Patent Application
20230320378
This disclosure relates to the production of alternative protein products, including plant based meat and dairy analogs, and more particularly to plant based products having the protein content, texture and, appearance of meat or fish, and the ability to be flavored as desired.
Consumer standards for instant, home-cooked meals have evolved rapidly in recent years, and demand for products that can be prepared at home has increased. When cooking instant food at home, consumers have always wanted meals that can be prepared rapidly and taste good. More recently, however, consumers demand instant foods that are fresh, healthy, clean label, plant based and sustainably produced.
One method of producing instant, textured plant based meat alternatives at home involves using dry vegetable proteins, typically pre-texturized vegetable proteins, as an ingredient or component that contributes texture. Instant food, as used herein, may be defined as a convenience food that requires minimal preparation, and typically involves adding just one or two components to a pre-prepared base composition. Instant food may require less than five minutes of preparation. Typically, proteins used as ingredients in preparation of plant based meat analog instant foods are derived from soy or pea, however, products using these proteins have generally not been commercially successful. Hemp based instant food products, or meat and dairy analogs, have generally not been described in food industry or food science literature. When used as an ingredient in food products, hemp protein is generally considered to be inferior to soy and pea protein, particularly with regard to the properties required for the production of meat analogs.
Currently, soy and pea protein-based products dominate the meat analog market, with companies like Impossible Foods® and Beyond Meat® producing a large percentage of meat analog products. Meat analogs produced by these companies are pre-prepared and use a high number of ingredients, and are generally sold pre-packaged, like fresh or frozen animal meat products. Most pre-prepared plant based meat analogs must be cooked, generally using a stove or oven, prior to consumption. Manufacture of these products generally requires extrusion at relatively high temperatures of approximately 120° C. to 140° C. in order to obtain a texturized protein. Blending of the pre and post texturized protein with other ingredients such as cellulose, starch, sugars, oil and binders is generally required for formation of the protein blend to have the appearance of a fresh hamburger or other animal meat product. These products also generally require immediate microbiological stabilization by continued refrigeration or freezing for example, and packaging prior to sale. Currently, these types of products do not have valid claims with regard to sustainability and as a clean label material.
Soy, pea, wheat gluten and other protein isolates used in producing conventional meat analogs are not capable of forming a well-texturized or meat-like product without prior extrusion of the protein. U.S. Pat. No. 3,662,673 to Boyer discloses the use of microwaves to produce a textured protein product. The texturized protein products produced using proteins like those described in Boyer, such as soy protein isolate, or even by traditional soy-based tofu processing which requires chemicals such as Calcium chloride, however, have a low degree of expansion and result in products that are not acceptable to most consumers. The texture for products produced generally by the methods according to Boyer or soy tofu processing, are essentially uniform in a cross-sectional view and lack the elasticity, fibration and texture of meat.
The inability of soy and pea protein isolates to properly texturize without first subjecting the isolate to conventional extrusion at temperatures well above 100° C., limits their utility for use in rapid, or instant, meat and dairy analog applications. Additionally, the extrusion process due to the temperatures above 100° C. limits the inclusion of water into the extruded texturized soy and pea protein which then requires pre-hydration of the extruded texturized protein prior to use. Importantly, after extrusion, the protein has been destroyed such that its ability to hold water within the protein structure itself (instead of between the protein pockets as in a sponge), such that other ingredients are required to hold the moisture to mimic the natural moisture held within the structure of meats.
Therefore, it is clear that there exists a need for instant, fresh, texturized plant meat analogs that can replicate the texture of meat or fish; that can readily be made if desired in the home without industrial equipment or chemicals like extruders and retorts, or calcium chloride; without using temperatures above 100° C. to achieve texturization of the protein; without allergenic materials such as soy or wheat gluten; and without numerous ingredients such as starches, gums, and emulsifiers to hold the necessary water and oil to mimic the meat texture and nutritional composition of a variety of meat and fish analogs.
Hemp based meat or dairy analogs, produced using only hemp grain as a protein source, are not known to be commercially available and have not been described in food industry or food science literature. For use in food products, hemp protein is thought to be inferior to soy and pea protein, particularly with regard to properties required for the production of meat and dairy analogs. Meat and dairy analogs, which may also be referred to herein as structured protein food products, require proteins capable of forming a strong gel matrix, and hemp protein has not been found to have strong capability in that regard.
According to Wang, the “emulsifying and gel-forming properties of hemp protein are found to be generally inferior to those of soy protein.” (Wang et al., 2019). While Malomo showed that salt micellization isolation of hemp protein can improve its gel forming capability, Shen discloses that this complex, costly and time consuming method of protein isolation negatively impacts protein structure, and that chemical crosslinking agents may be required for sufficient gel forming capability in hemp protein. (Shen et al., 2021; Malomo et al, 2014; Wang et al., 2019).
As indicated by Wang, soy protein is currently favored over hemp protein for production of meat analogs. “Currently, mostly soy proteins are used to mimic animal proteins because of their favorable gelling properties and the resulting creation of an interlaced, fibrous matrix.” (Schreuders et al., 2019). The latter fibration of soy occurring at typical temperatures of 130° C. (266° F.). For example, IMPOSSIBLE FOODS uses soy protein in its IMPOSSIBLE BURGER. Due primarily to health and nutrition-related concerns about soy products, however, BEYOND MEAT, the largest competitor for IMPOSSIBLE FOODS, uses yellow pea protein in its BEYOND BURGER. Yellow pea, however, “has a much lower gelling capacity than soy protein” and “heat induced gels of soy protein isolate (SPI) are stronger than heat induced gels of pea protein isolate (PPI).” (Schreuders et al., 2019).
While soy and pea protein have known taste, texture and phytochemicals limitations as a protein source for meat and dairy analog production, no successful plant based alternative protein replacement has yet been found for meat analogs. Hemp protein, however, has been investigated as a potential substitute for soy protein in meat analogs. Recently, Zahari reported that, while hemp protein has been recognized for its superior nutritional and functional properties, it had not yet been used in meat analog production. “Previous works have shown that hemp seed protein in particular, has a high protein quality and functionality. However, no study uses hemp seed protein as a raw material for meat analog production.” (Zahari et al, 2020).
Zahari went on to demonstrate that hemp protein concentrate (HPC) could be used in combination with soy protein isolate (SPI) to produce a meat analog by conventional extrusion, but not as a sole source of protein. The study concluded that, “HPC could therefore be a promising novel material to be included into extruded products and this study shows that the resulting meat analog gave a comparable texture to SPI alone, and that soy protein could be substituted by hemp protein by up to 60%.” (Zahari et al, 2020). With regard to the use of higher concentrations of hemp protein in the formulation, the study showed that this resulted in unacceptable decreases in hardness and chewiness in the meat analog product. Thus,
Zahari, Wang and Shen teach away from the use of hemp protein as a sole protein source in meat analog production.
Despite the need for new and improved sources of plant protein to meet the growing demands of the plant based food industry, hemp protein has not yet achieved significant market share in food production. Soy and pea protein continue to dominate the plant based food market, despite the nutritional and environmental advantages of hemp. Soy and pea protein benefit from decades of study and wide commercial availability and use, in meat analog production and other food products, has resulted in great improvements in ingredient and product quality and cost benefits in scale.
Improvements in soy and pea-based meat analogs have come through extensive research and development in all stages of meat and dairy analog production. Meat analog production generally involves four steps. The first step involves protein isolation from a selected plant material. The second step involves combining the isolated protein with water and oil to form a matrix for thermal gelation or extrusion. The third step involves thermal gelation or extrusion of the raw material to set and texturize the protein. The final step is using binders and water binding agents such as carrageenan, cellulose fibers, starch, gluten, or flours to form a meat analog product that may then be cooked to simulate products such as hamburger, filets, chicken pieces and pulled pork.
The first step of meat analog production involves protein isolation from a plant material. Conventionally, soy and pea protein are use as plant material for protein isolation. Hemp grain protein, however, has excellent digestibility and desirable essential amino acid composition and has been considered as a possible source of protein for meat analogs (Tang, Ten, Wang, & Yang, 2006; Wang, Tang, Yang, & Gao, 2008; Russo and Reggiani, 2015a; Callaway, 2004; House et al., 2010; Docimo et al., 2014; Zahari et al., 2020). A recent proteomic characterization of hemp grain concluded that hemp grain is an underexploited nonlegume, protein-rich grain (Aiello et al., 2016).
While the nutritional potential of hemp proteins is high, the nutritional quality of plant proteins, as measured by their amino acid composition and digestibility, is influenced by numerous factors. The amino acid composition may be influenced by genotypic variability or agronomic conditions such as soil fertility and postharvest processing that alters the ratio of grain components (e.g., hulling). The digestibility of proteins may be affected by protein structure and the presence of antinutritional compounds in the plant material or formed during alkaline or high temperature processing (Sarwar, 1997). Aiello, however, found that antinutritional factors including condensed tannins, phytic acid and trypsin inhibitors are present in low concentrations in hemp grain (Aiello et al., 2016).
Functional characteristics of hemp protein have hindered its use as a protein source in food products. Hemp protein concentrates commercially have been available as the result of hemp seed oil production. Hemp seeds after being milled and pressed for the lucrative oil, result in a protein rich seed cake. The seed cake is green in color, high in fiber and represents a protein concentrate of about 40%. Unfortunately it has a very green, and earthy flavor not acceptable in the majority of food products. Milling of this cake and dry sifting can increase the protein content to about 50%. Many researchers who recognized the nutritional value of this protein rich source, have used it as the starting material to isolate and improve the taste and functional qualities of the hemp protein. Tang found that hemp protein isolate (HPI) from the seed cake was inferior to SPI for use in making plant based foods (Tang et al., 2006). Tang showed that, for HPI, the poor water solubility of hemp globulin is believed to result in its poor emulsifying and water holding properties when compared with soy protein isolate (Tang et al., 2006; Hadnadev et al. 2020). According to Tang, “[t]he data suggest that HPI can be used as a valuable source of nutrition for infants and children but has poor functional properties when compared with SPI. The poor functional properties of HPI have been largely attributed to the formation of covalent disulfide bonds between individual proteins and subsequent aggregation at neutral or acidic pH, due to its high free sulfhydryl content from sulfur-containing amino acids.” (Tang et al., 2006). Further, “Differential scanning calorimetry (DSC) analysis showed that HPI had only one endothermic peak with denaturation temperature (T(d)) of about 95.0° C., attributed to the edestin component.” (Tang et al., 2006).
Despite the apparent inferior functional aspects of hemp protein, its superior nutritional qualities have generated continued interest in its use in food production. To this end, individual proteins have been isolated from hemp and further studied for potential functional properties. Additionally, researchers have investigated whether different methods of extraction and isolation of hemp protein could improve functionality. “The value and application of hemp protein in food products are closely related to the protein structure and functional properties.” (Wang et al., 2019).
To investigate the nutritional and functional properties of individual hemp grain proteins, researchers have employed methods to extract and separate two of the primary proteins present in hemp grain. Hemp grain protein is primarily comprised of the proteins edestin and albumin. Edestin, a globulin, accounts for approximately 60% to 80% of the total protein content (Odani & Odani 1998; Tang et al., 2006), while albumin, a globular protein, but not a globulin, makes up the difference. Edestin and albumin have different amino acid composition and functional characteristics.
Malamo studied the nutritional differences between edestin and albumin in hemp grain and concluded that the edestin fraction of hemp protein is nutritionally superior, with higher sulfur-containing (methionine and cysteine), aromatic (AAA), branched-chain, and hydrophobic amino acids (Malomo and Aluko 2015). Malamo separated edestin from albumin and measured characteristics of each for nutritional value and functionality. These characteristic include solubility in water, amino acid content and digestibility.
Malomo reported that the albumin fraction is soluble in water, whereas the edestin fraction is soluble in salt solution. Extracted edestin has extremely low solubility in water at neutral or acidic pH and is soluble only at high ionic strength or alkaline pH (Malomo & Aluko, 2015). “Many protein functionalities such as surface-active properties are correlated with protein solubility.” (Jackman & Yada, 1989; Malomo & Aluko, 2015). In hemp grain, edestin was found to have better emulsion forming ability, while the solubility and foaming capacity of albumin are higher than those of edestin (Malomo & Aluko, 2015).
Research indicates that edestin may be found only in hemp grain, although edestin-like proteins, may exist in grains from a family that includes pumpkin and squash (Vickery, 1940). Therefore, the present disclosure and its applications may relate to edestin and edestin like proteins, which may have similar or identical properties to edestin. Vickery disclosed that potential substitutes for edestin might found in plants of the family Cucurbitaceae, which includes squash seed. Hirohata has examined the globulins of 38 varieties and species of eight genera of this family and has drawn attention to the close similarity of the globulins from closely allied species (Vickery, 1940; Hirotata, 1932). Vickery suggested that the globulin of the Cucurbitacea family may include edestin-like proteins that fulfill the requirements of a nutritional substitute for hemp-grain edestin (Vickery 1940).
