Gluten-Free Pulse Pasta via Protein Fractionation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pasta production methods using gluten-containing wheat flours are not suitable for gluten-free applications, and pulse-based pasta often has an unappealing aftertaste due to high protein and starch content, which can lead to texture issues during cooking.
Innovation Solution
A method involving the separation of raw pulse flour into limited and medium-protein fractions, followed by hydration, heat and moisture treatment, and extrusion to produce a gluten-free pasta with improved flavor and texture, using a twin screw mixer and extruder to achieve a protein content of 7-16% and moisture content of 7-12.5%, resulting in a pasta with a more appealing taste and cooking properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pulse flour with high protein and starch content is used to make pasta, then the pasta can be made gluten-free, but the pasta develops an unappealing aftertaste and texture issues during cooking
Solution Approach 1:
The pulse flour is separated into different protein fractions using classification equipment, dividing the original homogeneous flour into low-protein and medium-protein fractions. This segmentation allows selective use of protein fractions to achieve desired pasta properties without the unappealing taste associated with high-protein pulse flour.
Solution Approach 2:
The protein content parameter of the pulse flour is modified by blending low-protein and medium-protein fractions in specific ratios. This parameter change reduces the total protein content from typically high levels to an optimized range that eliminates the unappealing aftertaste while maintaining gluten-free status and acceptable texture during cooking.
2Ease of manufacture
If pulse flour with high protein content is used, then the pasta can be made, but the high protein and starch content lead to texture issues during cooking
Solution Approach 1:
By separating pulse flour into protein fractions and selectively blending them, the invention creates a flour composition that maintains structural integrity during cooking. The optimized protein content provides sufficient framework formation without the excessive starch-protein interactions that cause texture degradation.
Solution Approach 2:
The invention uses a composite flour formulation combining low-protein and medium-protein pulse fractions in specific ratios. This composite material achieves balanced properties: enough protein for structural stability during cooking, but reduced total protein and optimized starch content to prevent texture issues, while maintaining gluten-free characteristics.
3Strength
If conventional wheat flour is used for pasta production, then strong protein and starch network is formed, but the pasta is not suitable for gluten-free applications
Solution Approach 1:
The invention modifies the protein content parameter of pulse flour by blending low-protein and medium-protein fractions. This creates a pulse flour with optimized protein levels that can form adequate structural networks for pasta production while maintaining gluten-free status, replacing conventional wheat flour's strong gluten network with a balanced pulse-based structure.
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 enhances the sensory and flavor attributes of pulse-based pasta, reducing bitterness and introducing a roasted flavor, while maintaining nutritional properties similar to durum wheat pasta, making it suitable for gluten-free and allergen-free consumption.
Implementation Method 1
hot extrusion causes starch within the low-protein flour to gelatinize. The gelatinized starch compensates for the lack of protein network structure caused by using a low-protein flour
Implementation Method 2
A mixer may hydrate a limited protein pulse fraction to between about 18% to about 50% by weight with water
Implementation Method 3
The agglomerated pulse dough may be heated at about 95° C. to about 150° C. to cook and dry the agglomerated pulse dough to a moisture content of less than about 10% moisture
Implementation Method 4
The cooked pulse dough may be extruded to produce an extruded pasta
Implementation Method 5
The extruded pasta may be dried to produce a dried pasta with a moisture content between about 7% to 12.5% by weight
Data Source
AI summary
A pulse-based pasta and a method of manufacturing the pulse based-pasta using a heat and moisture treatment process. The method may comprise hydrating and heating a limited protein pulse fraction to produce a hydrated pulse dough; agglomerating the dough; drying the dough to a moisture content of less than about 10% moisture; rehydrating the dough and cooking the dough to produce a cooked pulse dough; extruding the cooked pulse dough to produce an extruded pasta; and drying the extruded pasta to produce a dried pasta with a moisture content between about 5% to 12.5% by weight. The pulse pasta may comprise a protein of about 11.8% by weight or in a range of 4% to 16%; carbohydrates of about 73% by weight or in a range of 10 73% to 90%; and a moisture of about 10% by weight or in a range of 5% to 12.5%.