Samosa Pastry Baking Process with Steam Injection
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Solution Overview
Problem
Existing methods for producing samosa pastry shells and wraps fail to replicate the quality characteristics of traditional authentic samosas, such as crunchiness, elasticity, non-porous surface, and moisture content, while also being inefficient for mass production and prone to drying out.
Innovation Solution
A process involving the use of wheat flour dough with controlled humidity during baking, achieved by introducing water vapor or steam into the oven, and pre-baking treatment with canola oil to maintain moisture and prevent greasiness, along with a specific sheet thickness and folding method to ensure crispy and non-crumbly pastry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional slow cooking method is used one at a time, then authenticity and quality are maintained, but productivity is extremely low and time-consuming
Solution Approach 1:
The cooking process is segmented into distinct phases: initial high-temperature phase for crust formation, followed by steam injection phase for moisture retention, and final drying phase for crispiness. This segmentation allows simultaneous cooking of multiple pastry while maintaining quality characteristics of traditional slow cooking.
Solution Approach 2:
The patent dynamically changes cooking parameters during the process: temperature is adjusted in stages, humidity is modified by steam injection, and cooking time is optimized. These parameter changes enable mass production while preserving the quality attributes of traditionally slow-cooked pastry.
2Productivity
If pastry is cooked quickly for mass production, then productivity increases, but quality characteristics such as crunchiness, elasticity, and moisture content deteriorate
Solution Approach 1:
The patent implements continuous cooking in industrial ovens with multiple pastry being cooked simultaneously throughout the process, eliminating the intermittent nature of traditional methods. This continuous action maintains quality while enabling mass production.
Solution Approach 2:
The patent utilizes phase transitions of water (liquid to vapor) through steam injection during cooking. This phase transition enables moisture retention in the pastry interior while the exterior develops crispiness, achieving quality characteristics that would otherwise require slow cooking.
3Ease of operation
If pastry is stored after cooking, then availability increases, but moisture content decreases and pastry dries out quickly
Solution Approach 1:
The patent performs preliminary steam injection during the cooking process to establish optimal moisture content before storage. This preliminary action ensures that pastry retains moisture during subsequent storage and handling, enabling availability without rapid drying.
Solution Approach 2:
The patent creates a controlled atmosphere during cooking and storage that prevents moisture loss. By managing the environmental conditions (humidity, temperature) during storage, the pastry maintains its moisture content and quality characteristics over extended periods.
4Reliability
If oil is applied to pastry surface, then crunchiness and non-greasy appearance are improved, but excessive oil causes greasiness and surface bubbles
Solution Approach 1:
The patent optimizes the amount and application method of oil as a critical parameter. By precisely controlling oil quantity and application timing, the pastry achieves enhanced crunchiness and non-greasy appearance without the harmful effects of excessive oil such as greasiness and surface bubbles.
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 samosa pastry with extended shelf life and improved quality, maintaining crispiness and non-greasiness, suitable for mass production and use in various food products, while avoiding surface bubbles and dryness.
Implementation Method 1
introducing water vapor or steam into the oven
Data Source
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AI summary
An improved method of making a baked pastry, particularly, a shell or wrap for a samosa from a pastry dough in a convection baking oven having a convection atmosphere, the method comprising baking the dough in the oven at a baking temperature for a baking period of time, the improvement having the convection atmosphere with a sufficiently moist atmosphere for the duration of the baking time to prevent the pastry from becoming dry.