Edestin was first isolated and analyzed by Thomas Osborne (Osborne, 1892). In its full native form, edestin is composed of six identical subunits, each consisting of an acidic (AS) and a basic (BS) subunit linked by one disulfide bond (Farinon 2020; Patel, Cudney, & McPherson 1994). Recently, it has been shown that edestin can exist in several forms, even within a single variety of hemp (Docimo et al., 2014). For example, in one variety of Cannabis Sativa, seven genes code for edestin globulins, and they result in divergent forms of two edestin types. Within certain strains of hemp, edestin of one type are practically identical to each other, whereas edestin of the second type are substantially different from the first. Ponzoni identified a type 3 edestin gene, CsEde3, which shows approximatively 65% and 58% sequence homology when compared to the genomic forms of CsEdeland CsEde2, respectively (Ponzoni, Brambilla, and Galasso, 2018). Amino acid composition may vary significantly between the two types of edestin, with some types having greater nutritional quality (Docimo et al., 2014).
Edestin itself has a large particle weight of 309,000, but on denaturation depolymerizes to 51,000 in concentrated urea solutions [Burk & Greenberg, 1930] and to 17,000 in dilute HCI [Adair & Adair, 1934]. These units are respectively about ⅙ and 1/18 the size of the native molecule. In the native state they possess a specific polypeptide pattern, and are integrated partly perhaps by some form of chemical linkage (e.g. S—S bonds), but chiefly by lateral attractions between neighbouring CO and NH groups and by interactions between free acid and basic groups of the side chains. The number of these latter groups is high, as can be seen from the following analytical data: glutamic acid, 19-2 %; aspartic acid, 10-2 % [Jones & Moeller, 1928]; arginine, 17-76 % [Vickery, 1940]; lysine, 2-4 %, histidine, 2-03 % [Tristram, 1939]; amide-N, 1-73 % [Bailey, 1937, 2]. Allowing for amidized COOH groups, they correspond to a total of 670 charged groups per molecule of 309,000. The spatial arrangement of such charges gives rise to a specific charge symmetry on which the stability of the molecule must ultimately depend, and this is capable of some variation, as reflected in a change of dipole moment, within definite limits of pH. Outside these limits, a further suppression in the ionization of acid or basic groups sets up within the molecule attractions and repulsions which, especially in the absence of small mobile ions, distort and finally destroy the unique polypeptide configuration. (Bailey, 1940).
Therefore, edestin, as referred to in the present disclosure may incorporate all forms of edestin, as may be currently known or currently unknown, that have similar or identical properties to the edestin disclosed for the purposes of the present disclosure.
Edestin is subject to rapid degradation to edestan under mildly acidic conditions. Edestan, an intermediate product derived from edestin, occurs during the denaturation of edestin and was first identified by Osborne (Osborne, 1901; 1902). Edestan is formed when edestin comes into contact with dilute acids. Edestan results in the liberation of SH groups (Bailey, 1942). Bailey demonstrated that under acidic conditions edestin can be rapidly converted to edestan in less than 20 minutes (Bailey, 1942). This study showed that liberation of SH groups is concomitant with the conversion of edestin to edestan. Bailey also reports a decrease in nitrogen content for edestan when compared to edestin, which could be explained by a reduction in tryptophan in edestin. Edestin in its non-denatured, native state has different functional properties than denatured or partially denatured edestin or edestan.
Conventional techniques for isolating hemp protein, or separating edestin from albumin, may cause structural changes in the protein, some of which may be irreversible. Different protein extraction and isolation techniques and conditions (pH, presence or absence of mono- and polyvalent salts, ionic strength of medium used for protein extraction, time, temperature, etc.) can influence protein functional properties (Hadnadev et al., 2018). These changes can negatively affect the functionality of the protein (Hadnadev et al, 2018; Shen et al., 2021). These negative effects may include changes to digestibility, protein-oil interactions, taste, solubility, and emulsifying and gel formation capability (Shen et al., 2021). Therefore, when extracting and isolating edestin, particularly for use in food products, it is critical to maintain the native structure of the protein to the greatest extent possible.
A number of different techniques have been utilized to isolate hemp proteins and edestin. These techniques include the use in aqueous or solvent slurries, of high temperatures, alkaline or acidic conditions, isoelectric precipitation, isoelectric focusing, micellization, ultrafiltration, and mechanical processes, including pressing, milling or sifting the grain or hulled grain, or milling the grain and sifting a grain slurry. Any one of these techniques has the potential to alter protein structure and decrease its functionality.
High temperatures created by mechanical processes can negatively affect protein functionality. For example, milling grain to produce flour may generate temperatures high enough to alter the structure of proteins. These temperatures may cause denaturing of the edestin and binding or aggregation between edestin,albumin or fiber potentially, thereby interfering with their independent isolation.
Dry milling of grain may generate temperatures of at least 80° C. to 100° C., potentially denaturing edestin. Mohammad found that heat and mechanical forces generated during milling can denature globular proteins (Mohommad, 2015). Mohommad showed that mechanical stresses applied during the milling can change the bulk properties of globular proteins.
The high temperatures caused by dry milling to produce flour may, therefore, alter hemp protein structure. Farinon calculated the denaturation temperature of hemp grain protein (edestin) to be 92° C. (Farinon et al., 2020). Further, Malamo showed that heat treatment, as well as changes in pH, may alter the secondary structure of hemp grain albumin and edestin (Malomo and Aluko, 2015). High temperatures may cause proteins to unfold, thereby exposing their hydrophobic groups and favoring protein-protein interactions over protein-water interactions.
Heating during extraction may be avoided or minimized by using chemical means of protein extraction, however, many chemical methods of extraction first require mechanical reduction in grain size. Solvent extraction is a common method of separating proteins from plant material involving the use of a liquid solvent into which the protein containing material is added. The solvent may be water, alcohol, acetone, hexane or other liquid solvent. Solvent extraction may be combined with mechanical or other means of extraction that first break down the plant material allowing proteins to be released. Solvent extraction may involve the use of solvents that break down plant cell walls or fibrous material, thereby releasing proteins.
Some solvents used in protein extraction have the disadvantage of denaturing proteins. Further, these solvents may be toxic and not suitable for ingestion, even in small quantities. Additionally, solvents generally require long extraction time, labor-intensive procedures, leave residual solvent in a food product and may be difficult to dispose of safely. Hexane is an example of this type of solvent. Many solvents cannot be used to produce certified organic food products under United States Department of Agriculture’s (USDA) guidelines for organic food labeling.
One alternative process of protein extraction that does not require solvents is aqueous extraction, which involves adding plant material, which has been milled or pressed, to water, followed by separation of proteins based on solubility of proteins in the aqueous fraction or the solubility of proteins in the fat containing fraction when fats in the plant material separate from the water. Aqueous extraction may be followed by isoelectric precipitation or focusing or salt extraction to isolate a protein.
Alkaline extraction is a common technique where a highly basic solvent breaks cell structures, thereby releasing proteins from the cell. This process, however, can result in damage to the protein, including amino acid racemization, lysinoalanine formation, digestibility decrease and loss of essential amino acids (Moure et al., 2006). According to Xu, under alkaline conditions, polyphenols, found in many plant materials including hemp grain, oxidize and subsequently can react with protein, resulting in dark green or brown color of extracted protein solutions (Xu and Diosady, 2002).
When used during hemp grain protein extraction, alkaline extraction pH is generally raised to 9 or 10, higher than that for legume protein extraction (pH 8), because native hemp grain proteins are tightly compacted, and may be closely integrated with other components, for example, phenolic compounds (Wang and Xiong, 2019). Alkaline extraction is generally followed by precipitation of a target hemp protein at an isoelectric point, and after several washing steps, often, the induced color cannot be removed from protein isolates.
Aqueous or alkaline extraction is generally followed by isoelectric precipitation or salt extraction to isolate a protein. Isoelectric precipitation may be used after alkaline or solvent extraction to extract a soluble protein and involves adjusting the pH until an equilibrium of charge between the target protein and the solvent is reached, thereby causing the protein to precipitate from solution. Isoelectric precipitation requires changes in pH that may alter protein structure, thereby negatively affecting protein functionality.
With regard to isoelectric precipitation for edestin, Bailey discloses that the isoelectric zone of edestin is pH 5.5 (Bailey, 1942). In this process, albumins can largely be eliminated during precipitation of edestin at its isoelectric point (Papalamprou et al., 2009). This result may be ascribed to high solubility of hemp grain albumins (>75%) at pH 5.0, in comparison to hemp grain globulins (<10%) (Malomo & Aluko, 2015). One advantage of isoelectric precipitation over other protein isolation methods is that water binding capacity has been found to be higher for protein isolates obtained by isoelectric precipitation in comparison to the same isolates derived by micellization extraction (Krause et al., 2002). A disadvantage of isoelectric precipitation during edestin isolation, however, is that solubility of the protein is lower when compared to edestin isolated by salt extraction, suggesting that the protein is no longer in its native state (Hadnadev, 2018).
When compared to alkaline extraction and isoelectric precipitation, salt extraction, which may involve micellization, represents a milder extraction procedure, one that does not cause polyphenol oxidation, polymerization and co-extraction with protein. Salt extraction involves “salting in” a group of proteins followed “salting out” of a target protein. “Salting in” refers to an effect where increasing the ionic strength of a solution increases the solubility of a solute, such as a protein. This effect tends to be observed at lower ionic strengths. “Salting out” involves increasing the salt concentration further, such that the abundance of the salt ions decreases the solvating power of salt ions, resulting in the decrease in the solubility of a target protein and precipitation.
One method of salt extraction, as described in U.S. Pat. No. 6,005,076 to Murray, includes a micellization step. Salt extraction using micellization involves first solubilizing proteins with a salt solution having a certain ionic strength. Next, the saline solvent is diluted in the concentrated protein solution to reduce the ionic strength below a certain level, thereby causing the formation of discrete protein particles in the aqueous phase at least partially in the form of protein micelles. The protein micelles then settle to form a mass of target protein isolate. The protein isolate may then be separated from supernatant liquid.
Salt based micellization extraction, such as that disclosed by Murray, has the advantage of producing protein isolates of higher solubility in comparison to isolates obtained by isoelectric precipitation (Karaca et al., 2011; Krause et al., 2002; Paredes-López and Ordorica-Falomir 1986). In addition to improved solubility, interfacial activity was higher for protein isolates obtained by the micellization technique when compared to isoelectric precipitation. Further, according to Krause and Papalamprou, micellization extraction resulted in protein isolates of more preserved native protein structure when compared to isoelectric precipitated proteins (Krause et al., 2002; Papalamprou et al. 2009). Generally, isoelectric precipitation results in some degree of denaturation of extracted proteins, and this can result in hydrophobic interactions between protein molecules, leading to the formation of insoluble protein aggregates. While salt extraction and micellization may be the least damaging of the known methods of hemp protein isolation, the addition of salt during isolation does have a negative impact on protein structure and function. “The addition of NaCl also exerts different influence on the gel structures. Specifically, increasing NaCl concentration (up to 300 mM) promotes intensive protein-protein interactions and aggregation, causing the formation of HMI [Hemp Protein Micellization Isolates] gel structure with larger pore sizes.” (Shen et al., 2021).
Salt extraction was the first method used to isolate edestin from hemp grain (Osborne, 1892). This method was further developed by Malomo, who utilized the micellization technique to extract edestin (Malomo and Aluko, 2015). As Malomo demonstrates, during salt based micellization extraction, albumins remain in the supernatant after salt removal in the dialysis step, while globulins precipitate and can be collected by centrifugation. In Malomo, a globulin isolate was produced through salt extraction of hemp grain meal followed by dialysis in dialysis tubing against water.
Dialysis of a salt extract of hemp grain meal led to precipitation of the water-insoluble globulin in micelle form while albumin remained in solution (Malomo and Aluko, 2015). The precipitate was then collected and freeze-dried. When comparing hemp protein albumin and globulin fractions, albumin had significantly higher protein solubility and foaming capacity than globulin, while no differences in emulsion forming ability were observed between the two protein fractions. Salt extraction, and micellization, has high labor, time, material, equipment and waste disposal costs, and is not currently considered to be commercially viable for protein extraction for use in food products.
Ultrafiltration is another method that may be used to generate protein isolates having improved functional properties when compared to other conventional protein extraction techniques. For example, when compared to alkaline extraction, protein isolates obtained by ultrafiltration generally have better emulsifying properties. One disadvantage of ultrafiltration, however, is membrane clogging due to the precipitates forming in the final product, which can result in high extraction costs.
Newer methods of protein extraction include ultrasound assisted extraction, enzymatic assisted protein extraction, and electrical methods of protein extraction. These methods have disadvantages including high cost, low yield, protein degradation and protein impurity. Conventional methods of extraction, including salt extraction, alkaline extraction and isoelectric precipitation therefore still predominate as methods of extracting proteins from plant material such as hemp grain.
