Snack Chip Dough Dehydration for Flavor Retention
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Solution Overview
Problem
Existing snack products made from starch-based doughs struggle to maintain authentic flavor and nutritional value of ingredients like fruits, vegetables, meats, and dairy due to high temperatures and moisture content, leading to off-flavors and degradation of nutritional content during processing.
Innovation Solution
A snack chip formulation using a dough comprising 10-50% nutritional material, 0-25% oatmeal, 25-90% pre-gelatinized starch, and 0.1-5% water, which is sheeted and dried at low temperatures to create a shelf-stable half-product that can be cooked later by baking, frying, or microwaving, retaining natural flavors and textures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high temperatures and extended cooking times are used to produce thin, crisp snack products, then the crispiness and shelf stability are improved, but the authentic flavor and nutritional value of nutritional additives degrade
Solution Approach 1:
The patent applies preliminary action by pre-cooking the nutritional additives before incorporating them into the dough. This pre-cooking step (such as blanching vegetables or pre-cooking meats) prepares the nutritional components to withstand subsequent processing while preserving their flavor and nutritional value. The pre-treated ingredients are then mixed into the dough and subjected to minimal additional cooking, thereby maintaining authenticity while achieving the desired crispiness.
2Reliability
If fresh fruit and vegetables are used in snack products, then nutritional value and authentic flavor are improved, but moisture content increases causing burning and off-flavors during cooking
Solution Approach 1:
The patent removes excess moisture from fresh fruits and vegetables through preliminary drying or dehydration processes before incorporating them into the dough. This pre-drying step reduces the water content to levels that prevent burning during subsequent cooking while preserving the authentic flavor and nutritional benefits. The partially dried ingredients are then combined with the dough and subjected to controlled cooking.
Solution Approach 2:
The patent changes the moisture content parameter of fresh fruits and vegetables by controlling the water activity and drying conditions. By adjusting drying temperature, time, and humidity levels, the patent optimizes the moisture reduction to prevent burning while maintaining flavor authenticity. This parameter control allows fresh ingredients to be used without the harmful effects of excessive moisture during cooking.
3Duration of action of stationary object
If dehydration is performed to reduce moisture content for crispiness, then shelf stability is improved, but authentic flavor and nutritional value are degraded
Solution Approach 1:
The patent performs preliminary cooking or blanching of nutritional additives before dehydration. This pre-treatment stabilizes the flavor compounds and nutritional components, making them more resistant to degradation during the subsequent drying process. The pre-cooked ingredients are then dehydrated at controlled temperatures that preserve authenticity while achieving the low moisture content needed for shelf stability.
4Duration of action of stationary object
If preservatives are added to fruit and vegetable ingredients, then shelf stability is improved, but natural product status is compromised and discoloration occurs
Solution Approach 1:
The patent uses controlled atmosphere packaging and modified storage conditions as temporary, preservative-free methods to extend shelf stability. By creating an oxygen-modified environment during packaging and storage, the patent prevents oxidation and discoloration without adding chemical preservatives, thereby maintaining natural product status while achieving adequate shelf life for the application.
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 solution allows for the production of snack chips with authentic flavors and nutritional benefits, providing a full or half serving of fruit, vegetable, or protein in a single serving, with a crispy texture and low off-flavors, while being low in fat and calories.
Implementation Method 1
25-90% pre-gelatinized starch
Implementation Method 2
sheeted and dried at low temperatures to create a shelf-stable half-product
Implementation Method 3
cooked later by baking, frying, or microwaving
Data Source
AI summary
A snack chip comprising from about 10% to about 50% of dehydrated fruit material; optionally oatmeal; from about 30% to about 90% of starch material made from materials selected from the group consisting of tapioca, rice and mixtures thereof; from about 0.1% to about 5.0% water; and from about 1% to about 20% of optional ingredients. At least about 40% of the starch material can be pre-gelatinized. The snack chip is made by combining dry ingredients with water to form a dough which is then sheeted, dried without the use of a heated extruder to form a half product, which is cooked to form the snack chip.