Patent Description:
With growing consumer awareness of issues such as climate change; sustainability and animal rights matters arising from practices such as fish farming and aquaculture; and unwanted toxins associated with harvested fish, there is a growing desire for edible seafood analog products, also known as imitation seafood.

However, many available analog products do not sufficiently resemble the seafood sought to be imitated. For example, some fish analog products are made from an extruded paste that fails to adequately mimic the texture, taste, and/or appearance of the target fish. Such analogs may also require different methods of preparation prior to consumption. Such differences between the analogs and their target seafood products make the analogs less appealing to consumers, who may thus still prefer to purchase, prepare and/or consume real fish.

The present disclosure is primarily directed to a salmon analog product, such as a cut of salmon steak or fillet, and an associated method, system and mold for use in making the analog product. However, it will be appreciated that the teachings herein are similarly applicable to form other seafood analogs.

<CIT> describes a method for providing a crab leg/crab claw-like fish paste product, including the steps of: providing a mold where a concave recessed portion having a shape corresponding to a product shape is formed; producing a fibrous core from raw ground fish meat; placing the fibrous core inside the concave recessed portion; coating the fibrous core with raw ground fish meat inside the concave recessed portion to form a coating; and steaming the fibrous core on which the coating has been formed with the fibrous core in the concave recessed portion.

<CIT> describes the use of hydrocolloid gels or films as structural components of meat analog food products.

<CIT> describes a process for producing "cookable", fibrous meat analogs employing directional freezing. The process includes subjecting an ingestible hydrocolloid to directional freezing for inducing formation of elongated ice crystals in which the elongated ice crystals are aligned in a given direction in the directionally frozen hydrocolloid. Following this, elongated ice crystals are removed and are replaced by proteins and any other additives such as supplements which are located in the aligned channels originally containing the aligned ice crystals. Once the desired amount of protein loading is achieved, the protein-loaded hydrocolloid is subjected to conditions suitable to induce gelling of some of proteins to form protein gels in the aligned elongated channels.

<CIT> describes scalable methods for the production of artificial meat products that mimic the appearance, texture, and mouthfeel (ATM) of natural meat cuts. These methods involve providing multiple building blocks of edible protein, such as grooved sheets, fibrils or fibres of edible protein, and combining the building blocks with an edible binder to produce the artificial meat product. Methods are provided along with apparatus for performing the methods and artificial meat products produced by the methods.

<CIT> describes a food product and method of manufacture.

<CIT> describes a mold for producing a frozen and pressed fish fillet molded product, and a method for producing the same. This is achieved by providing an arrangement of linear, web-like elevations in the mold, the distribution and course of which are modeled on the natural muscle structure or grain in the fish fillet.

The subject matter of the present description is directed to a method and system for forming a fish analog product from plant-based material. The subject matter described is also directed to the fish analog product formed, and a mold for use in forming the fish analog product. It is envisaged that the resulting fish analog product can be prepared, presented and consumed similarly to that of the actual fish of which the product is an analog. Moreover, the analog product preferably is of similar nutritional value, while being free of things like bones and toxins, and other negatives associated with consuming the actual fish.

In some examples, there is provided a method of forming a fish analog product, being analog to a target fish, from layers of plant-based material stacked on one another, the method comprising steps:.

It is envisaged that in successively stacking alternating layers on one another, a first of the alternating layers may correspond with artificial muscle tissue of the analog to be formed, and a second of the alternating layers may correspond with artificial connective tissue of the analog to be formed. In this way, the stack of alternating layers mimics the visual appearance and flaking behavior of fish, such as salmon, when it is cut.

In some examples of the present method, prior to slicing the stack through the upper and lower planes, the disclosed method may include compacting the stacked layers in the stacking direction such that the stacked layers conform to the undulating upper surface of the profiling bottom. For example, compaction of the stacked layers may comprise sandwiching the layers between the profiling bottom and a profiling top having an undulating lower surface complementary to the undulating upper surface of the profiling bottom. The sandwiching of the stacked layers may simply comprise moving at least one of the profiling top and the profiling bottom toward the other to compact the stacked layers therebetween. In this way, the stacked layers can be firmly pressed between the profiling top and bottom and thus adopt the shape of the undulating topographies thereof; this compaction of the layers against one another may also minimize the likelihood of the layers detaching from one another.

The present method may further comprise (iv) cutting the central segment along the stacking direction to form a cross-sectional shape of the analog product. For example, this cutting step may include arranging at least one cutting template adjacent to the central segment, the cutting template having a cutting shape formed therethrough which corresponds with the cross-section of the analog to be formed. In one example, a cutting element can be guided along a perimeter of the cutting shape so as to cut through the retained central segment in the stacking direction. In an alternative example, the at least one cutting template can be pressed along the stacking direction through the retained central segment so that the stacked layers thereof extrude through the cutting shape to form the fish analog product.

In some examples of the presently disclosed method, it is envisaged that each layer may be performed into similarly shaped strips which are sized for stacking on the undulating upper surface of the profiling bottom.

In some examples, there is provided a system for use in a method of forming a fish analog product, being analog to a target fish, from stacked layers of plant-based material, the system comprising a molding assembly having: a profiling bottom having an undulating upper surface corresponding to that of a naturally occurring myomere of the target fish and upon which successive layers of the plant-based material can be stacked such that at least the first stacked layer conforms to the undulating upper surface.

In utilizing an undulating upper surface which corresponds to naturally occurring myomere of a target fish, it becomes possible to form thereon a stack of plant-based layers which can be subsequently processed so as to resemble the flesh of the target fish. As such, the geometry and construction of the profiling bottom is significant. In one example, a lengthwise cross-section of the profiling bottom is nonuniform. Additionally, it is envisaged that for any lengthwise cross-section of the profiling bottom, the undulating upper edge of that cross-section is in the form of at least one cycle of a sinusoidal-like wave. It is also envisaged that a widthwise cross-section of the profiling bottom is nonuniform and that for any widthwise cross-section of the profiling bottom, the upper edge of that cross-section is in the form of an arc progressing from a lowermost first end through an uppermost point to a second end.

