Thermally Processed Pulses for Ready-to-Eat Snacks
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Solution Overview
Problem
Pulses are typically dry and hard, requiring hydration and cooking to become edible, resulting in a soft texture that is difficult to consume without utensils and necessitates preservation methods, whereas a product that is ready to eat with a firmer texture and lower water activity is desired.
Innovation Solution
Thermally processing pulses to achieve a moisture content between 0.25 and 0.75 grams of water per gram of dry matter and a water activity of 0.85 to 0.97, allowing for a firmer texture and reduced water content, eliminating the need for additional preservation methods and enabling direct consumption or use in other food products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pulses are fully hydrated by cooking, then they become soft and chewable, but they become wet and require preservation methods
Solution Approach 1:
The patent applies parameter changes by controlling the water activity (aw) to a specific range of 0.92 to 0.96 and total moisture content to 35-65%, rather than using traditional full hydration. This parameter optimization allows the pulses to achieve adequate softness for consumption while maintaining stability without requiring additional preservation methods like acids or humectants.
Solution Approach 2:
The patent uses partial hydration by limiting the water content to specific ranges rather than full saturation. The pulses are hydrated to a degree that provides sufficient chewability (partial action) but stops before reaching the point where excessive moisture would require preservation, thus avoiding the need for additives.
2Reliability
If pulses are kept dry, then they are stable for storage, but they remain hard and inedible
Solution Approach 1:
The patent changes the moisture parameters from traditional dry storage conditions to a controlled intermediate state with water activity of 0.92-0.96 and moisture content of 35-65%. This parameter transformation enables the pulses to maintain storage stability while simultaneously achieving edibility without requiring full cooking hydration.
3Ease of operation
If pulses are fully hydrated and cooked, then they become soft and ready to eat, but they require preservation methods and utensils for consumption
Solution Approach 1:
By optimizing water activity to 0.92-0.96 and moisture content to 35-65%, the patent creates a product that is ready-to-eat without requiring preservation additives or humectants. The texture is sufficiently soft for direct consumption without utensils, eliminating the complexity of preservation systems and consumption equipment.
4Ease of operation
If traditional hydration and cooking methods are used, then pulses become edible, but energy consumption increases
Solution Approach 1:
The patent applies partial hydration by limiting water content to 35-65% rather than full saturation, which reduces the energy required for heating and cooking. The pulses achieve edibility with reduced thermal processing time and energy input compared to traditional methods that require complete hydration and extended cooking.
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 processed pulses maintain a firm texture and high quality, are shelf-stable, and can be consumed directly as a snack or used in meals without further cooking, while reducing energy consumption and environmental impact compared to traditional hydration and drying methods.
Implementation Method 1
The starch is substantially gelatinized as indicated by loss of birefringence under polarized light
Implementation Method 2
Thermally processing pulses to achieve a moisture content between 0.25 and 0.75 grams of water per gram of dry matter
Data Source
AI summary
A food product and method are provided. The food product includes a pulse having a total water content below that of a fully hydrated pulse and a chewier texture. It is formed from a dry pulse and is hydrated, but only partially, resulting in a total water content in the range of between about 0.25 grams water/gram dry matter and about 0.75 grams water per gram dry matter. The pulse is in an intact form and has not been fully hydrated after harvest.