Shelf-Stable Fried Product Processing for Fat Migration Control
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Solution Overview
Problem
Existing processes for creating shelf stable fried food products result in undesirable texture, flavor, and appearance due to unmanaged fat and moisture migration, cell degradation, and inconsistent product quality.
Innovation Solution
A multi-step process involving tempering, priming, moisture reduction, and surface application to manage fat and moisture migration, maintain cell structure integrity, and enhance texture, resulting in a crispy and crunchy texture with desirable fat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If prior processes are used to create shelf stable fried food products, then the products can be stored without preparation, but the aesthetic properties (color, flavor, texture, appearance) are degraded
Solution Approach 1:
The product is flash-frozen before packaging to lock in the desired aesthetic properties and prevent fat and moisture migration during storage. This preliminary freezing action ensures that the product maintains its color, flavor, texture, and appearance throughout the shelf life without requiring preparation.
Solution Approach 2:
The invention changes the temperature parameter by flash-freezing the fried product to extremely low temperatures immediately after frying. This parameter change preserves the aesthetic properties by preventing chemical and physical degradation that would otherwise occur during storage at higher temperatures.
2Ease of manufacture
If fat and moisture migration is not managed during processing, then the processing is simpler, but the texture and flavor become undesirable
Solution Approach 1:
The invention uses rapid freezing to extremely low temperatures to change the physical state of fats and moisture, preventing their migration during storage and processing. This parameter change maintains desirable texture and flavor without requiring complex active management systems.
Solution Approach 2:
The fried product undergoes a phase transition to frozen state, which locks the fat and moisture in place. This phase change prevents unwanted migration and maintains the desired texture and flavor characteristics throughout the shelf life.
3Productivity
If cell structures are degraded during processing, then the processing is more efficient, but fat and moisture migration increases uncontrollably
Solution Approach 1:
The product is flash-frozen at the optimal point in the processing sequence to preserve cell structure integrity. This preliminary freezing action prevents subsequent degradation and uncontrolled fat and moisture migration during storage and distribution.
Solution Approach 2:
Rapid freezing causes water to form ice crystals that physically support the cell structure, preventing collapse and degradation. This phase transition maintains the stability of fat and moisture distribution within the product matrix.
4Manufacturing precision
If the product is fried to achieve crispy texture, then the flavor and appearance improve, but fat absorption increases and shelf stability decreases
Solution Approach 1:
The product is flash-frozen immediately after frying to lock in the crispy texture and desirable appearance while preventing further fat absorption. This preliminary freezing action also stabilizes the fat content by solidifying it, preventing migration during storage.
Solution Approach 2:
The rapid freezing process transitions the product to a frozen state where fat is solidified and cannot migrate. This phase change preserves the crispy texture achieved during frying while limiting total fat content by preventing additional absorption during storage.
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 enhances the aesthetic and textural properties of shelf stable fried products by reducing fat and moisture migration, improving adhesion, and maintaining cell structure, resulting in a crispy and crunchy texture with enhanced flavor and appearance.
Implementation Method 1
The shelf stable fried product can include a frozen portion
Implementation Method 2
frying or vacuum frying
Data Source
AI summary
A shelf stable fried product and a process for creating a shelf stable fried product is disclosed. Aspects include a process for managing fat migration, moisture migration, and cell degrading of a food product during frying. Aspects further include a resulting shelf stable food product that includes a crispy and/or crunchy texture and a desirable fat distribution.