Pulse-Based Bread Crumb Coating Process for Gluten-Free Texture
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional bread crumb coatings often contain gluten, making them unsuitable for individuals with gluten-related disorders, and pulse-based alternatives can have an unappealing flavor and texture.
Innovation Solution
A method involving the separation, hydration, agglomeration, and heat treatment of pulse flours to produce gluten-free, low-protein pulse-based bread crumbs with improved taste and sensory properties, using processes like dehulling, fine milling, classification, and heat and moisture treatment to reduce protein and starch separation, and milling into various particle sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wheat flour is used to produce bread crumb coatings, then the product has good taste and texture, but it contains gluten making it unsuitable for individuals with gluten-related disorders
Solution Approach 1:
The patent applies parameter changes by modifying the protein content parameter of pulse flour through classification to create low-protein fractions (10-20% protein), and by changing the physical state parameters through heat and moisture treatment (95-150°C at 18-55% moisture) to improve texture and flavor. These parameter transformations enable pulse-based products to match the sensory properties of wheat-based products while maintaining gluten-free status.
2Reliability
If pulse flour is used directly to create gluten-free bread crumbs, then the product is suitable for gluten-sensitive consumers, but it has unappealing flavor and texture
Solution Approach 1:
The patent applies preliminary action through pre-treatment steps including classification to separate low-protein fractions, hydration to 18-55% moisture content, and heat treatment at 95-150°C before final drying. These preliminary transformations modify the pulse flour properties in advance, eliminating unappealing flavors and improving texture, so that the final product closely resembles traditional wheat-based bread crumbs in sensory quality.
3Reliability
If pulse flour undergoes classification to reduce protein content, then the product becomes more suitable for gluten-free applications, but the processing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing pulse flour into different protein fractions through classification, separating low-protein (10-20%) from medium-protein (20-36%) fractions. This segmentation enables selective use of the low-protein fraction for gluten-free applications where wheat-like texture is desired, while the process remains systematic and manageable through standardized classification equipment.
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 gluten-free, allergen-free bread crumb coatings with enhanced flavor and texture, suitable for gluten-sensitive consumers, maintaining crispiness and suitable for various food products, including fried foods and bakery items.
Implementation Method 1
hydrating, in a reactor, the limited protein pulse flour fraction and the medium protein pulse flour fraction is blended from a protein range from 7-24% to between about 18% to about 55% by weight with water
Implementation Method 2
heating the agglomerated pulse dough at 95° C. to 150° C. cooked and dried to a moisture content of less than about 12% moisture
Data Source
AI summary
Pulse-based bread crumbs, coatings, and pre-dust products having an improved taste, texture and end use properties. The bread crumb, coating, and pre-dust products are produced by heat and moisture treatment at 100% by dry weight with pulse flours, e.g. pea flour, lentil flour, chickpea flour, faba bean flour, navy bean flour, pinto bean flour, black eye bean flour and black bean flour.