Patent Description:
Prior art disclosures of analog cheese products may be found in e.g., <CIT>.

Analog cheese, as used in this specification, is a non-dairy food composition intended to mimic a dairy cheese. The described analog cheeses include a plant protein source and other ingredients which combined are intended to provide the functionality of dairy cheese. While analog cheese is known, because plant proteins functions differently than milk protein, present analog cheese products do not provide equivalent protein content to dairy cheese. At least in part this is because at higher protein content it has proved difficult to avoid ingredient separation during analog cheese making, including for example oil separation.

The technology disclosed in this specification pertains to high protein analog cheese and method of making such products. In any embodiment, an analog cheese, as described in this specification has a protein content greater than about <NUM>% by weight or greater than about <NUM>% or greater than about <NUM>% or from about <NUM>% to about <NUM>%, from about <NUM>% to about <NUM>% by weight. Such analog cheese has firmness that is like that of dairy cheese. In any embodiment, an analog cheese, as described in this specification has firmness of greater than about <NUM>, or greater than about <NUM>, from about <NUM> to about <NUM>.

The present invention is defined by the claims and relates to:
An analog cheese comprising:.

wherein, optionally, the protein content is from a pulse protein.

A method of making an analog cheese comprising:.

In any embodiment, an analog cheese, as described in this specification includes a starch component. In any embodiment, a starch component of an analog cheese contains all starch within the analog cheese. In any embodiment starch component of an analog cheese consists of native starch. In any embodiment, an analog cheese as described in this specification does not comprise a modified starch. In any embodiment starch component of an analog cheese consists of native pea starch in an amount greater than about <NUM>% by weight, or greater than about <NUM>%, or greater than about <NUM>%, or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>%. In any embodiment described in this specification an analog cheese comprises a pea starch having an apparent amylose content of from about <NUM>% to about <NUM>% or about <NUM>%.

In any embodiment an analog cheese, as described in this specification, comprises pea starch as the sole native starch in a starch component for the purpose of increasing the firmness of an analog cheese compared to analog cheese using other native or modified starches. In any embodiment, a test analog cheese as described in this specification using a native pea starch has greater than <NUM> times the firmness of a comparative test analog cheese using a native starch other than pea starch, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times. In any embodiment, a test analog cheese as described in this specification using a native pea starch has greater than <NUM> times the firmness of a comparative test analog cheese using an oxidized potato starch, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times. In any embodiment, a test analog cheese as described in this specification using a native pea starch has greater than <NUM> times the firmness of a comparative test analog cheese using a native starch <NUM>% amylose corn starch, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times.

In any embodiment, a test analog cheese as described in this specification using a native pea starch has less oil separation during processing than a test analog cheese using a native starch other than a pea starch. In any embodiment a composition for making an analog cheese comprising native pea starch can be obtained using higher protein content without oil separation being evident than the same composition for making an analog cheese comprising a native starch that is not native pea starch.

In any embodiment of an analog cheese, as described in this specification the protein content of the analog cheese is supplied by a protein component. In any embodiment a protein component for use in an analog cheese, as described in this specification, consists of one or more pulse proteins. Pulse proteins useful for making an analog cheese include but are not limited pea protein, lentil protein, chickpea protein, and fava bean protein. In any embodiment of an analog cheese described in this specification the protein is provided as a pulse protein isolate. In any embodiment, an analog cheese, as described in this specification includes a pea protein in an amount of at least about <NUM>% by weight or at least about <NUM>% or at least about <NUM>%, or of from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>%. In any embodiment, an analog cheese includes a fava bean protein in an amount of at least about <NUM>% by weight or at least about <NUM>% or at least about <NUM>%, or of from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>%. In any embodiment, an analog cheese, as described in this specification includes a pulse protein isolate or a pulse protein concentrate, or a mixture of two pulse protein isolates, or a mixture of pulse protein concentrate and a pulse protein isolate, or a mixture of two pulse protein concentrates. In any embodiment, an analog cheese, as described in this specification includes a protein component having a fava bean protein isolate and a pea protein in a ratio of about <NUM>:<NUM>, or about <NUM>:<NUM>, or about <NUM>:<NUM>, or about <NUM>:<NUM>, or about <NUM>:<NUM>, or about <NUM>:<NUM>. In any embodiment, an analog cheese, as described in this specification includes a protein component, which contains all of the protein in the analog cheese, and which consists of a mixture of a fava bean protein isolate and a pea protein isolate.

