阅读说明：本技术 包含不溶性颗粒的质构化食物产品以及制备此类食物产品的方法 (Texturized food products comprising insoluble particles and methods of making such food products ) 是由 P·皮巴罗 M-H·莫雷尔 C·桑切斯 于 2020-04-08 设计创作，主要内容包括：本发明涉及一种仿肉制品,该仿肉制品可包含凝固蛋白质乳糜,该蛋白质乳糜具有蛋白质和至少一种不溶性颗粒。在一些实施方案中,该颗粒的至少一部分可包含：至少一种矿物材料,该至少一种矿物材料选自由以下项组成的组：硅和钙,诸如菱面体方解石、偏三角面体方解石、二氧化硅和氧化镁中的一种或多种；至少一种有机材料,该至少一种有机材料选自由以下项组成的组：骨粉、软骨粉、磨碎的甲壳类动物壳、磨碎的海水鱼壳和磨碎的蛋壳；和/或胶化植物胶、胶化水性胶体、聚合植物胶、聚合水性胶体或其混合物。可通过挤出该蛋白质乳糜并冷却该挤出的乳糜来制备该仿肉制品。可将该仿肉制品切成块和/或添加到另一种可食用组合物诸如肉汁或肉汤中。(The present invention relates to a meat analog that can comprise coagulated protein chyle having protein and at least one insoluble particle. In some embodiments, at least a portion of the particles may comprise: at least one mineral material selected from the group consisting of: silicon and calcium, such as one or more of rhombohedral calcite, scalenohedral calcite, silica, and magnesia; at least one organic material selected from the group consisting of: bone meal, cartilage meal, ground crustacean shells, ground marine fish shells and ground egg shells; and/or a gelled vegetable gum, a gelled hydrocolloid, a polymeric vegetable gum, a polymeric hydrocolloid, or a mixture thereof. The meat analog can be prepared by extruding the protein emulsion and cooling the extruded emulsion. The meat analog can be cut into pieces and/or added to another edible composition such as a gravy or broth.)

1. A protein chyle comprising protein and from about 1% to about 30% by weight of added insoluble particles having a solubility in water at 25 ℃ of from about 0.0001mg/L to about 25mg/L and a median particle size of from about 0.05 μ ι η to about 100 μ ι η.

2. The protein chyle of claim 1, wherein the particle is selected from the group consisting of: mineral materials, organic materials and mixtures thereof.

3. The protein chyle of claim 2, wherein the mineral material is selected from the group consisting of: calcium carbonate, calcium sulfate, silica, and magnesium oxide.

4. The protein chyle of claim 3, wherein the calcium carbonate comprises calcite.

5. The protein chyle of claim 4, wherein the calcite comprises rhombohedral calcite or scalenohedral calcite.

6. The protein chyle of claim 2, wherein the organic material is selected from the group consisting of: bone meal, cartilage meal, ground crustacean shells, ground marine fish shells, ground eggs, gelled vegetable gums, gelled hydrocolloids, polymeric vegetable gums, starches, heat resistant starches, polymeric hydrocolloids and mixtures thereof.

7. A protein chyle as claimed in claims 1 to 6 wherein the particles have at least one characteristic selected from the group consisting of: a median particle size of from about 1 μm to about 50 μm, a bulk density of from about 0.5g/cm3 to about 5g/cm3, and a specific surface area of from about 1m2/g to about 20m 2/g.

8. A protein chyle as claimed in claims 1 to 6 wherein the particle further comprises a coating.

9. The protein chyle of claim 8, wherein the coating comprises a stearate.

10. The protein chyle of claims 1 to 9, wherein the protein is from about 25% to about 55% by weight of the chyle, and further comprises from about 4% to about 9% by weight of fat of the chyle, and has a moisture content of from about 45% to about 80% by weight of the chyle.

11. Protein chyle as claimed in claims 1 to 10, wherein the chyle comprises at least one meat selected from the group consisting of: poultry, beef, pork, and fish, and the at least one meat provides at least a portion of the protein.

12. Protein chyle as claimed in claims 1 to 11, wherein the chyle comprises a plant protein providing at least a part of the protein.

13. A meat analog made from the protein emulsion of any one of claims 1 to 12 wherein said meat analog comprises a fibrous and layered structure.

14. A food for animals comprising a meat analog made from the protein emulsion of any one of claims 1 to 12, wherein the meat analog comprises a fibrous and layered structure.

15. The food of claim 14 wherein the animal is a human, cat, or dog.

16. A method of making a simulated meat product, the method comprising:

mixing protein, water, and particles to form chylomicrons, wherein the chylomicrons comprise from about 1% to about 30% by weight of added insoluble particles having a solubility in water at 25 ℃ of from about 0.0001mg/L to about 25mg/L and a median particle size of from about 0.05 μm to about 100 μm;

heating the chyle to a temperature of from about 80 ℃ to about 200 ℃ by extruding the chyle through a die; and

cooling the heated chyle to form the meat analog, wherein the meat analog comprises a fibrous and layered structure.

17. The method of claim 16, wherein a heat exchanger is used to cool the heated chyle.

18. The method of claims 16-17, further comprising cutting the meat analog to form a block.

19. The method of claim 18 further comprising combining the pieces with an edible composition to form a blended food composition; and cooking or pasteurizing the blended food composition in a container.

