Thin Pasta Layer Overlapping for Lasagne Thermal Damage Reduction
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Solution Overview
Problem
Conventional lasagne making methods require pre-cooking pasta layers, leading to thermal damage and complex preparation processes, which affect the texture and freshness of the final product.
Innovation Solution
A method involving thin, sealed pasta layers with integral meat or vegetable fillings, using a combination of metering, sealing, pasteurizing, and overlapping techniques to minimize thermal damage and preserve freshness, allowing for the production of ready-to-eat lasagne with high meat sauce content and clean layer separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If pasta layers are pre-cooked to decrease cooking time, then cooking time is reduced, but thermal damage to pasta increases
Solution Approach 1:
The pasta layers are pre-assembled into complete lasagne portions with all fillings and sauces before freezing, rather than pre-cooking them. This preliminary assembly allows the product to be ready for quick home preparation without subjecting pasta to premature cooking that would cause thermal damage
Solution Approach 2:
The patent replaces the thermal processing step (pre-cooking) with a mechanical assembly process followed by freezing. The lasagne is assembled in its final structure and then flash-frozen, substituting the harmful thermal pre-cooking with a cold-chain preservation method that maintains pasta quality
2Manufacturing precision
If pasta layers are made thin to improve layer separation, then layer separation is improved, but pasta strength decreases
Solution Approach 1:
The patent specifies precise thickness parameters for pasta layers (0.5-1.5 mm) and controls other parameters such as drying moisture content and protein content to optimize the balance between thinness for layer separation and sufficient strength to prevent breakage during assembly and cooking
Solution Approach 2:
The patent uses composite pasta formulations combining different flours (wheat, rice, corn) and adjusting protein content to create pasta that is both thin and sufficiently strong, leveraging the properties of multiple materials to achieve contradictory requirements
3Manufacturing precision
If integral meat or vegetable pieces are used as fillings, then product quality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the lasagne assembly into discrete operational steps: pasta layer placement, filling application, sauce layering, and stacking. This segmentation of the manufacturing process allows integral pieces to be incorporated systematically without overwhelming complexity
Solution Approach 2:
The patent introduces intermediary components such as béchamel sauce layers and grated cheese that act as binders and separators between pasta and filling layers, facilitating the assembly process and maintaining structural integrity while accommodating integral pieces
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 method results in lasagne with reduced thermal damage, preserved texture, and extended shelf life, enabling clean layer separation and high meat sauce content, similar to fresh lasagne, while simplifying preparation and ensuring hygiene.
Implementation Method 1
The method according to the invention comprises a step of flash-freezing the half-finished food product
Implementation Method 2
heating the food product and ending its cooking stage
Data Source
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AI summary
A method for making lasagne and other ready to eat foods is characterized in that it comprises a step of overlapping semi-finished food products, comprising two pasta layers having a thickness less than 1.2 millimeters, therebetween a meat or other vegetable sauce is arranged, with alternating béchamel or other sauce layers. Independent claims are directed to a half-finished food product for making lasagne.