Sugar-Free Binder for Shelf Stable Snack Bars
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Solution Overview
Problem
Shelf stable snack bars often rely on sugar-based binders to hold particulates together, which limits the ability to formulate sugar-free options and introduces unwanted sweetness, while also making it difficult to maintain a chewy texture over shelf life.
Innovation Solution
A shelf stable food product using a pliable binder comprising sprouted whole grain ingredient, gum acacia, oil, and glycerin, with a ratio of sprouted whole grain to gum acacia of at least 2:1 to 6:1, and a combined oil and glycerin content not exceeding 35% by weight, which binds particulates together without using non-intact sugar sources, maintaining chewiness and preventing sogginess over shelf life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sugar-based binders are used to bind particulates together, then the aggregate holds together well, but the product contains unwanted sweetness and cannot be formulated as sugar-free
Solution Approach 1:
The patent changes the chemical composition parameters of the binder by replacing sugar-based binders with a novel formulation consisting of sprouted whole grain ingredient (25-55% of binder), gum acacia (6-18% of binder), oil (12-20% of binder), and glycerin (12-20% of binder). This parameter change eliminates non-intact sugar sources while maintaining binding effectiveness through the synergistic combination of these ingredients.
Solution Approach 2:
The patent employs a composite binder material combining multiple ingredients with different functional properties: sprouted whole grain ingredient provides binding and structural properties, gum acacia provides adhesive and moisture-retention properties, oil provides plasticity and mouthfeel, and glycerin provides humectant properties. This composite approach achieves sugar-free formulation while maintaining binding strength and chewy texture.
2Ease of operation
If conventional binders are used to create chewy texture, then the snack is palatable, but the product becomes soggy over shelf life
Solution Approach 1:
The patent optimizes moisture content parameters (8% to less than 25% of binder) and the specific ratios of hydrophilic ingredients (sprouted whole grain and gum acacia) to hydrophobic ingredients (oil and glycerin). This parameter optimization creates a binder that maintains chewy texture while resisting moisture absorption that causes sogginess during shelf storage.
Solution Approach 2:
The composite binder formulation combines ingredients with complementary properties: gum acacia provides moisture retention without sogginess, oil provides plasticity and prevents drying, glycerin acts as a humectant to maintain texture, and sprouted whole grain provides structural integrity. This composite system maintains texture stability over shelf life while preserving chewiness.
3Strength
If sugar is used as a binder, then particulates bind together effectively, but the product relies on sugar which limits sugar-free formulation options
Solution Approach 1:
The patent fundamentally changes the binder composition parameters by eliminating non-intact sugar sources and replacing them with a formulation based on sprouted whole grain ingredient (25-55% of binder), gum acacia (6-18% of binder), oil (12-20% of binder), and glycerin (12-20% of binder). This parameter change achieves binding effectiveness without sugar dependence.
Solution Approach 2:
The patent extracts and removes sugar from the binder formulation, separating the binding function from sugar. The binding effectiveness is achieved through alternative mechanisms provided by sprouted whole grain proteins and carbohydrates, gum acacia adhesives, and the emulsifying properties of oil and glycerin combinations.
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 creation of a chewy, sugar-free shelf stable snack that remains effective over its shelf life without becoming soggy, providing a satisfying texture and avoiding the use of non-intact sugar sources, while maintaining a water activity below 0.6 and a shelf life of at least 6 months.
Implementation Method 1
gum acacia in an amount of 6% to about 18% by weight of the pliable binder
Implementation Method 2
a shelf stable, ready-to-eat aggregate snack... the pliable binder binds the particulates together in the aggregate to form the shelf stable food
Implementation Method 3
oil in an amount of about 12% to 20% by weight of the pliable binder; glycerin in an amount of about 12% to 20% by weight of the pliable binder, where the combined amount oil and glycerin does not exceed 35% by weight of the pliable binder; moisture content of about 8% to less than 25% by weight of the pliable binder
Data Source
AI summary
Shelf stable aggregate foods are described that include a chewy binder that includes essentially no non-intact sugar sources. A binder in a shelf stable aggregate food remains chewy over shelf life and contains a sprouted whole grain ingredient, gum Arabic, an oil, and glycerin. Also described are methods of making a shelf stable aggregate food.