阅读说明：本技术 仿肉制品和仿肉制品挤出装置和方法 (Meat analog and meat analog extrusion apparatus and method ) 是由 P·皮巴罗 C·J·E·施密特 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,该仿肉制品可包含彼此平行取向的连接的剪切纤维的宏观结构和定位在该剪切纤维之间的间隙。该宏观结构可包含肉并且可包含植物蛋白质。挤出系统可包括挤出机和模具。该挤出系统可生产仿肉制品。仿肉制品可包含动物蛋白质。该挤出机可连接到该模具。该挤出系统可被构造成将包含动物蛋白质的材料从该挤出机引导到该模具并穿过延伸穿过该模具的流体路径。该模具可被构造成将脂肪或脂肪仿制品注入该材料中,使得当该脂肪或该脂肪仿制品以及该材料离开该模具时,该脂肪或该脂肪仿制品嵌入包含该动物蛋白质的该材料中但在视觉上不同于包含该动物蛋白质的该材料。(The present invention relates to a meat analog that can comprise a macrostructure of connected shear fibers oriented parallel to each other and gaps positioned between the shear fibers. The macrostructures may comprise meat and may comprise vegetable proteins. The extrusion system may include an extruder and a die. The extrusion system can produce meat analog products. The meat analog may comprise animal protein. The extruder may be connected to the die. The extrusion system can be configured to direct material comprising animal protein from the extruder to the die and through a fluid path extending through the die. The mould may be configured to inject fat or a fat mimetic into the material such that when the fat or the fat mimetic and the material exit the mould, the fat or the fat mimetic embeds into the material comprising the animal protein but is visually distinct from the material comprising the animal protein.)

1. A meat analog comprising:

a macrostructure of connected sheared fibers oriented substantially parallel to each other; and

a gap positioned between the sheared fibers,

wherein the macrostructures comprise meat and further comprise added insoluble particles.

2. The meat analog of claim 1, wherein the vertical gap has been injected with fat such that the meat analog comprises a plurality of alternating visually distinct regions,

the visually distinct regions include one or more first visually distinct regions comprising the fat and one or more second visually distinct regions comprising the macrostructures.

3. The meat analog of claim 1, wherein the vertical gap has been injected with a fat analog such that the meat analog comprises a plurality of alternating visually distinct regions,

the visually distinct regions include one or more first visually distinct regions comprising the fat mimetic and one or more second visually distinct regions comprising the macrostructures.

4. The meat analog of claims 1 to 3, wherein said vertical gap has been immersed in a fat solution such that said meat analog comprises a plurality of alternating visually distinct regions,

the visually distinct regions include one or more first visually distinct regions comprising the fat and one or more second visually distinct regions comprising the macrostructures.

5. The meat analog of claims 1-4 wherein the added insoluble particles comprise a micronized plant matter, wherein the micronized plant matter is selected from the group consisting of a shell, a fiber, and mixtures thereof.

6. The meat analog of claims 1 to 5 wherein the meat analog is shaped like marbled meat.

7. The meat analog of claims 1-6 wherein the macrostructures are heterogeneous structures.

8. The meat analog of claims 1-7, wherein the meat analog is a wet moisture composition.

9. The meat analog of claims 1-8, wherein the meat analog contains gluten.

10. An extrusion system for a meat analog, the extrusion system comprising:

an extruder; and

a short mold;

wherein the extruder is connectable to the short die and is configured to direct material comprising animal protein from the extruder to the short die and through a fluid path extending through the short die,

wherein the short mold is configured to inject fat or a fat mimetic into the material such that when the fat or the fat mimetic and the material exit the short mold, the fat or the fat mimetic embeds into the material comprising the animal protein but is visually distinct from the material comprising the animal protein.

11. A method of extruding a meat analog comprising animal protein, the method comprising:

applying pressure to the meat analog with an extruder; and

passing the meat analog through a short die in a flow direction, wherein the short die is part of and/or connected to the extruder, and

as the meat analog passes through the short die, shear fibers are created in the meat analog that are substantially perpendicular to the direction of flow of the meat analog.

12. The method of claim 11, further comprising injecting fat or a fat analog into the meat analog as the meat analog passes through the short die.

13. The method of claim 12, further comprising injecting the fat or the fat mimetic such that the fat or the fat mimetic is embedded in but visually distinct from the meat mimetic.

14. The method according to claims 11 to 13, further comprising adding one or more plant-derived insoluble particles.

15. The method according to claims 11 to 14, further comprising adding pea shells to the meat analog.

16. The method of claims 11-15, further comprising maintaining the short dies at a temperature below about the boiling temperature of water as a function of temperature and pressure in the meat analog at the outlet of the short dies.

17. The method of claims 11-16, further comprising cutting the meat analog into marbled-like steaks.

18. The method of claims 11-17, wherein the meat analog contains at least one of soy protein, pea protein, or broad bean protein.

19. The method of claims 11-18, further comprising producing a periodic increase or decrease in flow rate within the meat analog as it passes through the short die.

20. The method of claims 11-19, further comprising cooling the meat analog from an initial temperature while passing the meat analog through the short die.