According to examples of the present system the molding assembly may also comprise a first barrier for enclosing the undulating upper surface of the profiling bottom so as to maintain alignment of the stacked layers on the undulating upper surface of the profiling bottom. For example, the first barrier may comprise sidewalls that form part of the molding assembly which, in use, can border the stacked layers and keep them on the undulating upper surface.

The present system may further comprise a thickness-defining portion for defining the thickness of the analog product to be formed, wherein the thickness-defining portion comprises a frame configured to bound a central segment of the stacked layers, a height of which central segment corresponds with the thickness of the analog product to be formed. For example, the frame may comprise an upper surface and/or a lower surface across which a cutting element can be passed to remove a respective upper segment and/or a lower segment of the stacked layers unbounded by the frame. In so doing, a central segment of the stacked layers may be retained within the thickness-defining portion, which central segment can then be further shaped to form a fish analog product. Preferably, a height of the frame of the thickness-defining portion is less than a peak-to-peak distance of the undulating upper surface of the profiling bottom.

In examples of the present system, the molding assembly may further comprise a profiling top having an undulating lower surface which is complementary to the undulating upper surface of the profiling bottom, wherein in use, the stacked layers are compacted between the respective undulating surfaces of the profiling top and the profiling bottom. For example, in use, at least one of the profiling top and the profiling bottom is moved toward the other to sandwich the stacked layers therebetween. In one example, the profiling top is driven downwardly toward the profiling bottom to compress the stacked layers therebetween.

Similar to the aforementioned first barrier, the molding assembly of the presently disclosed system may also comprise a second barrier for enclosing the upper segment and locating the profiling top thereon. Like the first barrier, the second barrier may also comprise sidewalls that form part of the molding assembly. In this way, the second barrier helps maintain alignment of the stacked layers, and particularly the upper segment thereof which protrudes out a top of the thickness-defining portion. Preferably, the thickness-defining portion would be arranged between the respective sidewalls of the first and second barriers.

The presently disclosed system may further comprise: an upper cutting template; and/or a lower cutting template, the or each template having a cutting shape formed therethrough which corresponds with a cross-section of the analog product to be formed. The cutting templates can thus be utilized to obtain a final form of the fish product analog from the retained central segment of stacked layers within the thickness-defining portion. Preferably, a footprint of the cutting shape falls over at least one peak and at least one trough of the undulating upper surface of the profiling bottom.

In use, the thickness-defining portion can be sandwiched between the upper cutting template and the lower cutting template such that a cutting element can cut through the stacked layers and along a perimeter of the cutting shapes of the respective cutting templates to form the analog product. Preferably, a peak-to-peak distance of the undulating upper surface of the profiling bottom is greater than a thickness of the analog product to be formed.

In examples of the presently disclosed system the myomere in respect of which the undulating upper surface of the profiling bottom corresponds is that of a fish species the analog product of which is to be formed. For example, the undulating upper surface of the profiling bottom may correspond with that of the myomere of salmon. As such, the presently disclosed system may be utilized to form an edible plant-based salmon analog, such as salmon fillet, salmon steak or salmon flakes.

It is envisaged that the above-described system may be used in a method according to a first aspect of the present disclosure.

In some examples, there is provided a fish analog product, being analog to a target fish, made from undulating layers of plant-based material stacked on one another in a stacking direction such that the stack of layers comprises at least one convex zone and at least one concave zone, wherein each lengthwise cross-section of the product passes through at least one convex zone in which the layers are curved in a convex manner and at least one concave zone in which the layers are curved in a concave manner. According to the invention, the layers of the fish analog product are compacted together in the stacking direction such that each layer adheres to at least one other adjacent layer. It is envisaged that such a fish analog product may resemble the target fish of which it is an analog and may even mimic the flaking behavior of the flesh of the target fish during cooking and/or consumption.

Preferably, the undulating layers may comprise alternating layers successively stacked on one another, a first of the alternating layers corresponding with artificial muscle tissue of the fish analog product, a second of the alternating layers corresponding with artificial connective tissue of the fish analog product. This manner of constructing the stack more closely approximates the layered flesh of the target fish and can promote the flaking behavior of the flesh during cooking or consumption.

In some examples, the presently disclosed fish analog product may be formed from a central segment of the stacked layers that remains after removal of an upper segment and a lower segment of the stacked layers via slicing therethrough along respective predetermined upper and lower planes oriented perpendicular to the stacking direction. In this way, the analog product has a thickness that corresponds with a height of the central segment of stacked layers.

Preferably, the upper and lower planes are positioned such that, upon slicing, an exposed surface of the central segment comprises at least one set of generally curved contour lines radiating radially outwardly. These curved contour lines preferably mimic those existing in the actual flesh of the target fish.

According to some examples of the present analog product, the undulation of each layer corresponds with that of a naturally occurring myomere of the fish the analog product of which resembles. For example, the naturally occurring myomere may be that of a salmon, in which case the analog product may be that of a cut of salmon, such as a cut of salmon fillet, a cut of salmon steak or salmon flakes.

In some examples, there is provided a mold for use in a method of forming a fish analog product from stacked layers of plant-based material, the mold having an undulating upper surface wherein: for any lengthwise cross-section of the mold, the upper edge of that cross-section follows an undulating path; and for any widthwise cross-section of the mold, the upper edge of that cross-section is in the form of an arc progressing from a lowermost first end through an uppermost point to a second end.

The mold helps to define the structure of the resulting fish analog product, and thus the geometry of the mold is significant. To this end, in some examples, the undulating upper edge of any lengthwise cross-section of the mold comprises at least one cycle of a sinusoidal-like wave such that the undulation includes at least one peak and at least one trough. In some examples, it is envisaged that the lengthwise cross-section of the mold is nonuniform; and/or the widthwise cross-section of the mold is nonuniform.