With regard to published methods of extracting and isolating hemp using the methods described herein above, an example of aqueous protein extraction of hemp grain followed by isoelectric precipitation is disclosed in U.S. Pat. No. 10,555,542 to Crank. Crank discloses first milling of the hemp grain using any suitable means including grinding using a hammer mill, roller mill or a screw-type mill. Milling by these processes is a high energy process that generally results in high temperatures, generally around 140° F. to 150° F. To achieve a paste, these high temperatures are required, as paste formation from solid does require a certain high temperature, as is known in the art of peanut butter production. These temperatures may cause undesirable interaction between protein components of the grain material, in some cases, depending on the final application of the product. In Crank, milling produces a paste or a flour (a flour when the grain is first pressed to remove oil), where water may be added to the milled material in a ratio of about 4 to about 16 parts by weight to each part of plant material. Crank discloses adjusting the pH to approximately 7.5 by adding a base, such as calcium hydroxide, to facilitate extraction of the proteins.
The resulting solution is then centrifuged to separate the fat fraction from the aqueous fraction, or reduced-fat extract. The reduced-fat extract can be used as reduced-fat plant milk or be further processed to produce protein concentrate or protein isolate. In Crank, proteins in the reduced-fat extract were concentrated by precipitation and separated to produce a plant protein concentrate or isolate from partially defatted plant material. Crank discloses the proteins in the reduced-fat extract can be precipitated by adding acid, such as citric acid, to the isoelectric point of the protein. Crank does not disclose that aqueous extraction alone may be used to separate edestin and albumin. Further, while Crank does mention in the application that hemp seed may be a source of protein isolated for food products according to the Crank process and that the hemp seed contains edestin, Crank does not disclose the purification and isolation of edestin. Crank discloses discarding the fiber and protein containing portion of hemp protein after centrifugation.
Czechoslovakia Pat. No. 33,545 to Beran discloses a method for extracting edestin from hemp grain to produce a protein for human consumption. In the background section of the patent, Beran discloses that hemp protein is often produced as a spray dried hemp protein isolate, which often utilizes high heat, and may cause protein denaturation. According to Beran, spray drying may require temperatures between 150° C. and 250° C.; temperatures that are likely to denature hemp proteins. Beran discloses that “[t]hermal denaturation of proteins adversely affects the solubility and dispersibility, foaming and emulsifying properties.”
In order to avoid thermal denaturation during preparation of edestin caused by spray drying, Beran discloses a method that includes first grinding or pressing hemp grain to remove the oil, followed by aqueous extraction and either isoelectric precipitation or salt extraction to purify edestin. The preferred method of grain size reduction used in Beran appears to be dry milling. According to the patent, the milled flour is then added to water in a concentration of 5:1 water to flour ratio. Beran then discloses shaking the solution to produce an albumin containing water fraction and a sediment fraction.
Beran does disclose that the sediment contains edestin, however, Beran discloses further steps to isolate edestin for use in food products. These steps include protein extraction by either isoelectric precipitation, salt extraction or ultrafiltration. Beran does not discloses a level of purity of the edestin in the sediment prior to the additional steps to isolate edestin, however, the need for such additional steps indicates that the purity of the edestin in the sediment is not sufficient for the stated purpose of the Beran patent, which is to use edestin to “increase the protein content of high protein foods and smoothies protein beverages.” In conclusion Beran discloses that “[t]his product can be used in these foods due to its emulsifying properties and beneficial effect on the organoleptic properties of the final product.”
Both Crank and Beran generally disclose the use of milled or pressed hemp grain, (to remove the oil), and subsequently ground to hemp flour as a starting material for protein extraction. Consequently, the hemp flour has been subject to dry milling or grinding, and oil pressing processes that affect the structure and functionality of the protein. Further, both Crank and Beran disclose isolation of edestin by at least isoelectric precipitation, which results in structural changes to the protein, thereby decreasing its functionality.
During the process of extracting protein from grain for use in a plant based meat, oil may also be extracted from the grain. Extraction of oil may, in some cases, be a primary objective, as plant based oils have value as food and cosmetic products. Common methods of extracting oils from grains, nuts and seeds include press-based methods of extraction, including cold pressing and expeller pressing, as well as solvent extraction.
Pressing grain to extract oil involves mechanical compaction of the plant material to force oil from the solids. Solvent extraction involves placing plant material into a liquid to extract the oil. Pressing and solvent extraction may, in some cases, be combined. Oil recovery from an extruder press method may be relatively inefficient and a fairly high percentage of fat may remain in the cake. Consequently, the pressed cake may be further extracted using an oil solubilizing solvent. Commercially available cakes and flour produced by press methods or press and solvent methods, are thought to have reduced protein functionality.
Conventionally produced hemp grain oil may have a green color that can result from the rupturing of protoplastids or chloroplasts during extraction. Hemp grain may contain chlorophyll containing bodies that release chlorophyll when ruptured. Hemp grain, when compared to other types of grains, contains a greater number of these bodies, and therefore tends to have a green color when hemp oil is extracted by conventional methods.
According to Leonard et al. “Unrefined hempseed oil is dark green in color, which is due to its chlorophyll content.” (Leonard et al., 2019). Further, the presence of chlorophyll in oil can cause oxidation of fats, leading to off-flavors. U.S. Pat. No. 9,493,749 to Soe discloses “vegetable oils derived from oilseeds such as soybean, palm or rape seed (canola), cotton seed and peanut oil typically contain some chlorophyll. However, the presence of high levels of chlorophyll pigments in vegetable oils is generally undesirable. This is because chlorophyll imparts an undesirable green colour and can induce oxidation of oil during storage, leading to a deterioration of the oil.”
Various methods have been employed in order to remove chlorophyll from vegetable oils. These methods including chemical bleaching and ultrasonic bleaching. Chlorophyll may be removed during many stages of the oil production process, including the grain crushing, oil extraction, degumming, caustic treatment and bleaching steps. The bleaching step, however, is usually the most significant for reducing chlorophyll residues to an acceptable level. During bleaching, the oil is typically heated and passed through an adsorbent to remove chlorophyll and other color-bearing compounds that impact the appearance and/or stability of the finished oil. The adsorbent used in the bleaching step is typically clay.
Conventional methods for removing chlorophyll from hemp oil are costly and may create problems for waste disposal. Further, methods that remove chlorophyll from hemp oil after the chloroplast has been ruptured allow for oxidation of the oil due to temporary exposure to chlorophyll. Therefore, improved methods for extracting oil from hemp grain are needed.
In the production of meat and dairy analogs, after obtaining the protein isolate and a preferred source of oil, step two involves combining the isolated protein with water and possibly oil to form a material for setting or extrusion. After protein has been isolated from hemp grain or other plant products, it must be combined with other components of a meat or dairy analog in order to form a final meat analog product. Three basic ingredients for meat analog production are protein, water and fat. These components may be combined in different concentrations and processed in different ways in order to form meat and dairy analogs.
Given that meat analogs require gelation, or structuring resulting in a chewy meat-like texture, the protein is typically combined with water and possibly oil to form a gel that can be set by heat creating a texture. With regard to hemp protein isolate gel formation using these components, or protein and water only, research has shown that hemp protein does not have good gel forming properties. As disclosed above, Wang, Shen, and Zahari teach that hemp does not have good gel forming capability, which would make it an unlikely candidate for its use as a primary protein in a meat or dairy analog (Wang et al., 2019; Shen et al., 2021; Zahari et al., 2020). Wang, for example showed that the combination of hemp protein isolate and water, alone, when heated, did not form a desirable gel. Wang also showed that even when oil was added to the protein and water mixture in Wang and heated, again, the hemp protein, water and oil mixture did not form a desirable gel upon heating.
In meat analog production, the third step of thermal setting of the protein, water and oil typically includes extrusion, which texturizes the product to form a more meat-like material. In order to form a texturized meat, an extruder may be used to form a Textured Vegetable Protein (TVP). TVP is typically a soy-based product, however, other plant proteins, such as pea, may be used alone or in combination with soy. To generate TVP, plant based ingredients are fed into an extruder to be texturized. Conventionally, dry plant protein is fed into the extruder, whereupon water, starch, and occasionally fat are added to the protein through separate inputs as the protein is conveyed through the extruder. After extrusion, the extruder output may go through marination, coating, and/or cooling steps.
Common problems with conventional plant based meat substitute products, including TVP and HMMA, relate to a non-dispersing texture and rubbery mouthfeel when compared to meat. This texture and mouthfeel of conventional meat analogs results in part from the lack of incorporation of either fat, oil or combination thereof into the molecular structure of the protein peptide strands or “fiber”. Meat sourced from animals has fat molecules incorporated between these muscle fibers, which comprise the majority of an animal meat product. This fat is released during chewing, providing a consumer with positive and continuous sensory feedback in terms of taste and mouthfeel as mastication is continued. The sensory feedback provided during the chewing of current conventional meat analogs is not equivalent to that of meat, in part because there is no fat between the peptide layers of the protein. In conventional meat analogs, fat is added after the protein has been fully denatured and hence, may surround the significant sized pieces of cooked protein, but is not incorporated within the peptide layers of the protein itself.
Soy and pea proteins, which are commonly used to create fibers in TVP and HMMA, may only hold approximately 10% of their weight in fat. Typically, a muscle fiber in meat incorporates anywhere from 5 to approximately 50% of its weight as fat within the protein fibers, depending on the source of meat. Therefore, with conventional soy and pea meat analogs, much of the fat added to the product during extrusion rests outside of the fibers, creating a greasy, unappealing product that doesn’t release fat in a controlled and succulent manner as it is chewed. As a result, conventional meat analog products mainly appeal to a limited number of committed vegan or vegetarian consumers, and have failed to appeal to the majority of consumers who eat meat.
Different extrusion methods may produce different meat analog textures. Extrusion has been developed over decades to create more meat-like meat analogs. Extrusion, and preparation for extrusion, of a meat analog involves complex chemical changes and processes within the protein component of the extrusion mixture. During extrusion, protein isolate structure is significantly altered, whereby the protein may be partially or wholly denatured or unfolded, as well as repositioned and cross-linked with other protein molecules and chemically bound to the other components of the extrusion mixture. The extruder induces these changes through the application of shear forces applied by screws as the mixture moves through the machine, in addition to changes in temperature and pressure. The final texture, taste and mouthfeel of a meat analog produced by extrusion is determined by the various types of chemical bonds that form between the components of the extrusion mixture prior to, during, and after extrusion.
With regard to the early development of extrusion processes for producing textured meat analogs, U.S. Pat. No. 6,319,539 to Shemer et al. disclosed mixing proteins with a large proportion of water and potentially fats, and subjecting the resulting paste to heating, gelling and shaping in an extruding machine. During transfer into the extruding device, Shemer discloses the paste being heated and conveyed at a determined rate and then extruded through an opening. The resulting food product has a fibrous texture comprising substantially aligned axial fibers. The problem with this process, however, is that it has a limited flow rate and can only be implemented using certain raw materials, in particular gluten, which resulted in a limited variety of products. Gluten is a known allergen which also has limited to date the uses of soy based TVP.
An additional drawback of the Shemer process, and other early extruder processes, is that the heated product would expand as it was conveyed from the extruder due to water vapor release as the high temperature product cooled. The water vapor caused disordering of the aligned protein fibers, which is undesirable for acceptable texture in a meat analog.
To solve this problem, WO 2003/007729 to Bouvier et al. discloses a twin screw rotor extruding machine, as opposed to a single screw device, having an elongate cooling chamber, allowing for the raw material to be mixed and extruded at a controlled temperature, such that steam would not disrupt the alignment of the protein fibers in the final product. In addition to addressing the cooling and water vapor problem, the ‘729 application also recognized a problem in the existing art with incorporating the desired amount of oil and fat into an extruded product using conventional formulations of raw material.
To achieve the desired fat content, the ‘729 application disclosed a novel extrusion mixture containing fatty ingredients mixed with lecithins or caseinates, protein, fibers, starches and water. This mixture was kneaded to obtain a paste which would be subjected to heating and gelation in the extruder. Inclusion of significant quantities of carbohydrates such as starch in a meat analog, however, is undesirable due to taste and nutritional concerns.
To solve the problem of introducing fat into a meat analog without the addition of starch and without other associated problems with introducing oil into an extruder WO 2012/158023 to Giezen et al. discloses an extrusion process for turning vegetable protein compositions such as soy protein into a fibrous, meat-like structure. Giezen discloses an extrusion exit temperature above the boiling point of water, resulting in an open product structure capable of being infused with an oil to reach a desirable fat content. Problems with Giezen include the addition of a process step after extrusion and a final product perceived as too greasy and fatty by the consumer.
