Egg jerky product and method of preparation

There is disclosed a product and a process for preparing a jerky-type product from whole eggs, flavoring ingredients and with or without added textured vegetable protein. A fluid mixture containing at least about 35% by weight of hydrated whole eggs is coagulated as a flat sheet having an average thickness of about 1 to 10 millimeters. The coagulated flat sheet is dried to a moisture level of 18 to 24% by weight having a water activity below 0.8. There is obtained a final product of elongated strips characterized by a flexible, deformable and chewy condition.

FIELD OF INVENTION, BACKGROUND, AND PRIOR ART 
The field of this invention is the preparation of jerky-type products, and 
more particularly products of this kind which can be prepared without 
using meat as an essential ingredient. Meat jerky products are a well 
known type of snack food. They are marketed in sticks or strips which can 
be stored without refrigeration. These products have a moisture content at 
which they are storable while retaining a malleable, chewy character. They 
are usually very highly seasoned, and commonly are smoked or have added 
smoke flavor. They are packaged in moisture-retaining casings or wrappers 
to maintain the desired consistency. 
While the formulas of such products have varied with respect to ingredients 
and proportions, it is believed that jerky-type products have heretofore 
included meat as a principal ingredient, and they have not, as far as is 
known, included eggs as an essential component of the formula. 
SUMMARY OF INVENTION 
This invention is based on the discovery that a simulated meat jerky 
product can be prepared without using meat as an ingredient, providing 
that whole eggs are used as a major component. Surprisingly, a chewy 
malleable texture can be obtained by forming the base mixture into sheets 
or other shapes, applying heat to coagulate the egg protein, and drying 
the sheets or strips made therefrom to a storable moisture content. The 
texture is further improved by incorporating textured vegetable protein. 
By adding flavoring ingredients to the base mix of the kind used in jerky 
products, a taste very similar to that of meat jerky products can be 
obtained. The products can be packaged in vapor retaining packages and 
marketed in a manner similar to meat jerky. 
The novel method of this invention can be used to produce a highly 
nutritious shelfstable snack item in which the eggs provide a rich source 
of high-quality protein. In comparison to beef jerky, the egg jerky 
products of this invention can be produced at a lower ingredient cost. 
Relatively low cost egg sources can be used such as pasteurized whole 
frozen eggs. The egg jerky products can be smoked or smoke added to the 
formula as with meat jerky products.

