Triple-Extruded Snack Casing and Filling for High Protein Texture
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Solution Overview
Problem
Existing extruded dough-based snack products face a challenge in balancing high protein content with maintaining a pleasing texture, as higher protein levels often detract from the appealing texture of these products.
Innovation Solution
A triple-extruded bite-size snack product featuring a casing component with at least 6% soy flour protein and a filling component, both triple-extruded with an air die, resulting in a crispy exterior and soft interior, with a weight ratio of 60:40 casing to filling, ensuring a high protein content while maintaining a desirable texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If higher protein levels are increased in extruded dough-based products, then health benefits are improved, but texture appeal deteriorates
Solution Approach 1:
The product is divided into two distinct components: a dough-based casing containing the protein source and a separate filling component. This segmentation allows the casing to provide high protein content (at least 6% protein level from soy flour protein) while the filling provides the creamy, soft texture that maintains consumer appeal. The triple extrusion process with air die creates a distinct separation between these functional components.
Solution Approach 2:
Different regions of the product have different qualities optimized for their specific functions. The casing component is formulated with high protein content (soy flour protein, whole wheat flour, brown rice flour) to meet health requirements, while the filling component is formulated with fats, sugars, and flavorings to provide sensory appeal. This local differentiation resolves the contradiction between health benefits and texture appeal.
2Ease of manufacture
If triple extrusion with air die is used, then texture quality is improved (crispy exterior, soft interior), but device complexity increases
Solution Approach 1:
The extrusion system is segmented into three separate extrusion streams that are combined through the air die: the dough-based casing, the filling material, and air. This segmentation of the extrusion process enables the creation of the dual-texture product with a crispy exterior shell and soft interior filling, as each component is extruded and positioned separately before being combined in the final product structure.
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 product achieves a high protein level of at least 5 grams per 30 grams of product, providing a good source of protein and maintaining a dual texture for an extended period, including a crispy casing and soft filling, which is both appealing and nutritious.
Implementation Method 1
The casing component and filling component are triple extruded with an air die
Data Source
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AI summary
Compositions related to a baked, extruded, bite-size foodstuff comprising a dough-based casing component including at least 6 wt% protein such that at least 5 grams of protein are included in 30 grams of product, wherein the protein is derived from a soy flour; and, a filling component substantially completely surrounded by the casing component, wherein the casing component has a light, crispy texture; and, wherein the weight ratio of the casing component to the filling component in the extruded food stuff is about 60:40.