In any embodiment, an analog cheese includes a pea starch, a protein component and a third ingredient. A third ingredient may be a liquid ingredient for example, an oil (including but not limited to coconut oil, or other vegetable oil), or water or salt, or an acidulent, for example including but not limited to lactic acid. In any embodiment, an analog cheese as described in this specification has a moisture content of from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>%. A third ingredient may be a hydrocolloid or a gum, or may be gum acacia, xanthan gum, locust bean gum, konjac gum, guar gum, and agar and mixtures thereof. A third ingredient may be salt or lactic acid, or another flavoring agent.

The technology disclosed in this specification pertains to methods of making an analog cheese. In any embodiment, a method of making an analog cheese, as described in this specification includes (a) mixing a first mixture comprising water, a plant protein component, and a pea starch at a first mixing rate, (b) mixing at second mixing rate, which is less than the first mixing rate, an oil and the first mixture to form a second mixture, (c) mixing at a third mixing rate, which is less than the second mixing rate, lactic acid with the second mixture to form a third mixture, (d) heating the third mixture and (e) allowing the third mixture to cool. In any embodiment, a method for making an analog cheese, as described in this specification includes hydrating a gum or mixture of gums in an aqueous solution at a first mixing rate.

In any embodiment, a method for making an analog cheese, as described in this specification includes mixing a mixture at a first mixing rate of from about <NUM> to about <NUM> revolutions per minute ("RPM") RPM, or from about <NUM> to about <NUM> RPM, or from about <NUM> to about <NUM> RPM or from about <NUM> to about <NUM> RPM, or from about <NUM> to about <NUM> RPM. In any embodiment, a method for making an analog cheese, as described in this specification includes mixing a mixture at a second mixing rate of from about <NUM> RPM to about <NUM> RPM, or from about <NUM> RPM to about <NUM> RPM, or from about <NUM> RPM to about <NUM> RPM or from about <NUM> RPM to about <NUM> RPM. In any embodiment, a method for making an analog cheese, as described in this specification includes mixing a mixture at a third mixing rate of from about <NUM> RPM to about <NUM> RPM, or from about <NUM> RPM to about <NUM> RPM, or from about <NUM> RPM to about <NUM> RPM.

In any embodiment, a method for making an analog cheese, as described in this specification includes heating a mixture for from about <NUM> to about <NUM> seconds, or from about <NUM> to about <NUM> seconds, or from about <NUM> to about <NUM> seconds, or from about <NUM> to about <NUM> seconds, or from about <NUM> to about <NUM> seconds. In any embodiment, a method for making an analog cheese, as described in this specification includes mixing a mixture at from about <NUM> RPM to about <NUM> RPM, or from about <NUM> RPM to about <NUM> RPM, or from about <NUM> RPM to about <NUM> RPM while heating the mixture. In an embodiment, a method of making an analog cheese, as described in this specification, heats a mixture at a temperature of from about <NUM>° to about <NUM>° C, or from about <NUM>° to about <NUM>° C, or from about <NUM>° C to about <NUM>°. In any embodiment, of the methods described in this specification a mixture is heated by applying direct or indirect heat, either using for example but not limited to electrical heating or steam heating or other method of heating the mixture within the mixer.

In any embodiment, a method of making an analog cheese as described in this specification is useful for making an analog cheese from any formulation described in this specification. In any embodiment, a method of making an analog cheese, as described in this specification substituting on a one for one basis a native pea starch for all native starch, such methods being useful for preventing separation of liquid and solid ingredients during making the analog cheeses, and being useful for increasing the firmness of an analog cheese.

Reference in this specification to "analog cheese" refers to a non-dairy food composition intended to mimic dairy cheese. The analog cheese described in this specification may mimic any target dairy cheese in texture and flavor, but in some embodiments analog cheese is intended to mimic semi-soft to hard cheese including for example commercially available Cheddar cheese sticks or cubes.

Reference in this specification to a "test analog cheese" means an analog cheese product, which is not according to the present invention, having the formula of Table <NUM>.