DETAILED DESCRIPTION 
A preferred formula for the egg jerky products of this invention is as 
follows: 
______________________________________ 
General Formula 
Ingredients Wt. % 
______________________________________ 
Whole eggs 35-65 
Textured vegetable protein 
10-30 
Jerky seasonings 15-35 
______________________________________ 
It is believed to be important to employ whole eggs, including both egg 
protein and egg lipid components. When whole eggs are employed in the 
amounts specified, some additional egg whites may be added. The preferred 
formulas utilize only egg ingredients in the form of uncooked hydrated 
whole eggs. If dried whole eggs are used, they should be rehydrated before 
use. From the standpoint of cost and convenience, pasteurized whole frozen 
eggs are advantageous. 
The textured vegetable protein (TVP) selected from the commercial products 
currently available in which the vegetable protein, such as soy protein, 
has been processed, such as by extrusion, to impart a fibrous structure. 
Textured soy protein (TSP) is preferred. Such TVP products are prepared by 
extruding vegetable meals of high protein content (viz. soybean, peanut, 
and cottonseed meals) under head and pressure to restructure the protein 
to a fibrous condition. See U.S. Pat. Nos. 3,940,495; 3,480,442; and 
3,488,770. Commercial TVP products are available from Ralston Purina 
Company, St. Louis, MO, and ADM Company, Minneapolis, MN. In certain 
embodiments the textured vegetable protein can be omitted, since the whole 
eggs provide a chewy type consistency when processed as described herein. 
The seasoning ingredients are those commonly employed in jerky products, 
such as beef jerky. They include spices like paprika, coriander, black 
pepper, etc. Salt may be added and may be hickory flavored slat, and also 
monosodium glutamate (MSG) may be used. Vegetable seasonings may be used 
such as onion powder, chili powder, etc. as well as prepared seasonings 
like Worcestershire sauce and soy sauce. Sweetening ingredients may be 
included such as corn syrup. Smoke flavor may be obtained by adding liquid 
smoke, or by smoking the product. For protection against microbial 
contamination, calcium propionate may be added to the base mixture, or the 
products may be dipped in a potassium sorbate or lysozyme solution. 
As a first step in the process, a blended fluid mixture is prepared 
consisting essentially of uncooked hydrated whole eggs, textured vegetable 
protein, and flavoring ingredients. The mixture should contain at least 
1.5 parts of the eggs per part of TVP, and preferably at least 2.0 parts. 
In one procedure, the liquid whole eggs are blended, and then the 
seasoning ingredients are added, which may be in the form of a dry spice 
mix or a liquid spice mix. If the textured vegetable protein is 
dehydrated, it should be rehydrated, and thereafter added to the egg-spice 
mixture. After further mixing and blending, the formulation is ready to be 
further processed. 
The fluid mixture formed as described above can be formed into flat sheets 
or strips either manually or mechanically. For example, shallow trays can 
be used to provide the means for forming the mixture into sheets. The 
thickness of the sheets can be controlled by the depth of the mix. In 
general, it is desirable to produce thin sheets, such as sheets of a 
thickness less than 20 millimeters. To permit the sheets to be handled, a 
thickness of at least 1 mm is desirable. The general range of advantageous 
thickness is from 1 to 10 mm, such as 2 to 5 mm. As the next step in the 
method, the mix is heated to solidify and integrate the sheets. In 
general, the heating should be at a non-burning temperature sufficient to 
coagulate the egg protein. Suitable temperatures range from about 
150.degree. to 200.degree. F., depending on the time of heating. It may be 
advantageous to use a two stage heating, such as an initial heating at a 
temperature of around 200.degree. F. for a time of from 10 to 20 minutes 
to coagulate the egg, followed by a longer heating such as at a 
temperature of around 150.degree. F. for several hours, to evaporate 
water. The degree of heating should not be such as to produce undue 
discoloration or offtastes due to burning of the protein or lipids. After 
a first period of heating, it may be desirable to turn the sheets for 
subsequent drying. The heating and drying should be controlled, to avoid 
forming tough or case hardened surface layers. 
On completion of the coagulation and integration of the mix in sheet form, 
the sheets may be cut into strips for further processing. The cut strips 
can then be subjected to a drying operation. The drying should be carried 
out at a temperature and with drying equipment which avoids alteration of 
the character of the products. The drying is for water removal and not for 
cooking. Temperatures no more than 135.degree.-150.degree. F. are 
desirable. Even lower temperatures can be used with vacuum drying. The 
drying is carried to a point at which the moisture content of the sheets 
or strips is in the range from about 18 to 24% by weight. To assure 
stability under non-refrigerated storage, the water activity should be 
below 0.8. 
In one procedure, the sheets are partially dried to an intermediate 
moisture content above 24%, and then the sheets are sliced or cut into 
strips. The strips are then subjected to further drying to the moisture 
content and water activity specified above. This procedure has the 
advantage of producing strips with edges which are sealed and have the 
same appearance as the top and bottom of the strips. However, in general, 
the sheets may be sliced into strips before, during, or after drying. 
Where smoke flavor has not been added to the mix before formation of the 
strips, they may be smoked in a smokehouse. On completion of smoking, the 
strips should have the moisture content and water activity specified 
above. 
The products resulting from the process described have physical properties 
which simulate meat jerky products such as beef jerky. The egg jerky 
strips are in a flexible, deformable, chewy condition, and can be 
maintained in this condition by proper packaging. A vapor-impermeable 
packaging material should be used, which may be in the form of bags, 
envelopes, or casings. Vacuum packaging may be desirable. 
A presently preferred embodiment of the method of this invention is as 
follows: 
______________________________________ 
Mix Formula 
Ingredients Parts by Weight 
______________________________________ 
Whole homogenized eggs 
148 
Textured soy protein 
61.1 
Worcestershire sauce 
19.4 
Soy sauce 13.0 
Onion powder 0.9 
Chili powder 1.4 
Monosodium glutamate 
0.3 
Paprika 0.4 
Beef flavoring 5.9 
Coriander 0.3 
Black pepper 1.2 
Dark corn syrup 14.1 
Liquid smoke 26.6 
Hickory flavored salt 
0.8 
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The above ingredients are blended to form a substantially homogeneous 
mixture. The completed mix is then poured into greased pans (12 
in..times.10 in.) to approximate depth of 3.0 mm. The pans are baked in a 
conventional oven for 15 minutes at 200.degree. F. At this point, the 
sheets are sufficiently integrated to permit them to be removed from the 
pans. The sheets can be sliced, or the sheets can be dried, and sliced 
after drying. For example, the drying may be carried out in a conventional 
oven at a temperature of around 150.degree. F., the drying being continued 
for several hours, such as for 5 hours, or until the moisture content is 
around 22% by weight. The final water activity is preferably in the range 
from 0.6 to 0.7. As an alternative to oven drying, the integrated sheets, 
or cut strips, may be dried in a smokehouse, such as at a temperature of 
around 134.degree. F. for 6 to 7 hours. If smokehouse drying is to be 
used, liquid smoke can be omitted from the mix. The completed sheets or 
strips should be flexible and be deformable to provide a definite chewy 
character when eaten. 
In the formula set out above, and following the process conditions as 
described, including the conventional oven drying, products were obtained 
having average moisture contents of around 22% and an average water 
activity (A.sub.w) of 0.655. These figures were based on averages of 
several determinations. 
The above formula can be modified by omitting the textured soy protein and 
correspondingly increasing the amount of whole eggs. Processing is 
otherwise identical.