Two-Stage Fermentation Mushy Mass for Controlled Porosity
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Solution Overview
Problem
Existing methods for producing vegetarian and vegan batter dishes, such as idli, face issues with porosity, elasticity, and glycemic index, leading to unsatisfactory results and challenges in industrial-scale production due to the spontaneous formation of acidifying cultures which can include pathogenic microorganisms and result in rapid blood sugar spikes.
Innovation Solution
A method involving a two-stage fermentation process where cereals, pseudo cereals, pulses, and oilseeds are allowed to swell and then wet-ground, followed by separate acid and gas formation fermentations using specific microorganisms to create a mushy mass with high porosity and elasticity, allowing for controlled acidification and gas formation, and maintaining consistency throughout the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spontaneous acidifying cultures are used for fermentation, then the process is simple and traditional, but pathogenic microorganisms may occur and product quality is unsatisfactory
Solution Approach 1:
The single spontaneous fermentation process is segmented into two distinct controlled fermentation stages: first fermentation using a defined acidifying culture (Lactobacillus delbrueckii subsp. bulgaricus and Streptococcus thermophilus) for 8-12 hours to achieve pH 4.0-4.5, and second fermentation using a defined leavening culture (Saccharomyces cerevisiae) for 15-30 minutes to achieve volume increase. This segmentation eliminates pathogenic microorganisms while maintaining process control and product quality.
2Device complexity
If traditional fermentation methods are used, then the process is simple, but porosity and elasticity of the dish are inadequate
Solution Approach 1:
The first fermentation stage performs preliminary acidification of the batter to pH 4.0-4.5 before the second fermentation stage. This preliminary action creates optimal conditions for the leavening microorganisms to produce CO2 gas, which forms the porous structure. The acidified environment also enhances the elasticity of the final product by modifying the starch and protein structures in advance.
3Use of energy by moving object
If carbohydrates are rapidly digested, then energy is quickly available, but blood sugar level increases rapidly and then drops rapidly
Solution Approach 1:
The fermentation process fundamentally changes the chemical parameters of the carbohydrates in the batter. Lactic acid bacteria convert simple sugars into lactic acid, and yeast converts sugars into alcohol and CO2. This transformation creates a complex matrix of fibers, proteins, and fermented compounds that slow down carbohydrate digestion and glucose absorption, preventing rapid blood sugar spikes while still providing energy.
4Ease of operation
If ground products are added between fermentations, then consistency can be adjusted, but the mushy mass consistency changes and uniformity is lost
Solution Approach 1:
The process uses feedback control by measuring the pH level after the first fermentation (targeting pH 4.0-4.5) and the volume increase during the second fermentation (targeting 1.5-2.5 times expansion). These feedback measurements ensure that the fermentation processes are complete before proceeding to cooking, maintaining consistent composition without needing to add ground products that would disrupt uniformity.
Data Source
AI summary
The present invention relates to a method for producing a mushy mass having preferably high porosity and/or elasticity, using (pseudo) cereals, pulses and/or oilseeds. The mushy mass is suitable for producing a very porous, very elastic, non-sticky dish. The present invention therefore also relates to dishes that can be produced by way of methods that are particularly suitable for people with specific health needs.