Hard Taco Shell Base Plasticization and Oxygen Barrier Packaging
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Solution Overview
Problem
Hard taco shells tend to break apart easily at the base, leading to a messy eating experience and reduced shelf life when packaged with conventional methods, as they dry out and crack.
Innovation Solution
Applying a plasticizing agent, such as glycerin, to the base or spine portion of the taco shell to increase flexibility and prevent cracking, while using a migration limiting agent to contain the plasticizer, and packaging them in a hermetically sealed environment to maintain freshness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a plasticizing agent is applied to the base portion of the taco shell to increase flexibility and prevent breaking, then the structural integrity during consumption is improved, but the shelf life is reduced due to drying out and cracking
Solution Approach 1:
A flexible film barrier layer is applied to the taco shell base portion to prevent moisture loss while allowing the plasticizing agent to maintain flexibility. The film acts as a protective barrier that prevents the shell from drying out and cracking during storage, thereby extending shelf life without compromising the flexibility improvements gained from the plasticizing agent.
Solution Approach 2:
The packaging structure uses a composite material system combining a plasticizing agent (such as glycerin or propylene glycol) with a flexible film barrier layer. This composite approach allows the plasticizer to provide flexibility and prevent breaking during consumption, while the film barrier prevents moisture loss during storage, resolving the contradiction between improved strength and extended shelf life.
2Ease of operation
If the taco shell base portion is made softer to prevent breaking, then the ease of operation is improved, but the manufacturing precision becomes more difficult to control
Solution Approach 1:
The plasticizing agent and flexible film barrier are applied selectively to the base portion of the taco shell rather than the entire shell. This localized treatment provides the necessary flexibility and breaking prevention at the critical base area while maintaining the traditional crisp texture and manufacturing consistency of the rest of the shell, thus resolving the contradiction between ease of operation and manufacturing precision.
Solution Approach 2:
The invention changes the physical-chemical parameters of the base portion by introducing plasticizing agents and flexible film barriers, which modify the moisture content and flexibility characteristics locally. This parameter change allows the base portion to exhibit different properties (softer, more flexible) than the rest of the shell, enabling improved ease of operation without compromising overall manufacturing precision and consistency.
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 treated taco shells exhibit improved structural integrity during consumption, reducing filling loss and extending shelf life by maintaining flexibility and preventing drying out.
Implementation Method 1
a preferred embodiment employs glycerin which has been found effective to raise the relevant Aw into a rubbery region
Implementation Method 2
the outer package body being hermetically sealed and formed from a material establishing a barrier to the transmission of oxygen into the package interior
Data Source
AI summary
A hard taco shell, having a plasticizing agent applied to a targeted region of a base or spine portion of the hard taco shell and lower sections of taco shell sidewalls to softening the targeted region such that, when the taco shell is bitten, the softened targeted region has some hinging flexibility or pliability which reduces the potential for any crack propagation, is hermetically sealed in a package body formed from a material establishing a barrier to the transmission of oxygen into an interior of the package body. With this arrangement, premature drying and cracking of the agent treated hard taco shell is prevented.