Freeze-Dried Tea Powder Granules for Dissolution and Mouthfeel
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Solution Overview
Problem
Existing instant powdered tea beverages face issues with particle shape affecting aroma preservation, dissolution, and mouthfeel, leading to scattering, clumping, and unpleasant texture during consumption.
Innovation Solution
A tea powder composition with specific particle diameters and thicknesses, ranging from 1 mm to 5.6 mm, and a total content of 10-100% by weight, optimized for ease of dissolution and pleasant mouthfeel, produced using a freeze drying method to preserve aroma.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spray drying method is used to produce instant powdered tea, then manufacturing cost is reduced and mass production is facilitated, but the powder scatters during use, forms lumps when dissolved, and provides unpleasant mouthfeel
Solution Approach 1:
The invention segments the powder into two distinct size categories: fine powder (10-100 μm) for flavor and large granules (0.5-5 mm) for structural integrity. This segmentation allows each particle size to fulfill different functions - fine powder dissolves quickly while large granules prevent clumping and reduce scattering, resolving the contradiction between ease of manufacture and ease of operation
Solution Approach 2:
The invention creates a composite powder system combining fine tea powder and large tea granules in specific proportions (fine powder 10-60 wt%, large granules 40-90 wt%). This composite structure leverages the advantages of both particle sizes: fine powder provides rapid dissolution and flavor release, while large granules maintain structural stability during handling and prevent clumping, thus improving dissolution performance and mouthfeel while maintaining manufacturing efficiency
2Ease of operation
If freeze drying method is used to produce instant powdered tea, then aroma components are preserved and dissolution is improved, but manufacturing equipment cost and running costs increase
Solution Approach 1:
The invention segments the drying process outcomes into fine powder from spray drying and large granules from freeze drying, combining them in a composite mixture. This allows the product to benefit from aroma preservation and dissolution improvement provided by freeze-dried granules while using spray-dried fine powder to maintain cost-effectiveness, thus resolving the contradiction between operational performance and manufacturing cost
Solution Approach 2:
The invention applies different drying methods to different portions of the final product: freeze drying is used for the large granule fraction (40-90 wt%) where aroma preservation and dissolution are critical, while spray drying is used for the fine powder fraction (10-60 wt%) where cost-effectiveness is prioritized. This local application of different quality standards optimizes both aroma preservation and manufacturing cost
3Adaptability or versatility
If very fine powder (particle diameter several tens of micrometers) is used, then flavor can be added without impairing confectionery texture, but the powder scatters during use and forms lumps when dissolved
Solution Approach 1:
The invention segments the powder into fine particles (10-100 μm) suitable for confectionery applications and large granules (0.5-5 mm) for stability. The fine powder fraction (10-60 wt%) can be sprinkled on confectionery without impairing texture, while the large granule fraction (40-90 wt%) acts as a structural framework that prevents scattering and clumping during use, thus resolving the contradiction between adaptability and ease of operation
4Ease of operation
If large particle size powder (several millimeters) is used, then scattering and fluttering during use are prevented and dissolution is improved, but the powder provides coarse texture and is unsuitable for confectionery topping
Solution Approach 1:
The invention segments the powder into two size fractions with complementary functions: large granules (0.5-5 mm, 40-90 wt%) that prevent scattering and improve dissolution, and fine powder (10-100 μm, 10-60 wt%) that provides smooth texture suitable for confectionery toppings. This segmentation allows the product to exhibit both scattering prevention and confectionery compatibility simultaneously
Solution Approach 2:
The invention applies different particle size qualities to different functional requirements: large granules provide the structural framework for scattering prevention and dissolution enhancement, while fine powder provides the surface quality needed for confectionery applications. This local quality assignment resolves the contradiction between operational performance and adaptability
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 composition provides a preferable sensation with easy dissolution, coarse texture, and smooth swallowing, while maintaining aroma integrity, addressing scattering and clumping issues.
Implementation Method 1
the freeze drying method is a method of drying a frozen liquid under a vacuum condition, in which moisture is volatilized at a relatively low temperature
Implementation Method 2
drying a frozen liquid under a vacuum condition
Data Source
AI summary
The tea powder composition includes one or more of: solid particle A having a particle diameter larger than 4 mm and equal to or less than 5.6 mm and a thickness of 4 mm or less; solid particle B having a particle diameter larger than 2.8 mm and equal to or less than 4 mm and a thickness of 2.8 mm or less; solid particle C having a particle diameter larger than 2 mm and equal to or less than 2.8 mm and a thickness of 2 mm or less; solid particle D having a particle diameter larger than 1.4 mm and equal to or less than 2 mm and a thickness of 1.4 mm or less; and solid particle E having a particle diameter larger than 1 mm and equal to or less than 1.4 mm and a thickness of 1 mm or less.