Quick-Cook Grains via Controlled Porosity
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Solution Overview
Problem
Current methods for processing grains and pulses to make quick-cooking products are inefficient, expensive, and alter the original texture and appearance, leading to consumer skepticism.
Innovation Solution
The method involves controlling porosity through flat plate compression or gun puffing, reducing bulk density, and maintaining moisture levels to create stable, porous whole kernel products with controlled puffing, allowing for rapid hydration and retention of the original identity and texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If grains and pulses are processed using conventional methods to reduce cooking time, then cooking speed is improved, but the original texture, flavor, and appearance are compromised
Solution Approach 1:
The patent applies parameter changes by controlling porosity (a physical parameter) through specific processing methods to achieve rapid rehydration. By adjusting the porosity parameter within optimal ranges, the grains and pulses can quickly absorb water during cooking without becoming overly puffed, thus reducing cooking time while preserving texture and appearance quality.
Solution Approach 2:
The patent utilizes porous materials by creating controlled porosity in the grains and pulses. This porous structure enables rapid water absorption during cooking, significantly reducing cooking time. The porosity is carefully controlled to prevent excessive puffing, thereby maintaining the original texture, flavor, and appearance characteristics.
2Speed
If grains and pulses are pre-hydrated to high moisture and then freeze-dried to create porous structure, then rehydration speed is improved, but production cost and energy consumption increase
Solution Approach 1:
The patent applies parameter changes by directly controlling porosity through processing parameters without requiring extreme pre-hydration and freeze-drying cycles. This approach achieves sufficient rehydration speed while avoiding the high energy consumption associated with freeze-drying processes.
Solution Approach 2:
The patent employs more economical processing methods that create adequate porosity without the need for expensive and energy-intensive freeze-drying. The approach uses cost-effective processing techniques that achieve the desired rehydration performance with lower energy input.
3Loss of time
If grains are pre-cooked in extruder and formed into grain-like shapes, then cooking time is reduced, but the natural appearance is lost and consumer acceptance decreases
Solution Approach 1:
The patent applies parameter changes by controlling porosity and physical structure through processing parameters rather than extensive cooking and reforming. This maintains the natural grain shape and appearance while achieving rapid rehydration and reduced preparation time.
Solution Approach 2:
The patent applies preliminary action by creating the desired porous structure and physical characteristics before the final product is presented to consumers. This pre-processing creates optimal rehydration properties while preserving the natural appearance, eliminating the need for subsequent cooking and reforming steps.
4Productivity
If conventional processing methods are used to create quick-cooking grains, then production efficiency is improved, but the identity of the caryopsis changes significantly
Solution Approach 1:
The patent applies parameter changes by controlling porosity and physical structure through processing parameters while maintaining the fundamental identity of the caryopsis. This approach enables efficient production of quick-cooking grains that retain their original characteristics.
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
This approach results in grains and pulses that cook in under 15 minutes while maintaining their natural appearance and texture, offering a cost-effective and efficient solution for quick-cooking without compromising the original identity of the caryopsis.
Implementation Method 1
controlling their porosity using flat plate compression
Implementation Method 2
controlling their porosity using flat plate compression or gun puffing
Implementation Method 3
enables infusion of liquids into the grain or legume structure
Data Source
AI summary
A method for making a quick-cook grain or pulse via flat plate compression or gun puffing by controlling the porosity of the grain or pulse. Further, the grain or pulse made in accordance with this invention retains the texture, flavor and appearance of the original grain or pulse.