A problem commonly recognized in the art of meat analog extrusion is that higher amounts of oil in the extrusion mixture interfere with obtaining a product having the texture of animal meat. In conventional meat analog extrusion, the presence of oil reduces the high mechanical shear forces within the extruder that form the fiber structure of an ideal meat analog. Therefore, using conventional processes, addition of optimal amounts of oil results in a meat analog with suboptimal fiber structure and texture.
To overcome the problem of higher oil content causing suboptimal texture in textured meat analogs U.S. Pat. App. No. 20180064137 to Trottet et al. discloses adding oil separately from the other raw materials during extrusion. This process includes feeding an extruder barrel with 40-70 wt % water and 15-35 wt % plant protein, followed by injection of 2-15 wt % oil into the extruder barrel at a point downstream of the feeder. According to the disclosure, the downstream location of injecting the liquid oil is preferably within the second half of the total length of the extruder barrel. Ostensibly, this configuration allows for high shear forces in the first half of the extruder to promote fiber formation, while the oil can be added downstream without interfering in fiber formation.
While Trottet’s process results in an improved product when compared to the prior art, Trottet does not result in a significant amount of oil being incorporated into the core of the protein fiber. Without the oil being incorporated into the fiber, the resulting product is perceived as greasy by a consumer, and lacks a controlled release of fats during chewing. This unsatisfactory result is because people are accustomed to eating animal meat, in which a large amount of fat is incorporated into the muscle fiber. Animal meat protein fibers incorporate up to approximately 50% of their weight in fat, although this varies depending on the source of the meat. With the Trottet process, fat is only incorporated into the fiber in an amount of about 10% of the weight of the plant protein fiber. This problem with Trottet’s process is caused by both the type of proteins used as raw material for extrusion, which for Trottet are disclosed as soy and wheat, and the method by which oil is added to the protein fiber.
In another patent application addressing the fat content of meat analogs, WO 2020/208104 to Pibarot was filed in 2020. In a filing entitled “Meat analogs and meat analog extrusion devices and methods”, Pibarot acknowledges the problem of mimicking the fat content of animal meat, which has inclusions of fat tissue within and without the protein matrix. Pibarot suggests that this complex architecture may drive the appearance of the meat as well as texture and juiciness of the meat.
To solve this problem, Pibarot discloses injecting fat into the interior of an extrusion mixture as it is being cooled in the die. In Pibarot, gaps are generated between protein fibers of the extrusion mixture during extrusion. As the heated and sheared product is conveyed through the cooling die, fat is injected between these gaps, such that fat is deposited between the protein fibers. Pibarot submits that this process produces a marbled appearance, similar to that of red meat, and improves the texture and palatability of the product. Pibarot discloses using this process with soy, pea and other conventional plant protein sources. Pibarot does not, however, teach a method of incorporating the fat into the molecular structure of the protein fiber.
To summarize, the Shemer process could only be used with a limited number of ingredients and the lack of controlled temperature and cooling resulted in an inferior product. While Bouvier solved the cooling problem of Shemer, to achieve the desired fat content, Bouvier blended the raw extrusion material with high amounts of starch, resulting in undesirable taste and nutritional qualities. Giezen solved the starch problem of the Bouvier process by adding fat after extrusion, however, this required an additional step and resulted in a greasy, unpalatable product. Trottet improved upon both Giezen and Bouvier by introducing oil at a late stage of extrusion, however, Trottet still suffers from the problem of low incorporation of oil into the protein fibers of the meat analog. Pibarot discloses injection of fat into the meat analog as it is cooled, which introduces fat between protein fibers, but does not produce a final product that incorporates fat into the protein fibers.
Hemp grain has great value both as a source of protein and as a source of oil. While a wide variety of methods for producing food products from hemp grain exist, it is clear that more effective, efficient, cleaner and less costly methods of extracting proteins and oil from hemp grain are needed to produce a clean and bland tasting, un-oxidized hemp protein having significant purity, gelling functionality, nutritional value, digestibility and flavor, as well as an oxidatively stable oil having a clean flavor and light color suitable for cooking and cosmetics. Further, there is a continued need for a processes and raw materials that can be used to create a variety of meat analogues having the appearance, taste, texture, juiciness and mastication of a variety of animal meat and dairy products. More specifically, there is a need for a meat analog that has the appearance, texture and taste of meat with an optimal amount of oil or saturated fat in the final product, where the oil or saturated fat is incorporated into the protein fibers at a level approximating that of an animal meat or dairy source.
This document discloses an instant meat or food analog material based on a Native Edestin Protein Isolate (NEPI). In accordance with the process of the present disclosure, NEPI, when combined with water and oil, may form an instant, texturized meat analog. The present disclosure describes a process that includes using a NEPI concentrate, or combining a NEPI powder with water to form a hydrated protein suspension,, followed by addition of oil to form a protein-fat hydrosol. When using a NEPI concentrate, it is critical that after any necessary further dilution with water is added to the NEPI concentrate to achieve the desired moisture level of the formula, that the hydration temperature of between 60° C. and 70° C. is achieved to fully hydrate and open the protein structure. It is critical that prior to addition of the oil to form the protein-fat hydrosol, that the NEPI protein be fully hydrated and opened at the specified temperature above. It should be noted that if it is necessary heat the NEPI water suspension prior to the addition of oil, it should be a gentle heating either directly or preferably in a water bath of between 60° C. and 70° C. with gentle agitation to equalize the rate of heating until the temperature of the hydrated NEPI has reached that of the water bath. When making the hydrated protein suspension using the dry powdered NEPI, it is preferable to more preferably use hot water, the temperature of the water preferably between 60° C. and 80° C. Once the hydrated NEPI protein has been opened by achieving a minimum temperature of 60° C., the addition of the oil can be made. After the addition and incorporation of the oil to either the heated NEPI concentrate or the NEPI protein that has been hydrated with hot water, it is then possible to cool the formed protein-fat hydrosol to refrigerated temperatures for microbiological stability for at least 48 hours. If the protein-fat hydrosol has been cooled for microbiological stability purposes, prior to microwave setting of the protein-fat hydrosol, the protein hydrosol should again be gently heated and preferably in a water bath of between 60° C. and 70° C. with very gentle and occasional agitation to equalize the rate of heating until the temperature of the protein-fat hydrosol has reached that of the water bath. It is most preferable to make the protein-fat hydrosol and having reached a minimum temperature of 60° C. as described above, immediately before the protein-fat hydrosol has time to cool below 60° C., heating using microwaves to further heat and set the protein-fat hydrosol to a solid hydrogel, in a microwave oven to set the protein-fat hydrosol, thereby forming a hydrogel, or meat analog. The water, NEPI protein, and oil hydrosol may be blended mixed in a microwavable container or blended separately and poured into a microwaveable container. The container being comprised, preferably, of a microwave insulator material such as paper, glass, plastic, or ceramic that does not absorb microwaves, but allows the microwaves to pass through to the material within the container. In some embodiments, an irregular surface may help the protein-fat hydrosol and protein-fat hydrogel adhere to the sidewall of the container.
The protein hydrosol may be mixed in a microwavable container being comprised, preferably, of a material having an irregular or rough surface, such as paper or rough plastic and having dimensions conducive to forming a meat analog from the protein-fat hydrosol when heated in a microwave. Materials required for production of a meat analog at home from the NEPI powder may be provided as a convenient kit for production of an instant meat analog.
The present disclosure solves the problems of the prior art with regard to hemp protein isolation, raw material input preparation, and processing of the raw material input, in order to produce a superior plant based meat and dairy analog. The composition and process of the present disclosure includes a process for hemp grain protein isolation, pasteurization, liquid solution, gel formation, texturization and meat and dairy analog production. The process of the present disclosure results in a structure protein food product, or meat analog, having superior properties when compared to existing products or similar products manufactured using known technology.
Preparation of a meat or dairy analog according to the process of the present disclosure may be divided into three broad steps. The first step involves protein extraction, or isolation, from a hemp grain. The second step involves combining the isolated protein with water and oil to form a raw material for thermal gelation or extrusion. The third step involves thermal gelation or extrusion of the raw material to set or texturize the meat analog. The final meat analog product may then be cooked to simulate meat or dairy products such as chicken, fish and cheese.
With regard to the first step, hemp protein isolation, the process of the present disclosure incorporates a known grain processing method, disclosed in U.S. Pat. No. 7,678,403 to Mitchell (“Mitchell” or the “‘403 patent”), with some modifications. The ‘403 patent is herein incorporated by reference in its entirety. The Mitchell process discloses aqueous wet milling at low temperature and sifting the resulting product. In the present disclosure, aqueous wet milling may preferably be done while maintaining the temperature of the slurry between, preferably 33° F. and 38° F. At higher temperatures, particularly at 42° F. and higher, microorganism growth becomes a concern.
In some embodiments, milling may be performed with whole hemp grain or hulled hemp grain (also referred to as dehulled hemp grain). Depending on whether whole or hulled hemp grain is used, the final meat or dairy analog product may have a different color. The use of whole hemp grain results in a darker, more beef-like color, while the use of hulled hemp grain produces a more white, chicken or fish-like color. Use of part whole hemp grain and part hulled hemp grain, in one embodiment, wherein the whole hemp grain is used in a concentration of about 20-30% by weight, relative to the amount of hulled hemp grain, results in a beef-like color to the final product. In one embodiment, hulls that have been previously removed by dehulling of hemp grain, may be reintroduced to the hulled hemp grain to add color; where, in one embodiment, to achieve a beef-like color, the hulls may be added to the hulled hemp grain in an amount of approximately 10-15% by weight relative to the hulled hemp grain.
After aqueous wet milling, Mitchell, in the ‘403 patent, teaches sifting at a different mesh size than the present disclosure, where in the present disclosure sifting at a 170 to 200 mesh size is preferred. Mitchell, in the ‘403 patent, when discussing the sifting of rice grain for milk production, disclosed mesh size of 150 or below, which is appropriate for certain grains, but not for chloroplast removal for hemp grain. The present disclosure has surprisingly discovered that a 170 to 200 mesh size, preferably, or between approximately 160 and 200 mesh, prevents passage of chloroplasts or chlorophyll containing particles through the filter, while not significantly decreasing protein or nutrient yield, such that sufficient protein particles may pass through the filter.
When hemp grain is processed according to the modified Mitchell process it results in an insoluble protein-containing precipitated byproduct. This protein-containing material was discovered by Mitchell to have unique and valuable properties and is particularly well-suited for producing meat and dairy analogs. This hemp grain protein-containing material has not been previously publicly disclosed. Upon further investigation, Mitchell determined that the material was comprised primarily of edestin and is, importantly, substantially free of albumin, the other primary protein component of hemp grain. Due to processing parameters of the Mitchell process, the edestin appears to be substantially maintained in its native state. Due to its high concentration of substantially native edestin, the material will be referred to hereafter as native edestin protein isolate (NEPI). Comprised of approximately 80% protein, NEPI also contains oil, fiber, carbohydrates and ash.
After milling and sifting, NEPI may be separated from an aqueous oil albumin emulsion (AOAE) by centrifugation and decanting. The aqueous oil albumin emulsion may optionally be further processed to produce hemp oil and albumin. NEPI extracted according to the present disclosure may be used in a variety of different plant based food product that replicate meat or dairy products. NEPI may optionally be combined with an oil to form a protein hydrosol and a protein-fat hydrosol, and may be processed to produce an evaporated or spray dried product. The hydrosol may be used to produce a plant based meat analog.
This disclosure is based on methods and materials for making plant based products that more closely replicate meat products, including the texture, juiciness, fibrousness and homogeneity in texture of animal meat. A process for producing meat analogs is described herein that includes selection of proteins based on their unfolding, or denaturation, properties and fat holding capacities. Further, the process described herein includes a method of preparing an extrusion mixture or input, which may be a protein-fat hydrosol, prior to extrusion, that incorporates water and fat into the selected protein in a manner such that the water and fat form a liquid matrix, which also may be referred to as a protein-fat hydrosol, with the protein. In some embodiments, the liquid matrix may have additional components, whereas the protein-fat hydrosol may not have more than protein, fat and water. Still further, the process described herein includes methods of extruding or otherwise heating of a liquid matrix, which may also be referred to herein as an extrusion input or extrusion mixture, where the liquid matrix may be a fat-protein hydrosol. The process of extruding the liquid matrix includes feeding the liquid matrix into a pump at a first end of an extrusion chamber. The liquid matrix is fed into an extruder, wherein the extruder is set for parameters tailored to the liquid matrix.
The present disclosure relates to a composition containing edestin or edestin-like proteins and methods for isolating edestin from hemp grain. As disclosed herein, edestin may be isolated from hemp grain or other grains and seeds that contain edestin or edestin-like proteins. In one embodiment, the hemp grain is wet milled during aqueous protein extraction, resulting in an edestin containing fraction and an aqueous oil albumin emulsion.