Technical Field

The present disclosure relates generally to meat analogs containing animal protein, methods of making such analogs, meat analog extrusion devices, and methods of using such devices. More particularly, the present disclosure further relates to meat analog products having a fibrous macrostructure and voids in the macrostructure, wherein fat is infused into the voids.

Background

Existing methods of making food products having the appearance and texture of meat ("meat analog") use protein isolates primarily in the extrusion process. However, the manner in which these proteins achieve a fibrous or layered structure is not clear, and therefore it is difficult to make formulation modifications or developments of new products having a specific structure.

To ensure a sustainable supply of protein, reconstituted meat analogs provide an interesting alternative. However, current products lack the taste and texture of red meat, particularly red meat such as marbled steaks. In addition, the variety of products offered to the consumer is small, and the consumer may think that these products are too over-processed.

Disclosure of Invention

One notable feature, in view of the structure and texture of red meat, is the complex hierarchical and multi-scale structure of muscle tissue, which is composed of actin and myosin protein fibrils embedded in collagen-based connective tissue. One key structural characteristic of protein fibrils is that they can reach lengths of several centimeters and are responsible for meat chewiness.

In addition to muscle protein structure, red meat contains adipose tissue both within and outside of the protein matrix. This complex architecture may affect the appearance of the meat as well as the texture and juiciness of the meat.

Furthermore, together with the protein fibrils and the fat content, red meat contains globular proteins, such as hemoglobin distributed in the serum contained in the network structure and several vitamins and minerals dispersed in the matrix.

Designing meat analog products to meet consumer demand, it may be beneficial to integrate all structural, textural and nutritional aspects of red meat (such as marbled meat). For example, marbled meat may contain complex hierarchical and multi-scale structures of muscle tissue, inclusions of adipose tissue within a protein matrix, and globular proteins distributed within serum contained in a network structure.

The applicant has therefore unexpectedly developed a meat analog which allows to visually achieve marbleizing (defined as the mutual entanglement or dispersion of the fat within lean beef), reaching the beef quality class "USDA Prime". If a bovine carcass has ribbing between the 12 th and 13 th ribs with a large and highly distributed marbleized pattern, the bovine rib eye muscle at the cut surface can obtain USDA Prime grades (defined as rich or moderately rich marbleized pattern, whereas beef with low USDA grades may have only trace, slight or no marbleized pattern).

Further, in this regard, the present disclosure provides a solution to the advantages and problems in the prior art of meat analogs and meat analog extrusion devices and methods. For example, the meat analog can comprise a fibrous macrostructure comprising voids in the macrostructure, wherein the voids are infused with fat and/or the fat analog. The meat analog extrusion device and method of using such device can achieve a fiber macrostructure and inject fat into the interstices of the fiber macrostructure. In a preferred embodiment, the meat analog comprises a parallel fiber macrostructure, wherein the meat analog fibers comprise fibers that are substantially parallel to one another.

In one embodiment, the die can have a configuration (e.g., a "hanger die" configuration) that can receive a protein-containing dough for high-moisture extrusion at elevated temperatures, after which the protein-containing dough can be formed into a thin, meat-like meat analog having a meat-like texture and appearance.

In one embodiment, the meat analog can be a pet food. Insoluble particles can be added to the raw material and used to make the meat analog, for example, as a powder (e.g., calcium carbonate powder). In one embodiment, the insoluble particles may be of mineral origin (e.g. silicon, calcium carbonate, calcium and/or carbon) and/or organic origin (e.g. bone meal, vegetable fibres, ground crustacean shells and/or marine fish shells and/or eggshell powder). In some embodiments, the insoluble particles may be made from the gelling and/or polymerization of plant gums and/or hydrocolloids (e.g., starch particles, pectin, cellulose, and/or derivatives).

Additionally or alternatively, the insoluble particle source may be: micro-milled bone; cartilage from the skeleton of fish, in the form of ground fresh material and/or frozen material; or meal (e.g., bone meal such as pork meal).

In one embodiment, the natural colorant and flavor components can be injected into the dough during and/or after the extrusion process. In one embodiment, one or more natural colorants (such as lycopene from tomato or betaine from beetroot and/or mixtures thereof) are used to simulate the natural flesh color of a meat analog. For example, the meat analog takes the form of marbled steaks, including a reddish-brown steak-like shape (such as ribbed meats or upper loins), and contains meat analog regions that are visually distinct from the fat and/or fat analog regions. In such embodiments, the visually distinct regions comprise formulas (i.e., animal protein or fat) that are different from one another.

In one embodiment, meat analog products having the same or substantially similar organoleptic properties as cold-cut animal meat and having improved taste and mouthfeel can be produced as disclosed herein. In a preferred embodiment, the meat analog comprises meat and/or animal protein. In one embodiment, the meat and/or animal protein content of the meat analog can range from above 0% to 100% by weight of the meat analog.

In one embodiment, the raw material ingredients used to form the meat analog can include protein, protein particles (e.g., textured vegetable protein), and water. The particles may be insoluble particles of plant and mineral origin. In one embodiment, the particles may comprise pea shells.

