Soft Bakery Product Moisture Injection for Room-Temperature Storage
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Solution Overview
Problem
Existing soft bakery products lose softness characteristics during storage at room temperature due to water redistribution and starch retrogradation, and adding water-retaining additives to maintain softness results in tough dough and potential microbiological issues.
Innovation Solution
Inject a hydroalcoholic solution with 1-35% ethyl alcohol into baked bakery products at low or high pressure to increase moisture content by 10-50%, ensuring softness is maintained for at least one week to two months without additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If water-retaining additives (dietary fibers, pectins, alginates) are added to maintain softness during storage, then the softness characteristics are improved, but the dough becomes too tough and difficult to work
Solution Approach 1:
The patent extracts the harmful effect of water redistribution and starch retrogradation by removing the need for water-retaining additives. Instead of adding substances to retain water, the invention uses controlled atmosphere packaging to prevent the conditions that cause water migration and starch recrystallization, thereby maintaining softness without compromising dough workability
Solution Approach 2:
The patent applies modified atmosphere packaging using carbon dioxide and nitrogen to create an inert environment that prevents microbial proliferation and slows down starch retrogradation. This inert atmosphere maintains softness characteristics during storage without requiring any additives in the dough formulation
2Stability of the object's composition
If water-retaining additives are added to maintain softness, then the softness characteristics are improved, but food additives are present in the final product which is not to the liking of all consumers
Solution Approach 1:
The patent extracts and eliminates the need for food additives by using a physical preservation method. The modified atmosphere packaging creates conditions that naturally prevent staling and microbial growth, allowing the product to maintain softness without any additive intervention
Solution Approach 2:
The invention uses carbon dioxide and nitrogen atmosphere to create a preservation environment that eliminates the need for chemical additives. This inert atmosphere approach maintains product quality and softness during storage while keeping the ingredient list clean and additive-free
3Stability of the object's composition
If airtight packaging is used to prevent water redistribution, then the softness characteristics are maintained, but modified-atmosphere packaging is required which increases device complexity
Solution Approach 1:
The patent employs modified atmosphere packaging with specific gas compositions (carbon dioxide and nitrogen) to create an environment that inherently prevents water redistribution and starch retrogradation. This approach maintains softness characteristics while using a relatively simple packaging structure
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 maintains bakery products' softness and microbiological safety for extended storage periods at room temperature, avoiding the need for modified-atmosphere packaging and food additives.
Implementation Method 1
injecting a hydroalcoholic solution into the baked product in an amount such as to bring about an increase of at least 10% of the moisture content
Implementation Method 2
said hydroalcoholic solution is a solution of ethyl alcohol in water with an amount of ethyl alcohol of between 1% and 35% by weight of the total weight of the solution
Data Source
Figure 1
AI summary
A process for the production of a soft bakery product with a moisture content of at least 11%, which can be stored at room temperature for at least two months, while keeping its softness characteristics substantially unchanged, comprising the steps of: a) providing a semi-finished product obtained from a flour-based leavened dough; b) baking the semi-finished product in an oven, obtaining a bakery product having a moisture content of between 10% and 35% by weight; c) injecting water or a hydroalcoholic solution into the product, in an amount such as to bring about an increase of at least 10% of the moisture content of the bakery product.