The present disclosure may, in one aspect, utilize a method of aqueous wet milling to separate fat stored within the hemp grain without rupturing the chloroplasts and releasing chlorophyll into the oil. Once the seeds have been milled by this process, the resulting milled product is sifted through different size mesh. Sifting over between approximately 170 mesh, or in some embodiments between 160 and 200 mesh, or in some embodiments between 200-270 mesh removes hulls, chloroplasts and fiber. More preferably, a mesh size of between 160 and 200 may be used. In one preferred embodiment a mesh size of 170 may be used. A mesh size of 150 has openings that are too large and may allow undesirable material into the filtrate, including fibers and chlorophyll containing material. Surprisingly, chlorophyll containing particles remain at a size greater than the pore openings of 170 mesh, while most protein containing particles pass through mesh of this size. According to the process of the present invention, sifting with different size mesh separates the chloroplasts, protoplastids or other chlorophyll containing particles from the hemp oil and protein containing fraction, resulting in a pale, yellow final oil product.
In the process of the present disclosure, after sifting, an insoluble fraction containing NEPI and albumin oil aqueous emulsion may be present in the filtrate. The AOAE may be decanted after centrifugation. The insoluble fraction and pellet containing portion may be washed to remove any residual oil. In some embodiments, washing with cold water may be performed twice.
In some embodiments, the AOAE may be chilled at between approximately 33° F. and 38° F., wherein 35° F. is preferred, until the albumin begins to separate from the oil in the emulsion and precipitate, which in some embodiments may be aided by centrifugation. According to the process of the present disclosure, albumin strongly binds hemp grain oil, thereby improving separation of oil and albumin from the insoluble edestin fraction, or NEPI. The albumin may be separated from the hemp grain oil by this process. Gel electrophoresis shows that substantially all albumin may be removed from the NEPI by this process, leaving primarily edestin in the NEPI. The AOAE may be removed from the NEPI by centrifuging and decanting, leaving the NEPI as a solid material that may be washed to remove residual material.
NEPI may, in one embodiment, then be heated to a temperature of approximately 145° F. for approximately 30 minutes to pasteurize the product. 145° F. may be a legal lower limit for pasteurization in some jurisdictions. Here, the temperature should be maintained at approximately 145° F., or between 145° F. to 155° F., in order to prevent granulation that has been observed in the present disclosure to occur at higher temperatures. Granulation may occur in NEPI at temperatures well below the denaturation of edestin, for example at approximately 158° F.; therefore, it is critical to pasteurize at temperatures that are below those typically used by those of ordinary skill in the art for pasteurization. Those of ordinary skill in the art conventionally pasteurize protein isolates at temperatures that would cause significant granulation in the present disclosure, in order to rapidly process the product. After pasteurization is complete, NEPI may be spray dried or stored as a concentrate for use in meat and dairy analogs. Spray drying should be done at lower temperatures, preferably around 145° F. to 155° F., as well, to prevent granulation or aggregation of the protein.
In some embodiments, particularly for commercial applications, the NEPI comes off the production line into a tank that is heated to 145° F., the product is allowed to incubate at this temperature for 30 minutes, prior to being sent to a cooling tank for cooling to approximately 35° F. After cooling, NEPI can be shipped if necessary for spray drying, freezing, freeze drying or vacuum microwave drying prior to use in production of meat and dairy analogs, or structured protein food products.
For meat analog production, the pasteurized product may be prepared by first hydrating the NEPI, if dried, or otherwise maintaining an appropriate degree of hydration. In one embodiment, the amount of water may be approximately 3 parts water to 1 part NEPI. Prior to addition to NEPI, the water may be preheated, preferably to approximately 135° F. to form a protein hydrosol prior to setting. Salt should not be added during this process, as it may disrupt protein hydrosol structure. Salt may be added just prior to the set or after the set, but not before. In some embodiments, protein hydration and opening may be performed at 100° F. to 135° F., or in some embodiments between 100° F. and 155° F.; or in other embodiments protein hydrosol formation may be performed at lower temperatures, however, the temperatures must be above cold temperatures which do not allow for protein opening. Preferably, temperatures during the hydration and protein-preparation step should remain as close as possible to 145° F., which is considered the lowest temperature for pasteurization, without reaching temperatures that produce granulation of the product.
Once the protein is hydrated, in one embodiment oil may be added and mixed with the protein hydrosol to form a protein-fat hydrosol. Oil should not be added until after the NEPI is sufficiently hydrated, such that the protein hydrosol has a smooth appearance. If oil is added prior to hydration and protein-preparation, granule formation may occur. Further, according to the process of the present disclosure, oil should be added prior to setting of the material, setting meaning where protein bonds are formed to create a more solid gel product, where aggregation of the proteins occur, generally at higher temperatures where protein denaturation occurs. In the case of the present disclosure, there is an absence of free oil during the setting process, and all oil is incorporated into an emulsion, or protein structure, prior to setting of the product in the extruder or other means of heat setting. In conventional extrusion, there will be free oil present with material that is partially or completely set in the extruder. It is therefore important, for the present disclosure, to add water to fully hydrate and open up the NEPI prior to addition of oil in order to have an absence of free oil during extrusion or setting. This protein-fat hydrosol may then be heated or extruded to form a meat analog. In conventional extrusion, using soy or pea protein for example, the oil is added to the protein material after setting has begun at high temperatures in the extruder more for lubrication rather than incorporation of the oil.
Once the protein hydrosol is sufficiently hydrated, oil may be added to form the protein-fat hydrosol. Oil may be preferably preheated, wherein the temperature of the oil may preferably be between approximately 130° F. to 135° F. In other embodiments, the oil may be preheated to between 100° F. to 135° F., or between 100° F. and 155° F., while in other embodiments the oil may be added at lower temperatures, however, the oil should not be added at cold temperatures that would disrupt the structure of the protein hydrosol and prevent incorporation of the oil into the protein hydrosol to form the protein-fat hydrosol. The material may also be set in a retort system, although retort may not produce a fibrated product as a does extrusion.
Texture of the retorted NEPI meat analog was surprisingly good and had textural properties, including hardness and chewiness that are far superior to commercially available hemp protein concentrates and isolates under the same conditions. The process of the present disclosure unexpectedly resulted in thermal gelling and extrusion of high quality fibrated meat analogs made using only hemp as a protein source. Due to the nature of conventionally used meat and dairy analog proteins, including soy and hemp, conventional meat and dairy analogs cannot reproduce a textured meat filet, such as chicken breast, that is similar to the animal meat product. The unexpectedly advantageous properties and results that have resulted from the use of NEPI and the processes of using it described in the present disclosure, a far superior structured meat analog has been created, when compared to other commercially available products, using only hemp protein as a protein source. Hemp protein, to this point, has only been known to be used in combination with soy or other plant proteins to produce a meat analog.
In one aspect, this document features a meat analog extrusion input, or liquid matrix, that may range from about 4:1 to 0.5:1 ratio of protein to fat.
In one aspect, this document features a process wherein water, in ratios as disclosed herein below, is added to a protein isolate, or wherein water is maintained in a protein isolate in a specific ratio, and wherein, after addition, or maintenance, of water with the protein isolate, fat is added to the protein and water mixture in approximately a certain ratio of water to fat and protein to fat.
In one aspect, this document features a product wherein the water content target is between 35 wt % and 75 wt %.
In any of the methods or compositions described herein, the isolated plant protein in the liquid matrix may include a seed oil protein, such as edestin, an albumin, a globulin, or mixtures thereof.
In any of the methods or compositions described herein, the isolated protein may be first isolated from all other plant proteins in the plant.
In any of the methods or compositions described herein, the isolated protein used may have been isolated in a native, or non-denatured, state; wherein native may be mean fully native, substantially native, native in-part, or otherwise identified as substantially native by conventional methods of detecting protein structure, or native as would be understood by a person of ordinary skill in the art.
In any of the methods or compositions described herein, the isolated protein from seed protein preferably has a cysteine content greater than that typically found in soy or casein.
In any of the methods or compositions described herein, the liquid matrix can include a flavoring agent, starch, fiber, or other carbohydrate source.
In some embodiments, the meat and dairy analog products provided herein can be free of animal products, wheat gluten, soy protein, or pea protein.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Although methods and materials similar or equivalent to those described herein can be used to practice the invention, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting. All references to percent are by weight.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the descriptions, drawings and examples and from the claims.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Although methods and materials similar or equivalent to those described herein can be used to practice the invention, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting. All references to percent are by weight unless specified otherwise. The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
In general, the present disclosure provides methods and materials for producing plant based meat or dairy analogs, also referred to herein as structured protein food products, from hemp grain protein. In any of the methods or compositions described herein, and in some embodiments, the extracted protein-containing product may be separated from other hemp grain proteins. In any of the methods or compositions described herein, edestin may be substantially isolated from some, or all, of the other proteins in hemp grain. In any of the methods or compositions described herein, the isolated protein from grain protein preferably has a cysteine content greater than that typically found in soy or casein.
The plant protein used in accordance with the present disclosure may be an isolated plant protein. For the purpose of the present disclosure, a “native” protein is that protein that may have the same tertiary and quaternary structure as in the living and active cell. In some embodiments, a “native” protein may be substantially native. In any of the methods or compositions described herein, the isolated protein may have been isolated in a generally native, substantially native, or non-denatured state. In any of the methods or compositions described herein, the isolated protein used may have been isolated in a native, or non-denatured, state; wherein native may be mean fully native, substantially native, native in-part, or otherwise identified as substantially native by conventional methods of detecting protein structure, or native as would be understood by a person of ordinary skill in the art. Changes and disruption of the subunit structures as well as the tertiary structure may occur with changes in temperature (typically above 41° C.), or contact with aqueous acid or alkali solutions, oxidizing or reducing agents, or organic solvents. Disruption of the quaternary structure renders, or may render, the protein biologically inactive in the living cell. However, the tertiary structure of the released subunits, having a specific shape created by hydrogen bonds, Van der Waals forces, disulfide linkages, may be functionally active and exhibit similar function as in the living cell. One example of this is the lock and key function of enzymes attributed to the tertiary shape of the protein.
Consequently, if the quaternary or tertiary structures are substantially maintained after extraction in the same state as in a living cell, for the purposes of the present disclosure, these may be considered “native” proteins. The present disclosure has found that certain oil grain globular proteins, which may be considered native in the sense that the tertiary structure has not been denatured by changes in temperature (typically above 41° C.), aqueous acid or alkali solutions, oxidizing or reducing agents, or organic solvents, have unique and superior functional properties.
Conventional plant protein extraction processes are known to disrupt the quaternary and tertiary structure of the protein. In some cases, this disruption may cause the functionality of the quaternary or tertiary structure to be lost or reduced. The tertiary structure may be denatured by disruption of functional bonds and forces, including hydrogen bonds, Van der Waals forces, or disulfide linkages, all of which work together to form a specific tertiary protein structure. Changes in the protein environment and mode of denaturation of the tertiary structure may change the tertiary structure or shape of the protein and its bonds, forces, and links.
As used herein, the term “isolated plant protein” indicates that the plant protein, which may include such proteins as edestin, glutelins, albumins, legumins, vicillins, convicillins, glycinins and protein isolates such as from any seed or bean, including soy, pea, lentil and the like or combinations thereof, or plant protein fraction (e.g., a 7S fraction) has been separated from other components of the source material (e.g., other animal, plant, fungal, algal, or bacterial proteins), such that the protein or protein fraction is at least 2% (e.g., at least 5%, 10%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 99%) free, by dry weight, of the other components of the source material. For example, an isolated native globular protein having high cysteine content can be used alone or in combination with one or more other proteins (e.g., albumin) or from any other protein source as soy, pea, whey and the like.
In any of the methods or compositions described herein, the fat can be a non-animal fat, an animal fat, or a mixture of non-animal and animal fat. The fat can be an algal oil, a fungal oil, corn oil, olive oil, soy oil, peanut oil, walnut oil, almond oil, sesame oil, cottonseed oil, rapeseed oil, canola oil, safflower oil, sunflower oil, flax seed oil, palm oil, palm kernel oil, coconut oil, ahi oil, babassu oil, shea butter, mango butter, cocoa butter, wheat germ oil, borage oil, black currant oil, sea-buckhorn oil, macadamia oil, saw palmetto oil, conjugated linoleic oil, arachidonic acid enriched oil, docosahexaenoic acid (DHA) enriched oil, eicosapentaenoic acid (EPA) enriched oil, palm stearic acid, sea-buckhorn berry oil, macadamia oil, saw palmetto oil, or rice bran oil; or margarine or other hydrogenated fats. In some embodiments, for example, the fat is algal oil. The fat can contain the flavoring agent and/or the isolated plant protein (e.g., a conglycinin protein). The fat or oil composition of the liquid matrix can be made to preferentially match the saturated and unsaturated composition of the target source material of the analogue.