In some examples of the presently disclosed mold, the undulating upper surface thereof corresponds to that of a naturally occurring myomere of the fish of which the formed product is an analog. For example, the undulating upper surface may correspond with the naturally occurring myomere of that of salmon, thereby enabling the construction of a salmon analog product.

In some examples, one or more slice molds are provided, each slice mold comprising a bottom portion having an upper surface, and a top portion having a lower surface. In some examples, the shape of the lower surface of the upper portion complements the shape of the upper surface of the bottom portion.

In some examples, for a first time period, the upper surface of the bottom portion, and the lower surface of the top portion, of each slice mold is heated to at least a first temperature; and for a second time period, the upper surface of the bottom portion, and the lower surface of the upper portion, of each slice mold is cooled to less than a second temperature.

The term "fillet" as used herein can denote to a fillet of any kind, i.e., steak, top loin, bottom loin, etc..

In some examples, a method is provided for forming a fish analog product, being analog to a target fish, from layers of plant-based material stacked on one another. In some examples, the method comprises providing a profiling bottom having an undulating upper surface that corresponds to that of a naturally occurring myomere of the target fish.

In some examples, the method comprises successively stacking layers of plant-based material on one another in a stacking direction on the undulating upper surface to form a stack of undulating layers.

In some examples, the method comprises slicing the stack through upper and lower planes oriented perpendicular to the stacking direction to remove respective upper and lower segments of the stack from a retained central segment comprising a plurality of the layers, a distance between the planes corresponding to a thickness of the analog to be formed.

In order to better understand the subject matter that is disclosed herein and to exemplify how it may be carried out in practice, examples will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:.

<FIG> shows a stack <NUM> of sheets or layers of plant-based material <NUM>, <NUM> stacked on one another in a generally vertical stacking direction. In examples of the present subject matter, the layers <NUM>, <NUM> may be initially formed as relatively flat sheets (not shown), and, as will be discussed, through the presently disclosed method, system and mold, the layers <NUM>, <NUM> can be shaped to assume the closely packed stack <NUM> of <FIG>. In other examples of the presently disclosed subject matter the layers <NUM>, <NUM> can be initially formed as deformed sheets stackable above one another in a tight manner, optionally undulated, and further optionally undulated as described with respect to the layers <NUM> and <NUM>. Each layer <NUM>, <NUM> has a predetermined and substantially identical undulating form and topography. It is from this stack <NUM> of undulating layers <NUM>, <NUM> of plant-based material that a fish analog product <NUM> can be formed, an example of which is shown in <FIG>. For ease of discussion, the target fish of which the present fish product is an analog shall be referred to as salmon, though it will be appreciated that the present teachings may be similarly applied to form plant-based analogs of various other types and species of fish. In some examples, the fish analog product is analog to a target fish. The term "analog to a target fish", as used herein, means that the fish analog product is similar to the target fish (e.g., salmon) in shape and/or texture.

Firstly, it will be appreciated that the plant-based layers <NUM>, <NUM> are edible and may be formed from things such as legume proteins and algae extracts. The layers <NUM>, <NUM> may be 3D printed, though other production methods are within the scope of the present description. Preferably, the composition of the plant-based material mimics the nutritional value of the target fish (e.g., salmon). However, examples of the present salmon analog product are free of things like bones and toxins. As such, it is envisaged that consumption of fish analog products according to examples of the present subject matter provides similar nutritional value to eating the target fish, while avoiding some undesirable attributes associated with eating the actual target fish. It is also envisaged that the end product, being a salmon analog product, may be prepared and cooked in a manner that is generally similar if not identical to that applicable to conventional salmon. As such, consumers may readily switch from conventional salmon to the present salmon analog product without modifying preparation or cooking routines and with minimal impact on taste, texture and nutritional value.

As shown in <FIG>, the stack of undulating layers <NUM> of plant-based material may be formed from two different types of sheets or layers <NUM>, <NUM>, alternatingly stacked on top of one another. For example, the alternating layers may comprise a first layer <NUM> having properties (e.g., texture, thickness, density) corresponding to that of muscle tissue of salmon, and a second layer <NUM> having properties (e.g., texture, thickness and density) corresponding to that of connective tissue (i.e., myoseptum) of salmon. In this way, the two types of layers <NUM>, <NUM> are representative of artificial connective and muscle tissue of salmon and are arranged in an alternating manner just like in conventional salmon so as to replicate the flaking phenomenon that occurs when conventional salmon is cut during consumption.

Having formed the alternating layers <NUM>, <NUM>, a first step in the presently disclosed method for forming a fish analog product involves shaping the layers <NUM>, <NUM> so that they have an undulating form, an example of which form is shown in <FIG>. As will be discussed, this undulating form is based on that of a naturally occurring myomere <NUM> (<FIG>) of salmon, enabling further predetermined cuts of the undulating layers <NUM>, <NUM> to be made to obtain desired salmon analog products that resemble whole-cuts of conventional salmon, such as salmon fillet and salmon steak.

Various methods for shaping and/or stacking the layers <NUM>, <NUM> so as to attain the undulating form are within the scope of the present description. With reference to <FIG>, there is shown an example molding assembly <NUM> that can be used to form the undulating stacked <NUM> of <FIG>. The molding assembly <NUM> may be part of an example system for use in a method for forming salmon analog products according to examples of the present subject matter.

<FIG> shows the molding assembly <NUM> in an exploded state, and <FIG> shows the assembly <NUM> being used to mold the stacked layers of plant-based material so that they attain the desired undulating form. The molding assembly <NUM> comprises a profiling bottom <NUM> having a generally rectangular footprint defined by opposed front and rear walls <NUM>, <NUM> and opposed sidewalls <NUM>. In other examples of the presently disclosed subject matter, the footprint of the profiling bottom can have a different shape than rectangular, e.g., a shape of the cut to be achieved. As will be discussed, the profiling bottom <NUM> has an undulating upper surface <NUM> which corresponds to that of a salmon myomere <NUM> (shown in <FIG>). The term "corresponds", as used herein, means that it has a shape that mimics the shape of the myomere. As further described below, the shape of undulating upper surface <NUM> is not limited to that of the myomere of salmon, and can be shaped to correspond to the myomere of any fish. The sheet-like layers <NUM>, <NUM> of plant-based material may be deposited, e.g., successively, onto the undulating surface <NUM> of the profiling bottom <NUM>. The profiling bottom <NUM> is also referred to as a 'mold' <NUM> in the present description, including the claims herein.

