Tortilla Rollability via Dual Enzyme Starch Modification
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Solution Overview
Problem
Current enzyme solutions for retarding staling in flat breads, such as tortillas, are less suitable for rapid baking times and do not effectively maintain rollability, moistness, and softness over time.
Innovation Solution
The method involves adding a maltogenic alpha-amylase and a beta-amylase to tortilla dough, specifically with at least 70% identity to provided sequences, to improve rollability, moistness, and softness, which are then baked and stored, allowing for better retention of these properties up to 14 days.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional amylases are used to retard staling in flat breads, then starch modification occurs, but the baking time required is too long for rapid flat bread production
Solution Approach 1:
The patent changes the biochemical parameters of the amylase enzyme by selecting specific types (maltogenic alpha-amylase and beta-amylase) that work effectively under rapid baking conditions. These enzymes have optimized catalytic properties that allow sufficient starch modification within the short baking time of flat breads, resolving the contradiction between effectiveness and time requirement
Solution Approach 2:
The patent uses a composite enzyme system combining maltogenic alpha-amylase and beta-amylase together. This composite approach leverages the complementary actions of both enzymes on starch - maltogenic alpha-amylase produces maltogenic oligosaccharides while beta-amylase produces maltose - creating a synergistic effect that retards staling more effectively within the constrained baking time
2Duration of action of stationary object
If tortillas are stored for extended periods, then shelf life increases, but rollability, moistness, and softness deteriorate
Solution Approach 1:
The patent applies preliminary action by adding maltogenic alpha-amylase and beta-amylase to the tortilla dough before baking. These enzymes pre-modify the starch structure during dough preparation and baking, creating a starch matrix that will maintain its properties during storage. This preliminary enzymatic modification ensures that rollability, moistness, and softness are preserved throughout the storage period
Solution Approach 2:
The patent changes the starch biochemical parameters through enzymatic modification, converting native starch into a more stable configuration that resists retrogradation during storage. This parameter change in the starch structure maintains the physical properties of the tortilla (rollability, softness) over extended storage periods while extending shelf life
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 combination of maltogenic alpha-amylase and beta-amylase significantly enhances the rollability, moistness, and softness of tortillas at 7 and 14 days post-baking compared to tortillas made without these enzymes, maintaining quality and shelf life.
Implementation Method 1
adding a maltogenic alpha-amylase (EC 3.2.1.133) and a beta amylase (EC 3.2.1.2) to a flour or to a dough comprising a corn flour
Data Source
AI summary
The present invention deals with a method for improving the rollability of flat breads comprising a) adding a maltogenic alpha-amylase and a beta amylase to a flour or directly to a dough comprising a flour; b) making the dough; and c) making flat breads from the dough.