20. The method of claims 16 to 19, comprising maintaining the temperature of the mold at about 80 ℃ to about 90 ℃.

Technical Field

The present invention relates generally to food compositions and, in particular, to meat analog products comprising protein and insoluble particles.

Background

Existing methods of making food products having the appearance and texture of meat ("meat analog") use gluten or soy protein isolate primarily in the extrusion process. However, the way in which these proteins achieve a fibrous or lamellar structure is not clear, and therefore it is difficult to modify the formulation or develop new products with a specific structure.

For example, the replacement of gluten or soy protein with other animal or vegetable protein sources can result in an unsatisfactory structure and texture of the product. Furthermore, the shape, texture and structure of restructured fibrous meat pieces are limited, mainly reproducing chicken or ham chunks. Meat analogs having a structure and texture corresponding to beef, lamb or pork or any other reference sliced meat are more difficult to manufacture.

These difficulties are mainly due to the inability to control protein aggregation during the heating and cooling process. The melted protein, upon cooling, will produce similar rheological and biochemical behavior, forming the same type of structure, with some differences in the firmness or elasticity of the mouth texture, but minimal differences in visual structure.

In addition to flavor, there is a need to control the firmness/elasticity and visual characteristics to reproduce a meat chunk that achieves good palatability or human consumer acceptance. Current processes and formulations do not produce structural and textural differences beyond existing meat analogs.

Disclosure of Invention

The inventors of the present invention have surprisingly found a method of controlling protein structuring during the production of meat analog products. In particular, the inventors of the present invention used an insoluble particulate phase that interacts with the melted protein to allow control of the formation of fibrous or lamellar protein structures.

Thus, in a general embodiment, the present disclosure provides a meat analog comprising chyle comprising protein and insoluble particles. The protein chyle comprises protein and from about 1% to about 30% by weight of particles having a solubility in water at 25 ℃ of from about 0.0001mg/L to about 25mg/L and a median particle size of from about 0.05 μm to about 100 μm.

In another embodiment, the present disclosure provides a meat analog made from protein chyle, wherein the meat analog comprises a fibrous and layered structure.

In another embodiment, the present disclosure provides a food for an animal comprising a meat analog made from protein chyle, wherein the meat analog comprises a fibrous and layered structure. The animal is a human, cat or dog.

In one other embodiment, the present disclosure provides a method of making a simulated meat product, the method comprising:

mixing protein, water, and particles to form protein chyle, wherein the chyle comprises from about 1% to about 30% by weight of particles having a solubility in water at 25 ℃ of from about 0.0001mg/L to about 25mg/L and a median particle size of from about 0.05 μm to about 100 μm;

heating the chyle to a temperature of from about 80 ℃ to about 200 ℃ by extruding the chyle through a die; and

cooling the heated chyle to form a meat analog, wherein the meat analog comprises a fibrous and layered structure.

Drawings

Fig. 1 is a table showing non-limiting examples of insoluble particulate materials suitable for use in the methods and compositions according to the present disclosure.

Fig. 2 is a table listing non-limiting examples of precipitated calcium carbonate materials suitable for use in the methods and compositions according to the present disclosure.

Fig. 3 is a table showing the formulations used in example 1 of the present disclosure.

Fig. 4 is a table showing the results of mechanical testing performed using the blocks of formulation 1 and formulation 3 in example 1 of the present disclosure.

Fig. 5 is a table listing the insoluble particles tested in example 2 of the present disclosure and their main properties.

Fig. 6 contains a table providing a description of "formula gluten-1" used in example 2 of the present disclosure, a description of the relevant parameters and a photograph of the resulting structure.

Figure 7 contains a table providing a description of "formula gluten-2" used in example 2 of the present disclosure, a description of the relevant parameters and a photograph of the resulting structure.

Fig. 8 contains a table providing a description of "formula gluten-3" used in example 2 of the present disclosure, a description of the relevant parameters, and a photograph of the resulting structure.

Fig. 9 contains a table providing a description of "formula gluten-4" used in example 2 of the present disclosure, a description of the relevant parameters, and a photograph of the resulting structure.

Figure 10 contains a table providing a description of "formula gluten-5" used in example 2 of the present disclosure, a description of the relevant parameters and a photograph of the resulting structure.

Figure 11 contains a table providing a description of "formula gluten-6" used in example 2 of the present disclosure, a description of the relevant parameters and a photograph of the resulting structure.

Figure 12 contains a table providing a description of "formula gluten-7" used in example 2 of the present disclosure, a description of the relevant parameters, and a photograph of the resulting structure.

Figure 13 contains a table providing a description of "formula gluten-8" used in example 2 of the present disclosure, a description of the relevant parameters, and a photograph of the resulting structure.

Figure 14 contains a table providing a description of "formula gluten-9" used in example 2 of the present disclosure, a description of the relevant parameters, and a photograph of the resulting structure.

Fig. 15 contains a table providing a description of "formula gluten-10" used in example 2 of the present disclosure, a description of the relevant parameters and a photograph of the resulting structure.

