Patent ID: 12239146

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Detailed embodiments of products, devices and methods are disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary of the devices and methods, which may be embodied in various forms. Therefore, specific functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims as a representative example for teaching one skilled in the art to variously employ the present disclosure.

As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. For example, reference to “an ingredient” or “a method” includes a plurality of such “ingredients” or “methods.” The term “and/or” used in the context of “X and/or Y” should be interpreted as “X,” or “Y,” or “X and Y.” Similarly, “at least one of X or Y” should be interpreted as “X,” or “Y,” or “both X and Y.”

As used herein, “about,” “approximately” and “substantially” are understood to refer to numbers in a range of numerals, for example the range of −10% to +10% of the referenced number, preferably −5% to +5% of the referenced number, more preferably −1% to +1% of the referenced number, most preferably −0.1% to +0.1% of the referenced number. All numerical ranges herein should be understood to include all integers, whole or fractions, within the range. Moreover, these numerical ranges should be construed as providing support for a claim directed to any number or subset of numbers in that range. For example, a disclosure of from 1 to 10 should be construed as supporting a range of from 1 to 8, from 3 to 7, from 1 to 9, from 3.6 to 4.6, from 3.5 to 9.9, and so forth.

All percentages expressed herein are by weight of the total weight of the meat analogue and/or the corresponding emulsion unless expressed otherwise. When reference is made to the pH, values correspond to pH measured at 25° C. with standard equipment.

The terms “food,” “food product” and “food composition” mean a product or composition that is intended for ingestion by an animal, including a human, and provides at least one nutrient to the animal. The term “pet food” means any food composition intended to be consumed by a pet. The term “pet” means any animal which could benefit from or enjoy the compositions provided by the present disclosure. For example, the pet can be an avian, bovine, canine, equine, feline, hircine, lupine, murine, ovine, or porcine animal, but the pet can be any suitable animal. The term “companion animal” means a dog or a cat.

A “blended” composition merely has at least two components having at least one different characteristic relative to each other, preferably at least moisture content and water activity in the context of the present disclosure. In this regard, description of a composition as “blended” does not imply that the blended composition has been subjected to processing sometimes referenced as “blending,” namely mixing components so that they are indistinguishable from each other, and preferably such processing is avoided when mixing the meat analogue with another comestible composition (e.g., a gravy or broth) to form the blended composition disclosed herein.

A “homogenous” structure is a structure of a meat analogue that is uniformly distributed along any direction or axis of the meat analogue. For example, a homogenous structure does not have a grain direction. Conversely, a “non-homogenous” structure of a meat analogue is non-uniform along at least one direction or axis of the meat analogue. For example, a non-homogenous structure has a grain direction.

A “dry” food composition has less than 10 wt. % moisture and/or a water activity less than 0.64, preferably both. A “semi-moist” food composition has 11 wt. % to 20 wt. % moisture and/or a water activity of 0.64 to 0.75, preferably both. A “wet” food composition has more than 20 wt. % moisture and/or a water activity higher than 0.75, preferably both.

A “meat analogue” is an emulsion product that resembles one or more pieces of natural meat in appearance, texture, and physical structure. As used herein, a meat analogue does not include meat; for example, a meat analogue that lacks meat may instead use vegetable protein such as gluten to achieve the appearance, texture, and physical structure of meat.

In the context of this document, meat analogues are preferably plant protein-based food products, which can substitute for pieces of red meat by mimicking the structure, texture, and taste of red meat. A specific feature of the meat analogues disclosed herein is the presence of a macroscopic fibrillar protein-based structure. Additionally or alternatively, meat analogues may contain a fat and/or fat analogue injected in voids within the macroscopic fibrillar protein-based structure. The fat and/or fat analogue content may range from 0% to about 100% by weight of the meat analogue. The plant and/or vegetable protein based content may range from 0% to 100% by weight of the meat analogue.

The preferred embodiments relate to meat analogues containing vegetable protein, methods of making such analogues, meat analogue extrusion devices, and methods of using such devices. More particularly, the present disclosure relates to meat analogues and meat analogue extrusion devices and methods for extruding meat analogues with a fibrous protein-gap macrostructure and/or a protein-fat macrostructure where fat is injected into the gaps within the protein-gap macrostructure.