Insoluble particles and particles as used in this disclosure may be interchangeable and may refer to materials that are particles, solids, and/or fibers. The insoluble particles are preferably not any kind or size of bone chips or particles remaining from the meat processing process. The insoluble particles can be particles added to the meat emulsion, i.e., the insoluble particles are not present in any of the ingredients used to prepare the meat emulsion, including the meat. These materials, i.e., insoluble particles, may be characterized by at least one property selected from the group consisting of: a solubility in water at 25 ℃ of from about 0.0001mg/L to about 25 mg/L; a diameter of about 0.05 μm to about 100 μm; about 0.5g/cm³To about 5g/cm³The bulk density of (a); and 1m²G to 20m²Specific surface area in g.

In one embodiment, the meat analog product may include 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 meat analog does not include one or more of gluten, soy, and grain.

In one embodiment, a method of making a simulated meat product comprises heating a dough, the method comprising subjecting the dough to an extruder operating at least one parameter selected from the group consisting of: a speed of about 50rpm to about 100 rpm; a mass flow rate of about 15kg/h to about 25 kg/h; and a temperature of about 140 ℃ to about 250 ℃. The dough may be prepared at a location selected from the group consisting of: (i) a mixer from which dough can be pumped into the extruder; and (ii) an extruder (e.g., by feeding the powder and liquid separately into the extruder).

In one embodiment, a method of making a simulated meat product can comprise: mixing animal protein, water, and particles to form a protein meat emulsion, wherein the meat emulsion 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 meat emulsion to a temperature of from about 80 ℃ to about 200 ℃ by extruding the emulsion through a short die; and cooling the heated meat emulsion to form a meat analog, wherein the meat analog comprises a fibrous and layered structure.

In one embodiment, the method comprises directing a dough (e.g., extruded dough) through a die selected from the group consisting of a hanger die, a fishtail die, and combinations thereof. The method may include maintaining the temperature of the mold at about 70 ℃ to about 95 ℃. In one embodiment, the method can include maintaining the temperature of the die at about less than about the boiling temperature of water based on the temperature and pressure in the meat analog at the die exit.

In one embodiment, the fibers can be organized in the mold when lateral expansion and/or contraction of the dough in a direction substantially perpendicular to the flow direction (e.g., within about +/-15 degrees of the direction perpendicular to the flow direction through the mold) creates periodic flow instabilities in the mold. Periodic flow instabilities can lead to pressure oscillations due to flow instabilities. When the characteristics of pressure oscillation are maintained as the dough exits the die (when the dough may be referred to as a meat analog), shear fibers and interstitial structures may be created in the dough and/or meat analog.

In one embodiment, the method includes cutting the meat analog to form pieces. The method can include mixing 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, a method according to the present disclosure can include administering a meat analog to a pet (e.g., companion animal), preferably by oral administration in a pet food.

Not all of the features and advantages described herein are included, and in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings and description. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter.

Drawings

Figure 1 illustrates one embodiment of a meat analog extrusion system according to the present disclosure.

Figure 2 illustrates a diagram depicting one embodiment of a meat analog extrusion process according to the present disclosure.

Figure 3 illustrates one embodiment of a flow diagram for a meat analog along a lower portion of a mold according to the present disclosure.

Fig. 4 illustrates one embodiment of a fiber generation orientation graph according to the present disclosure.

Fig. 5 illustrates one embodiment of a processed food replica having sheared fibers according to the present disclosure.

Figure 6 illustrates one embodiment of a meat analog having a shear fiber and gap configuration.

FIG. 7 shows stacked sheets of one embodiment of a meat analog having a sheared fiber and gap structure.

Figure 8 illustrates one embodiment of a meat analog having a shear fiber and gap configuration in which fat has been injected to fill the gaps between the shear fibers.

Figure 9 illustrates one embodiment of a meat analog having a shear fiber and gap configuration.

Figure 10 shows a meat analog having a compact, homogeneous structure.

Detailed Description

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 can 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 reference to a plurality of such ingredients or methods. 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, "at least one of X or Y" should be interpreted as "X" or "Y" or "both X and Y".

As used herein, "about" and "substantially" are understood to mean a number within a range of values, for example in the range of-10% to + 10% of the number referred to, preferably-5% to + 5% of the number referred to, more preferably-1% to + 1% of the number referred to, most preferably-0.1% to + 0.1% of the number referred to. 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 meat emulsion, unless otherwise indicated. 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 "homogeneous" structure is a structure of the meat analog that is uniformly distributed along any direction or axis of the meat analog. For example, a homogeneous structure has no grain direction. In contrast, the "heterogeneous" structure of the meat analog is not uniform along at least one direction or axis of the meat analog. For example, the heterogeneous structure has a grain direction.

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 one or more natural slices of meat in appearance, texture, and physical structure. As used herein, meat analog includes meat, such as poultry, beef, pork, fish, and mixtures thereof. The meat analog may optionally additionally comprise vegetable proteins, such as gluten, to help achieve the appearance, texture and physical structure of the meat.

