The invention relates to a foamed, resilient, protein-based product.
Furthermore, the invention relates to a method with method variants for producing such a product set with a defined degree of pore filling.
The invention also relates to a device with device variants for carrying out the method according to the invention.
Finally, the invention relates to a use of the product according to the invention as a food product that can be customized in terms of its sensory, nutritional and health-promoting functionalities, in particular on the basis of plant-protein-based meat analogs.
Foamed, open-pored (spongy) product systems are known in the food sector for baked goods or in the field of instant products (instant soups, drinks, sauces) /1/. For the latter, the wetting and penetrating behavior in contact with fluids as well as the rapid and complete dispersibility, possibly coupled with rapid dissolving, are crucial quality and convenience criteria /2/. For the first-mentioned category of baked goods, wetting and partial dispersion occur in the saliva or liquid supplied to the consumer's oral cavity.
Foamed food systems from dry extrusion methods are known in particular as starch-based snack foods. They have low water contents (approx. ≤3-5%) to ensure their crispiness. In the extrusion methods used for such products, foam formation takes place through steam expansion as a result of a sudden drop in static pressure at the extruder nozzle outlet. Due to its fast kinetics, this process can only be controlled within wide limits with regard to the setting of a foam structure. As a result, the resulting products usually have very large pores and mostly open pores /3/.
In a few recent developments, extrusion-based foaming processes with controlled adjustment of the resulting foam structure have been implemented. In these cases, the foam was generated in the usually highly viscous masses by gas dissolution and subsequent foam bubble nucleation and foam bubble growth under controlled pressure release. The process development for doughs carried out in this way is considered wet extrusion, but under “low temperature conditions” of approx. 40-60° C. /4, 5/.
More recently, the foaming of plant protein-based meat analogs was achieved using a further developed method variant of “High Moisture Extrusion Cooking (HMEC), which takes place at high static pressures of up to 80 bar and temperatures of up to 170° C. There are no publications on this topic yet.
Reference is made below to such foam products, which can have open and closed foam pores in different ratios.
So far, the problem of a targeted filling of foamed, partly to fully open-pored food systems has not been addressed according to the published state of knowledge. This is due to the fact that the few known open-pore food products such as baked goods or meringue-like marshmallows cannot be wetted with aqueous fluids without disintegrating, and oil-based fluids neither wet well nor are nutritionally or culinary relevant in this context. The novel, foamed, plant-protein-based meat analogs produced using HMECF technology represent something special with regard to the high bound water fraction of up to >60%. Since no free water separates in the foam pores as a result of the strong molecular or intermolecular water binding in the denatured, folded protein structure, the gas pore spaces created can be used to introduce further liquids into them. This can in principle occur at least in part via long-term (hours to days) immersion of such foamed products in liquids and fluid-gas exchange taking place by diffusion. This would correspond to a kind of “marinating process”. However, such an approach leaves little room for (i) industrial production with (ii) diverse variations for product personalization and in particular (iii) the integration of sensory and nutritional product functionalities.
The possibility of accelerated absorption of additional fluid fractions and their capillary fixation in the meat analogs already produced with a pronounced water content based on HMEC is given by their foaming and adjustment of the open porosity. This poses the task of creating new sensory and nutritional tailor-made products in a form that has not been possible up to now.
The publication “Albert Schweitzer Foundation: Vegane Großverpflegung-ein Leitfaden, 2. edition, as of May 2017” describes vegan large-scale catering, i.e. a guide for large kitchens with various recipes.
