Whole-Grain Thermal Inhibition for Lower-Hexanal Flour
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Solution Overview
Problem
Existing methods for thermally inhibiting flour result in higher hexanal content due to lipid oxidation, leading to off tastes and reduced shelf life, especially when high heat and long heating times are applied to flour after milling.
Innovation Solution
A method involving dehydrating whole grains to less than 5% moisture, followed by heat treatment at 120° C to 180° C, and optionally adjusting pH before milling, to produce thermally inhibited flour with reduced hexanal content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high heat and long heating times are applied to flour after milling to thermally inhibit it, then thermal inhibition is achieved, but lipid oxidation increases producing higher hexanal content and off tastes
Solution Approach 1:
The patent applies thermal inhibition treatment to the whole grain before milling rather than after. This preliminary action on the grain structure prevents lipid oxidation during subsequent storage and processing, achieving thermal inhibition without generating harmful hexanal compounds that would form if treatment were applied to milled flour.
Solution Approach 2:
The patent converts the potential harm of thermal inhibition (which causes lipid oxidation and hexanal formation when applied to flour) into a benefit by applying it to whole grain instead. This transforms the process into one that prevents oxidation rather than causing it, eliminating the harmful effect while maintaining the desired thermal inhibition stability.
2Stability of the object's composition
If high heat and long heating times are applied to flour after milling to thermally inhibit it, then thermal inhibition is achieved, but shelf life is reduced due to oxidation
Solution Approach 1:
By applying thermal inhibition to the whole grain before milling, the patent prevents lipid oxidation from occurring during storage. This preliminary treatment establishes stability in the grain structure before it is milled, ensuring longer shelf life while maintaining thermal inhibition properties.
Solution Approach 2:
The patent transforms the harmful effect of thermal inhibition (oxidation and reduced shelf life when applied to flour) into a beneficial process by applying it to whole grain. This converts a harmful action into a protective one, preventing oxidation and extending shelf life while achieving thermal inhibition.
3Stability of the object's composition
If thermal inhibition is applied to flour after milling, then thermal inhibition is achieved, but hexanal content is higher immediately after milling
Solution Approach 1:
The patent applies thermal inhibition to the whole grain before milling, which prevents the formation of hexanal compounds during subsequent storage and processing. This preliminary treatment ensures that the flour produced has lower hexanal content immediately after milling, while still achieving the desired thermal inhibition stability.
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 produces flour with at least 50% less hexanal immediately after milling and maintains lower hexanal levels over time, extending shelf life and improving flavor stability.
Implementation Method 1
The dehydration step will occur at a temperature of between about 80° C. and about 100° C. for between about 1 hour and about 24 hours
Implementation Method 2
The grain is then heat treated at a second temperature between about 120° C. to about 180° C. for between about 1 hour and 20 hours
Data Source
AI summary
A method of thermally inhibiting starch or flour is provided. The method involves thermally or non-thermally dehydrating a grain to anhydrous or substantially anhydrous, and then heat treating this dehydrated grain. The heat treated dehydrated grain is then milled, producing thermally inhibited flour and/or starch. Using this method, the shelf life of the resulting thermally inhibited whole grain flour is extended compared whole grain flours that are thermally inhibited after milling. The foregoing methods applied to starch (following milling of the grain) resulted in starch whiter than obtainable using prior art methods.