In the context of this document, the meat analog is preferably an animal protein-based food product that can replace red meat pieces by mimicking the structure, texture and taste of red meat. A particular feature of the meat analog disclosed herein is the presence of a macroscopic fibrous protein-based structure. Additionally or alternatively, the meat analog can contain fat and/or a fat analog infused into voids within the macroscopic fibrous protein-based structure. The fat and/or fat mimetic may be present in an amount ranging from 0% to about 100% by weight of the mimetic. The content of protein based on the animal may range from above 0% to 100% by weight of the meat analog.

Preferred embodiments relate to meat analogs containing animal protein, methods of making such analogs, meat analog extrusion devices, and methods of using such devices. More particularly, the present disclosure relates to meat analogs and meat analog extrusion devices and methods for extruding meat analogs having fibrous protein-interstitial macrostructures and/or protein-fat macrostructures, wherein fat is injected into the interstices within the protein-interstitial macrostructures.

Non-limiting examples of meat suitable for use in the meat analog include poultry, beef, pork, fish, and mixtures thereof.

The fibrous meat analog as described herein can further be used as a basis for the production of other meat analogs (such as hamburgers, meat minks, bacon, cold cut meats, and sausages.

For example, fig. 5 and 9 illustrate an embodiment of the mold 10. The mold 10 may include a conduit connection that directs the meat analog into the mold 10 for processing. The tubing connections may be connected to other elements of the meat analog production system to receive raw and/or pre-processed meat analogs for processing and/or further processing in the mold 10.

The mold 10 may be made of metal (i.e., aluminum, stainless steel), plastic (i.e., polyethylene terephthalate, high density polyethylene), organic materials (i.e., wood, bamboo), composite materials (i.e., ceramic matrix composites), other materials, and combinations thereof. The mold 10 may be manufactured by extrusion, machining, casting, 3D printing, and combinations thereof. The mold 10 may be coated with a material. For example, the mold 10 may be coated with a material to prevent bacteria and/or particles from accumulating on the mold 10.

As described herein, the mold 10 may be constructed of various parts or elements that are assembled together to form the mold 10. In one embodiment, the mold 10 is a single piece, e.g., a 3-D printed single piece and/or a single piece that has been computer numerically controlled ("CNC") machined from a single piece of substrate.

In a preferred embodiment, the meat analog can be introduced into the die 10 from a plumbing connection and extruded from the die 10. The extruded meat analog can then exit the die 10 through the gap 20, as shown in FIG. 5.

As the meat analog is passed through the die 10 and extruded, pressure may be applied to the meat analog to pass the meat analog through the die 10, thereby applying pressure to the die 10. In some embodiments, the mold 10 may need to withstand a pressure of about 40psi to about 200psi, and preferably about 60psi to about 100 psi. In one embodiment, the mold 10 may be constructed of multiple parts held together and/or attached using fasteners. The fasteners may be screws, snaps, bolts, clamps, interlocks, and/or other fastening components.

FIG. 1 illustrates an embodiment of a meat analog extrusion system 30 for processing a meat analog. In one embodiment, the meat analog is formed from a dough 31. Meat analog extrusion system 30 may first pre-process dough 31 at dough preparation area 32. For example, the dough 31 may comprise multiple ingredients, and the multiple ingredients may need to be mixed prior to further processing. Mixing can be performed by hand and/or can be performed by a mechanical mixer (e.g., a blender).

The dough 31 may then be placed in the pump 33 of the meat analog extrusion system 30. For example, the pump may be a piston pump. The dough 31 may be placed by hand in the pump 33 and/or may be automatically transported from the dough preparation area 32 to the pump 33. The pump 33 may transport the dough 31 through a line 39. Line 39 may be connected to extruder 34. For example, line 39 may be connected to a twin screw extruder. In one embodiment of meat analog extrusion system 30, line 39 is not included and pump 33 is connected directly to extruder 34.

An extruder 34 (e.g., a twin screw extruder) can apply pressure to the dough 31 to move the dough 31 from one side of the extruder 34 having the pump 33 to an opposite side of the extruder 34. Additionally or alternatively, the extruder 34 may apply heat to the dough 31. Additionally or alternatively, the extruder 34 can be configured with an injection port (not shown) to inject water and/or another material into the dough 31 as the dough 31 moves through the extruder 34.

An extruder 34 (e.g., a twin screw extruder) may be connected to the die 10. As shown in fig. 1, the mold 10 may optionally include an inlet manifold 36, a cooling mold 37, and/or one or more cooling devices 35. In other embodiments, one or more cooling devices 35 and inlet manifolds 36 may not be included in the mold 10. In other embodiments, the cooling mold 37 may be a short mold. A short die may be one in which the length of the die (defined as the length of material passing through the die when the die is in use) is less than the width of the die (defined as the longest dimension of the planar portion of the die exit through which material passes as it exits the die). For example, the short die may be about 9 inches long and about 15 inches wide.