WO 2012/158023 A1 describes a method for producing a structured plant protein extrudate, comprising the steps of
WO 2020/208104 A1 relates to a meat analog comprising a macrostructure of connected sheared fibers oriented substantially parallel to each other; and gaps located between the sheared fibers, wherein the macrostructure does not comprise meat and wherein the macrostructure comprises a plant protein. A fat and/or fat analog is injected into the vertical gaps such that the meat analog comprises a plurality of alternating visually distinct areas, the visually distinct areas comprising one or more first visually distinct areas comprising the fat and one or several second visually distinct areas comprising the plant protein. The vertical gaps can also be immersed in a fat solution such that the meat analog comprises a plurality of alternating visually distinct areas, the visually distinct areas being one or more first visually distinct areas comprising the fat and one or more second visually distinct areas comprising the plant protein. The macrostructure may comprise a texturized plant protein or micronized plant material, wherein the micronized plant material comprises at least one of the group consisting of hulls, fibers and mixtures thereof. The meat analog is shaped to resemble a marbled meat. The macrostructure should have a non-homogeneous structure. Also contemplated is an extrusion system for the production of a meat analog, the meat analog comprising a plant protein, the extrusion system comprising an extruder and a short nozzle; wherein the extruder is connectable to the short nozzle and configured to direct a material comprising a plant protein from the extruder to the short nozzle and through a fluid path extending through the short nozzle, wherein the short nozzle is configured to inject a fat or fat analog into the material such that the fat or fat analog is embedded but visually separated from the material comprising the plant protein when the fat or fat analog and the material leave the short nozzle. A method of extruding a meat analog is described, the following method steps to be applied: applying pressure to the meat analog with an extruder; and passing the meat analog through a short nozzle in a flow direction, the short nozzle being part of and/or connected to the extruder, and generating sheared fibers in the meat analog substantially perpendicular to the flow direction of the meat analog as the meat analog passes through the short nozzle. An addition of pea skin to the meat analog is also described, with the meat analog also being said to contain pea proteins or field bean proteins.
The invention is based on the object of creating a foamed product of the specified type with predetermined functional properties.
Furthermore, the invention is based on the object of providing a device for producing such a product.
In addition, the invention is based on the object of proposing a method with which such a product can be produced.
Finally, the invention is based on the object of proposing a use according to the invention of such products.
This object is achieved according to the invention by a foamed, resilient, protein-based product with a dry matter fraction of 20-98% by weight, bound water fraction of 2-80% by weight and a partially to fully filled open pore structure, the ratio of the volume of fluid-filled pores open towards the product surface (OGP) to the total volume of open pores in the product is set in the range 0.05.
The present invention is based on a generic concept for the personalization of sustainably produced food systems made from plant protein and plant fibers, with special consideration of meat analogs. “High Moisture Extrusion Cooking” (HMEC) technology has become more and more established for the production of meat analogs, which already come quite close to prepared meat in terms of their texturing. Compact, fibrillar, meat-like structures can thus be achieved. However, this technology has so far been limited in terms of further improvement and defined adjustment of the sensory aspects (1) tenderness, (2) juiciness, (3) crispiness and (4) taste/aroma. The development of HMEC microfoaming (HMECF) of plant protein-based meat analogs, which is in its initial phase, has shown new possibilities for implementing next development steps in terms of improving the relevant sensory quality aspects (1)-(4).
This is where the product, process and device development according to the invention begins. In an invention made parallel to the further development according to the invention described at this point, mechanisms for the production of open-pored, foamed meat analogs could be identified. This paved the way for the prominent use of open-pored HMECF-based meat analogs to advance the improvement of their properties and personalization.
The adjustable filling of open foam pores in terms of degree of filling and filling fluid as well as the diverse possibilities of integrating a range of sensory, nutritional and health-related components into corresponding filling fluids led to the product, process and device developments according to the invention presented at this point. For filling open pores with characteristic diameters of approx. 10-500 microns, (a) capillary forces, (b) pore elastic relaxation after deformation, (c) infusion and (d) ultrasonically forced diffusion were identified as the main physical mechanisms and which are to be applied individually or in combination. The method steps considered relevant were developed based on these mechanisms and the devices suitable for carrying out the same were derived.