Figure 16 contains a table providing a description of "formula gluten-11" used in example 2 of the present disclosure, a description of the relevant parameters, and a photograph of the resulting structure.

Figure 17 contains a table providing a description of "formula gluten-12" used in example 2 of the present disclosure, a description of the relevant parameters and a photograph of the resulting structure.

Fig. 18 contains a table providing a description of "formula gluten-13" used in example 2 of the present disclosure, a description of the relevant parameters, and a photograph of the resulting structure.

Fig. 19 contains a table providing a description of "formula gluten-14" used in example 2 of the present disclosure, a description of the relevant parameters, and a photograph of the resulting structure.

Figure 20 contains a table providing a description of "formula gluten-15" used in example 2 of the present disclosure, a description of the relevant parameters, and a photograph of the resulting structure.

Figure 21 contains a table providing a description of "formula gluten-16" used in example 2 of the present disclosure, a description of the relevant parameters, and a photograph of the resulting structure.

Figure 22 contains a table providing a description of "formula gluten-17" used in example 2 of the present disclosure, a description of the relevant parameters, and a photograph of the resulting structure.

Figure 23 contains a table providing a description of the "formula gluten-18" used in example 2 of the present disclosure, a description of the relevant parameters and a photograph of the resulting structure.

Figure 24 contains a table providing a description of "formula gluten-19" used in example 2 of the present disclosure, a description of the relevant parameters, and a photograph of the resulting structure.

Detailed Description

Definition of

Some definitions are provided below. However, definitions may be located in the "embodiments" section below, and the above heading "definitions" does not imply that such disclosure in the "embodiments" section is not a definition.

As used in this disclosure and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a composition" or "the composition" includes two or more compositions. The term "and/or" as used in the context of "X and/or Y" should be interpreted as "X" or "Y" or "X and Y". Similarly, the term "at least one" used in the context of "at least one of X or Y" should be interpreted as "X" or "Y" or "X and Y". As used herein, the term "exemplary" is exemplary and explanatory only, and should not be considered exclusive or comprehensive, particularly when followed by a list of terms.

As used herein, "about" is understood to mean a number within a numerical range, for example, in the range of-10% to + 10% of the number referred to, preferably in the range of-5% to + 5% of the number referred to, more preferably in the range of-1% to + 1% of the number referred to, and most preferably in the range of-0.1% to + 0.1% of the number referred to. A range "between" two values includes both values. Moreover, all numerical ranges herein should be understood to include all integers or fractions within the range. Additionally, these numerical ranges should be understood to provide support for claims directed to any number or subset of numbers within the range. For example, a disclosure of 1 to 10 should be understood to support a range of 1 to 8, 3 to 7, 1 to 9, 3.6 to 4.6, 3.5 to 9.9, and so forth.

All percentages expressed herein are by weight of the total weight of the meat analog and/or the corresponding emulsion, unless otherwise stated. When referring to pH, the value corresponds to the pH measured at 25 ℃ using standard equipment.

The terms "food," "food product," and "food composition" mean a product or composition intended for ingestion by an animal (including humans) and which provides at least one nutrient to the animal. The term "pet food" means any food composition intended for consumption by a pet. The term "companion animal" means any animal that can benefit from or enjoy the compositions provided by the present disclosure. For example, the pet may be an avian, bovine, canine, equine, feline, caprine, wolf, murine, ovine, or porcine animal, but the pet may be any suitable animal. The term "companion animal" means a dog or cat.

A "blended" composition has only at least two components that have at least one different property, preferably at least a moisture content and a water activity in the context of the present disclosure, relative to each other. In this regard, describing the composition as "blended" does not mean that the blended composition has been subjected to a process sometimes referred to as "blending" (i.e., mixing the components so that they are indistinguishable from one another), and it is preferred to avoid such a process when mixing the meat analog with another edible composition (e.g., gravy or broth) to form the blended composition disclosed herein.

A "dry" food composition has less than 10% by weight moisture and/or a water activity of less than 0.64, preferably both. The "semi-moist" food composition has a moisture content of from 11 to 20% by weight and/or a water activity of from 0.64 to 0.75, preferably both. The "wet" food composition has a moisture content of more than 20 wt.% and/or a water activity of more than 0.75, preferably both.

A "meat analog" is a meat emulsion product that resembles natural meat pieces in appearance, texture, and physical structure. Meat analog products do not necessarily include meat; for example, some embodiments of meat analogs do not contain meat, but rather use vegetable proteins such as gluten to obtain the appearance, texture, and physical structure of meat.

The compositions disclosed herein may be free of any elements not specifically disclosed herein. Thus, disclosure of embodiments using the term "comprising" includes disclosure of embodiments "consisting essentially of and embodiments" consisting of the indicated components. Similarly, the methods disclosed herein may be free of any steps not specifically disclosed herein. Thus, disclosure of embodiments using the term "comprising" includes disclosure of embodiments "consisting essentially of and embodiments" consisting of the indicated steps. Any embodiment disclosed herein may be combined with any other embodiment disclosed herein unless explicitly and directly stated otherwise.