The inlet manifold 36 may receive the dough 31 from the extruder 34 at an elevated pressure. The inlet manifold 36 may orient the dough 31 into a cooling mold 37 (e.g., a short cooling mold), for example, by transitioning the flow of dough 31 from a substantially circular cross-section to a substantially planar cross-section (i.e., a cross-section in which the width is many times the height, e.g., in which the width is about 20 times the height).

The inlet manifold 36 may be connected to a cooling die 37 (e.g., a short cooling die) configured to receive the dough 31 from the inlet manifold 36. The dough 31 may then be passed through a cooling die 37 as an extruder 34 (e.g., a twin screw extruder) advances. The cooling die 37 may be maintained at a constant temperature. Additionally or alternatively, the cooling die 37 can be maintained at a temperature profile along the path of the dough 31 as the dough 31 moves through the cooling die 37. Generally, mold 10, which optionally includes cooling mold 37, may be maintained at a constant temperature of between about 40 ℃ and about 95 ℃ at standard atmospheric pressure. More preferably, the mold 10 may be maintained at between about 70 ℃ and about 95 ℃. For example, the mold 10 may be maintained at a constant temperature of about 85 ℃.

The cooling device 35 may maintain the temperature of a cooling mold 37 (e.g., a short cooling mold). For example, the cooling mold 37 may contain one or more cooling lines integrated within the cooling mold 37 and connected to one or more cooling devices 35. The one or more cooling devices 35 may include a fluid reservoir. Cooling device 35 may direct a liquid (e.g., water, R134-a, and/or another refrigerant) through the cooling lines of cooling mold 37 to remove thermal energy from cooling mold 37. The cooling mold 37 may include a temperature sensor to sense the temperature of the cooling mold 37. The one or more cooling devices 35 may adjust the fluid flow rate and/or the fluid temperature in response to and/or based on feedback received from the temperature sensor. In one embodiment, a plurality of temperature sensors may be positioned along the flow path of the dough 31. After extrusion, the dough 31 may be considered a meat analog.

Meat analog extrusion system 30 may further include a cutting tool 38. The cutting tool 38 may cut the dough 31 to a predetermined size and/or a desired size. For example, the cutting tool 38 may cut the dough 31 into strips, substantially round forms, slices, steaks, and/or any other shape commonly associated with human and/or pet food, such as marbled steaks.

FIG. 2 shows a diagram depicting an embodiment of a meat analog extrusion method 40. For clarity, the various steps of the meat analog extrusion method 40 have been illustrated as arrows in FIG. 2 on a diagram generally corresponding to the meat analog extrusion system 30. The steps included herein have been assigned numerical identifiers, but the steps disclosed herein are not limited to being performed in numerical order assigned by step numbers. For example, step 46 may occur before, during, and/or after step 47.

In step 41, raw materials may be introduced into the meat analog extrusion system 30. The raw material may comprise non-meat matter. The raw material may be raw dough 31, a meat analog, and/or a combination of two or more materials. Non-limiting examples of suitable non-meat proteinaceous materials include wheat protein (e.g., whole grain wheat or gluten such as gluten meal), corn protein (e.g., corn meal or corn gluten), soy protein (e.g., soy flour, soy concentrate or soy isolate), canola protein, rice protein (e.g., rice flour or rice protein), cottonseed, peanut flour, pulse protein (e.g., pea protein, broad bean protein), whole eggs, egg white protein, milk protein, and mixtures thereof.

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

In some embodiments, the raw material can optionally contain a soy-based ingredient, a corn-based ingredient, or another cereal-based ingredient (e.g., amaranth, barley, buckwheat, fonio rice, millet, oat, 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.

The starting material may optionally comprise flour or protein isolate. If flour is used, the raw material may comprise non-animal meat based proteins. Thus, ingredients that are both vegetable proteins and powders 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. 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 starting material may comprise a fat, such as a vegetable fat and/or an animal fat. In some embodiments, the fat source is an animal fat source, such as chicken fat, beef fat, and/or grease. The fat may be used to fill voids in the processed meat analog. The processed meat analog may be referred to as a meat analog substrate. 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 one embodiment, the raw material used to fill the voids in the meat analog matrix can be a fat analog (e.g., a gelled emulsion of hydrocolloids, fat, and protein), a vegetable fiber, and/or a connective tissue analog (e.g., a protein gel matrix having a similar structure as meat connective tissue).

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

In addition to the protein and flour, the raw material may also comprise other components, such as one or more of micronutrients, vitamins, minerals, amino acids, preservatives, colorants and flavour enhancers.

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. A non-limiting example of a suitable odorant is yeast. 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 raw material may further comprise insoluble particles. The particles may include insoluble particles from non-animal sources, such as textured plant protein or micronized plant material, shells (e.g., pea shells), nuts, fibers (e.g., carrot or wheat), calcium carbonate, and/or particles that produce strain softening, which in turn exacerbates periodic instability. Non-limiting examples of suitable particle types are pea shells, carrot fibers and calcium carbonate.