For the sensory optimization of a foamed meat analog texture, gas volume fractions of 5-10% already show a significant reduction in product firmness. Above 30% gas volume fraction, the aspect of increased soft rubberiness (“marshmallow consistency”) can become detectable. This is particularly true in the case of closed foam pores, since the trapped gas fraction expands again after compression when biting/chewing deformation is imposed. In the case of open pores, the gas in the pores is pushed out of the pores into the environment without any associated damping effect on the deformation process under deforming stress and is (partially) sucked in again when it relaxes. The gas inflow and outflow does not have any significant influence on the texture perception. If the open pores are filled with fluid, as the fluid viscosity increases, the outflow from open pores, which is delayed or impeded as a result, contributes to a firmer texture perception.
Furthermore, the sensory aspect of crunchiness is supported by open pores, since a critical elongation at break of the pore walls is more likely to be reached without a damping effect, such as that occurring through a non-escape gas cushion in a closed pore. When the pores are filled with fluids that have a low viscosity (up to approx. 100 mPas), “juiciness” is also perceived more strongly when the pores are deformed and the fluid escapes from open pores.
Thus, fluid-filled, open foam pore systems can be expected to have improved sensory properties in meat analogs with regard to tenderness, crispiness and juiciness.
Further inventive configurations are described in claims 2 to 19.
According to claim 2, the invention is characterized in that the volume fraction of filled open pores based on the total volume of all open and closed pores is between 0.05-1, preferably between 0.2-0.95, and is set for values ≥0.1 with an accuracy of +/−0.05.
For the food group of plant protein-based meat analogs that is particularly under consideration, a maximum of 50% gas volume fraction due to foaming is targeted in order to avoid excessively pronounced “rubberiness”. The pores are opened by means of pore opening technologies using the mechanisms (a) pore opening by setting a rapid drop in ambient pressure (Flash-Opening, FOP), (b) pore opening by splitting or peeling the product (CUT-Opening, COP), (c) pore opening by multiple needle penetration (Penetration-Opening, POP) or (d) pore opening by generating a secondary mixed flow (Mix-Opening, MOP) in the extruder cooling nozzle, adjustable usually between 10-60%. This means that in the case of the preferred contemplated meat analogs there is between 5-30% open pores.
According to claims 3 to 10, compositional aspects (water, protein, fiber contents) of the product foam structure are addressed, which on the one hand relate to the mechanical properties (structure strength, fibrillar structure) thereof, and on the other hand also to nutritional aspects (fiber, fat/oil fractions).
Claim 10 also refers to the possibility of carrying out the filling of the pores in the dried state of the foamed framework matrix with water contents ≤10% by weight, based on the total mass, in the semi-moist state with water contents between 10-40% by weight, or in the moist state of the foamed framework matrix, as it is present directly after HMECF production with water contents of between 40-70% by weight, based on the total mass. Although a drying step of the product after HMECF extrusion means additional production and energy expenditure, it is of interest with regard to product packaging, storage and shelf life aspects. Due to their high water content, meat analogs produced by HMECF can only be placed in food retailing under cold storage conditions. However, for the open-pored, foamed meat analogs, in the case of drying, there is the possibility with less complex packaging, to design the product storage under room temperature conditions and the functionalization by pore filling during reconstitution using the special structure-related instant reconstitution properties due to open pores, in the dried or partially dried state.
Claims 11 to 19 relate to the composition and properties of the pore-filling fluids with the associated diverse possibilities of introducing a wide range of sensory, nutritional and health-promoting functionalities into the products with filled pores via these pore-filling fluids.
Against this background, with the products according to the invention, filled with functional fluid fillings in the open product pores, a variety of problem solutions with regard to more personalized nutrition can be addressed in a significantly simplified manner. In addition to facilitating the manufacture of sensory and nutritionally customized products on an industrial production level, the end consumer will also be able to make corresponding individual optimizations under optimal convenience boundary conditions.
This will initially relate to the foamed, open-pored plant protein-based meat analogs according to the invention, but will not remain limited thereto, since the generic concept of the functional filling of open-pored food product systems on which the invention is based can be transferred to further new product developments.