The fibrillar meat analogue as described herein may be further used as basis to produce other meat analogues such as burger, minced meat, bacon, cold cuts, and sausages.

For example,FIGS.5and9illustrate embodiments of a die10. The die10may include a line connection that directs a meat analogue into the die10for processing. The line connection may connected to other elements of a meat analogue production system to receive raw and/or preprocessed meat analogue for processing and/or further processing in the die10.

The die10may be manufactured from a metal (i.e., aluminum, stainless steel), a plastic (i.e., Polyethylene Terephthalate, High-Density Polyethylene), an organic material (i.e., wood, bamboo), a composite (i.e., ceramic matric composite), other material and combinations thereof. The die10may be manufactured through extrusion, machining, casting, 3D printing, and combinations thereof. The die10may be coated with a material. For example, the die10may be coated with a material to prevent bacterial and/or particulate buildup on the die10.

As described herein, the die10may be composed of various parts or elements assembled together to form the die10. In an embodiment, the die10is a single piece, for example a single piece that has been 3-D printed and/or a single piece that has been Computer Numeric Controlled (“CNC”) machined from a single block of base material.

In a preferred embodiment, the meat analogue may enter the die10from the line connection and be extruded from the die10. Then, the extruded meat analogue may exit the die10through the gap20, as shown inFIG.5.

When the meat analogue passes through the die10and is extruded, a pressure may be exerted on the meat analogue to pass the meat analogue through the die10thereby exerting a pressure on the die10. In some embodiments, the die10may be required to withstand a pressure of about 40 to about 200 psi and preferably about 60 to about 100 psi. In an embodiment, the die10may be composed of multiple components held together and/or affixed using fasteners. The fasteners may be screws, snaps, bolts, clips, interlocks, and/or other fastening components.

FIG.1illustrates an embodiment of a meat analogue extrusion system30for processing the meat analogue. In an embodiment, the meat analogue is formed by a dough31. The meat analogue extrusion system30may first preprocess the dough31at a dough preparation area32. For example, the dough31may include multiple ingredients, and the multiple ingredients may require mixing prior to further processing. The mixing may be performed by hand and/or may be performed by a mechanical mixer, for example a blender.

The dough31may then be placed in a pump33of the meat analogue extrusion system30. For example, the pump may be a piston pump. The dough31may be placed in the pump33by hand, and/or may be automatically transported from the dough preparation area32to the pump33. The pump33may transmit the dough31through a line39. The line39may be connected to an extruder34. For example, the line39may be connected to a twin screw extruder. In an embodiment of the meat analogue extrusion system30, the line39is not included, and the pump33is connected directly to the extruder34.

The extruder34(e.g., a twin screw extruder) may apply a pressure to the dough31to move the dough31from a side of the extruder34with the pump33to an opposite side of the extruder34. The extruder34may additionally or alternatively apply heat to the dough31. The extruder34may additionally or alternatively be configured with an injection port (not shown) to inject water and/or another material into the dough31as the dough31moves through the extruder34.

The extruder34(e.g., a twin screw extruder) may be connected to the die10ofFIGS.5and9. As shown inFIG.1, the meat analogue extrusion system30comprising an exemplary embodiment of the die10may optionally include an inlet manifold36, a cooling die37, and/or one or more cooling devices35. In other embodiments, the one or more cooling devices35and the inlet manifold36may not be included in the meat analogue extrusion system30comprising the exemplary embodiment of the die10. In other embodiments, the cooling die37may be a short die. A short die may be a die where the length of the die (defined as the length a material travels through the die when the die is in use) is less than the width of the die (defined as the longest dimension of a planar section of the die outlet through which the material passes when exiting the die). For example, a short die may be about 9 inches long and about 15 inches wide.

The inlet manifold36may receive the dough31at an elevated pressure from the extruder34. The inlet manifold36may orient the dough31to pass into the cooling die37(e.g., a short cooling die), for example, by converting a stream of the dough31from a substantially circular cross section to a substantially planar cross section (i.e., with a cross sectional area where the width is many times the height, for example where the width is about 20 times the height).

