Shell-Less Soft-Cooked Eggs With Runny Yolk Pasteurization
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Solution Overview
Problem
Existing methods struggle to produce soft cooked egg products with a runny yolk on a mass production basis, as they often fail to maintain the desired texture and consistency, making it difficult to provide a convenient and high-quality product that consumers demand.
Innovation Solution
A process involving shell-less egg preparation, controlled cooking to specific temperature ranges, cooling, packaging, and pasteurization ensures the yolk remains runny while the white is set, followed by optional chilling and sealing in modified or vacuum packages to preserve the texture and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional cooking methods are used for mass production, then productivity is improved, but manufacturing precision of yolk texture deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling cooking temperature and time parameters to achieve the desired yolk texture. The process specifies cooking at temperatures not exceeding 175°F for the egg and not exceeding 150°F for the yolk, which transforms the physical state of the yolk to a runny to semi-gelled consistency while maintaining manufacturing scalability.
Solution Approach 2:
The patent employs preliminary action by pre-cooling the cooked egg to 75°F or less before packaging and pasteurization. This preliminary cooling step ensures that the yolk maintains its runny to semi-gelled texture throughout subsequent processing and storage, preventing unwanted textural changes during mass production.
2Speed
If higher cooking temperatures are used, then cooking speed is improved, but yolk temperature and texture control deteriorates
Solution Approach 1:
The patent changes the temperature parameter from conventional high-temperature cooking to low-temperature cooking (maximum 175°F for egg, maximum 150°F for yolk). This parameter change slows the cooking speed but enables precise control over yolk temperature and texture, achieving the runny to semi-gelled consistency required for soft cooked egg products.
Solution Approach 2:
The patent employs periodic action through a multi-stage cooking and cooling process. The egg undergoes controlled cooking at specific temperature limits, followed by mandatory cooling to 75°F or less, and optionally to below 40°F. This periodic temperature control ensures the yolk reaches the desired runny to semi-gelled state while maintaining consistency across mass production.
3Reliability
If pasteurization is applied after cooking, then food safety is improved, but yolk texture may deteriorate
Solution Approach 1:
The patent applies preliminary action by cooling the cooked egg to 75°F or less (and optionally below 40°F) before packaging and pasteurization. This preliminary cooling preserves the runnym to semi-gelled yolk texture during the pasteurization process, preventing the yolk from becoming overcooked or rubbery while still achieving food safety through subsequent pasteurization.
Solution Approach 2:
The patent changes the temperature parameter by implementing a cooling step to 75°F or less before pasteurization. This parameter change ensures that when pasteurization is applied, the yolk temperature remains controlled, maintaining the runnym to semi-gelled texture while achieving the necessary food safety standards.
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 produces soft cooked egg products with excellent organoleptic properties, ensuring a ready-to-eat, food-safe product with consistent cooking quality and extended shelf life, suitable for both institutional and home use.
Implementation Method 1
Cooking the shell-less eggs for a time and temperature sufficient to provide a cooked egg wherein the egg white has a maximum temperature of no more than about 175° F. and the egg yolk has a maximum internal temperature (temperature inside the yolk) of no more than about 150° F.
Implementation Method 2
Cooling the cooked egg to an internal temperature (inside the yolk) of 75° F. or less
Implementation Method 3
Pasteurizing the cooked, packaged egg
Data Source
AI summary
Soft cooked egg products having a runny yolk are prepared by removing the eggs from their shells; cooking so that the egg white has a temperature of no more than about 175° F. and the egg yolk has a temperature of no more than about 150° F.; cooling the egg to an internal temperature of 75° F. or less; sealing the egg in a package; and pasteurizing. Alternatively, the shell-less eggs are packaged sealed in a package and cooked so that the egg white has a temperature of no more than about 175° F. and the egg yolk has an internal temperature of no more than about 150° F. The processes are carried out under processing conditions such that the pasteurized, cooked, packaged eggs have runny yolks. Products made by this process are also described.