Reference in this specification to "a test method of making an analog cheese" means use of the following method to make an analog cheese from the formula for making a test analog cheese. <NUM>) Mix gum hydrated in water in a cooking mixer (e.g. from Stephan Machinery) for <NUM> minutes at <NUM> RPM; <NUM>) add remaining dry ingredients (protein, starch, and salt) and blend for <NUM> minutes at <NUM> RPM; <NUM>) add oil and mix for <NUM> minutes at <NUM> RPM; <NUM>) add lactic acid and blend for <NUM> seconds at <NUM> RPM; <NUM>) heat mixture using direct steam to <NUM>° F (about <NUM>° C) and hold for <NUM> seconds at <NUM> RPM; and <NUM>) collect product and cool.

Reference in this specification to a "pulse protein isolate" means a composition obtained from a milled pulse that is substantially plant protein. Pulses, which are the seeds of legumes, include peas, fava beans, chickpeas, and lentils, among other things. Pulses, as seeds, comprise starch, protein, and fiber, and frequently (but not necessarily) comprise greater than <NUM>% starch and only around <NUM>% protein. Once milled, the components of the pulse flour can be separated to be substantially pure. Within this specification, a pulse protein isolate comprises greater than about <NUM>% protein by weight.

Reference in this specification to a "pulse protein concentrate" means a composition obtained from a milled pulse that is has increased plant protein content than would the unmilled pulse but less protein than a protein isolate. Within this specification, a pulse protein concentrate comprises from about <NUM>% to less than about <NUM>% protein by weight.

Reference in this specification to "native starch" means granular, unmodified starch. Starch being obtained by milling starch-containing plant parts may comprise trace amounts of other materials including but not limited to protein and fiber. Native starches for use in analog cheese are food grade starches and have starch content of at least about <NUM>% starch by weight.

Within this specification, firmness is measured using a texture analyzer. In any embodiment, measurements can be made on refrigerated (about <NUM>° C) blocks of analog cheese having height of about <NUM> to <NUM> millimeters or cores of analog cheese samples. In any embodiment a sample can be measured using the following procedure: measure sample using a TAXT II Plus Texture Analyzer and Exponent software equipped with a <NUM> load cell by a two-compression test with TA-<NUM><NUM> aluminum cylinder probe (<NUM>/sec pre-test, test, and post-test speed, <NUM> compression distance, <NUM> second test rate, <NUM> trigger force).

The technology is further described in the following aspects, which are intended to be illustrative, and are not intended to limit the full scope of the claims and their equivalents.

In a first aspect, the technology disclosed in this specification pertains to an analog cheese comprising protein content greater than about <NUM>% by weight or greater than about <NUM>% or greater than about <NUM>% or from about <NUM>% to about <NUM>%, from about <NUM>% to about <NUM>% by weight, and a native pea starch in an amount greater than about <NUM>% by weight, or greater than about <NUM>%, or greater than about <NUM>%, or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>%.

In a second aspect, the technology disclosed in this specification pertains to the analog cheese of the first aspect wherein the cheese has a firmness of greater than about <NUM>, or greater than about <NUM>, or from about <NUM> to about <NUM>.

In a third aspect, the technology disclosed in this specification pertains to the analog cheese of the first or second aspect wherein the protein content is from a pulse protein.

In a fourth aspect, the technology disclose in this specification pertains to the analog cheese of any one of the first to third aspect wherein the protein is provided as a protein component comprising a pea protein (as a first pulse protein) and protein in an amount of at least about <NUM>% by weight or at least about <NUM>% or at least about <NUM>%, of from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>% and a second pulse protein.

In a fifth aspect, the technology disclosed in this specification pertains to the analog cheese of any one of the first to fourth aspects wherein the protein is provided as a protein component comprising a fava bean protein in an amount of at least about <NUM>% by weight or at least about <NUM>% or at least about <NUM>%, of from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>% and a second pulse protein.

In a sixth aspect, the technology disclosed in this specification pertains to the analog cheese of any one of the first to fifth aspects wherein the protein is provided as a protein component consisting of one of a pea protein and a mixture of a fava bean protein and a pea protein, and optionally wherein the fava bean protein and pea protein are used in a ratio of from <NUM>:<NUM> (fava bean to pea), or about <NUM>:<NUM>, or about <NUM>:<NUM>, or about <NUM>:<NUM>, or <NUM>:<NUM>, or about <NUM>:<NUM>.

In a seventh aspect, the technology disclosed in this specification pertains to the analog cheese of any one of the first to sixth aspects further having a moisture content of from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>%.

In an eighth aspect, the technology disclosed in this specification pertains to the analog cheese of any one of the first to seventh aspects further comprising a gum selected from the group consisting of acacia, xanthan, locust bean and mixtures thereof.