The molding assembly <NUM> also comprises a bottom barrier <NUM> which, in use, is configured to generally enclose or bound the undulating upper surface <NUM> of the profiling bottom <NUM>. In <FIG> and <FIG>, the bottom barrier <NUM> is depicted as a generally rectangular frame having sidewalls <NUM> defining a rectangular opening <NUM> that fits snugly over and around the walls <NUM>, <NUM>, <NUM> of the profiling bottom <NUM>. For ease of visualization, the bottom barrier is shown as partially transparent. A height of the sidewalls <NUM> of the rectangular frame <NUM> extends vertically above the highest point or peak of the undulating upper surface <NUM> of the profiling bottom <NUM>. In this way, the rectangular barrier <NUM> helps to frame a lower segment of the layers <NUM>, <NUM> as they are stacked onto the undulating upper surface <NUM> of the profiling bottom <NUM>, thereby helping to maintain alignment of the stack of layers <NUM>, <NUM> thereon.

The molding assembly <NUM> further comprises a thickness-defining portion <NUM> configured to define a thickness of the salmon analog to be formed. The depicted thickness-defining portion <NUM> comprises a rectangular frame having four sidewalls <NUM> defining a rectangular opening <NUM> therein. The rectangular opening <NUM> is sized to fit around and bound a central segment of the stacked layers <NUM> of plant-based material as they are stacked vertically atop one another upon the profiling bottom <NUM>. The height of the sidewalls <NUM> of the thickness-defining portion <NUM> generally corresponds with a thickness of the salmon analog product to be formed and is preferably taller than a height of the sidewalls <NUM> of the bottom barrier. In particular, the height of the sidewalls <NUM> of the thickness-defining portion <NUM> is less than a peak-to-peak distance of the undulating upper surface <NUM> of the profiling bottom <NUM>.

The molding assembly <NUM> also comprises a top barrier <NUM> and a profiling top <NUM> which are analogous to and symmetrically disposed relative to the respective bottom barrier <NUM> and profiling bottom <NUM>. The top barrier <NUM> also comprises a rectangular frame having sidewalls <NUM> defining a rectangular opening <NUM> sized to snugly fit over and bound an upper segment of the stacked layers <NUM> so as to help maintain alignment thereof. The profiling top <NUM> has a lower undulating surface <NUM> complementary to the upper undulating surface <NUM> of the profiling bottom <NUM>. As such, the respective undulating surfaces <NUM>, <NUM> of the profiling bottom and top <NUM>, <NUM> can be arranged against one another such that the undulating surfaces <NUM>, <NUM> are almost able to tessellate with one another. The profiling top <NUM> similarly has a rectangular footprint defined by four sidewalls <NUM> configured to be snugly received within the correspondingly shaped rectangular opening <NUM> of the top barrier <NUM>.

In use, the thickness-defining portion <NUM> is sandwiched between the bottom and top barriers <NUM>, <NUM>. Referring also to <FIG>, the sidewalls <NUM> of the thickness-defining portion <NUM> are sandwiched between and against the respective sidewalls <NUM>, <NUM> of the top and bottom barriers <NUM>, <NUM> such that the rectangular openings of each barrier <NUM>, <NUM> and the rectangular opening <NUM> of the thickness-defining portion <NUM> are aligned with each other and form a continuous rectangular opening having a constant footprint in which the stacked layers <NUM> are snugly bound. The thickness-defining portion <NUM> may be located relative to the barriers <NUM>, <NUM> via complementary locating features 48a, 48b and/or may be removably secured thereto via corresponding fastening features 50a, 50b. The profiling top <NUM> may then be inserted into the rectangular opening <NUM> of the top barrier <NUM> and driven downward in the vertical stacking direction, thereby pressing into the stacked layers <NUM> and urging them down against the undulating upper surface <NUM> of the profiling bottom <NUM>. In this way, the stacked layers <NUM> are compacted between the profiling top <NUM> and the profiling bottom <NUM>, and in particular, the respective undulating surfaces <NUM>, <NUM> thereof, while being framed and aligned by the thickness-defining portion <NUM> and the top and bottom barriers <NUM>, <NUM>. As such, the deformable stacked layers <NUM> are compressed between the profiling top <NUM> and the profiling bottom <NUM> and thus each layer <NUM>, <NUM> is caused to deform and adopt (i.e., be imprinted by) the undulating form and topography of that of the respective undulating surfaces <NUM>, <NUM> of the profiling top <NUM> and bottom <NUM>, thereby achieving the intermediate stage of the stacked undulating layers <NUM> shown in <FIG>.

It is envisaged that one or more of the undulating layers <NUM>, <NUM> may be formed and/or stacked at a time to form the stack <NUM> from which the fish product analog <NUM> is to be formed. For example, it may be that only a single connective tissue layer <NUM> or a single muscle tissue layer <NUM> is initially deposited onto the undulating upper surface <NUM> of the profiling bottom <NUM>, whereupon the profiling top <NUM> can then be driven downwardly in the vertical stacking direction such that the layer <NUM> or <NUM> is pressed between the undulating surfaces <NUM>, <NUM> of the respective profiling bottom <NUM> and profiling top <NUM> so as to be shaped by their respective undulating topographies. The profiling top <NUM> can then be withdrawn upwardly and the next layer <NUM> or <NUM> may be deposited onto the already pressed layer and the above-described pressing process can be repeated for each subsequent layer until a stack <NUM> of undulating layers <NUM>, <NUM> is obtained. Of course, the process may involve sequentially molding one layer at a time, or two or more layers at a time. It is also envisaged that the molded layers <NUM>, <NUM>, instead of being stacked via the present molding assembly <NUM>, can be stacked elsewhere (e.g., at a stacking station). For example, after one or more layers <NUM>, <NUM> are molded, they can simply be removed from the molding assembly <NUM> ready to be stacked elsewhere.