The inlet manifold36may be connected to the cooling die37(e.g., a short cooling die) configured to receive the dough31from the inlet manifold36. The dough31may then pass, as propelled by the extruder34(e.g., a twin screw extruder), over the cooling die37. The cooling die37may be maintained at a constant temperature. Additionally or alternatively, the cooling die37may be maintained at a temperature profile along the path of the dough31as the dough31moves through the cooling die37. In general, the die10optionally including the cooling die37may be held at a constant temperature between about 40° C. and about 95° C. at normal atmospheric pressure. More preferably, the die10may be held between about 70° C. and about 95° C. For example, the die10may be held at a constant temperature of about 95° C., or about 85° C.

The cooling devices35may maintain a temperature of the cooling die37(e.g., a short cooling die). For example, the cooling die37may contain one or more cooling lines integrated within the cooling die37and connected to the one or more cooling devices35. The one or more cooling devices35may include a fluid reservoir. The cooling devices35may direct a liquid (e.g., water, R134-a, and/or another refrigerant) through the cooling lines of the cooling die37to remove heat energy from the cooling die37. The cooling die37may include a temperature sensor to sense the temperature of the cooling die37. The one or more cooling devices35may adjust a fluid flow rate and/or a fluid temperature in reply to and/or based on feedback received from the temperature sensor. In an embodiment, multiple temperature sensors may be positioned along a flow path of the dough31. After the extrusion, the dough31may be considered a meat analogue.

The meat analogue extrusion system30may further comprise a cutting tool38. The cutting tool38may cut the dough31to a predetermined size and/or desired dimensions. For example, the cutting tool38may cut the dough31into strips, substantially circular forms, slices, steaks, and/or any other shape commonly associated with human and/or pet food, such as marbled beef steak.

FIG.2illustrates a diagram depicting an embodiment of a meat analogue extrusion method40. For clarity, the various steps of the meat analogue extrusion method40have been shown as arrows inFIG.2on a diagram generally corresponding to the meat analogue extrusion system30. The steps included herein have been assigned numerical identifiers, but the steps disclosed herein are not limited to being performed in the numerical order assigned by the step numbers. For example, step46may occur before, during and/or after step47.

In step41, a raw material may be introduced to the meat analogue extrusion system30. The raw material may include a non-meat substance. The raw material may be the dough31, the meat analogue, and/or a combination of two or more materials. Non-limiting examples of suitable non-meat protein substances include wheat protein (e.g., whole grain wheat or wheat gluten such as vital wheat gluten), corn protein (e.g., ground corn or corn gluten), soy protein (e.g., soybean meal, soy concentrate, or soy isolate), canola protein, rice protein (e.g., ground rice or rice gluten), cottonseed, peanut meal, pulse proteins (e.g. pea protein, faba bean protein), whole eggs, egg albumin, milk proteins, and mixtures thereof.

In some embodiments, the raw material comprises a non-meat protein such as gluten (e.g., wheat gluten). In some embodiments, the raw material comprises a non-meat protein that does not include gluten.

In some embodiments, the raw material may contain a soy-based ingredient, a corn-based ingredient or another cereal-based ingredient (e.g., amaranth, barley, buckwheat, fonio, millet, oats, rice, wheat, rye, sorghum, triticale, or quinoa).

In some embodiments, the raw material may comprise pea protein and faba bean protein, or may comprise pea protein, faba bean protein, and rice, or may comprise pea protein, faba bean protein, and gluten.

The raw material may optionally comprise a flour or a protein isolate. If flour is used, the raw material may include protein. Therefore, an ingredient may be used that is both a vegetable protein and a flour. Non-limiting examples of a suitable flour are a starch flour, such as cereal flours, including flours from rice, wheat, corn, barley, and sorghum; root vegetable flours, including flours from potato, cassava, sweet potato, arrowroot, yam, and taro; and other flours, including sago, banana, plantain, and breadfruit flours. A further non-limiting example of a suitable flour is a legume flour, including flours from beans such as favas, lentils, mung beans, peas, chickpeas, and soybeans. If a protein isolate is used, the raw material may include, for example, protein isolate from faba bean, lentils, or mung beans.