The one or more insoluble particles can have any shape or geometry, for example, the one or more insoluble particles can be spherical, ovoid, ellipsoidal, cubic, cylindrical, prismatic, pyramidal, conical, rhombohedral, scalenohedral, tetragonal, dihedral, triangular, dihedral, hexagonal, dihedral, octahedral, tetragon, hexaoctahedral, rhombohedral, dihedral crystalline, hemioctahedral, diploid, helicoicosahedral, tetrahemihedral, pentahedral, tetrahedral, hexatetrahedron, or a combination thereof. The one or more insoluble particles may be particles having an aspect ratio of 1 to 20, or fibers having generally elongated and fibrous shapes.

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 rhombohedral calcite, scalenohedral calcite, silica, and magnesium oxide.

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, vegetable fibers, and ground eggs.

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 raw materials may be processed into a meat emulsion. For example, the meat emulsion can be formed from meat that 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 meat emulsion 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 emulsion, the amount of the other proteinaceous material can preferably vary from about 5% to about 35% by weight of the emulsion, depending on such factors as the intended use of the product, the quality of the meat material used in the emulsion, ingredient cost considerations, and the like. In a more 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 emulsion correspondingly increases.

While the formulation of the emulsion may vary widely, the emulsion should have a protein to fat ratio sufficient to form a firm emulsion product after the protein has coagulated without evidence of emulsion instability. The protein content of the meat emulsion should be such that the meat emulsion, when heated to a temperature above the boiling point of water, will coagulate and form a firm meat emulsion product within about five minutes, or preferably within 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 about 75% by weight, or between about 60% to about 70% by weight, based on the weight of the meat emulsion. In one 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 emulsion will depend on the amount of protein and fat in the emulsion.

In step 42, the raw materials or meat emulsion (hereinafter referred to as raw materials for brevity) may be transported by the system for further processing. In one embodiment, the mixing process of the raw materials may be performed remotely with respect to any extrusion and/or cutting processes associated with the meat analog extrusion system 40. Thus, the transporting step of step 42 may occur between any of the processing steps described herein and/or between any other processing steps known in the art. The raw material may be moved through the tube. The tube may be made of metal and/or plastic. The movement of the raw material through the tube may be performed by a pump (e.g., a progressive cavity pump) and/or gravity.

In step 43, pressure may be applied to the raw material by an extruder 34 (e.g., a twin screw extruder), as shown in fig. 1. Referring again to fig. 2, step 43 may include heating the raw material. Step 43 may further include moving the raw material from the inlet of extruder 34 through the extruded length of extruder 34 and out of extruder 34 into die 10.

The pressure applying step 43 may further comprise an injecting step 44. The injecting step 44 may include injecting water, one or more particulates, and/or one or more liquid components. In one embodiment, the infusing step 44 includes infusing fat and/or a material having the appearance and/or characteristics of fat. The injection of water, one or more particulates, and/or one or more liquid components may be performed as the raw materials move along the extruder 34. In step 44, water and/or liquid may be injected into the extruder 34. Water, one or more particulates, and/or one or more liquid ingredients may be mixed with the raw materials passing through the extruder 34.

In step 47, raw materials may be directed from the extruder 34 (e.g., twin screw extruder) into a die (e.g., die 10). As the extruder 34 forces the stock material through the die 10, the stock material may be formed into a stock slab of material. In one embodiment, the mold 10 includes holes for injecting material into the stock material on the downstream end of the mold 10. In one embodiment, step 45 comprises infusing fat and/or a fat mimetic. Fat and/or fat mimetics can be injected to fill the interstices between the fibrous macrostructures of the meat mimetic. The size of the panel may be predetermined by adjusting the mold 10 to a desired configuration.

Step 47 may optionally include steps 45 and 46. Step 45 may include injecting water, one or more particulates, and/or one or more liquid components. The injection of water, one or more particulates, and/or one or more liquid components may be performed as the raw material moves through the mold 10.

Step 46 may include setting and/or maintaining a temperature of mold 10. The mold 10 may contain one or more cooling lines (e.g., a plurality of cooling lines) integrated within the mold 10 and connected to one or more cooling devices 35. The one or more cooling devices 35 may direct the liquid through one or more cooling lines of the mold 10 to remove thermal energy from the mold 10. The mold 10 may include a temperature sensor to sense the temperature of the mold 10. The one or more cooling devices 35 may adjust the fluid flow rate and/or the fluid temperature in response to and/or based on feedback received from the temperature sensor. In one embodiment, the flow rate may be adjusted by varying the operating speed of the extruder 34 (e.g., a twin screw extruder). In one embodiment, a plurality of temperature sensors may be placed along the flow path of the raw material as it moves through the mold 10.

Step 48 may optionally be performed after the raw material has been directed through the die 10 to become a processed material. Step 48 may include cutting and/or molding the processed material using a cutting and/or molding apparatus. For example, cutting may include stamping the processed material to make the processed material into a substantially circular form associated with luncheon meat. As another example, the processed material may be directed into a mold to impart a shape to the processed material. For example, the processed material may be molded into the shape of a marbled 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).

In some embodiments, the processed material may be additionally or otherwise post-processed. For example, gravy may be prepared by heating a mixture of water, starch and spices. The processed material and gravy may be filled into cans in desired proportions to form a blended pet food product, 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.

