Shaped Egg Product with Low Binder via Extrusion
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Solution Overview
Problem
Existing methods for producing cooked egg products require significant investment in conveyor systems and are inflexible in terms of product size and shape changes, as they rely on heavy metal pans that need to be replaced for different configurations, limiting production efficiency and flexibility.
Innovation Solution
A method involving a liquid egg composition mixed with solid food inclusions, forming an extrudable egg-based matrix with a low binder additive content, allowing for the creation of self-supporting, shaped egg products that can be cooked without pans, enabling flexible production and automation with a forming mold that does not travel through the oven.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heavy metal pans are used to hold and support the flowable slurry during cooking, then the product can be cooked in desired shapes, but the production system becomes complex and requires significant capital investment in conveyor systems with fixed arrays of pans
Solution Approach 1:
The patent extracts the shaping function from the cooking pan, allowing the pan to be removed from the conveyor system. The egg composition is formed into desired shapes using molds or forming equipment before being placed in the pan for cooking, separating the shaping operation from the cooking operation and eliminating the need for complex conveyor systems with fixed pan arrays
Solution Approach 2:
The patent applies preliminary action by forming the egg composition into the desired shape before cooking. The composition is prepared in a formable state, shaped using molds or forming equipment, and then cooked in the pre-formed shape, eliminating the need for the pan to maintain shape during cooking
2Speed
If heavy metal pans are fixed to the conveyor belt in an array, then the pans can be conveyed stably through the oven, but the system requires significant initial investment and is inflexible for product size and shape changes
Solution Approach 1:
The patent introduces dynamics by allowing the pan array configuration to be changed. Instead of fixed pans, the system uses a conveyor that can accommodate different pan arrangements, enabling flexible adjustment of pan positions and configurations to match different product requirements without requiring complete system replacement
Solution Approach 2:
The patent applies universality by designing a conveyor system that can handle multiple product types and configurations. The conveyor is equipped with adjustable fixtures or movable pan holders that can be reconfigured for different product sizes and shapes, making the system versatile for producing various egg products on the same production line
3Ease of operation
If the liquid egg composition is made flowable at low temperature, then the composition can be easily poured and formed, but the composition lacks structural stability to support its own shape without pans
Solution Approach 1:
The patent applies parameter changes by controlling the temperature and viscosity of the egg composition at different stages. The composition is maintained at a temperature and viscosity range that allows easy pouring and forming, then rapidly cooled or set to achieve structural stability and self-supporting capability, using parameter transitions to balance workability and structural integrity
Solution Approach 2:
The patent utilizes phase transitions by controlling the transition of the egg composition from a liquid flowable state to a gel or solidified state. The composition is poured in a liquid state for easy forming, then undergoes phase transition through cooling or setting to become self-supporting, leveraging the phase change to achieve both ease of operation and structural stability
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 reduces capital equipment costs, facilitates easier product size and shape changes, and allows for higher production rates while providing a unique, visually appealing product with enhanced texture and nutritional benefits, as the egg-based matrix is self-supporting and can be formed into various shapes efficiently.
Implementation Method 1
a liquid egg composition comprising from about 60 wt % to 100 wt % of liquid egg based on the total weight of the liquid egg composition, and optional viscosity increasing ingredients in an amount sufficient so that the liquid egg composition is flowable at 35° F.
Implementation Method 2
from 5 to 45% of the solid food inclusions are at a temperature of less than 34° F. at the time of mixing
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. From 5 to 45% 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. The matrix additionally comprises a binder additive in an amount effective so that the shaped, ready-to-cook or ready-to-eat egg product is self-supporting for at least two minutes at an ambient temperature of 40° F.