In some embodiments, the raw material may comprise a fat such as a vegetable fat. The fat may be used to fill voids in a processed meat analogue. The processed meat analogue may be referred to as a meat analogue matrix. A vegetable oil, such as corn oil, sunflower oil, safflower oil, rape seed oil, soy bean oil, olive oil and other oils rich in monounsaturated and polyunsaturated fatty acids, may be used. In some embodiments, a source of omega-3 fatty acids is included, such as one or more of fish oil, krill oil, flaxseed oil, walnut oil, or algal oil. In an embodiment, the raw material used to fill the voids in the meat analogue matrix may be a fat analogue (e.g., hydrocolloids, gellified emulsion of fat and protein), vegetable fibers, connective tissue analogue (e.g., protein gum matrices which have a similar structure to meat connective tissues).

In some embodiments, the raw material and/or fat may comprise sea animal based ingredients such as shrimp, fish and krill. In other embodiments, sea animal based ingredients may be substantially or completely absent from the raw material and/or fat.

The raw material may include other components in addition to proteins and flours, for example one or more of a micronutrient, a vitamin, a mineral, an amino acid, a preservative, a colorant and a palatant.

Non-limiting examples of a suitable vitamin include vitamin A, any of the B vitamins, vitamin C, vitamin D, vitamin E, and vitamin K, including various salts, esters, or other derivatives of the foregoing. Non-limiting examples of a suitable mineral include calcium, phosphorous, potassium, sodium, iron, chloride, boron, copper, zinc, magnesium, manganese, iodine, selenium, and the like.

Non-limiting examples of a suitable preservative include potassium sorbate, sorbic acid, sodium methyl para-hydroxybenzoate, calcium propionate, propionic acid, and combinations thereof. Non-limiting examples of a suitable colorant include FD&C colors, such as blue no. 1, blue no. 2, green no. 3, red no. 3, red no. 40, yellow no. 5, yellow no. 6, and the like; natural colors, such as roasted malt flour, caramel coloring, annatto, chlorophyllin, cochineal, betanin, turmeric, saffron, paprika, lycopene, elderberry juice, pandan, butterfly pea and the like; titanium dioxide; and any suitable food colorant known to the skilled artisan. A non-limiting example of a suitable palatant is yeast.

The raw material may further include particles. The particles may include insoluble particles from non-animal origin for instance texturized vegetable proteins or micronized vegetable materials, hulls (for instance pea hulls), nuts, fibers (for instance carrot or wheat), calcium carbonate, and/or particles that yield strain softening which in turn accentuates the periodical instability. Non-limiting examples of suitable particle types are a pea hull, carrot fibers and calcium carbonate.

In step42, the raw material may be transported by the system for further processing. In an embodiment, mixing processes for the raw material may be performed remotely relative to any extrusion and/or cutting process associated with the meat analogue extrusion system40. Accordingly, the transportation step of step42may occur between any processing steps described herein and/or between any other processing steps known in the art. Locomotion of the raw material may occur through a tube. The tube may be manufactured from a metal and/or a plastic. Locomotion of the raw material through the tube may be performed by a pump, for example a screw pump, and/or by gravity.

In step43, pressure may be applied to the raw material by the extruder34(e.g., a twin screw extruder), shown inFIG.1. Referring again toFIG.2, step43may include heating the raw material. Step43may further include moving the raw material from an inlet of the extruder34through an extrusion length of the extruder34and out of the extruder34into the die10.

Step43of pressure application may further include injection step44. Injection step44may include injection of water, one or more particle and/or one or more liquid ingredient. In an embodiment, the injection step44includes the injection of a fat and/or a material that has the appearance and/or properties of a fat. The injection of water, one or more particle and/or one or more liquid ingredient may occur while the raw material is moving along the extruder34. In step44water and/or liquid may be injected into the extruder34. The water, one or more particle and/or one or more liquid ingredient may mix with the raw material passing through the extruder34.

In step47, the raw material may be directed from the extruder34(e.g., a twin screw extruder) and into a die, for example the die10. The raw material may be formed into a slab of raw material when forced through the die10by the extruder34. In an embodiment, the die10includes holes for injecting a material into the raw material on a downstream end of the die10. In an embodiment, step45includes the injection of a fat and/or a fat analogue. The fat and/or fat analogue may be injected to fill gaps between the fibrous macrostructure of the meat analogue. The size of the slab may be predetermined by adjusting the die10to a desired configuration.