This object is achieved according to claim 20 in that, for filling the open pores of the foamed product the four filling mechanisms are applied, individually or in combination, (a) filling by means of capillary forces (BK), (b) filling by means of elastic pore Relaxation (BE), (c) filling by infusion (BI), and (d) filling by diffusion (BD).
The mentioned filling mechanisms for open foam pores activated according to the invention can be combined in a simple manner with the HMEC extrusion technology and with the methods steps for opening the foam pores upstream of the filling of open pores, or can be integrated into a compact production process.
If, for example, pores are opened by static residual pressure release at the end of the extruder nozzle so that closed pores are opened towards the product surface, an associated elastic reverse deformation of the product matrix in the opened pore channel area can be used to suck in a fraction of pore-filling fluid, possibly supported by superimposed mechanical pressure deformation and elastic shape relaxation. The same applies to the combination of a pore opening via sudden vacuum application, which, when carried out in the immersion bath filled with pore-filling fluid, is followed by a subsequent suction of the fluid into open pores. Finally, pore opening by means of needle penetration can also be combined for filling using hollow needles. With regard to pore filling using hollow needles, it should be noted that this type of filling differs according to the invention from infusion methods known from the meat industry, such as those, e. g. used in the production of boiled ham, in that during needle penetration into a foam structure such as that in this case, the injected pore-filling fluid contributes to the rupture of pore walls as a result of the imposed filling pressure and thus further pores that are still closed are opened.
Claims 21 to 27 describe in detail the pore-filling methods by means of the mechanisms (a)-(d) in their respective procedural implementation. Aspects of adaptability to HMEC technology are highlighted.
This object is achieved by claim 28 with reference to the four pore-filling mechanisms (a-d) differentiated according to the invention. The following description of the devices associated with these mechanisms is supplemented by
The devices for filling the open foam pores assigned to the method steps according to the invention are also technically compatible with HMEC technology and the various method steps downstream of the HMEC extruder, either individually or in combination, for adjustable pore opening. The inventive at least partial combinability of the devices for opening the foam pores with the devices for filling the open foam pores described in more detail below is of considerable advantage in an integrated design of the overall production process of tailor-made functionalized meat analogs, but not limited to these products.
According to claims 29 to 35, the pore-filling devices are described in detail based on the associated method steps using the pore-filling mechanisms (a)-(d) in their respective process engineering environment. Again, aspects of adaptability to HMEC technology are highlighted.
This object is achieved by claim 36 for foodstuff with specific sensory, nutritional and health-promoting properties for specific consumers or patient target groups.
Although there has been talk of personalized nutrition for years, practical implementation concepts only include larger target groups (e. g. those with certain intolerances or allergies or deficiency symptoms, pregnant women, infants or the elderly). This is due in particular to the additional effort in the production methods required in the industrial production of food products with a further reduction in the size of target groups down to individuals, and in the production and distribution logistics.
The concept according to the invention of filling open-pored foam systems with fluid systems that can be individually tailored with regard to sensory, nutritional and health aspects allows to reach a new milestone by the industrial production of open-pored product matrices with a downstream simplified functionalization step by pore filling with an assortment of fluids, flavorings and aromas (incl. spices), micro-nutrients (vitamins, trace elements) as well as health-promoting components (antioxidants) with simplified methods and reduced logistic effort.
Claims 37 and 38 underscore the above-mentioned advantageous possibilities of the product applications according to the invention and emphasize the special reference to plant protein-based meat analogs.
In the drawing, the invention is—partly schematically—described using exemplary embodiments. In the drawings:
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The height adjustability of the lower deflection rollers is denoted by H1, while H2 indicates the overall height of the pore-filling fluid bath.
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The features described in the claims and in the description and evident from the drawing can be essential for the implementation of the invention both individually and in any combination.
Number | Date | Country | Kind |
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10 2020 007 888.5 | Dec 2020 | DE | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2021/000154 | 12/6/2021 | WO |