A subsequent step in the present method of forming the salmon analog product involves slicing through the stack <NUM> of undulating layers at predetermined locations so as to achieve an intermediate salmon analog product that has the desired thickness. Various means of implementing this slicing step are considered within the scope of the present description. <FIG> helps to illustrate how such a step can be carried out, wherein after the stacked layers <NUM> have been molded by the molding assembly, the top and bottom barriers <NUM>, <NUM> can be removed, thereby revealing the arrangement in <FIG>. In particular, the stacked layers <NUM> comprise: an upper segment <NUM> which extends above a height of the sidewalls <NUM> of the thickness-defining portion <NUM>; a lower segment <NUM> which extends below a height of the sidewalls <NUM> of the thickness-defining portion <NUM>; and a central segment <NUM> (see <FIG>) bound by the sidewalls <NUM> of the thickness-defining portion <NUM>. It is this central segment <NUM> of the stacked layers <NUM> which is to be retained for further shaping into the desired salmon analog product <NUM>. To this end, the sidewalls <NUM> of the thickness-defining portion <NUM> comprise an upper surface <NUM> and a lower surface <NUM> across which a cutting element (not shown) can be passed to remove the upper and lower segments <NUM>, <NUM> of the stacked layers <NUM>. In particular, the cutting element may be driven horizontally through the stacked layers <NUM>, that is, in a direction perpendicular to the stacking direction and parallel to the upper and lower surfaces <NUM>, <NUM> of the thickness-defining portion <NUM>, thereby removing the upper and lower segments <NUM>, <NUM> of the stacked layers <NUM>. What remains would be the central segment <NUM> bound within the rectangular opening <NUM> of the thickness-defining portion <NUM>. The central segment <NUM> may need to be held within the thickness-defining portion <NUM> so that it does not slide out therefrom through the opening <NUM> thereof.

<FIG> illustrate steps that can be taken to configure the molding assembly <NUM> and prepare the stacked layers <NUM> for slicing. After the shaped stack <NUM> has been formed, as shown in <FIG>, the top barrier <NUM> can then be removed, resulting in the configuration shown in <FIG>. Next, the profiling top <NUM> can be removed from the stack <NUM>, resulting in the configuration shown in <FIG>. Next, the upper segment <NUM> of the stacked layers <NUM> can be slicingly removed, resulting in the configuration shown in <FIG>. At this stage, a cutting template <NUM> (to be discussed) may be secured against the upper surface <NUM> of the thickness-defining portion <NUM>, resulting in the configuration shown in <FIG>. The configuration of <FIG> can then be inverted or flipped, whereupon the now upward facing profiling bottom <NUM> and the bottom barrier <NUM> can then be removed, thereby revealing the lower segment <NUM> of the stacked layers <NUM> which can similarly be slicingly removed. A second cutting template <NUM>, constituting a mirror part of the first cutting template <NUM>, can then be secured against the lower surface <NUM> of the thickness-defining portion <NUM>, as exemplified by <FIG>. The or each cutting template <NUM> can help retain the stacked layer <NUM> within the thickness-defining portion <NUM>, which is particularly advantageous when the configuration is inverted.

A final step of the present method involves cutting through the retained central segment <NUM> in the vertical stacking direction so as to form the cross-sectional shape of the salmon analog product <NUM>. For example, there may be provided one or more cutting templates having a cutting shape formed therethrough which corresponds with the desired cross-sectional shape of the salmon analog product.

A cutting element (not shown) may then be guided along the perimeter of the cutting shape so as to cut through the retained central segment <NUM> in the stacking direction, thereby obtaining the desired cross-sectional shape of the salmon analog product <NUM>. Alternatively, the cutting template may be configured such that it can simply be pressed through the retained central segment <NUM> whereby the stacked layers <NUM> extrude through the cutting shape.

<FIG> shows an example of a method for cutting using cutting template <NUM>. In some examples, cutting template <NUM> has cutting shapes <NUM> formed therethrough, perimeters <NUM> of which being sharp. In some examples, a platform <NUM> is placed under profiling bottom <NUM> and a translation mechanism <NUM> is secured to platform <NUM>. In some examples, translation mechanism <NUM> can comprise a motor, or any other suitable means of providing linear translation of platform <NUM>.

In some examples, translation mechanism <NUM> linearly translates platform <NUM> in the direction of cutting template <NUM> such that the stacked layer <NUM> is pushed against cutting shapes <NUM>. In some examples, the sharpness of perimeters <NUM> cause the material to be cut in the shape of cutting shapes <NUM> and the shaped product is thus pushed out. Although <FIG> is illustrated in relation to an example where cutting template <NUM> is placed on top, this is not meant to be limiting in any way. In some examples (not shown), cutting template <NUM> is placed on the bottom, replacing profiling bottom <NUM>, and platform <NUM> is placed on the top, opposing cutting template <NUM>.

<FIG> shows an example of a method for cutting using a guided cutting element <NUM>. In some examples, cutting element <NUM> comprises a wire. In some examples, the wire is sharp. In some examples, the wire is a heated wire. In some examples, the wire is an electrified wire. In some examples, cutting element <NUM> is secured to one or more translation mechanisms <NUM>. In some examples, each translation mechanism <NUM> can comprise a motor, or any other suitable means of providing translation of cutting element <NUM> in a plurality of directions.

In some examples, translation mechanisms <NUM> translate cutting element <NUM> in a predetermined pattern to cut the material. In some examples, the pattern conforms to the respective patterns of cutting shapes <NUM>. Although a single cutting element <NUM> is illustrated, this is not meant to be limiting in any way, and a plurality of cutting elements <NUM> may be provided, each secured to one or more respective translation mechanisms <NUM>, to thereby allow a plurality of products to be cut from the same block. In some examples (not shown), cutting element <NUM> is provided together with cutting template <NUM>, such that cutting element <NUM> is guided along perimeter <NUM> of cutting shape <NUM>.