Step47may optionally include steps45and46. Step45may include injection of water, one or more particle and/or one or more liquid ingredient. The injection of water, one or more particle and/or one or more liquid ingredient may occur while the raw material is moving through the die10.

Step46may include setting and/or maintaining a temperature of the die10. The die10may contain one or more cooling lines (e.g., a plurality of cooling lines) integrated within the die10and connected to the one or more cooling devices35. The one or more cooling devices35may direct a liquid through the one or more cooling lines of the die10to remove heat energy from the die10. The die10may include a temperature sensor to sense the temperature of the die10. The one or more cooling devices35may adjust a fluid flow rate and/or a fluid temperature in reply to and/or based on feedback received from the temperature sensor. In an embodiment, the flow rate may be adjusted by changing a speed of operation of the extruder34(e.g., a twin screw extruder). In an embodiment, multiple temperature sensors may be placed along the flow path of the raw material as the raw material moves through the die10.

Step48may optionally be performed after the raw material has been directed through the die10to become a processed material. Step48may include cutting and/or molding the processed material using cutting and/or molding equipment. For example, cutting may include stamping the processed material to put the processed material into a substantially circular form associated with lunchmeat. As another example, the processed material may be directed into a mold to apply a shape to the processed material. For example, the processed material may be molded to the shape of a marbled beef steak. As another example, the processed material may be packaged, for example by directing the processed material into a plastic container and then sealing the plastic container with the processed material therein.

FIG.3illustrates an embodiment of direction of flow101of the dough31through the die10. For illustrative purposes, a lower part82of the die10is shown. The direction of flow101shows how the dough31can move in the die10as the dough31moves from the extruder34(e.g., a twin screw extruder), into an analogue inlet100, into a channel103, and across an extrusion plane104. The lower part82of the die10may further comprise an extrusion portion inlet102positioned between the analogue inlet100and the channel103. The extrusion portion inlet102may reduce an area of the flow path of the dough31as the dough31moves from the analogue inlet100to the channel103. The extrusion portion inlet102may provide a consistent diameter flow restriction prior to dough31entering the channel103. For example, a connection positioned at the analogue inlet100may be of different sizes depending on the specific extruder used and/or the specific connection between an extruder and the die10. Accordingly, a more consistent product may be achieved through the use of the extrusion portion inlet102.

As the dough31enters the channel103from the extrusion portion inlet102, the dough31may extend along the channel103as shown by the direction of flow101arrows. While not shown inFIG.3, at the each end of the channel103the flow can be blocked by side portions of the die10. When the dough31is blocked by the side portions, the dough31is forced (e.g., by the pressure from the extruder34) across the extrusion plane104and over a die lip105as shown by the direction of flow101arrows. In a preferred embodiment, a cross sectional area of the flow path of the dough31in the channel103is greater than a cross sectional area of the flow path of the dough31across the extrusion plane104.

A fat and/or a fat analogue may be injected into the dough31as the dough31moves through the die10. While not shown inFIG.3, the extrusion plane104and/or the die lip105may comprise one or more injection ports. The injection ports may be configured to inject the fat and/or the fat analogue into the dough31. The fat may alternatively be injected through a slit immediately after the die exit. The geometry can be adapted to increase the void in between the fibers to optimize the fat injection in the slab.

FIG.4illustrates an embodiment of a fiber creation orientation diagram. In general, fiber creation orientation may change depending on the length of the die10as the dough31moves down the die10in a direction of flow171. The lines shown on the cross section of the dies inFIG.4indicate a general orientation of fibers that may be created in the dough31and/or a velocity profile of the dough31as the dough31moves through the dies inFIG.4. For example, in a traditional long-type die the fiber orientation may be as shown in diagram172. In contrast to the die shown in diagram172, the die10according to the embodiments disclosed herein, for example a short die, may have the general orientation of fibers and/or the velocity profile as shown in diagram173.