Detailed description of the preferred embodiments

One embodiment provides a protein chyle comprising protein and from about 1% to about 30% by weight of added insoluble particles having a solubility in water at 25 ℃ of from about 0.0001mg/L to about 25mg/L and a median particle size of from about 0.05 μm to about 100 μm.

In one embodiment, the particle is selected from the group consisting of: mineral materials, organic materials or mixtures thereof.

In one embodiment, at least a portion of the insoluble particles comprise at least one mineral material selected from the group consisting of: silicon, carbon and calcium.

In one embodiment, at least a portion of the insoluble particles comprise at least one mineral material selected from the group consisting of: calcium carbonate, calcium sulfate, silica, and magnesium oxide.

In one embodiment, at least a portion of the insoluble particles comprise calcite.

In one embodiment, at least a portion of the insoluble particles comprise at least one mineral material selected from the group consisting of: rhombohedral calcite, scalenohedral calcite, silica and magnesia.

In one embodiment, at least a portion of the insoluble particles comprise at least one organic material selected from the group consisting of: bone meal, cartilage meal, ground crustacean shells, ground marine fish shells, ground eggs, gelled vegetable gums, gelled hydrocolloids, polymeric vegetable gums, starches, heat resistant starches, polymeric hydrocolloids and mixtures thereof.

In one embodiment, at least a portion of the insoluble particles are selected from the group consisting of: gelled plant gums, gelled hydrocolloids, polymeric plant gums, polymeric hydrocolloids, and mixtures thereof.

In one embodiment, the insoluble particles comprise a first portion which is calcium carbonate and a second portion which is heat resistant starch.

In one embodiment, the insoluble particle has at least one characteristic selected from the group consisting of: a diameter of about 0.05 μm to about 100 μm; about 0.5g/cm³To about 5g/cm³(ii) bulk density of; and 1m²G to 20m²Specific surface area in g.

In one embodiment, the insoluble particles have a coating. The coating may comprise a stearate.

In one embodiment, the protein is from about 25% to about 55% by weight of the chyle.

In one embodiment, the chyle comprises from about 4% to about 9% by weight fat.

In one embodiment, the chyle comprises from about 45% to about 80% by weight moisture.

In one embodiment, the chyle comprises at least one meat selected from the group consisting of: poultry, beef, pork, and fish, and the at least one meat provides at least a portion of the protein.

In one embodiment, the chyle comprises a plant protein that provides at least a portion of the protein.

In one embodiment, the chyle comprises a vegetable protein that provides at least a portion of the protein, and the chyle is meat-free.

In one embodiment, the chyle does not comprise at least one of gluten, soy, or cereal.

In one embodiment, the present disclosure provides a meat analog made from protein chyle, wherein the meat analog comprises a fibrous and layered structure.

In one embodiment, the present disclosure provides a food for an animal comprising a meat analog made from protein chyle, wherein the meat analog comprises a fibrous and layered structure. The animal may be a human, cat or dog.

In one embodiment, the insoluble particles are from about 5% to about 30% v/v of the chyle.

In another embodiment, the present disclosure provides a method of making a simulated meat product. The method comprises the following steps: mixing protein, water and insoluble particles to form protein chyle; heating the chyle; and cooling the heated chyle to form a meat analog.

In one embodiment, the method provides for the preparation of a meat analog comprising: mixing protein, water, and particles to form chyle, wherein the chyle comprises from about 1% to about 30% by weight of added insoluble particles having a solubility in water at 25 ℃ of from about 0.0001mg/L to about 25mg/L and a median particle size of from about 0.05 μm to about 100 μm; heating the chyle to a temperature of from about 80 ℃ to about 200 ℃ by extruding the chyle through a die; and cooling the heated chyle to form a meat analog, wherein the meat analog comprises a fibrous and layered structure.

In one embodiment, a heat exchanger is used to cool the heated chyle.

In one embodiment, the method includes cutting the meat analog to form pieces. The method can include combining the pieces with another edible composition to form a blended food composition; and cooking or pasteurizing the blended food composition in the container.

In one embodiment, the chyle is heated to a temperature of from about 140 ℃ to about 250 ℃. Preparing chyle at a location selected from the group consisting of: (i) a mixer from which the chyle can be pumped to the extruder; and (ii) an extruder into which the powder and the liquid are separately fed.

In one embodiment, the method comprises directing the chyle through a die selected from the group consisting of: clothes hanger type mould, fishtail shape mould and combination thereof. The method may include maintaining the temperature of the mold at about 80 ℃ to about 90 ℃.

In another embodiment, the present disclosure provides a method of providing nutrition to a pet. The method comprises applying to the pet a meat analog comprising chyle comprising protein and insoluble particles.

In another embodiment, the present disclosure provides a method of formulating a meat analog to have a desired structure, the method comprising selecting one or more of a size, shape, deformability, or chemico-physical property of insoluble particles contained in the chyle that is at least a portion of the meat analog. The desired structure may include one or more of fiber diameter, fiber length, or fiber arrangement. The method may further comprise selecting one or more of a heating kinetics profile, a cooling kinetics profile, a process flow rate, or a cooling mold geometry design.