In a ninth aspect, the technology disclosed in this specification pertains to the analog cheese of any one of the first to eighth aspects, which does not comprise a modified starch.

In a tenth aspect, the technology disclosed in this specification pertains to a method of making an analog cheese comprising (a) mixing a first mixture comprising water, a plant protein component, and a pea starch at a first mixing rate, (b) mixing at second mixing rate, which is less than the first mixing rate, an oil and the first mixture and to form a second mixture, (c) mixing at a third mixing rate, which is less than the second mixing rate, lactic acid with the second mixture to form a third mixture, (d) heating the third mixture at a temperature of from about <NUM>° to about <NUM>° C, or from about <NUM>° to about <NUM>° C, or from about <NUM>° C to about <NUM>° C and (e) allowing the third mixture to cool, optionally wherein the analog cheese has a protein content of greater than about <NUM>% by weight or greater than about <NUM>% or greater than about <NUM>% or from about <NUM>% to about <NUM>%, from about <NUM>% to about <NUM>% by weight.

In an eleventh aspect, the technology disclosed in this specification pertains to the method of the tenth aspect wherein the pea starch is used in an amount greater than about <NUM>% by weight, or greater than about <NUM>%, or greater than about <NUM>%, or from about <NUM>% and about <NUM>% or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>%.

In a twelfth aspect, the technology disclosed in this specification pertains to the method of the tenth or eleventh aspects wherein protein component consists of a fava bean protein and a pea protein, and optionally wherein the fava bean protein and pea protein are used in a ratio of from <NUM>:<NUM>, or about <NUM>:<NUM>, or about <NUM>:<NUM>, or about <NUM>:<NUM>, or <NUM>:<NUM>, or about <NUM>:<NUM>.

In a thirteenth aspect, the technology disclosed in this specification pertains to the method of any one of the tenth to twelfth aspects further comprises, prior to mixing the first mixture, hydrating a gum in an aqueous solution at the first mixing rate.

In a fourteenth aspect, the technology disclosed in this specification pertains to the method of any one of the tenth to thirteenth wherein the gum selected from the group consisting of acacia, xanthan, locust bean and mixtures thereof.

In a fifteenth aspect, the technology disclosed in this specification pertains to the method of any one of the tenth to fourteenth aspects wherein the first mixing rate is from about <NUM> to about <NUM> RPM, or from ab out <NUM> to about <NUM> RPM, or from about <NUM> to about <NUM> RPM or from about <NUM> to about <NUM> RPM, or from about <NUM> to about <NUM> RPM.

In a sixteenth aspect, the technology disclosed in this specification pertains to the method of any one of the tenth to fifteenth aspects wherein the second mixing rate is from about <NUM> RPM to about <NUM> RPM, or from about <NUM> RPM to about <NUM> RPM, or from about <NUM> RPM to about <NUM> RPM or from about <NUM> RPM to about <NUM> RPM.

In a seventeenth aspect, the technology disclosed in this specification pertains to the method of any one of the tenth to sixteenth aspects wherein the third mixing rate is from about <NUM> RPM to about <NUM> RPM, or from about <NUM> RPM to about <NUM> RPM, or from about <NUM> RPM to about <NUM> RPM.

In an eighteenth aspect, the technology disclosed in this specification pertains to the method of any one of the tenth to seventeenth aspects wherein the mixture is heated for from about <NUM> to about <NUM>, or from about <NUM> to about <NUM> seconds, or from about <NUM> to about <NUM> seconds, or from about <NUM> to about <NUM> seconds, or from about <NUM> to about <NUM> seconds.

In a nineteenth aspect, the technology disclosed in this specification pertains to the use of a native pea starch as described in any foregoing claims to increase the firmness of a high protein analog cheese.

In a twentieth aspect, the technology disclosed in this specification pertains a method for increasing the firmness of an analog cheese comprising: (a) a starch component of native starches, the method comprising substituting on a one for one basis a native pea starch for all native starch, and (b) making an analog cheese using a method comprising (i) mixing a first mixture comprising water, a plant protein component, and a pea starch at a first mixing rate, (ii) mixing at second mixing rate, which is less than the first mixing rate, an oil and the first mixture and to form a second mixture, (iii) mixing at a third mixing rate, which is less than the second mixing rate, lactic acid with the second mixture to form a third mixture, (iv) heating the third mixture at a temperature of from about <NUM>° to about <NUM>° C, or from about <NUM>° to about <NUM>° C, or from about <NUM>° C to about <NUM>° C and (v) allowing the third mixture to cool, optionally wherein the analog cheese has a protein content of greater than about <NUM>% by weight or greater than about <NUM>% or greater than about <NUM>% or from about <NUM>% to about <NUM>%, from about <NUM>% to about <NUM>% by weight.