Referring back to diagram172, the fibers (as represented by the lines) and/or the velocity profile may be similar to a Hagen-Poiseuille flow distribution as the dough31moves from a die inlet174to a die outlet175. Accordingly, the longer the distance from the die inlet174to the die outlet175, the more the fibers become parallel to the direction of flow171. However, in diagram173, the fibers remain perpendicular to the direction of flow171from the die inlet174to the die outlet175. Accordingly, the preferred embodiment of the die10according to the present disclosure (e.g., a short die) and the diagram173can achieve a more desirable and predictable manufacturing process using the dough31.

The fibers may be created in the die10when the length of the die10and the pressure conditions of the dough31create a periodical flow instability in the die10. The periodical flow instability may result in a periodical pressure oscillation. The pressure oscillation may occur at a particular shear rate and shear stress. When the pressure oscillation occurs, the dough31, which may include a protein, may not be given time to relax. For example, an article entitled “Polymer Processing Extrusion Instabilities and Methods for their Elimination or Minimisation” by Agassant, J.-F. et al. published on polymer-process.com reviews findings related to instabilities in polymer processing. (Agassant, J.-F. et al.,Polymer Processing Extrusion Instabilities and Methods for their Elimination or Minimisation, International Polymer Processing (XXI), 2006-3, at 239.).

When the die10is a short die the dough31may not relax and therefore may retain the properties of the pressure oscillation. When the properties of the pressure oscillation are maintained, a sheared fiber and gap structure may be created. The speed at which the dough31moves through the die10and the decompression of the dough31due to shear stress may influence the periodical instability of the dough31as it moves through the die10.

For example, as the shear rate of the dough31increases, the shear stress of the dough31may generally also increase. At a relatively low shear rate, the shear stress is relatively low and the flow of the dough31through the die10may be generally laminar. In contrast, at a relatively high shear rate, the shear stress may be relatively high and the flow of the dough31through the die10may be generally grossly fractured or turbulent. However, at a shear rate between a relatively low and a relatively high shear rate, pressure oscillations may occur along the flow of the dough31. When pressure oscillations occur, the dough31may expand along the direction of flow through the die10to form voids. The dough10that remains between the voids may become the fibers shown inFIG.4. Thereafter, a fat and/or fat analogue may be injected into and/or otherwise introduced within the voids to substantially fill the voids.

In an embodiment, when the dough31is below a critical temperature, a phase separation of the dough31may occur. Therefore, the temperature of the dough31may be reduced while passing through the die10. Further temperature reduction of the dough31may solidify the dough31and/or may set the structure of the dough31. If the structure of the dough31is set during the phase separation of the dough31, the dough31may retain a fibrous meat-like appearance including sheared fibers. In addition to temperature, flow output and viscosity of the dough31may change the properties of the fibers created in the dough31.

FIG.5illustrates an embodiment of a processed food analogue181exiting from a die10with the sheared fibers71and gaps72between the sheared fibers71, a “sheared fiber and gap structure.” As described in reference toFIG.4, the sheared fibers71that remain substantially perpendicular to a direction of flow171of the dough31are desirable when producing a meat analogue. As used herein, substantially perpendicular may include sheared fiber orientations that are about +/−15 degrees from a direction perpendicular to the direction of flow. In some embodiments, sheared fibers71that remain substantially perpendicular to the direction of flow171may be bounded by smaller fibers at other angles relative to the direction of flow. However, even when considering the smaller fibers as included in the sheared fibers71, an average angle of the sheared fibers71with respect to the direction of flow171may remain substantially perpendicular to the direction of flow171.

FIG.6illustrates an embodiment of a meat analogue with the sheared fiber and gap structure. InFIG.6the processed food analogue181has been removed from the die10. The sheared fibers71and the gaps72between the sheared fibers are shown in the processed food analogue181.FIG.6illustrates an embodiment of a substantially non-homogenous meat analogue structure.

FIG.7illustrates stacked sheets of an embodiment of a meat analogue with the sheared fiber and gap structure. InFIG.7the processed food analogue181has been removed from the die10and stacked. The sheared fibers71and the gaps72between the sheared fibers are shown in the processed food analogue181. In some embodiments, the stacked sheets of the meat analogue with the sheared fiber and gap structure may be immersed into a fat and/or fat analogue. In some embodiments, the meat analogue with the sheared fiber and gap structure may be immersed in and/or sprayed with the fat and/or fat analogue. In either and/or both cases, the fat may fill the voids of the gap structure in the meat analogue to yield a marbled meat analogue. Such processes may be used in conjunction with and as an alternative to fat injection processes.