The inventors of the present invention have realised that the meat analogue manufacturing process is based on protein heating, which results in a reduction of the viscosity of the protein to a very fluid medium, followed by a cooling step, which results in the protein re-polymerising, the structure of which depends on the flow characteristics of the product when it sets. Therefore, the melted protein flow pattern at the cooling step affects the stability of the specific structure. The melt protein flow pattern depends on the viscoelastic properties of the protein, the rheological behavior of the dough in the cooling die, and the solid materials in the dough that may disrupt and/or disrupt or direct the melt protein flow.

Accordingly, one aspect of the present disclosure is a method of making a simulated meat product comprising using insoluble particles having defined size, shape and surface properties to control the flow of molten protein during the cooling step of the method to obtain a target protein structure. The meat analog can be a pet food.

The insoluble particles may be part of the raw materials used to make the meat analog (e.g., ground carcass or fishbone) or may be added as a powder (e.g., calcium carbonate powder). The insoluble particles may be of mineral origin (e.g. silicon, bentonite, carbon or calcium) or of organic origin (e.g. bone meal, ground crustacean or marine fish shells or eggshell powder). The particles may include insoluble particles such as textured plant proteins or micronized plant material, shells (e.g., pea shells), nuts, fibers (e.g., carrots or wheat), and/or particles that produce strain softening that in turn exacerbates periodic instability. A non-limiting example of a mineral particle suitable for use in one or more embodiments is calcium carbonate. In some embodiments, the insoluble particles may be made from the gelling and/or polymerization of a vegetable gum or hydrocolloid (e.g., starch particles, pectin, cellulose, or derivatives thereof).

One or more of the size, shape, deformability, and chemical-physical properties of the insoluble particles may be adjusted or selected to orient the conversion of the dough during heating and cooling under longitudinal flow to achieve a particular target structure. In some embodiments, the target structure includes variations in fiber diameter and length and/or specific fiber arrangements in spatial dimensions.

For example, the fibers may associate in the micro-ropes and/or may associate to form parallel sheets formed from micro-fibers or from micro-ropes. In some embodiments, the insoluble particles may be ordered in a particular pattern, depending on the viscoelastic behavior of the melted protein and on the geometric and physical properties of the insoluble particles themselves. The interaction between the insoluble particles and the thawed protein may also play an important role. Under dynamic cooling conditions, these complex interactions can stabilize controlled flow patterns through protein aggregation. These stable and frozen flow patterns can provide the final structure of the meat analog.

The flow pattern of the composite medium comprising the protein and the insoluble particles may depend on one or more of the heating kinetics profile, the cooling kinetics profile, the process flow rate, or the cooling mold geometry design. Slow cooling kinetics associated with laminar flow profiles can result in more ordered structures, while short cooling profiles and/or turbulence can result in less ordered structures.

One mechanism by which the visible fibrous or layered structure can be achieved is the separation between the insoluble polymeric protein fibers and the more soluble/gellified medium between the protein insoluble fibers. The phase properties of the insoluble particles can be used to facilitate and enhance this phase separation by altering the redistribution of water and by creating local disruptions in protein flow and local instability of protein water uptake.

The insoluble particles may be from any source. In one embodiment, the insoluble particles are from a mineral source. The table in fig. 1 provides non-limiting examples of suitable mineral particles.

The mineral particles can have a crystal form (e.g., rhombohedral or scalenohedral) that can be from different chemical sources. The size of the mineral particles and the size of the particle aggregates may vary from a diameter of about 0.05 μm to a diameter of about 100 μm, for example 1 μm to 20 μm or 2 μm to 10 μm. The bulk density and porosity of the mineral particles may be about 0.5g/cm³To about 5g/cm³. The specific surface area of the particulate powder may beAbout 1m²G to about 20m²(ii) in terms of/g. These physical parameters may affect the structuring effect of the insoluble particles on the fibrous or layered structure of the resulting meat analog.

Additionally or alternatively, the insoluble particle source may be: micro-milled bone; cartilage or fish bone in the form of ground fresh or frozen material; or meal (e.g., bone meal such as pig bone meal). Non-limiting examples of insoluble particles suitable for use in one or more embodiments are a combination of mineral particles (e.g., calcium carbonate) and heat resistant starch.

Another aspect of the disclosure is a method of providing nutrition to a pet (e.g., a companion animal). The method comprises administering to the pet any meat analog disclosed herein, preferably by oral administration in the pet food.

In one embodiment, the meat analog can be prepared by a process that includes combining water, protein (e.g., protein powder such as meat meal), and insoluble particles in a mixer (e.g., planetary mixer) to prepare a dough. As a non-limiting example, meat meal may be mixed with gluten powder, followed by the addition of water up to a maximum temperature of 10 ℃. In some embodiments, the insoluble particles are from about 5% to about 30% v/v of chyle, for example from about 5% to about 15% v/v of chyle, or from about 5% to about 10% v/v of chyle.

Non-limiting examples of meat suitable for use in the chyle include poultry, beef, pork, fish, and mixtures thereof. Non-limiting examples of suitable non-meat proteins include wheat proteins (e.g., whole grain wheat or gluten such as gluten meal), corn proteins (e.g., corn meal or corn gluten), soy proteins (e.g., soy flour, soy concentrate, or soy isolate), canola proteins, rice proteins (e.g., rice flour or rice proteins), cottonseed, peanut flour, pulse proteins (e.g., pea proteins, broad bean proteins), whole eggs, egg white proteins, milk proteins, and mixtures thereof.

