Vegan Snack Matrix Vacuum Compaction for Uniform Strand Production
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Solution Overview
Problem
The existing methods for producing vegan snacks face challenges in achieving consistent texture and scalability, as they are often produced manually, leading to variations in size and length, and are not suitable for industrial processing due to texture requirements.
Innovation Solution
A method involving the creation of a legume-based vegan matrix using a combination of vegetable oil, starch, thickener, water, vegetable protein, vegetable flour, salt, and emulsifier, processed using a vacuum filling machine and filling flow divider to achieve uniform strands, followed by cooking, cooling, and ripening to achieve the desired texture and consistency for industrial production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual production method is used, then flexibility in production is maintained, but manufacturing precision and productivity are reduced
Solution Approach 1:
The patent modifies the physical-chemical parameters of the vegan matrix by adjusting the ratio of binding agents (starch, protein, hydrocolloids) and processing conditions (temperature, pressure, humidity) to achieve optimal extrudability and dimensional stability for machine production while maintaining product uniformity
Solution Approach 2:
The patent employs composite material formulations combining multiple binding agents (starch, plant proteins, hydrocolloids like guar gum or carrageenan) with fat substitutes and flavorings to create a matrix that simultaneously provides manual handling flexibility and machine-processing uniformity
2Ease of manufacture
If manual production method is used, then production simplicity is maintained, but productivity is reduced
Solution Approach 1:
The patent replaces manual mechanical assembly with automated extrusion and molding systems that form vegan snacks from processed matrix material, enabling high-volume production while maintaining product consistency through controlled mechanical processes
Solution Approach 2:
The patent performs preliminary processing of the vegan matrix including pre-cooking, pre-seasoning, and pre-forming operations to prepare the material for rapid automated assembly and finishing, thereby increasing overall production throughput
3Productivity
If industrial processing is implemented, then productivity is improved, but texture requirements become more difficult to meet
Solution Approach 1:
The patent optimizes processing parameters including extrusion temperature, pressure profiles, moisture content, and cooking conditions to maintain authentic vegan snack texture while enabling high-volume automated production through precise control of rheological properties
Solution Approach 2:
The patent introduces intermediate processing steps such as steam injection, controlled cooling zones, and anti-sticking coatings on machinery surfaces to prevent texture degradation during automated processing while maintaining production efficiency
4Productivity
If uniform texture for machine processing is provided, then productivity is improved, but product variability increases
Solution Approach 1:
The patent implements feedback control systems with sensors that monitor matrix viscosity, moisture content, and temperature during processing, automatically adjusting parameters to maintain product consistency while enabling continuous high-volume production
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
Enables the production of vegan snacks with consistent texture and appearance, suitable for large-scale industrial processing, ensuring uniformity and extended storage at room temperature by controlling aw value and processing conditions.
Implementation Method 1
Conveying the vegan matrix as the first vegan food product to a filling flow divider under a pressure provided by a rotary vane pump
Implementation Method 2
Pouring the vegan matrix into a filling funnel of a vacuum filling machine, Compacting the vegan matrix in the vacuum filling machine
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for producing a vegan food product, wherein a vegan matrix 1 is produced by mixing vegetable oil, starch, thickener, water, vegetable protein, vegetable flour, salt and emulsifier, the vegan matrix 1 is filled into a filling hopper 2 of a vacuum filling machine 3, the vegan matrix 1 is compacted in the vacuum filling machine 3, the vegan matrix 1 is conveyed as the first vegan food product to a filling flow divider 4 under a pressure provided by a rotary vane pump in the vacuum filling machine 3, the first vegan food product 1 is divided into at least two strands of a second vegan food product 5 in the filling flow divider 4, and the strands are separated from the filling flow divider as third vegan food products, the strands each having a round profile.