With reference to <FIG>, the present system may comprise sheet-like upper and lower cutting templates <NUM>, each of which has identical cutting shapes <NUM> formed therethrough, perimeters <NUM> of which correspond with that of the salmon fillets <NUM> shown in <FIG>. In use, the cutting templates <NUM> are arranged to sandwich against the upper and lower surfaces <NUM>, <NUM> of the thickness-defining portion <NUM> (as shown in <FIG>). The cutting templates <NUM> may be located relative to the thickness-defining portion <NUM> via complementary locating features 48b, 48c, and/or removably secured to the thickness-defining portion <NUM> via cooperating fastening features 50b, 50c. After the cutting templates <NUM> are positioned in place so as to sandwich the thickness-defining portion <NUM>, a cutting element (not shown) may be guided along the perimeter <NUM> of the cutting shapes <NUM> so as to cut through the retained central segment <NUM> in the stacking direction so as to form the cross-sectional shape of the desired salmon analog product <NUM>. Of course, as shown in <FIG>, other cross-sectional shapes can be formed with the use of cutting templates <NUM>' having different cutting shapes. Alternate cutting templates may be configured and formed such that they can simply be pressed through the layered stack <NUM> to form the shape of the desired fish product analog, functioning not unlike a cookie cutter pressing through dough. Of course, in an alternate method, the layers <NUM>, <NUM> may be pre-shaped (e.g., precut or preformed) to have the desired shape prior to stacking, in which case the final fish product would be achieved upon slicingly removing the upper and lower segments <NUM>, <NUM> and extracting the retained central segment <NUM> from the thickness-defining portion <NUM>.

Although the above has been described in relation to a fish analog product corresponding to a salmon fillet, this is not meant to be limiting in any way. Particularly, the fish analog product can correspond to any type of fish. Additionally, the fish analog product can correspond to any desired product, including, without limitation, fillets, steaks, flakes, or other fish products or derivatives.

<FIG> show an example profiling bottom <NUM> which is usable as part of the disclosed molding assembly <NUM> and in the presently disclosed system and method for forming a fish product analog. The profiling bottom <NUM> is itself a mold that can be used to shape the sheet-like layers <NUM>, <NUM> such that they have an undulating form. The profiling bottom <NUM> has a generally rectangular footprint and comprises an undulating upper surface <NUM> upon which the layers <NUM>, <NUM> of plant-based material can be stacked.

Significantly, the undulating form of the upper surface <NUM> may correspond with or mimic the undulating form present in naturally occurring myomere of the fish in respect of which the product to be formed is an analog. For example, the undulating surface <NUM> of the mold <NUM> of <FIG> is based on and corresponds with the undulating form of a single salmon myomere <NUM>, a schematic of which is shown in <FIG>. The geometric properties of the undulating upper surface <NUM> of the profiling bottom <NUM> (and thus the complementary undulating lower surface <NUM> of the profiling top <NUM>) will now be described.

In some examples, the shape of the myomere is retrieved from a database. In some examples (not shown), a system for scanning a fish to determine the shape of its myomere is provided. For example, the system can comprise a laser scanning device configured to scan slices of fish to determine the shape of the myomere. In some examples, a plurality of fish of the same type are scanned, and a predetermined operator is applied to the scanned shapes to provide an accurate approximation of the shape of the myomere of the particular type of fish.

<FIG> shows a front wall <NUM> of the profiling bottom <NUM>, which front wall <NUM> is illustrative of a lengthwise cross-sectional shape of the profiling bottom <NUM> (i.e., a cross-section taken across the length of the profiling bottom <NUM> between the opposed sidewalls <NUM>). The lengthwise cross-section of the profiling bottom <NUM> taken at the front wall <NUM> comprises an upper edge <NUM> that follows an undulating path. The undulating path is in the form of a sinusoidal-like wave. In the depicted example, the undulating upper edge <NUM> follows the path of approximately <NUM> wave cycles having a some amplitude (complete with peaks <NUM> and troughs <NUM>) and period corresponding to that of the target myomere, though of course other numbers of cycles, including non-full cycles, are within the scope of the present description.

<FIG> shows a rear wall <NUM> of the profiling bottom <NUM>, which rear wall <NUM> is also illustrative of a lengthwise cross-sectional shape of the profiling bottom <NUM>. The shape of the lengthwise cross-section of the profiling bottom <NUM> taken at the rear wall <NUM> is similar to that of the front wall, wherein the upper undulating edge <NUM>' also follows the path of approximately <NUM> wave cycles having the same amplitude and period corresponding to that of the target myomere, except that the undulating upper edge <NUM>' of the rear wall <NUM> is vertically higher than that of the front wall <NUM>. In other words, travelling in the widthwise direction from the front wall <NUM> to the rear wall <NUM>, the undulating upper edge of each lengthwise cross-section gradually rises along an arcuate path. This can be seen via the opposed sidewalls <NUM> which are illustrative of the widthwise cross-sectional shape of the profiling bottom <NUM>. Each sidewall <NUM> has an upper edge <NUM> that follows an arcuate path. In particular, the upper edge <NUM> of each sidewall <NUM> has a lowermost point <NUM> coincident with the undulating upper edge <NUM> of the front wall <NUM>. Then, travelling in the widthwise direction toward the rear wall <NUM>, the upper edge <NUM> of the sidewall <NUM> gradually increases in height to reach a peak <NUM> before arching downward slightly to a second point <NUM> coincident with the upper undulating edge <NUM>' of the rear wall <NUM>. Travelling in the lengthwise direction from one sidewall <NUM> to the opposite sidewall <NUM>, the arched upper edge of each widthwise cross-section gradually rises and falls in accordance with the aforementioned sinusoidal wave-like undulation of the upper surface <NUM>. In this way, the profiling bottom <NUM> has a nonuniform cross-section in both the width and lengthwise directions.