In some embodiments, the chyle comprises meat and comprises gluten (e.g., gluten). In an alternative embodiment, the chyle comprises meat and does not comprise any gluten.

In some embodiments, the emulsion comprises non-meat proteins, such as gluten (e.g., gluten), and does not comprise meat or meat by-products. In an alternative embodiment, the emulsion comprises non-meat proteins and does not comprise any gluten or any meat or meat by-products.

In some embodiments disclosed above, the chyle does not comprise soy and/or does not comprise corn or other cereal-based ingredients (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 bean protein, or may comprise pea protein, bean protein and rice, or may comprise pea protein, bean protein and gluten.

In one embodiment, the chyle comprises flour and is thus raw dough. If flour is used, it will also provide some protein. Thus, materials that are both vegetable proteins and flours may be used. Non-limiting examples of suitable powders are: starches, such as cereal flours, including flours made of rice, wheat, corn, barley, and sorghum; root vegetable powders including powders of potato, tapioca, sweet potato, arrowroot, yam and taro; and other flours including sago, banana, plantain and breadfruit flours. Another non-limiting example of a suitable flour is a legume flour, including flours made from legumes such as fava beans, lentils, mung beans, peas, chickpeas, and soybeans.

Additionally or alternatively, the starting material may optionally comprise a protein isolate. If protein isolates are used, the starting material may include, for example, protein isolates made from fava beans, lentils or mung beans.

In some embodiments, the chyle may comprise a fat, such as an animal fat and/or a vegetable fat. In one embodiment, the fat source is an animal fat source, such as chicken fat, beef fat, or grease. Additionally or alternatively, vegetable oils such as corn oil, sunflower oil, safflower oil, rapeseed oil, soybean oil, olive oil, and other oils rich in monounsaturated and polyunsaturated fatty acids can be used. In some embodiments, a source of omega-3 fatty acids is included, such as one or more of fish oil, krill oil, linseed oil, walnut oil, or algae oil.

In addition to the protein and optional flour, the chyle may also comprise other components, such as one or more of vitamins, minerals, preservatives, colorants or flavoring agents.

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

Non-limiting examples of suitable preservatives include potassium sorbate, sorbic acid, sodium methyl paraben, calcium propionate, propionic acid, and combinations thereof. Non-limiting examples of suitable colorants include FD & C pigments such as blue No. 1, blue No. 2, green No. 3, red No. 40, yellow No. 5, yellow No. 6, and the like; natural pigments such as roasted malt flour, caramel pigment, annatto, chlorophyllin, cochineal, betanin, turmeric, saffron, paprika, lycopene, elderberry juice, bamboos, sphenoidea, and the like; titanium dioxide; and any suitable food coloring agent known to the skilled artisan. Non-limiting examples of suitable flavoring agents include yeast, tallow, rendered bone meal (e.g., poultry, beef, lamb, and pork), flavor extracts or blends (e.g., roast beef), animal digest, and the like.

The prepared dough can be fed into a piston pump and installed at the inlet of an extruder (e.g., a twin screw extruder). The dough can then be extruded at a temperature of about 140 ℃ to about 250 ℃, for example, using an extruder at a speed of about 200rpm to about 400 rpm.

In some embodiments, instead of preparing the dough and pumping it into the extruder, the process may include feeding the powder and the liquid separately into the extruder.

In one embodiment, the chyle is at a pressure in the extruder of from about 40psi to about 200psi, or from about 60psi to 100 psi. The high temperature in combination with the increased pressure provides a fibrous definition to the product (e.g., linear alignment with smaller long fibers).

In one embodiment, the extruder has a short coat hanger die (CHSD). In one embodiment, the CHSD temperature is between about 80 ℃ and about 90 ℃ to obtain the most suitable texture.

In some embodiments, the meat analog can be prepared by a method comprising applying microwave and/or radio frequency waves to a dough to heat the dough. After heating, the resulting textured product can be cooled, shaped, and cut into appropriately sized pieces.

In some embodiments, the gravy may be prepared by heating a mixture of water, starch, and spices. The meat analog and gravy may be filled into cans in desired proportions to form a blended pet food, and the cans may be vacuum sealed and then cooked under time-temperature conditions sufficient to effect commercial sterilization. Conventional cooking procedures, such as at cooking temperatures of about 118 ℃ to 121 ℃ for about 40 minutes to 90 minutes, can be used to produce commercial sterile products.

For example, the pieces may be mixed with another edible composition, such as a gravy (e.g., starch and/or gums in water), a gravy in which the other edible composition is stewed, a vegetable (e.g., potato, pumpkin, zucchini, spinach, radish, asparagus, tomato, cabbage, pea, carrot, spinach, corn, green bean, lima bean, broccoli, brussels sprout, cauliflower, celery, cucumber, turnip, yam, and mixtures thereof), a condiment (e.g., parsley, oregano and/or spinach flakes), or a kibble.

