Self-Supporting Egg Product via Low-Temperature Gelation
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Solution Overview
Problem
Existing methods for preparing cooked egg products require pouring a liquid egg blend into heavy metal pans, which necessitates significant initial investment in conveyor systems and limits flexibility in product size and shape changes.
Innovation Solution
A method involving a liquid egg composition mixed with solid food inclusions, where at least 50% of the inclusions are at a low temperature, forming an extrudable egg-based matrix that can be shaped and cooked without pan support, allowing for easier product variations and reduced capital equipment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heavy metal pans are used to hold and support the liquid egg blend during cooking, then the product can be cooked in a controlled manner, but significant initial investment in conveyor systems is required and flexibility in product size and shape changes is limited
Solution Approach 1:
The patent extracts the support function from heavy metal pans by using a griddle surface with a retaining ring that defines the product perimeter. The egg composition is deposited directly onto the griddle surface rather than being contained in pans, eliminating the need for complex conveyor systems while maintaining cooking control through the retaining ring boundary.
Solution Approach 2:
The patent replaces expensive, fixed conveyor systems with simple, interchangeable retaining rings that can be easily changed to accommodate different product sizes and shapes. The retaining ring serves as a temporary, disposable boundary definition tool rather than a permanent fixture.
2Shape
If heavy metal pans are used to hold the liquid egg blend, then the product shape is maintained during cooking, but product size and shape changes require removing and replacing all pans
Solution Approach 1:
The patent implements dynamic adaptability by using a retaining ring that can be repositioned and resized on the griddle surface. The retaining ring is not fixed to the conveyor system but can be adjusted to define different product perimeters, allowing flexible changes in product size and shape without replacing entire pans.
Solution Approach 2:
The patent segments the shape-defining function from the cooking surface by using a separate retaining ring component. This allows the retaining ring to be independently adjusted or replaced to change product dimensions while the griddle surface remains constant.
3Ease of operation
If the liquid egg composition is made flowable at 35°F, then the composition can be easily deposited and shaped, but the composition may lack structural stability to support itself without pan support
Solution Approach 1:
The patent utilizes phase transition by cooling the deposited egg composition to temperatures below 35°F, causing it to transition from a flowable state to a more rigid, self-supporting state. This temperature-induced phase change provides the necessary structural stability while maintaining ease of deposition at the higher temperature.
Solution Approach 2:
The patent applies preliminary cooling to the deposited composition to enhance its structural properties before cooking begins. The composition is deposited in its flowable state, then cooled to gain self-supporting strength, allowing it to maintain its shape without pan support during the subsequent cooking process.
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 method enables the production of self-supporting, uniquely textured egg products that can be cooked without pans, facilitating faster production, easier product size and shape changes, and a more appealing product appearance.
Implementation Method 1
the liquid egg composition has a gel point at a temperature of from about 30° F. to about 40° F. The shaped, ready-to-cook egg product is at a temperature below the gel point of the liquid egg composition such that the egg product gels and is self-supporting
Data Source
AI summary
Formed, ready-to-cook or ready-to-eat egg products are prepared by mixing a liquid egg composition comprising liquid egg in an amount sufficient so that the liquid egg composition is flowable at 35° F. with solid food inclusions, wherein at least 50% of the solid food inclusions have a longest dimension size of from 0.6 to 12 cm. At least about 50% of the solid food inclusions are at a temperature of less than 34° F. at the time of mixing. The resulting extrudable egg-based matrix comprises from 50 wt % to 90 wt % of the solid food inclusions, and is formed into a predetermined shape to provide a shaped, ready-to-cook or ready-to-eat egg product that is self-supporting for at least two minutes at an ambient temperature of 40° F. The shaped, ready-to-cook egg product may then be cooked.