By using a profiling bottom <NUM> that comprises an undulating surface <NUM> mimicking that of naturally occurring myomere <NUM> of the target fish, the profiling bottom <NUM> can be used to mold stacked layers <NUM>, <NUM> of plant-based material to have a corresponding undulating form so as to mimic the musculature of the target fish. It will be appreciated that the form of the undulating upper surface <NUM> of the example profiling bottom <NUM> is such that it comprises three concave zones <NUM> separated therebetween by two convex <NUM> zones. Upon molding the stacked layers <NUM> with the profiling bottom <NUM>, the undulating layers <NUM>, <NUM> are also formed with corresponding concave and convex zones <NUM>, <NUM> (see <FIG>). Then, by slicing along predetermined planes perpendicular or otherwise angled relative to the stacking direction of the stack <NUM>, it is possible to obtain a product <NUM> (e.g., <FIG>) that visually resembles a whole-cut of the target fish, complete with one or more sets of generally curved contour lines <NUM> radiating radially outwardly from a central 'eye' <NUM>, which lines <NUM> are visible in the cross-sectional profile of the cut <NUM> and visually resemble the musculature of the target fish. To this end, in forming the fish analog product, it is preferable that the cutting shape <NUM> of the cutting templates <NUM> are sized and positioned such that they extend over at least one concave zone <NUM> and at least one convex zone <NUM> so as to reveal the radially radiating contoured lines <NUM> when the stacked layers <NUM> are sliced.

<FIG> shows a perspective view of a slice mold <NUM>. In some examples, slice mold <NUM> comprises a bottom portion <NUM> and a top portion <NUM>. <FIG> shows a perspective view of bottom portion <NUM> and <FIG> shows a perspective view of top portion <NUM>. In some examples, bottom portion <NUM> has an upper surface <NUM> and top portion <NUM> has a lower surface <NUM>.

In some examples, the shape of lower surface <NUM> of top portion <NUM> complements the shape of upper surface <NUM> of bottom portion <NUM>. The term "complements", as used herein, means that the shape of one can fit into the shape of the other. In some examples, as shown, each of lower surface <NUM> of top portion <NUM> and upper surface <NUM> of bottom portion <NUM> has an undulating shape that corresponds to that of a naturally occurring myomere of a target fish. In some examples, each of lower surface <NUM> of top portion <NUM> and upper surface <NUM> of bottom portion <NUM> has a shape that corresponds to that of a respective portion of the naturally occurring myomere of the target fish. In some examples, the shape can correspond to a layer of a fillet, or a portion thereof. In some examples, the shape can correspond to a layer of a steak, or a portion thereof. In some examples, the shape can correspond to a layer of a flake, or a portion thereof.

In some examples, as will be described below, a sheet of plant-base material, or a predetermined amount of plant-based material in a liquid state is inserted into a space <NUM> between upper surface <NUM> of bottom portion <NUM> and lower surface <NUM> of top portion <NUM>. In some examples, the liquid plant-based material has a viscosity between <NUM> - <NUM>,<NUM> Pa*s. In some examples, the shape of space <NUM> shapes the plant-base material accordingly.

In some examples, slice mold <NUM> embodies only a portion of the overall layer of the fish analog product being produced (e.g., layers <NUM> and <NUM> described above). In some examples, an array of slice molds <NUM> are provided, each forming a respective portion of the layer.

<FIG> shows a perspective view of a system <NUM>. In some examples, system <NUM> comprises: slice mold <NUM>; and a temperature adjustment mechanism <NUM>. In some examples, system <NUM> further comprises a control circuitry <NUM> configured to control temperature adjustment mechanism <NUM>. In some examples, temperature adjustment mechanism <NUM> comprises: a bottom section <NUM>, associated with bottom portion <NUM> of slice mold <NUM>; and a top section <NUM>, associated with top portion <NUM> of slice mold <NUM>. In some examples, bottom section <NUM> of temperature adjustment mechanism <NUM> is configured to adjust the temperature of upper surface <NUM> of bottom portion <NUM> of slice mold <NUM>, and top section <NUM> of temperature adjustment mechanism <NUM> is configured to adjust the temperature of lower surface <NUM> of top portion <NUM> of slice mold <NUM>, as will be described below.

Although temperature adjustment mechanism <NUM> is described herein as having separate components for bottom portion <NUM> and top portion <NUM> of slice mold <NUM>, this is not meant to be limiting in any way. In some examples, as shown, temperature adjustment mechanism <NUM> is positioned externally to slice mold <NUM>, however this is not meant to be limiting in any way. In some examples (not shown) temperature adjustment mechanism <NUM> is at least partially situated within a section of bottom portion <NUM> and/or top portion <NUM>.

In some examples, temperature adjustment mechanism <NUM>, and optionally each of bottom section <NUM> and top section <NUM>, comprises a heating element configured to heat upper surface <NUM> and lower surface <NUM> of slice mold <NUM> to at least a first temperature. In some examples, the first temperature is between <NUM> - <NUM> degrees C. In some examples, the first temperature is between <NUM> - <NUM> degrees C.

In some examples, the heating element of temperature adjustment mechanism <NUM> is configured to apply heat directly to slice mold <NUM>. In some examples, this can include: applying heated liquid, or gas, to slice mold <NUM>, as will be described below; and/or a heat source connected to slice mold <NUM>, or positioned within one or more sections thereof. In some examples, the heating element of temperature adjustment mechanism <NUM> is configured to also heat the ambient air surrounding slice mold <NUM>, such as a convection heater.

In some examples, temperature adjustment mechanism <NUM>, and optionally each of bottom section <NUM> and top section <NUM>, comprises a cooling element configured to cool upper surface <NUM> and lower surface <NUM> of slice mold <NUM> to less than a second temperature. In some examples, the second temperature is between <NUM> - <NUM> degrees C. In some examples, the second temperature is about <NUM> degrees C. In some examples, the second temperature is between <NUM> - <NUM> degrees C. The second temperature (of the cooling) is less than the first temperature (of the heating).