Some embodiments of a method of making a highly textured meat analog (e.g., meat analog chunk) disclosed herein use the compositions of U.S. Pat. nos. 6,379,738; 6,649,206, respectively; and 7,736,676, each assigned to the applicant of the present application and incorporated herein by reference in its entirety.

For example, the chyle may be formed from meat, which in some embodiments includes natural meat material (i.e., skeletal tissue and non-skeletal muscle) and/or meat by-products from one or more of mammals, fish, or poultry. The meat and/or meat by-product may be selected from a wide variety of components, with the type and amount of meat material depending on a variety of considerations, such as the intended use of the product, the desired flavor of the product, palatability, cost, availability of ingredients, and the like. As used herein, the term meat material includes non-dehydrated meat and/or meat by-products, including frozen materials.

In addition to or in lieu of meat, the chyle may comprise one or more other proteinaceous materials, such as gluten, soy flour, soy protein concentrate, soy protein isolate, egg albumin, or skim milk powder. If another proteinaceous material is included in the chyle of the pulp, the amount of the other proteinaceous material can vary from about 5% to about 35% by weight of the chyle, depending on factors such as the intended use of the product, the quality of the meat material used in the chyle, ingredient cost considerations, and the like. In a preferred embodiment, the content of the other proteinaceous material is between about 25 wt.% and about 35 wt.% by weight, such as between about 28 wt.% and about 31 wt.% by weight. Generally, as the fat content and/or moisture content of the meat material used increases, the content of other proteinaceous materials in the chyle correspondingly increases.

Although the formulation of meat chyle may vary widely, the chyle should have a protein to fat ratio sufficient to form a firm meat chyle product after protein coagulation without signs of chyle instability. The protein content of the chyle should be such that when heated to a temperature above the boiling point of water, the chyle will coagulate and form a firm chyle product within about five minutes, or within about three minutes, of being heated to that temperature. Thus, the meat material, the dry proteinaceous material (if used), and any additives are mixed together in proportions such that the meat material is present in an amount between about 50% to 75% by weight, or between about 60% to about 70% by weight, based on the weight of the meat emulsion. In a preferred embodiment, the starting ingredients of the meat emulsion comprise from about 29% to about 31% by weight protein and from about 4% to about 9% by weight fat, for example from about 4% to about 6% by weight fat. The resulting meat emulsion product should have a substantially similar distribution as the starting ingredients; however, if a gravy or broth is added to the product, this characteristic may change due to the moisture, protein and/or fat content of the gravy/broth.

In some embodiments, the meat emulsion is formulated to contain between about 45 and about 80 weight percent moisture by weight, or between about 49 and about 56 weight percent meat emulsion by weight, or between about 52 and about 56 weight percent meat emulsion by weight. The exact concentration of water in the chyle depends on the amount of protein and fat in the chyle.

The preparation of the meat emulsion may include comminuting a uniformly heated mixture of ground meat particles under conditions to emulsify the meat material and form a meat emulsion in which the protein of the meat mixture and water form a matrix encapsulating the fat globules. The meat material may be emulsified by a mixer, blender, mincer, silent meat slicer, emulsifier or any other device capable of breaking up and dispersing fat into globules in a meat mixture to form an emulsion.

Prior to emulsification, additives to be incorporated into the chyle, including any proteinaceous material and insoluble particles, may be added to the meat. Alternatively, the additives may be added to the meat after the meat is emulsified.

The meat emulsion can then be comminuted again to increase the fineness of the emulsion and rapidly heated to a temperature above the boiling point of water at which coagulation of the proteins in the emulsion can proceed rapidly, allowing the emulsion to coagulate and form a compacted emulsion product in a short period of time (e.g., twenty seconds or less).

At this stage of the process, the chyle may be under a pressure of about 40psi to about 200psi, or about 60psi to 100 psi. The high temperature in combination with the increased pressure may provide fiber definition for the product, e.g., linear alignment with the smaller long fibers.

In some embodiments, the chyle is treated in the apparatus by: when the chyle is comminuted, for example by mechanical heating and/or steam injection, the chyle is heated to the above-mentioned high temperatures. When heating the chyle to such high temperatures in this way, further significant shearing and cutting of the chyle should be avoided. Controlling the emulsion temperature within the desired range can be accomplished by adjusting factors such as the feed rate of the emulsifier, the rotational speed of the emulsifier, and the like, and can be readily determined by one skilled in the art.

The product may be pumped into the processing zone at high pressures of from about 80psi to about 600psi, or from about 100psi to about 500psi, and or from 140psi to about 200 psi. The period of time required for the hot chyle to set sufficiently to form a compact product may depend on many factors, such as the temperature at which the chyle is heated and the amount and type of protein in the chyle. In one embodiment, a residence time in the elongated tube of about 5 seconds to about 3 minutes or between about 1 minute to about 1.5 minutes may be sufficient for the protein to fully coagulate and form a compact chyle product that will retain its shape, integrity and physical properties.

In one embodiment, the solidified meat emulsion pieces may be discharged from the enclosed processing zone as product strips of varying piece sizes. Upon discharge from the processing zone, the sheets may be rapidly cooled by evaporation. If desired, suitable cutting means (such as a rotary cutoff knife, a water jet knife, a knife net, etc.) may be mounted at the discharge end of the elongated tube for cutting the product into pieces of the desired size. The product can be cut off therefrom to allow the product to cool more quickly if desired. The meat emulsion chunks so formed have excellent integrity and strength and will retain their shape and fiber characteristics when subjected to commercial canning and cooking procedures, such as those required in the production of canned foods having high moisture content.