Thus, in some embodiments, the isolated protein may substantially be a protein, such as native edestin, isolated from hemp grain, or any other grain that may have edestin or edestin like protein. In some embodiments, proteins may be separated on the basis of their molecular weight, for example, by size exclusion chromatography, ultrafiltration through membranes, or density centrifugation. In some embodiments, the proteins can be separated based on their surface charge, for example, by isoelectric precipitation, anion exchange chromatography, or cation exchange chromatography. Proteins also can be separated on the basis of their solubility, for example, by ammonium sulfate precipitation, isoelectric precipitation, surfactants, detergents or solvent extraction, including aqueous extraction. Proteins also can be separated by their affinity to another molecule, using, for example, hydrophobic interaction chromatography, reactive dyes, or hydroxyapatite. Affinity chromatography also can include using antibodies having specific binding affinity for the heme-containing protein, nickel nitroloacetic acid (NTA) for His-tagged recombinant proteins, lectins to bind to sugar moieties on a glycoprotein, or other molecules which specifically binds the protein. In some embodiments, the plant based meats described herein are substantially or entirely composed of ingredients derived from non-animal sources, e.g., plant, fungal, or microbial-based sources. In some embodiments, a plant based meat or plant based dairy product may include one or more animal-based products. For example, a meat replica can be made from a combination of plant based and animal-based sources.
The following documents are herein incorporated by reference in their entirety: U.S. Pat. Application Ser. No. 17/551,163 to Mitchell Ellis; U.S. Pat. No. 7,678,403 to Mitchell and Mitchell.
Hemp Seed (HS) is herein generally defined as viable seeds normally used for further propagation and planting. HS may or may not be food grade based on cleaning practices and seed agricultural preservation practices.
Whole Hemp Grain (WHG) is herein generally defined as hemp grain that includes both viable hemp grain and pasteurized hemp grain.
Viable Hemp Grain (VHG) is herein generally defined as viable hemp seeds that have been further cleaned of all dust and foreign material, are food grade suitable, the heart and hull being fully intact.
Pasteurized Hemp Grain (PHG) is herein generally defined as hemp grain that has been treated by heat or irradiation to destroy the viability of the seed.
Defatted Hemp Grain Cake (DHGC) is herein generally defined as the dry solid residuals resulting from the non-aqueous removal of oil from Hemp Grain.
Hemp Grain Oil (HGO) is herein generally defined as a virgin green oil resulting from the non-aqueous extraction of Hemp Grain.
Hemp Grain Oil Sludge (HGOS) is herein generally defined as crude oil sludge slurry resulting from the non-aqueous extraction of oil from Hemp Grain.
Hulled Hemp Grain (HHG) is herein generally defined as equivalent to hemp hearts or hemp nuts; hemp grain in which the outer hull has been removed.
Defatted Hulled Hemp Grain Cake (DHHGC) is herein generally defined as the dry solid residuals resulting from the non-aqueous removal of oil from hulled hemp grain.
Hulled Hemp Grain Oil (HHGO) is herein generally defined as a yellow oil resulting from the non-aqueous extraction of Hulled Hemp Grain.
Hemp Protein Isolate (HPI) is herein generally defined as isolates of albumin, edestin or aggregates thereof.
Aqueous Oil Albumin Emulsion (AOAE) is herein generally defined as the water based emulsion of oil and soluble albumin proteins.
Native edestin protein isolate (NEPI) is herein generally defined as a product of the protein isolation process as disclosed herein, and may refer to NEPI in liquid, slurry and powder form, as would be understood by one of ordinary skill in the art in the appropriate context of its use.
All products described in flow charts may be present in various physical forms, including liquid, gel, or solid as would be understood by one of ordinary skill in the art in the appropriate context of its use.
The present disclosure may relate to a composition containing native edestin protein isolate (NEPI), which contains edestin or edestin-like proteins and methods for extracting and using NEPI to produce meat and dairy analogs. The present disclosure solves the problems of the prior art with regard to hemp protein isolation, raw material input preparation, and processing of the raw material input, in order to produce a superior plant based meat and dairy analog. The composition and process of the present disclosure includes a process for hemp grain protein isolation, pasteurization, sol formation, gel formation, texturization and meat and dairy analog production. The process of the present disclosure results in a meat or dairy analog product having superior properties when compared to existing products or similar products manufactured using known technology.
In addition to protein isolation, this document is based on methods and materials for making plant based products that more closely replicate meat products, including the texture, juiciness, fibrousness and homogeneity in texture of animal meat. A process for producing meat analogs is described herein that may include selection of proteins based on their unfolding, or denaturation, properties and fat holding capacities. Further, the process described herein includes a method of preparing an extrusion mixture, prior to extrusion, that incorporates water and fat into a selected protein in a manner such that the water and fat form a liquid matrix (which may also be referred to herein as a liquid-fat hydrosol, a hydrosol, an extruder or extrusion input, and an input material) with the protein. Still further, the process described herein includes methods of extruding or otherwise heating the liquid matrix. The process of extruding the liquid matrix includes feeding the liquid matrix into a pump at a first end of an extrusion chamber. The liquid matrix is fed into an extrusion chamber of an extruder, wherein the extruder is set for parameters tailored to the liquid matrix.
As disclosed herein, NEPI may be extracted from hemp grain or other grains, nuts or seeds that contain edestin or edestin-like proteins; although it is currently thought that hemp grain is the only source of edestin. In one embodiment, the hemp grain is wet milled and subject to aqueous extraction, thereby producing an insoluble edestin-containing extract, which is herein referred to as NEPI, and an aqueous oil albumin emulsion.
The process according to the present disclosure may produce a pasteurized and functional hemp grain protein concentrate, where the concentrate may be a concentrated liquid coming off a production line or from centrifugation and decanting, or a NEPI powder, which, in some embodiments may have a low, or no, amount of trypsin inhibitor and having high nutritional value and functionality. The process may not use isoelectric extraction, alkali or CO2 solubilization methods. A texturizable protein NEPI concentrate or NEPI powder is thought to be produced by an oil extraction and separation of albumin, utilizing the natural pH and oil content of the hemp grain in conjunction with water. The emulsion forming capability of soluble albumin may form an emulsion which may readily be separated from the insoluble edestin by centrifugation. Lyopholisis, pH readjustment and ultrafiltration separation are not required. Additionally, fiber and chlorophyll may be removed during the NEPI process. Maintaining low temperatures, preferably between 33° F. and 38° F., promotes globulin insolubility and also coagulation of the albumin.
One aspect of the present disclosure relates to the isolation of edestin and edestin-like proteins from plant material, including hemp grain. Edestin is found in the hemp plant; particularly the hemp grain. While hemp grain is thought to be the most common, or only, source of edestin, it is possible that other plants may contain edestin.
The edestin extract compositions, or native edestin protein isolate (NEPI), prepared according to the methods of the present disclosure may be used to make protein-containing compositions. NEPI may preferably be comprised of approximately 80% dry basis protein; in some embodiments NEPI may contain at least 65% dry basis protein, and in some embodiments may contain at least 90% dry basis protein. As such, NEPI may be defined as an edestin containing composition produced according to the methods described in the present disclosure resulting in a product having the functional characteristics described in the present disclosure. The aqueous oil albumin emulsion (AOAE) described in the present disclosure may be further processed to produce other plant based products including hemp oil or grain oil and albumin.
The present disclosure may be practiced using suitable grains, seeds or plant material that contain edestin or edestin-like proteins, wherein such edestin-like proteins may be homologous or have similar structure and function.
The grain used in the present disclosure may be substantially full fat plant grain, i.e. grains that have not been defatted, or pressed, prior to milling. In some embodiments, the grain may be partially defatted. A partially defatted grain includes any plant material from which at least a portion of the fat has been removed.
Substantially full fat hemp grains may have a fat (or oil) content of 10% or more fat by weight, as would be known to a person of ordinary skill in the art. In the present disclosure, the terms fat and oil may be used interchangeably. Suitably, the fat content of a substantially full fat grain is at least about 10%, 15%, 20%, 30%, 40% or even 50% by weight. The fat content of hemp grain is typically at least 30%. The fat content of a partially defatted plant material may be greater than about 5%, 10% or 15% fat by weight. After removal of the hull, the edible portion of the hemp grain contains, on average, 46.7% oil and 35.9% protein.
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Referring now to
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Oil may then be added to the protein hydrosol 110, followed by high shear mixing 112. In some embodiments, after high shear mixing 112 the mixture may be optionally incubated without mixing 113. Addition of oil 110 and mixing 112 produces protein-fat hydrosol 114.
Protein-fat hydrosol 114 is used as an input for a means of heating protein-fat hydrosol to set the product 116. Setting may involve heating through means including microwave, steam tunnels, ovens, retort, and extrusion (as shown in
As shown in
In the present process, no adjustment of pH is required to isolate NEPI. Preferably, throughout structured protein food product process 100 the pH remains approximately neutral at between 6.5 and 7. In one embodiment, the pH of the solution does not vary during milling of the grain to any substantial degree.
Hemp grain mixture 204 may be wet milled 206 substantially as described in U.S. Pat. No. 7,678,403 to Mitchell. In one embodiment, milling hemp grain 206 may be performed using a Silverson rotor stator type mill. Wet milling 206 may be performed as part of an aqueous extraction process. Suitably, aqueous wet milling 206 may conducted for a suitable period, and more suitably wet milling 206 is conducted for a suitable period. As one of skill in the art will appreciate, longer extraction periods may be used. In some embodiments enzymes may be used to aid in processing. For example, liquefaction may be accomplished using an alpha-amylase enzyme having dextrinizing activity to yield a liquefied slurry. Such enzymes may include amylase, or other carbohydrases known in the art of food processing. The present disclosure may, in one aspect, utilize a method of aqueous wet milling to separate fat stored within the hemp grain 102 without rupturing the chloroplasts and releasing chlorophyll into the oil. Calcium chloride may be added to NEPI 250 to improve flavor after centrifugal decanting 222.
After aqueous wet milling hemp grain 206, the extract may be separated from at least a portion of an insoluble byproduct or fibrous slurry 210 (e.g., insoluble fiber fraction) with a mesh. In some embodiments, hemp grain slurry 208 may be sifted in two steps. Sifting may remove unwanted impurities that give the edestin unpleasant colors or taste. Insoluble fibers can be removed by a first sifting step. Another undesirable product that may, surprisingly, be removed by sifting without substantially affecting protein yield is chlorophyll from the chloroplasts in the hemp grain and hulled hemp, which can produce unwanted color, taste and fat oxidation in the oil fraction or protein fraction. In some embodiments, chlorophyll containing particles may be removed in a second sifting step 212. After sifting 212 a chloroplast and fiber sludge may be in the retentate, along with raw hemp milk having a fat to protein ration on a DSB of about 1:3:1 in the filtrate.
In a first sifting step, hemp grain slurry may, in some embodiments, be sifted over 30 mesh to remove hulls. The byproduct of the first sifting step may be a fibrous slurry 210. In a second sifting step 212, hemp grain slurry may be sifted 212 to remove chloroplasts with approximately 170 mesh, or in some embodiments between 160 and 200 mesh, or in some embodiments between 200 and 220 mesh to removes chloroplasts, or chlorophyll containing material and any remaining fiber. A mesh size of 150 has openings that may be generally too large and may allow undesirable material into the filtrate, including fibers and chlorophyll-containing particles. Surprisingly, chlorophyll containing particles remain at a size greater than the pore openings of 170 mesh, while most protein containing particles pass through mesh of this size. Sifting with different size mesh separates the chloroplasts, protoplastids or other chlorophyll containing particles from the hemp oil and protein containing fraction, resulting in a pale, yellow final oil product.
Chloroplasts isolated by edestin extraction process 100 may, in some embodiments, be used as a food supplement. According to the process of the present disclosure, chlorophyll containing particles 214 are selectively removed from hemp grain slurry 208 while allowing protein containing particles to pass through into the filtrate. This method is effective for both whole hemp grain, where the hull has not been removed prior to aqueous wet milling and hulled hemp grain.
After sifting hemp grain slurry with 170 mesh to remove chlorophyll containing particles 212, the resulting product is an aqueous oil albumin emulsion (AOAE) and edestin mixture 220, which may also comprise other components of hemp grain 102 to greater or lesser degrees. AOAE and edestin mixture 220 may be centrifugally decanted 222, resulting in NEPI 250 and AOAE 230. After being separated from NEPI 250, AOAE 230 may be further processed to produce albumin 550 and hemp oil 560, as shown in
NEPI 250 may, in some embodiments, be comprised of approximately 76% protein, 2% oil, 4% fibers, 1% carbohydrates and 17% ash. AOAE 220 may be comprised of approximately 14% protein, 76% oil, 3% fiber, 4% carbohydrates, and 3% ash. In some embodiments, NEPI may preferably be comprised of approximately 80% dry basis protein; in some embodiments NEPI may contain at least 65% dry basis protein, and in some embodiments may contain at least 90% dry basis protein. As such, NEPI may be defined as an edestin containing composition produced according to the methods described in the present disclosure resulting in a product having the functional characteristics described in the present disclosure. In some embodiments, NEPI may contain at least about 65%, 75%, 85% or 90% protein on a dry weight basis.