Fig. 3 shows one embodiment of the flow direction 101 of the dough 31 through the die 10. For purposes of illustration, the lower portion 82 of the mold 10 is shown. The flow direction 101 illustrates how the dough 31 may move in the die 10 as the dough 31 moves from the extruder 34 (e.g., a twin screw extruder) into the simulated inlet 100, into the channel 103, and across the extrusion plane 104. The lower portion 82 of the die 10 may further include an extruded portion inlet 102 disposed between the simulated inlet 100 and the passageway 103. The extrusion portion inlet 102 may cause the area of the flow path of the dough 31 to decrease as the dough 31 moves from the simulated inlet 100 to the channel 103. The extrusion section inlet 102 may provide a uniform diametric flow restriction before the dough 31 enters the channel 103. For example, the connections positioned at the simulated inlet 100 may have different sizes depending on the particular extruder used and/or the particular connections between the extruder and the die 10. Thus, a more consistent product may be achieved by using the extrusion section inlet 102.

When dough 31 enters the channel 103 from the extrusion inlet 102, the dough 31 may extend along the channel 103, as indicated by the flow direction 101 arrows. Although not shown in fig. 3, at each end of the channel 103, flow may be blocked by the sides of the mold 10. When the dough 31 is laterally interrupted, the dough 31 is forced (e.g., by pressure from the extruder 34) across the extrusion plane 104 and over the die lip 105, as indicated by the flow direction 101 arrow. In a preferred embodiment, the cross-sectional area of the flow path of the dough 31 in the channel 103 is greater than the cross-sectional area of the flow path of the dough 31 across the extrusion plane 104.

The fat and/or fat mimetic may be injected into the dough 31 as the dough 31 moves through the die 10. Although not shown in fig. 3, extrusion plane 104 and/or die lip 105 may include one or more injection ports. The injection port may be configured to inject fat and/or a fat mimetic into the dough 31. Alternatively, the fat may be injected through a slit immediately after the die exit. The geometry may be adjusted to increase the spacing between the fibers to optimize fat injection in the panel.

Figure 4 illustrates one embodiment of a fiber generation orientation graph. Generally, as the dough 31 moves down the die 10 in the flow direction 171, the fiber-producing orientation may vary depending on the length of the die 10. The lines shown on the cross section of the die in fig. 4 indicate the overall orientation of the fibers that may be produced in the dough 31 and/or the velocity profile of the dough 31 as the dough 31 moves through the die in fig. 4. For example, in a conventional elongated die, the fiber orientation may be as shown in fig. 172. In contrast to the mold shown in fig. 172, the mold 10 (e.g., a short mold) according to embodiments disclosed herein may have an overall orientation and/or velocity profile of the fibers as shown in fig. 173.

Referring again to fig. 172, as the dough 31 moves from the die inlet 174 to the die outlet 175, the fiber (as shown by the lines) and/or velocity profile may resemble a hargen-poisson flow profile. Thus, the longer the distance from the die inlet 174 to the die outlet 175, the more parallel the fibers become to the flow direction 171. However, in fig. 173, the fibers remain perpendicular to the flow direction 171 from the die inlet 174 to the die outlet 175. Thus, a preferred embodiment of the mold 10 according to the present disclosure (e.g., a short mold) and the graph 173 can enable a more desirable and more predictable manufacturing process using the dough 31.

Fibers may be generated in the mold 10 when the length of the mold 10 and the pressure conditions of the dough 31 create periodic flow instabilities in the mold 10. Periodic flow instabilities may result in periodic pressure oscillations. Pressure oscillations may occur at a particular shear rate and shear stress. When the pressure oscillations occur, the dough 31 (which may include protein) may not have time to relax. For example, an article published by Agassant, j. -f. et al on Polymer-process.com entitled "Polymer Processing Extrusion instability and Methods for the Elimination or minimization thereof" reviews findings related to instability in Polymer Processing. (Agassant, J. -F. et al, methods of polymer processing extrusion instability and elimination or minimization thereof: (Polymer Processing Extrusion Instabilities and Methods for their Elimination or Minimisation) International Polymer processing (XXI), 2006-3, page 239).

When the mold 10 is a short mold, the dough 31 may not be loosened, and thus the pressure oscillation characteristic may be maintained. While maintaining the characteristics of pressure oscillations, a shear fiber and gap structure may be created. The speed at which the dough 31 moves through the die 10 and the decompression of the dough 31 due to shear stress may affect the periodic instability of the dough 31 as it moves through the die 10.

For example, as the shear rate of the dough 31 increases, the shear stress of the dough 31 may generally increase. At relatively low shear rates, the shear stress is relatively low, and the flow of the dough 31 through the die 10 may be generally laminar. In contrast, at relatively high shear rates, the shear stress may be relatively high, and the flow of the dough 31 through the die 10 may generally be severely fractured or turbulent. However, at shear rates between relatively low and high shear rates, pressure oscillations can occur along the flow of the dough 31. When the pressure oscillation occurs, the dough 31 may expand in the direction of flow through the die 10 to form voids. The dough 10 remaining between the voids may become fibers as shown in fig. 4. The fat and/or fat mimetic may then be injected into and/or otherwise introduced into the void to substantially fill the void.