An advantage of one or more embodiments provided by the present disclosure is the ability to manufacture meat analogs using a variety of protein sources. Another advantage of one or more embodiments provided by the present disclosure is to improve existing meat analog production processes. Yet another advantage of one or more embodiments provided by the present disclosure is the ability to create new food concepts that include meat analogs. Yet another advantage of one or more embodiments provided by the present disclosure is the manufacture of meat analog products with less or no cereal protein. Another advantage of one or more embodiments provided by the present disclosure is a gluten-free meat analog. Yet another advantage of one or more embodiments provided by the present disclosure is to facilitate the structuring of replicas that resemble any desired reference meat (e.g., beef, lamb, or pork). Yet another advantage of one or more embodiments provided by the present disclosure is the use of insoluble particles to produce food products having a fibrous or layered structure. Another advantage of one or more embodiments provided by the present disclosure is the texture modification of food products by physical treatment, such as wet foods for companion animals.

Additional features and advantages are described herein, and will be apparent from, the description and drawings herein.

Examples

The following non-limiting examples are illustrative of the embodiments provided by the present disclosure.

Example 1

The experiments were performed using the formulations listed in figure 3. A portion of the water (about 30 wt%) was mixed with fat (tallow) and insoluble particle powder in a high shear mixer to produce a homogeneous and stable suspension. Then, the mixture was poured into a kneading mixer, and gluten powder was gradually added. Mix at fifty rpm for three minutes to give a dough. The process temperature of the mixer was adjusted from 150 ℃ to 170 ℃ to obtain a highly textured product with a transparent layered or fibrous structure.

The obtained pieces were compared in terms of mechanical properties with two known meat analog products using a texture meter (texturometer). The test involves measuring the force (N) during displacement of the probe through the sample. The probe had a shape of 12mm diameter and the probe speed was 2mm^-1. The force is plotted as a function of the descent distance and the slope of the plot and the force at 4mm penetration are calculated or recorded. The pair formulas are shown in FIG. 41 and 3.

The blocks of formulations 1 and 3 formed a firmness and elasticity comparable to those of known meat analogs, as indicated by the slope values and standard deviations. Formulation 1 had a breaking force higher than the first known meat analog and lower than the second known meat analog. For formulation 3 (in which a portion of the carbonate was replaced by pig bone meal), the breaking force was greater and reached a level comparable to the second known meat analog, and significantly higher than the first known meat analog.

These experimental results show that the addition of insoluble particles improves the structuring and texturization of gluten lumps. In particular, these tests show that during the cooling phase, the particles have a significant effect on the melting protein behaviour. The related use of insoluble particles with targeted properties constitutes a method to control the structuring of the melted protein during cooling and to produce a product with a new texture to complete the range of pet foods and other meat analogs.

Example 2

This example is a systematic study on the effect of particle size, shape and properties on protein structuring. For gluten doughs, particle granulometry is identified as the major factor affecting the continuity and uniformity of the gluten pieces. The particle shape also has an influence, mainly between the fibers and the more or less spherical aggregates. Particle hydrophobicity also has a significant effect, suggesting that water/protein interactions are another key factor in protein structuring.

One of the most interesting results was obtained by replacing 30% v/v of precipitated calcium carbonate with heat resistant starch. Organized, complex and multidimensional structures are achieved, indicating the importance of the overall rheology (viscosity) of the system to achieve a given structure.

The tests were carried out using a laboratory extruder (TSE 16mm) and a clothes hanger cooling die (CHSD, appendix 1).

The first experiment was carried out with precipitated calcium carbonate Particles (PCC) as the insoluble particle phase. These PCC 1RE particles have a controlled granulometry, D₅₀About 2.4 μm in size, in the shape of a cubeEssentially spherical objects. A range of particles of different size, shape and properties were then selected to investigate the effect of insoluble phase properties on protein structuring.

The table in fig. 5 identifies the main characteristics of the particles tested. When these pellets were tested, the standard gluten/water (WG/H2O) ratio was 1.83, corresponding to 65% (w/w) water in gluten. The gluten/pellet (filler) ratio is adjusted to give approximately equal volume ratios of pellets in the protein matrix, taking into account the apparent density of the pellet powder. The results of each experiment using different test particles and different PCC 1RE volume fractions are given in figures 6 to 24, which give a description of the formulations used and pictures of the structures obtained.

The conclusion drawn by the calcium carbonate particles appears to be valid with respect to the effect of particle size. In fact, when the fiber size is too long, the blocks become discontinuous. However, the restriction between well-organized webs and non-continuous fiber masses appears to be at a higher concentration. In practice, a 20 μm fiber is still capable of producing a semi-continuous mass, whereas for spherical particles the limit is about 5 μm-10 μm.

It should be understood that various changes and modifications to the presently preferred embodiments described herein 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. Accordingly, such changes and modifications are intended to be covered by the appended claims.