Rotary-Cooked Whole Grain Puffing for Durable Rice Cakes
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Solution Overview
Problem
Existing methods for preparing puffed whole grain and legume cakes result in a homogeneous, unappealing appearance due to the destruction of non-homogeneity when higher levels of grains or legumes are used, and they are time-consuming and costly.
Innovation Solution
A method involving rotary cooking of whole grains and legumes to achieve partial gelatinization without destroying non-homogeneity, followed by blending and puffing in a rice cake machine, which includes introducing grains and legumes into separate rotary cookers, cooking, drying, and then puffing them together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If higher levels of whole grains and legumes are added to rice cakes, then the nutritional value and health benefits are improved, but the puffing is reduced and the appearance becomes dense and unappealing
Solution Approach 1:
The patent applies preliminary action by pre-cooking the whole grains and legumes in a rotary cooker before the puffing process. This pre-cooking gelatinizes the starches and softens the grains, enabling them to puff effectively when subjected to the rapid pressure change in the puffing chamber, thus resolving the contradiction between high grain content and poor puffing
2Productivity
If an extruder is used to pre-gelatinize the starch component, then the puffing problem is overcome, but the non-homogeneity of the grain or legume components is destroyed
Solution Approach 1:
The patent replaces the mechanical extrusion system with a rotary cooking system that uses thermal energy and rotational motion. The rotary cooker gently tumbles and cooks the grains and legumes without the intense mechanical shear forces of an extruder, thereby gelatinizing starches for good puffing while preserving the natural non-homogeneous appearance of the whole grain components
3Ease of manufacture
If traditional methods are used to prepare puffed cakes, then the production process is established, but the production time is long and drying costs are high
Solution Approach 1:
The patent merges the cooking and drying functions into a single rotary cooker operation. The rotary cooker cooks the grains and legumes while simultaneously reducing moisture through its rotating motion and exposed surface area, eliminating the need for separate prolonged drying processes and thereby reducing both production time and drying costs
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
Produces a natural-looking, healthier puffed cake with improved fusion and durability, reduced production time, and lower drying costs, while maintaining the nutritional value and appearance of whole grains and legumes.
Implementation Method 1
introducing at least one whole grain into a first rotary cooker and cooking the grains with steam and water
Implementation Method 2
drying the cooked grains and drying the cooked legumes
Implementation Method 3
puffing the product in a rice cake machine
Data Source
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AI summary
A method for preparing a grain or legume cake by cooking the whole grains or legumes is a rotary cooker and subsequently puffing the cooked whole grain or legume into a rice cake form. The whole grain or legume cakes produced by this method have a natural, appealing appearance and produce a more durable grain or legume cake.