FIG.8illustrates an embodiment of a meat analogue with the sheared fiber and gap structure where a fat131has been injected to fill the gaps between the sheared fibers.FIG.8illustrates an embodiment of a substantially steak-like color and shape. The fat131may be a high melting point fat and/or fat analogue. The fat131may fill the gaps72created by the flow instability of the dough31as the dough31moves through the die10. The processed food analogue181including the fat131in the gaps72may improve mouthfeel perception for a consumer when compared to the processed food analogue181without the inclusion of the fat131.

For example, the die10may include fat injection sites in the die10that inject the fat or the fat analogue into the dough31as the dough31moves through the die10to yield visually distinct regions of (1) a fat and/or fat analogue and (2) a plant and/or vegetable protein in the processed food analogue181. In such an embodiment, the visually distinct regions are connected but not substantially mixed. For example, substantially all or completely all of the plant and/or vegetable protein can be confined to one or more visually distinct regions of the analogue (e.g., a body and/or macrostructure of the analogue), and/or substantially or completely all of the injected fat can be confined to one or more other visually distinct regions of the analogue (e.g., within one or more gaps in the body of the analogue). As shown inFIG.8, the meat analogue with the sheared fiber and gap structure where the fat131has been injected to fill the gaps may create a plurality of alternating, visually distinct regions (i.e., fat, macrostructure, fat, macrostructure, etc.) in the meat analogue. The fat injection sites may further inject lard and/or tallow flavor in addition to the fat and/or the fat analogue to optimize meat flavor release in the mouth of a consumer.

FIG.9illustrates an additional or alternative embodiment of a meat analogue with the sheared fiber and gap structure.FIG.9illustrates an embodiment of a processed food analogue181exiting from a die10with the sheared fibers71and gaps72between the sheared fibers71. As described in reference toFIGS.4and5, the sheared fibers71that remain substantially perpendicular to a direction of flow171of the dough31are desirable when producing a meat analogue.

FIG.10illustrates a meat analogue with an undesirable compact, substantially homogeneous structure. In contrast, preferred embodiments of the meat analogue comprise a non-homogenous structure with a fiber-like appearance. The meat analogue inFIG.10has been cut after passing through a cooling die that is not a short cooling die. Notably, there is no sheared fiber and gap structure in the embodiment of a meat analogue according toFIG.10.

EXAMPLE EMBODIMENTS

Several non-limiting example embodiments of dough and dough extrusion devices and processes are provided hereafter.

Example 1

In this example a twin screw extruder with a diameter of 25 mm is used to prepare a structured meat analogue having aligned fibers on the basis of wheat gluten proteins. A dough is prepared in a mixer at 30 rpm by mixing the ingredients provided in Table 1.

TABLE 1IngredientWeight (kg)Vital Wheat gluten8.5Precipitated Calcium Carbonate4.5Water12.5

The mixture is mixed for three minutes to form a homogeneous dough. This dough is then pumped to the first barrel of the extruder at 15 kg/h. The extruder temperature is set according to Table 2.

TABLE 2ExittoBarrelBarrelBarrelBarrelBarrelBarrelBarrelBarrelBarrelBarrelthe12345678910dieT ° C.20207513016516516516510075

A die is connected to the exit of the extruder and water circulation in the die is set at 80° C. to maintain temperature of the die below 95° C. Flavor and coloring ingredients are injected into barrel10for adjusting the extruded product color and flavor to reproduce beef veal or chicken meat organoleptic properties.

After equilibration of the flow and temperature of the extrusion and die, a texturized meat analogue with fibers in average perpendicularly aligned to the direction of flow of dough at the exit of the die is produced.

Example 2

In this example a twin screw extruder with a diameter of 25 mm is used to prepare a structured meat analogue having aligned fibers on the basis of wheat gluten proteins. A dough is prepared in a mixer at 30 rpm by mixing the ingredients provided in Table 3.

