Sugar Glaze Stability for Continuous Snack Production
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Solution Overview
Problem
The challenge in producing glazed snack food products is the tendency for crystallization or sedimentation in sugar-based glazes, which leads to equipment clogging and production delays, especially during mass production, and the need for a glaze that enhances flavor and visual appeal without hydrocolloids, additives, and high sugar or salt content.
Innovation Solution
A stable aqueous sugar coating comprising at least 60% sugar, a juice concentrate, and no cornstarch, with specific pH and viscosity ranges, is applied to uncooked dough, ensuring the glaze remains liquid and free of solids, allowing for continuous application and baking without clogging, while providing a glossy appearance and appealing taste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a sugar-based glaze is used to achieve glossy appearance and enhanced flavor, then the visual appeal and taste of the snack food product is improved, but crystallization or sedimentation occurs within the glazing leading to equipment clogging and production delays
Solution Approach 1:
The patent modifies the chemical composition parameters of the glaze by incorporating specific ingredients (pectin, citric acid, malic acid, natural flavors) and controlling sugar content to prevent crystallization while maintaining gloss. The glaze is formulated with specific pH levels and viscosity ranges to ensure stability during mass production without clogging equipment.
Solution Approach 2:
The patent creates a composite glaze formulation combining multiple ingredients (sugars, pectin, citric acid, malic acid, natural flavors, water) that work together synergistically. This composite material provides both the desired glossy appearance and the stability needed to prevent sedimentation and equipment clogging during continuous production.
2Illumination intensity
If traditional glazing ingredients are used to achieve appealing shine, then the visual appeal is improved, but the glaze contains high sugar and salt content which is undesirable for health reasons
Solution Approach 1:
The patent reformulates the glaze to reduce sugar and salt content while maintaining appealing shine through the use of alternative ingredients such as pectin as a thickening agent and citric/malic acids for flavor enhancement. The glaze achieves gloss without relying on high concentrations of traditional high-sugar, high-salt formulations.
3Ease of manufacture
If the glaze is applied to enhance flavor and appearance, then the taste and visual appeal of the product is improved, but the glaze tends to crystallize or sedimentate during mass production
Solution Approach 1:
The patent adjusts the chemical parameters of the glaze including pH level (using citric and malic acids), viscosity (using pectin), and sugar composition to prevent crystallization. These parameter changes ensure the glaze remains stable and homogeneous during storage and application in mass production while still providing enhanced flavor.
Solution Approach 2:
The patent uses pectin as an intermediary substance that acts as a stabilizer and thickening agent. This intermediary prevents the sugars and other ingredients from separating or crystallizing, maintaining a homogeneous mixture that can be easily applied during mass production without sedimentation issues.
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 results in shelf-stable, visually appealing, and tasty glazed snack food products with reduced sugar and salt content, maintaining a smooth, shiny coating and preventing sedimentation, enabling continuous production without equipment stoppages.
Implementation Method 1
A liquid described herein may be used to form a coat on a surface of an uncooked dough, which is then baked, resulting in a smooth, shiny coat or glaze on the baked snack
Data Source
AI summary
A glaze with a viscosity ranging between 170 and 650 cP, less than 20% sugar, and less than 4% salt, is applied onto an uncooked dough product during a continuous process in the production of baked snack foods. The glaze maintains its form as a liquid free of solids at room temperatures despite the presence of over 15% sugar. The glaze is applied onto a dough the glazed product is then baked, forming a glazed baked snack food product having at least 5% of a smooth, shiny glaze on a surface of the snack food product.