Table 2 shows proximate analysis data of the nutrient composition of NEPI 250 and commercially available hemp protein products. Table 2 shows that the NEPI 250 products have high protein content and protein to fat ratios, as does VICTORY HEMP. The other commercially available products have much lower protein contents and protein to fat ratios. This indicates that of the products tested, NEPI 250 and VICTORY HEMP are likely far superior to the other products.
Collectively,
Table 3 shows differential scanning calorimetry thermographs that provide structural information regarding the edestin contained in the NEPI 250 and commercially available products. DSC thermographs for two NEPI products (
When compared to hemp protein isolates produced by conventional means, as described previously in the background, the quality of the edestin in NEPI 250 is superior. Additionally, when compared to the process of the present disclosure, prior art methods of protein extraction have significant disadvantages and limitations. For example, salt extraction and dialysis in the HMI process does not remove residual phenolics from the final product. Further, HMI is less commercially viable.
The process of the present disclosure has numerous advantages over the prior art. The present process may release phenolics and tocopherols from NEPI 250 and AOAE 230. The process of the present disclosure may make hemp oil 560 more oxidatively stable. In the process of the present disclosure, during aqueous wet milling, phenolics may separate with hemp oil 560, thereby providing stability.
The process of the present disclosure differs from conventional methods of protein extraction from hemp grain in that conventional methods generally involve pressing the grain to extract the oil and produce a hemp grain cake, which may then be milled and sifted to produce a flour. The resulting cake or flour may contain aggregated edestin and albumin, along with oil, carbohydrates, phenolics and minerals. The seed may, in some cases, also be dry milled directly produce a flour.
Mechanical processes that result in high heat or pressure, such as pressing the grain, may lead to chemical bonds being formed between edestin and albumin. Pressing either whole hemp grain or hulled hemp grain may result in aggregation of edestin and albumin.
High pressure can change protein structure and cause protein aggregation. According to Yang, high-pressure modification of proteins involves changes in protein secondary, tertiary, and quaternary structures from the native state through intermediate states to the fully denatured state (Yang et al., 2016). High pressure changes protein structure primarily through changes in non-covalent bond-electronic interactions, hydrophobic interactions, and hydrogen bonds. High pressure can also cause new disulfide bonds to form, thereby stabilizing the denatured proteins or producing protein aggregation (Yang et al., 2016).
Heat, also, is known to alter protein structure. Heat caused by friction during milling of the grain can lead to changes in protein structure. Heat can lead to denaturation of proteins and formation of protein aggregates. Aggregation between edestin and albumin is likely to occur during dry milling, where temperatures can reach 100° C. or higher.
NEPI may, in one embodiment, then be heated to a temperature of approximately 145° F. for approximately 30 minutes to pasteurize the product. In some jurisdictions,145° F. may be a legal lower limit for pasteurization. In one embodiment, the temperature may be maintained at approximately 145° F., or between 145° F. to 155° F., in order to prevent granulation. Formation of granules has been observed in the present disclosure to occur at temperatures of approximately 158° F. Granulation may occur in NEPI at temperatures well below the denaturation temperature of edestin, for example at approximately 158° F., wherein the denaturation temperature of edestin has been shown to be approximately 95° C. It is critical to pasteurize NEPI at temperatures below those typically used by those of ordinary skill in the art for pasteurization of plant proteins for use in food products. Those of ordinary skill in the art conventionally pasteurize protein isolates at temperatures that would cause significant granulation in the present disclosure, in order to rapidly process the product. Pasteurized NEPI 270 is the result of washing and diluting with cold water 232.
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In some embodiments, the preheated water may be tap water, and in some embodiments may be tap water supplied from Lake Erie and may be substantially free of solutes (e.g., tap water, distilled water or deionized water). Salt should not be added to the solution during the hydration and protein preparation process, as it may disrupt protein hydrosol 108 or protein-fat hydrosol 114 structure. Salt may be added after setting, but not before. In some embodiments, protein hydration and opening (such that, without being bound by theory, protein structure may be slightly altered, or opened, to allow appropriate interaction with oil during formation of the protein-fat hydrosol 114) which may be performed at 100° F. to 135° F., or in some embodiments between 100° F. and 155° F.; or in other embodiments protein hydrosol formation may be performed at lower temperatures, however, the temperatures must be above cold temperatures which do not allow for protein hydration and opening. Preferably, temperatures during the hydration and protein-preparation step should remain as close to 145° F., or pasteurization 104 temperature, as possible, without reaching temperatures that may results in protein aggregation and granulation. Once protein hydrosol is formed, preheated oil 109, which may be heated, in some embodiments to between 110° F. to 115° F., and in other embodiments to between 100° F. and 155° F., or in some cases kept at a temperature above that considered cold, such that protein hydrosol structure is disrupted by addition of oil, but below temperatures that produce granulation of protein-fat hydrosol 114.
In some embodiments, protein-fat hydrosol 114 can be produced by combining a fat with a warmed suspension of hydrated protein (for example, a protein isolate containing edestin) having a pH between 6.5 and pH 7.8 (for example, pH 7.5). Rapid agitation, such as in a Waring type blender or a hand held homogenizer, or homogenization of this mixture leads to the formation of an emulsion. Physical properties of protein-fat hydrosol 114 may be controlled by changing protein type, protein concentration, pH level at the time of homogenization, speed of homogenization and fat-to-water ratio.
To form protein-fat hydrosol 114, a polyunsaturated fatty acid (PUFA) oil, or fat, which may preferably be coconut oil or fat, may be heated just past the melting point of the fat, and added to protein hydrosol 108. Without being bound by theory, the fat may form a layer surrounding the hydrated native edestin, thereby forming a liquid matrix, or protein-fat hydrosol 114, that essentially encapsulates the hydrated protein, forming a hydrated protein in oil emulsion which effectively creates a thick and stable gel. Effectively, the oil may seal and protect the hydrated protein structure. Hydrated protein can hold considerably more fat in a gel state than a dry protein. In general, it has been found that a native globular protein, as discussed in this application, that is first hydrated and then gently heated to below its denaturation temperature, may hold up to two times its weight in fat. The moisture content of protein-fat hydrosol may, in some embodiments, range from about 30 wt % to about 70 wt %. The moisture content refers to the amount of moisture in a material as measured by an analytical method calculated as percentage change in mass following the evaporation of water from a sample.
In any of the methods or compositions described herein, protein-fat hydrosol 114 may include a flavoring agent or other additional ingredients. The following ingredients may be added optionally at typically less than 2 wt % on a finished protein-fat hydrosol 114 basis: fat soluble or other flavor systems, salts including sodium chloride, plant based albumin sources, plant based insoluble or soluble fibers. Starch may be added alone or in combination with other soluble carbohydrates including complex carbohydrates or sugars if desired at levels up to about 10 wt % but more preferably less than 5 wt %. The adjunct ingredients may be added to protein-fat hydrosol 114 prior to the set for the purpose of improving and altering flavor or texture. Fiber may be added to decrease “squeakiness” of the structured protein food product 120.
In one embodiment, protein-fat hydrosol 114 may include, in one aspect, about 15 wt % to about 25 wt %, or more preferably about 18 wt % to about 22 wt %, by weight of a protein, wherein the protein may be a native oil seed protein; wherein in one embodiment about 75 wt % to about 85 wt % of the protein isolate comprises a globular protein, and preferably the protein isolate comprises less than 15 wt % albumin, and more preferably less than 5 wt % albumin. More importantly, the globular protein may be in its native state and preferably having a significant content of the amino acid cysteine, in an amount greater than casein or soy protein isolate. The balance of the protein composition may, in some embodiments, be primarily minerals such as calcium and phosphorus. The native oil seed globular protein preferably may have substantial amounts of cysteine.
Protein-fat hydrosol 114 may include, in one aspect, about 40% to about 70%, or more preferably 40%-60%, by weight of a water.
Protein-fat hydrosol 114 may include, in one aspect, about 0% to about 35% by weight of fat; the ratio of saturated to polyunsaturated fatty acid (PUFA) being between 100 wt % saturated fat and 100 wt % PUFA. Combinations between these two amounts of fats provide a variety of unique textures heretofore not reported, depending on the amount of protein used in combination with the fat.
Protein-fat hydrosol 114 may optionally include, in some embodiments, about 0% to about 5% by weight of a starch. The amount of starch added may be dependent on the amount of water added, beyond the amount of water added to the protein that is required for hydration of the protein.
Protein-fat hydrosol 114 may be formed by mixing, manually or mechanically, the ingredients for forming protein-fat hydrosol 114. Preferably, the hydrated protein is first warmed to just below the granulation temperature of the protein, the oil and/or melted fat is added, and preferably the mixture is gently homogenized.
In one aspect, protein-fat hydrosol 114 may be combined at a temperature of between 120° F. and 150° F. The temperature range to set the protein in a heated environment, without disruption of the formed gel or matrix, has been found to be between 70° C. and 100° C. These temperatures are significantly lower than the extrusion temperatures generally required for the extrusion of conventional meat analog proteins, such as soy. The temperature of denaturation and fibration of soy protein under conditions typically used in extruders is in the range of approximately 130° C. to 140° C. According to the present disclosure, good texturization may be obtained by oven heating of the protein-fat hydrosol 114, and/or by pressure cooking (retorting) the protein-fat hydrosol 114 to actively set the protein.
The physical properties of protein-fat hydrosol 114 are that of a hydrosol. The viscosity is dependent on the oil, fat and water and protein content. Variations of higher moisture and will reduce the viscosity substantially even with low protein to fat ratio. Likewise, very low protein to fat ratio and low moisture can result in a very high viscosity. The quality and choice of fat systems and protein systems also significantly impact the viscosity.
Formation of the protein-fat hydrosol 114 can be done below the denaturation point of the native protein. However, according to the present disclosure, it is not desirable to store the protein-fat hydrosol 114 at that temperature, as it is not microbiologically stable. It is preferable to immediately process by heat to set the protein shape. The liquid matrix can otherwise be cooled via heat exchanger or other method to below 6° C. to store prior to further processing.
With regard to retort according to the present disclosure,
The POWERHEATER PH 100, while known to be used with fibrated input material, is generally known to be used to set starch in its input material, rather than protein. Protein-set extrusion is generally performed at temperatures well above 100° C., and therefore protein set input material is not thought to be used with the POWERHEATER PH 100. The protein-fat hydrosol of the present disclosure, however, was effectively texturized and fibrated by the POWERHEATER PH 100 at 75° C., in fibrating the protein-fat hydrosol of the present disclosure, which was accomplished at a relatively low temperature of approximately between 75° C.-85° C., and wherein the auger and extruder may be preheated to between 75° C.-85° C. 802, and extrusion may occur in a range of approximately between 70° C.-95° C. In one embodiment, the protein-fat hydrosol extruder uses an 8 mm screw size, rather than a 3 mm screw size, using the POWERHEATER PH 100 at 75° C. The protein-fat hydrosol may be input into the POWERHEATER PH 100 using a sucking pump or a stuffing pump, wherein the onset temperature may be approximately 85° C. 802. After pumping the protein-fat hydrosol into the extruder 804, extruding at approximately 75° C.-85° C. may proceed, wherein the protein-fat hydrosol does not stick to the inner wall of the extruding pipe 806. This process produces a texturized structured protein food product 120. Texturized structured protein food product 120 extruded in accordance with the present disclosure, in tests, has been demonstrated to have texture, fibration and color similar to that of a cooked chicken breast possesses superior and unexpected properties when considering the prior art and the knowledge of a person of ordinary skill in the art.
In most extrusions, including the extrusion of soy based meat analogs, it has been seen that the protein to fat ratio is typically greater than 10:1. As such, extruded, denatured and fibrated soy, can hold very little fat. The hydrated gel of native globular proteins such as edestin, however, according to the present disclosure, can hold up to twice its weight in fat, even after formation of the set, or solid form of the gel, produced by the application of radiant, microwave, or other form of heating, including direct heating or extrusion.
In accordance with the process of the present disclosure, protein-fat hydrosol 114 may be set to a solid state at temperatures of between approximately 70° C. to 100° C., depending on the concentration of the protein in the system. The lower set temperature is consistent with the denaturation of native proteins in NEPI 250.
The solid structure formed during extrusion, according to the present disclosure, may be cooled and is representative of a set, but with incomplete denaturation, similar to an uncooked protein or “raw” meat. Further heating of the “uncooked” protein strengthens the shape, elasticity, texture and the like by further denaturing the protein, a process which ultimately also releases some water. According to the process of the present disclosure, it is undesirable to heat the product to the extent that a significant amount of water is released from the set in the extruder, rather, it is desirable to merely solidify the gel and shape or texture of the protein. In one embodiment, the present disclosure describes a process for preparing a raw meat or dairy analog, or structured protein food product 120, similar to raw animal meat, in the extruder. Further cooking of this raw meat analog, by traditional or commercial means, strengthens and toughens the meat.