TABLE 3IngredientWeight (kg)Vital Wheat gluten2.15Pea protein isolate 1 (84% protein)2.5Pea protein isolate 2 (86% protein)2.5Salt0.1Flavor 10.09Flavor 20.016Flavor 30.034Flavor 40.210Protein texturized particles1.65Water10.9

The mixture is mixed for three minutes to form a homogeneous dough. This dough is then pumped to the first barrel of the extruder at 15 kg/h. The extruder temperature is set according to Table 2.

A die is connected to the exit of the extruder and water circulation in the die is set at 80° C. to maintain temperature of the die below 95° C. Flavor and coloring ingredients are injected into barrel10for adjusting the color and flavor of the extruded product to reproduce pork meat organoleptic properties.

After equilibration of the flow and temperature of the extrusion and die, a texturized meat analogue with fibers in average perpendicularly aligned to the direction of flow of dough at the exit of the die is produced.

Example 3

In this example a twin screw extruder with a diameter of 25 mm is used to prepare a structured meat analogue having aligned fibers on the basis of wheat gluten proteins. An emulsion is prepared by homogenizing a mixture according to Table 4 at pressures of 50 and 150 bars.

TABLE 4IngredientWeight (kg)Soya protein isolate0.204Canola oil0.54Water11.3

Then, a dough is prepared in a mixer at 30 rpm by mixing the ingredients provided in Table 5.

TABLE 5IngredientWeight (kg)Vital Wheat gluten2.15Pea protein isolate 1 (84% protein)2.5Pea protein isolate 2 (86% protein)2.5Salt0.1Flavor 10.09Flavor 20.016Flavor 30.034Flavor 40.210Protein texturized particles1.65Water10.9Emulsion12

The mixture is mixed for three minutes to form a homogeneous dough. This dough is then pumped into the first barrel of the extruder at 15 kg/h. The extruder temperature is set according to Table 2.

A die is connected to the exit of the extruder and water circulation in the die is set at 80° C. to maintain temperature of the die below 95° C. Flavor and coloring ingredients are injected into barrel10for adjusting the extruded meat analogue color and flavor to reproduce sausage organoleptic properties. The completed meat analogue contains about 2.5% fat to simulate a nutritional meat composition.

Example 4

In this example a twin screw extruder with a diameter of 25 mm is used to prepare a structured meat analogue having aligned fibers on the basis of soya and wheat gluten proteins (50:50) and pea and faba bean protein isolates (60:40). An emulsion is prepared as described in Example 3. Then, the dough is prepared in a mixer at 30 rpm by mixing the ingredients provided in Table 6.

TABLE 6Soya and wheatPea and FabaPea and Soyagluten (50:50)(60:40)(60:40)IngredientWeight (kg)Weight (kg)Weight (kg)Soya protein5—4Vital wheat gluten5——Pea protein isolate—66Faba bean protein—4—isolatesPrecipitated calcium1.21.22.4carbonateRed color0.20.20.2Water161516.5

The mixtures are mixed for three minutes to form a homogeneous dough. The doughs are then pumped into the first barrel of the extruder at 15 kg/h. The extruder temperature is set according to Table 2.

A die is connected to the exit of the extruder and water circulation in the die is set at 80° C. to maintain temperature of the die below 95° C. Fat was injected at the exit of the 2D short die with three injection ports in a slit along the die slit length. Flavor and coloring ingredients are injected into barrel10for adjusting the extruded meat analogue color and flavor to reproduce sausage organoleptic properties. The completed meat analogue contains about 2.5% fat to simulate a nutritional meat composition.FIG.11shows the meat analogue for the soya and wheat gluten blend.FIG.12shows the meat analogue for the pea and faba bean blend.FIG.13shows the meat analogue for the pea and soya protein blend,FIG.14show the pea and faba bean meat analogue piece with fat analogue inclusion in the fiber structure.

It should be understood that various changes and modifications to the examples described here will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims. Further, the present embodiments are thus not to be limited to the precise details of methodology or construction set forth above as such variations and modification are intended to be included within the scope of the present disclosure. Moreover, unless specifically stated any use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are merely used to distinguish one element from another.