In some examples, the cooling element of temperature adjustment mechanism <NUM> is configured to cool slice mold <NUM> directly. In some examples, this can include: applying cooled liquid, or gas, to slice mold <NUM>, as will be described below; and/or a cooling source connected to slice mold <NUM>, or positioned within one or more sections thereof, such as a refrigeration unit. In some examples, the cooling element of temperature adjustment mechanism <NUM> is configured to also cool the ambient air surrounding slice mold <NUM>, such as with a fan and/or external refrigeration.

In some examples, control circuitry <NUM> controls temperature adjustment mechanism <NUM> to heat upper surface <NUM> of bottom portion <NUM> of slice mold <NUM>, and lower surface <NUM> of top portion <NUM> of slice mold <NUM>, to at least the first temperature for a first time period. In some examples, the first time period and the first temperature are sufficient such that the plant-based material is cooked. In some examples, where a generally straight sheet is inserted into space <NUM> of slice mold <NUM>, the first time period and the first temperature are sufficient to allow the shape of the sheet to be altered to match the shapes of upper surface <NUM> and lower surface <NUM>.

Following the first time period, control circuitry <NUM> controls temperature adjustment mechanism <NUM> to cool upper surface <NUM> of bottom portion <NUM> of slice mold <NUM>, and lower surface <NUM> of top portion <NUM> of slice <NUM>, to below the second temperature for a second time period. In some examples, the second time period is sufficient such that the plant-based material hardens. In some examples, the cooling prevents the plant-based material from partially, or completely, returning to its original shape. In some examples, the cooling allows the plant-based material to be easily separated from upper surface <NUM> of bottom portion <NUM> and lower surface <NUM> of top portion <NUM>. In some examples, the cooling period does not immediately follow the heating period, and an intermediate time period is provided between the first time period (i.e., the heating period) and the second time period (i.e., the cooling period).

In some examples, where the inserted plant-based material is in a liquid state, the material is hardened to a semi-solid state. In some examples, for a percent elongation of <NUM> - <NUM>,<NUM>%, the semi-solid state material maintains a storage modulus in the range of <NUM> - <NUM>,<NUM> Pa.

<FIG> illustrate an example of a liquid based method of heating and cooling. In some examples, as shown in <FIG>, a bottom inlet pipe <NUM>, a bottom outlet pipe <NUM>, a top inlet pipe <NUM> and a top outlet pipe <NUM> are provided. In some examples, as shown in <FIG>, each of bottom portion <NUM> and top portion <NUM> of slice mold <NUM> have a respective cavity <NUM>. Bottom inlet pipe <NUM> presents a fluid flow path into the cavity <NUM> of bottom portion <NUM> and bottom outlet pipe <NUM> presents a fluid flow path out of the cavity <NUM> of bottom portion <NUM>. Top inlet pipe <NUM> presents a fluid flow path into the cavity <NUM> of top portion <NUM> and top outlet pipe <NUM> presents a fluid flow path out of the cavity <NUM> of bottom portion <NUM>. The term "fluid flow path", as used herein, means a path that fluid can flow through.

In some examples, during a heating cycle, control circuitry <NUM> controls a fluid flow mechanism (not shown), such as a pump, to generate flow of a hot liquid into cavities <NUM>, via inlet pipes <NUM> and <NUM>. In some examples, upon completion of the heating cycle, control circuitry <NUM> controls the fluid flow mechanism to generate flow of the hot liquid out of cavities <NUM>, via outlet pipes <NUM> and <NUM>.

In some examples, during a cooling cycle, control circuitry <NUM> controls a fluid flow mechanism (not shown), such as a pump, to generate flow of a cold liquid into cavities <NUM>, via inlet pipes <NUM> and <NUM>. In some examples, upon completion of the cooling cycle, control circuitry <NUM> controls the fluid flow mechanism to generate flow of the cold liquid out of cavities <NUM>, via outlet pipes <NUM> and <NUM>.

<FIG> shows a side view of a slice mold <NUM> and a material insertion mechanism <NUM>. As shown, material insertion mechanism <NUM> provides a liquid flow path into the space <NUM> between bottom portion <NUM> and top portion <NUM>, thus allowing plant-based material to be inserted (e.g., injected) into slice mold <NUM> in a liquid state. In some examples (not shown), material insertion mechanism <NUM> can be secured to a pipe, or other mechanism, that provides the liquid plant-based material thereto. In some examples, material insertion mechanism <NUM> comprises a nozzle.

It is noted that the configuration of material insertion mechanism <NUM> shown in <FIG> is only a single non-limiting example. In some examples, any number of material insertion mechanisms, exhibiting any shape, can be provided without exceeding the scope of the disclosure.

In some examples, once the plant-based material is removed from slice mold <NUM>, it is stacked with other layers (e.g., layers <NUM> and <NUM> described above) on the molding assembly <NUM> described above. However, it is noted that slice mold <NUM> can be utilized without the above described features of molding assembly <NUM>, without exceeding the scope of the disclosure.

While various examples have been described herein, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made without departing from the scope of the invention, as defined in the claims. Thus, the scope of the present description should not be limited by the examples described and depicted herein.

Throughout this description and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Claim 1:
A method of forming a fish analog product (<NUM>), being analog to a target fish, from layers (<NUM>, <NUM>) of plant-based material stacked on one another, the method comprising steps:
(i) providing a profiling bottom (<NUM>) having an undulating upper surface (<NUM>); and
(ii) successively stacking layers of plant-based material on one another in a stacking direction on the undulating upper surface to form a stack (<NUM>) of undulating layers,
CHARACTERIZED BY:
(iii) slicing the stack through upper and lower planes oriented perpendicular to the stacking direction to remove respective upper and lower segments (<NUM>, <NUM>) of the stack from a retained central segment (<NUM>) comprising a plurality of the layers, a distance between the planes corresponding to a thickness of the analog to be formed.