In a twenty-first aspect, the technology disclosed in this specification pertains to the twentieth aspect wherein the analog cheese is a test analog cheese that was made by a test method of making an analog cheese, and wherein the test analog cheese comprising pea starch has greater than <NUM> times the firmness of a comparative test analog cheese using a native starch other than pea starch, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times.

In a twenty-second aspect, the technology disclosed in this specification pertains to the method of claims twenty or twenty-first aspects wherein the analog cheese is a test analog cheese that was made by a test method of making an analog cheese, and wherein the test analog cheese comprising pea starch has greater than <NUM> times the firmness of a comparative test analog cheese using a native starch <NUM>% amylose corn starch, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times, or greater than about <NUM> times. The technology is further described by the following examples, which are intended to be illustrative and are not intended to limit the full scope of the claims or their equivalents.

Analog cheeses were made using various starches and various amount of starch and were evaluated for firmness using refrigerated (about <NUM>° C) blocks of analog cheese having heights of about <NUM> to <NUM> millimeters. Samples were measured using a TAXTII Plus Texture Analyzer and Exponent software equipped with a <NUM> load cell by a two-compression test with TA-<NUM><NUM> aluminum cylinder probe (<NUM>/sec pre-test, test, and post-test speed, <NUM> compression distance, <NUM> second test rate, <NUM> trigger force).

An analog cheese was made as follows. Gum mix was hydrated in water in a cooking mixer available from Stephan Machinery for <NUM> minutes at <NUM> RPM. Remaining dry ingredients (protein, starch, and salt) were added and the mixture was blended for <NUM> minutes at <NUM> RPM. Oil was added and mixed for <NUM> minutes at <NUM> RPM. Lactic acid was added and blended for <NUM> seconds at <NUM> RPM. The mixture was heated using direct steam to <NUM>° F (about <NUM>° C) and held for <NUM> seconds at <NUM> RPM. The product was collected and cooled.

The formula reported in Table <NUM> was used to make <NUM>% protein analog cheeses.

Using the formula of Table <NUM> and foregoing method, analog cheeses were made using various starches. The analog cheeses were measured for firmness. The results are reported in Table <NUM>.

As shown in Table <NUM> analog cheeses made from native pea starch (Sample <NUM>) were firmer from analog cheeses made using other native starches (<NUM>, <NUM>-<NUM>). Also as shown, the analog cheeses made from native pea starch had similar firmness to starches made from crosslinked potato starch, but were firmer than analog cheeses made using oxidized potato starch.

Also, it was observed that during processes analog cheese batters made using pea starch suffered from less oil separation than was observed for analog cheese using native potato starch or native tapioca starch. With reference to <FIG> this can be seen in the oil sheen on the <FIG> (potato starch) and <FIG> (tapioca starch) samples, which is not seen on the pea starch sample, <FIG>.

Analog cheeses using various amounts of pea starch were made using the formula of Table <NUM> except water content was reduced to account for increased pea starch. For example a <NUM>% pea starch analog cheese used <NUM>% water, and an analog cheese made using <NUM>% pea starch had <NUM>% water. The firmness of analog cheese using <NUM>%, <NUM>%, and <NUM>% pea protein is reported in Table <NUM>.

Analog cheeses using various proteins and protein amounts were analyzed for firmness. All samples were made from formulations based on that of Table <NUM> but with reduced amounts of water as protein content increased. Table <NUM> shows the effect of increasing protein content while maintaining the ratio of pea protein to fava bean protein.

Claim 1:
An analog cheese comprising:
a protein content greater than about <NUM>% by weight or greater than about <NUM>% or greater than about <NUM>% or from greater than about <NUM>% to about <NUM>%, or from greater than about <NUM>% to about <NUM>% by weight, and
a native pea starch in an amount greater than about <NUM>% by weight, or greater than about <NUM>%, or greater than about <NUM>%, or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>% or from about <NUM>% to about <NUM>%
wherein, optionally, the protein content is from a pulse protein.