In one embodiment, the dough 31 may phase separate when the dough 31 is below the critical temperature. Thus, the temperature of the dough 31 may be reduced as it passes through the die 10. In addition, the temperature of the dough 31 may be reduced to solidify the dough 31 and/or to set the structure of the dough 31. If the structure of the dough 31 is set during phase separation of the dough 31, the dough 31 may retain a fiber-meat-like appearance including sheared fibers. In addition to temperature, the flow output and viscosity of the dough 31 can alter the characteristics of the fibers produced in the dough 31.

Fig. 5 shows one embodiment of a processed food replica 181 having sheared fibers 71 and interstices 72 between the sheared fibers 71, i.e., a "sheared fiber and interstices structure," exiting from the mold 10. As described with reference to fig. 4, it is desirable to maintain the shear fibers 71 substantially perpendicular to the flow direction 171 of the dough 31 when producing a meat analog. As used herein, substantially perpendicular may include a shear fiber orientation of about +/-15 degrees from a direction perpendicular to the flow direction. In some embodiments, shear fibers 71 that remain substantially perpendicular to the flow direction 171 may be defined by smaller fibers that are at other angles relative to the flow direction. However, even when considering the smaller fibers contained in the sheared fibers 71, the average angle of the sheared fibers 71 relative to the flow direction 171 may remain substantially perpendicular to the flow direction 171.

Figure 6 illustrates one embodiment of a meat analog having a shear fiber and gap configuration. In fig. 6, the processed food replica 181 has been removed from the mold 10. Sheared fibers 71 and gaps 72 between the sheared fibers are shown in the processed food replica 181. FIG. 6 illustrates one embodiment of a substantially heterogeneous meat analog configuration.

FIG. 7 shows stacked sheets of one embodiment of a meat analog having a sheared fiber and gap structure. In fig. 7, the processed food replica 181 has been removed from the mold 10 and stacked. Sheared fibers 71 and gaps 72 between the sheared fibers are shown in the processed food replica 181. In some embodiments, stacked sheets of meat analog having a sheared fiber and interstitial structure may be immersed in fat and/or a fat analog. In some embodiments, the meat analog having a sheared fiber and interstitial structure may be dipped into and/or sprayed with fat and/or a fat analog. In either and/or both cases, the fat can fill the voids of the interstitial structure in the meat analog, resulting in a marbled meat analog. Such methods may be used in conjunction with and as an alternative to fat infusion methods.

Figure 8 shows an embodiment of a meat analog having a shear fiber and gap structure in which fat 131 has been injected to fill the gaps between the shear fibers. FIG. 8 illustrates one embodiment of a substantially steak-like color and shape. The fat 131 may be a high melting point fat and/or a fat mimetic. The fat 131 may fill the gap 72 created by the flow instability of the dough 31 as the dough 31 moves through the die 10. A processed food replica 181 comprising fat 131 in the gap 72 can improve the mouthfeel of the consumer compared to a processed food replica 181 not comprising fat 131.

For example, the mold 10 may include a fat injection site in the mold 10 that injects a fat or fat mimetic into the dough 31 as the dough 31 moves through the mold 10 to create a visually distinct region consisting of (1) fat and/or fat mimetic and (2) animal protein in the processed food mimetic 181. In such embodiments, the visually distinct regions are contiguous, but do not substantially mix. For example, substantially all or all of the animal protein can be limited to one or more visually distinct regions of the replica (e.g., the body and/or macrostructure of the replica), and/or substantially all or all of the infused fat can be limited to one or more other visually distinct regions of the replica (e.g., within one or more gaps in the body of the replica). As shown in fig. 8, a meat analog having a sheared fiber and gap structure into which fat 131 has been injected to fill the gaps can produce a plurality of alternating visually distinct regions (i.e., fat, macrostructures, etc.) in the meat analog. In addition to the fat and/or fat mimetics, the fat injection site may be further injected with lard and/or tallow flavors to optimize the meat flavor release in the mouth of the consumer.

Figure 9 illustrates an additional or alternative embodiment of a meat analog having a shear fiber and gap configuration. Fig. 9 shows an embodiment of a processed food replica 181 having sheared fibers 71 and gaps 72 between the sheared fibers 71 exiting from the mold 10. As described with reference to fig. 4 and 5, it is desirable to maintain the shear fibers 71 substantially perpendicular to the flow direction 171 of the dough 31 when producing a meat analog.

Figure 10 shows a meat analog having an undesirable compact, substantially homogeneous structure. In contrast, preferred embodiments of the meat analog include a heterogeneous structure having a fiber-like appearance. The meat analog in figure 10 has been cut after passing through a cooling die that is not a short cooling die. It is noteworthy that no shear fibers and interstitial structures are present in the embodiment of the meat analog according to fig. 10.

It should be understood that various changes and modifications to the 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. Furthermore, embodiments of the invention are therefore not limited to the precise details of methodology or construction set forth above, as such variations and modifications 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 used merely to distinguish one element from another.