidprotein content

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The patent creates a composite material by combining acid-treated casein with starch and other ingredients to form an intermediate pellet. This composite approach allows the dairy protein to serve as both a structural component (providing crunch) and a nutritional component (high protein content), while the starch provides the necessary puffing characteristics. The resulting product is a protein-enriched puffed snack that maintains convenience and crispy texture.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If moisture content is increased in pellets to improve texture, then puffing performance is improved, but shelf stability is reduced

Engineering Contradiction:

Improvepuffing performanceVSAvoidshelf stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The patent applies preliminary action by pre-treating the acid-treated casein and other ingredients before pellet formation. This pre-treatment optimizes the moisture absorption characteristics and gelation properties of the ingredients, allowing the final pellet to achieve optimal puffing performance when exposed to steam during processing, while maintaining lower equilibrium moisture content for shelf stability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the functional parameters of the ingredients through acid treatment of the casein, which alters its moisture binding characteristics. This parameter change allows the protein to contribute to gel formation and texture development without requiring excessive moisture content, thereby maintaining shelf stability while achieving good puffing performance.

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 process produces a shelf-stable, puffed dairy snack with a light and crispy texture, providing a good source of protein and calcium while avoiding browning and associated off-flavors, using common food processing equipment and maintaining nutritional quality.

Implementation Method 1

employing calcium caseinate, whey protein isolate, or milk protein isolate, to minimize browning and ensure gel formation

Methodology Applied

Scientific EffectGel formation: Gel

Implementation Method 2

The resultant extrudate is then sliced and dried in a series of dryers. Processing conditions also allow for a finished product with little to no browning

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS8313788B2Method for developing a dairy protein cake

Publication Date: 2012.11.20 FRITO LAY NORTH AMERICA INC

AI summary

A method for producing a shelf-stable protein-based pellet that is capable of expansion into a light, crispy snack cake, while providing a good source of protein and calcium. The method, in preferred embodiments, involves making dough from tapioca and potato starches and a milk protein derivative consisting of whey protein isolate, milk protein isolate or calcium caseinate. The mixture is extruded, sliced and dried in a series of dyers. The method produces a shelf-stable pellet having a moisture level of approximately 9-13% by weight which is further processed to produce a puffed dairy protein snack product, having a moisture level typically less than 2%.