Shaped Savoury Concentrate Extrusion Without Maturation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The industrial production of bouillon cubes requires a maturation step to allow the fat component to solidify and crystallize, which is time-consuming and inefficient, necessitating a buffer container for several hours to achieve stable pressing or extrusion.
Innovation Solution
A process where edible salt and particulate ingredients are mixed with a fat component having a solid fat content of at least 10% (N20) to form a paste, which is then extruded into a shaped savory concentrate without the need for maturation, utilizing a crystalline fat network for shape retention and hardness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a maturation step is used to allow fat component to solidify and crystallize, then the stability and shape retention of the savoury concentrate is improved, but the processing time increases significantly
Solution Approach 1:
The fat component is pre-cooled to a temperature (10-45°C) that maintains its solid fat content at least 10% before mixing with the powder mixture. This preliminary cooling action ensures the fat is already in a suitable crystalline state for immediate extrusion, eliminating the need for subsequent maturation time while maintaining product stability
Solution Approach 2:
The invention changes the temperature parameter of the fat component to control its solid fat content. By maintaining the fat at a specific temperature range where solid fat content is at least 10%, the fat achieves optimal crystalline structure for shape retention without requiring extended maturation time
2Strength
If high melting point fats are used to provide shape retention and hardness, then the structural stability is improved, but the fat content requirements become more restrictive
Solution Approach 1:
Instead of changing the chemical composition to use higher melting point fats, the invention changes the physical parameter (temperature) of the same fat component. By controlling temperature to maintain at least 10% solid fat content, the fat provides adequate hardness and shape retention without requiring high-melting-point varieties
Solution Approach 2:
The invention creates a functional equivalent to high-melting-point fat by using temperature-controlled solid fat content. The cooled fat component replicates the structural properties of high-melting-point fats without actually being high-melting-point fats, allowing flexibility in fat selection
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
Enables the production of stable, dissolvable savory concentrates with reduced processing time and without the need for maturation, maintaining the desired hardness and appearance while using less high-melting-point fats.
Implementation Method 1
it usually takes at least several hours for molten fat in the bouillon concentrate mass to crystallize in a crystal-form and to an extent that enables the pressing or extrusion of stable bouillon cubes
Implementation Method 2
a fat component having a solid fat content of at least 10% (N20) to form a paste, which is then extruded into a shaped savory concentrate without the need for maturation, utilizing a crystalline fat network for shape retention and hardness
Data Source
AI summary
The invention relates to a process of preparing a shaped savoury concentrate having a water activity of less than 0.8 and a total fat content of 10-35 wt.%, said process comprising: a) combining the following ingredients to prepare a powder mixture: -100 parts by weight of edible salt selected from sodium chloride, potassium chloride and combinations thereof, - 2-150 parts by weight of one or more particulate ingredients selected from b) admixing 5-150 parts by weight of a fat component to the powder mixture, wherein the fat component has an N20 of at least 20% and a N35 of less than 30%, wherein on admixing with the powder mixture the fat component has an N20 of at least 10%, to form a paste, c) extruding the paste into shaped savoury concentrate.