The process according to the present disclosure is in contrast to existing technology, in which meat analog texture is created by using fully denatured proteins and then co-blending with other binders including fat, starches, and other proteins to form an appearance of a hamburger type of material. This type of set, according to existing technology, is achieved during cooking primarily through the gelation of starches or added raw proteins such as gluten.
The final texture of the structured protein food product 120 may depend on the properties of the liquid matrix, including the ratios of protein, fat and water, as well as the extrusion conditions. As described herein, the extruded mixture of isolated plant proteins may be referred to as a structured protein food product 120, which may be a meat analog, and the fibrousness and tensile strength of the meat analog may be controlled by co-variation of extrusion parameters such as temperature, pressure, throughput, and die size. For example, combinations of lower extrusion temperatures, medium/low throughputs and smaller dies favor production of highly fibrous tissues with low tensile strength, while higher extrusion temperatures, higher throughputs and larger dies favor production of low fibrousness tissue replicas with very high tensile strengths.
The fibrosity and tensile strength of the meat analog also can be modulated by changing the composition of the extrusion mixture. For example, by increasing the ratio of isolated plant protein to fat and water, or by decreasing water content in the extrusion mixture a meat analog with thinner fibers and larger tensile strength can be made.
Extruding the liquid matrix involves feeding the liquid matrix into an extruder. In some embodiments, the extruder may be a SOURCE TECHNOLOGY POWERHEATER PH 100. CLEXTRAL and WENGER twin screw extruders were tested but provided unsatisfactory results. In extrusion, according to the process of the present disclosure, cooling is important in order to achieve temperatures below 21° C. so that the saturated fats are readily set in the structure and the product can more efficiently be cooled to refrigerated or frozen temperatures.
For each product, the wet ingredient blend will be transferred to a feeder that may meter the liquid matrix through a feed port of an extruder at a certain input rate. In conventional extrusion, a dry protein product is fed into an input in the machine. As the dry product is moved through the machine, and water and fat are introduced from separate inputs. In contrast, during the process according to the present disclosure, the hydrated protein and oil are mixed first, as described herein above, in order to closely regulate the chemical reactions that take place during formation of protein-fat hydrosol 114. Therefore, in some embodiments, additional water, starch, or fat may or may not be added to the extruder during extrusion. Fiber may also be added in some embodiments.
In conventional extrusion of plant based meat analogs, addition of water and fat prior to beginning extrusion may result in an unwanted release of steam as the water escapes from the product as temperature increases. Therefore, the process of adding water and fat is closely regulated during extrusion for the present disclosure. In the process according to the present disclosure, the liquid matrix extrusion mixture is specifically designed to prevent the release of water from the product by the formation of a gel. During preparation of the liquid matrix according to the present disclosure, addition of oil to the hydrated protein forms an emulsion gel that prevents the release of water from the product during extrusion, which would otherwise be released as steam from the machine. The formation of the gel also allows for maintenance of high moisture in the liquid matrix during extrusion and in the final product, which is desirable for superior texture of structured protein food product 120.
Temperature during extrusion is important for the resulting product. Temperature should be increased gradually and maintained at approximately between 70° C. and 100° C., or between 100° C. and 110° C. In conventional extrusion, temperatures within the extruder are generally above 130° C. In the process of the present disclosure, low temperature prevents disruption of protein-fat hydrosol 114, thereby allowing the molecular structure of the compound to remain substantially, or partially, intact. The temperature of protein-fat hydrosol 114 may be maintained at approximately between 75° C. and 85° C., preferably, to set protein-fat hydrosol 114 and then cooled to reduce the temperature below 21° C. during the extrusion process. For the process of the present disclosure, it is important to maintain a lower temperature than is used during conventional extrusion. Here, the temperature is increased only to a point that allows for setting of the disulfide bonds, such that fat is fully incorporated between all the peptide layers of the protein. The residence time in the extruder or any heating environment, should be enough so that the input temperature of the liquid matrix is able to reach at between 70° C. to 110° C., or preferably between 75° C. and 85° C.
Preferably, the extruder rotates protein-fat hydrosol 114 at a relatively low screw speed, as measured in revolutions per minute (rpm), during extrusion to form a meat analog product that maintains the gel structure and maintains a high degree of moisture in the product. Screw speed may be closely monitored to prevent temperature increases and to prevent disruption of the chemical structure of the liquid matrix.
To prevent the destruction of the structure of a loose protein-fat hydrosol 114 formed by the hydration of the protein and fat encapsulation, it may be essential to move the gel slowly through the heat system to maintain the initial gel set (partial protein denaturation) while forming shape and some fibration. Fermentation (as would occur in cheese manufacture), or full cook and denaturation, would eventually occur during later use of the product. The finished, extruded product, having, in some embodiments, a moisture content of between 35 wt % and 75 wt %, could then be fermented, refrigerated or frozen for microbiological stability until such time that, if desired, it would be fully cooked at higher temperatures by ordinary or commercial cooking processes to obtain the desired finished texture prior to consumption. Additional relevant extrusion parameters may include die diameter, die length, product temperature at the end of the die, and feed rate.
After extrusion, the final product may have a structure that is more similar to animal meat than conventional or known structured protein food products such as meat and dairy analogs. Without being bound by theory, extrusion of protein-fat hydrosol 114, in accordance with the present disclosure, may cause proteins to form substantially aligned protein fibers, where protein fibers may be defined as a continuous filament of discrete length made up of protein held together by intermolecular forces such as disulfide bonds, hydrogen bonds, electrostatic bonds, hydrophobic interactions, peptide strand entanglement, and Maillard reaction chemistry creating covalent cross-links between side chains of proteins. The strength of the set after the initial extruder is not complete or as strong as it could be. In fact, it may be desirable to take the finished heat set product and subject it to further heating by direct or indirect heat, common cookery such as boiling, baking, frying, roasting, microwaving, fermentation and pressing (as in the making of cheese which may include salting and addition of acid) to name a few to finish setting the strength or form of the initial set product.
The preparation and extrusion conditions for protein-fat hydrosol 114, according to the process of the present disclosure, may allow for the substantially aligned protein fibers to, in some embodiments, retain up to approximately 50% by weight of fat within the proteins. Thus, the final product is not greasy and has a mouthfeel and fat release during chewing that more closely matches that of animal meat than existing meat analogs. Mouthfeel may refer to a combination of characteristics including moistness, chewiness, bite force, degradation, and fattiness that together provide a satisfactory sensory experience.
The anticipated final structure of structured protein food product 120 may vary based on the composition of the protein-fat hydrosol 114. The anticipated final composition of structured protein food product 120, in one embodiment of the present disclosure, by weight of protein, weight of carbohydrate (if any), by weight of lipid, and by weight of water, along with any other potential components, is represented in Table 4. Table 5 shows physical properties of for the structured protein food product 120 shown in Table 4. After extrusion is complete, the product may be cooled, shaped or cut. Post-processing steps may be performed on the extruded product.
A meat analog, which may also be referred to herein as a structured protein food product 120, may be produced from protein-fat hydrosol 114 by methods other than extrusion. Additional methods of producing a meat analog from protein-fat hydrosol 114 include the application of mechanical energy (e.g., shearing, pressure, friction), radiation energy (e.g., microwave, electromagnetic), thermal energy (e.g., heating, steam texturizing).
The invention will be further described in the following examples, which do not limit the scope of the invention described in the claims.
Hemp grain was obtained from Hemp Oil Canada, Manitoba Canada and River Valley Specialty Farms, Manitoba Canada. Hulled hemp grain was obtained from River Valley Specialty Farms company and whole hemp grain was obtained from Hemp Oil Canada company.
The HHG contained 5.5% moisture, 46% dry basis Kjeldahl protein, 35% dry basis fat and a 1.3 to 1 protein to fat ratio by weight. The WHG contained 8.8% moisture, 22% dry basis Kjeldahl protein, 30% dry basis fat and a 0.7 to 1 protein to fat ratio by weight.
1000 pounds of the HHG was mixed with 5000 pounds of water at 34° F. in a 800 gallon agitated tank. The HHG was wet milled maintaining the temperature between 34° F. and 38° F. The hemp slurry was milled in the SILVERSON rotor stator tank at a rate of 56 gallons per minute for 30 minutes to wet mill the HHG. The diluted slurry was held for a mean time of 30 minutes. The extract was separated from the insoluble by-product using a mesh of size 120 mesh SWECO 60 inch screen to remove the bulk of the solids. The through of the 120 mesh screen were then passed over a 200 mesh screen on another SWECO vibratory sifter to obtain a slurry that was then transferred to a 500 gallon jacketed tank to maintain the temperature of the slurry at between 34F and 38F. The slurry was then fed to a DELAVAL centrifugal decanter at a rate of 13 gpm to obtain a separation of the edestin solids from the AOAE emulsion. The AOAE emulsion was then pasteurized through a tubular heat exchanger system at a temperature at a maximum temperature of 185F for 10 minutes. The AOAE was then held in a 900 gallon tank for processing. The edestin solids at 40% solids were diluted with cold water to 30% solids and pumped through a pre-heated tubular system set below 150F and exited that system at 146F into a jacketed hold tank having a temperature of 145F in the jacket. After 30 minutes, the material was cooled through a heat exchanger and to 35F and placed in a tote in the refrigerator for further processing and drying by a spray dryer.
1000 pounds of the WHG was mixed with 5000 pounds of water at 34° F. in a 800 gallon agitated tank. The HHG was wet milled maintaining the temperature between 34F and 38F. The hemp slurry was milled in the SILVERSON rotor stator tank at a rate of 48 gallons per minute for 30 minutes to wet mill the WHG. The diluted slurry was held for a mean time of 30 minutes. The extract was separated from the insoluble by-product using a mesh of size 60 mesh on a double stage Sweco 60 inch screen to remove the hulls. The second stage of the SWECO was fitted with a 200 mesh screen such that the slurry from the SILVERSON passed first through the 60 mesh removing the hulls and immediately fell on top of the 200 mesh screen which removed the chloroplasts and fine fibers. The rate through the SWECO was about 6 gpm and the sifted slurry went directly to a jacketed 500 gallon jacketed tank to maintain the temperature of the slurry at between 34F and 38F. When the tank was full, the slurry without hulls, fiber or chloroplasts, was then fed to a DELAVAL centrifugal decanter at a rate of 13 gpm to obtain a separation of the edestin solids from the AOAE emulsion. The AOAE emulsion was then pasteurized through a tubular heat exchanger system at a temperature maximum of 185F for 10 minutes. The AOAE was then held in a 900 gallon tank for processing. The light brown colored edestin solids at 40% solids out of the decanter were diluted with cold water to 30% solids and pumped through a pre-heated tubular system set below 150F and exited that system at 146F into a jacketed hold tank having a temperature of 145F in the jacket. After 30 minutes, the material was cooled through a heat exchanger and to 35F and placed in a tote in the refrigerator for further processing and drying by a spray dryer. The dry substance basis yield of the NEPI based on the WGH weight starting material was 15% or 79% of theoretical. AOAE yield was 25.3% DSB and Hull, Fiber and Chloroplast fraction was 46.9% on a DSB Overall recovery was 92%. The NEPI yield from HHG was 30% or 86% of theoretical. AOAE yield was 40.9% DSB and Hull, Fiber and Chloroplast fraction was 22.5% on a DSB Overall recovery was 98%. Analysis of the NEPI products obtained from the WGH and the HHG are shown in Tables 1 and 2 below.
NEPI concentrates prepared by the process of this disclosure even while maintaining process temperatures below 38F, still exhibit high microbiological activity prior to pasteurization and spray drying to the Powders. (See Table 1). The incoming raw materials whether from hemp grain or hulled hemp have Total Plate Counts (TPC) ranging typically from 2,000 TPC to 250,000 TPC. In an aqueous media that is rich in protein, it is essential to maintain the temperatures well below 42F and preferably less than 38F. In spite of the low temperatures, the TPC will continue to increase and result in spoilage of the protein if not pasteurized soon after the aqueous milling begins. The short duration of the process and the ability to pasteurize both the AOAE and the edestin slurry immediately after separation by centrifugal decanter, is an essential factor in the process. The resulting edestin product being pasteurized at low temperatures of 145F preserve the gelling functionality as previously mentioned. The AOAE can be heated at much higher temperatures in excess of 145F and more preferably 195F for short periods of time which is advantageous for further processing to remove remaining insoluble solids via centrifugation and then emulsion disruption to separate the aqueous albumin phase and the oil phase. The success of the pasteurization of the NEPI Product in final powder form is reflected in TPC of the products in Table 1.
Table 3 shows DSC thermographs. The structure of NEPI, as measured by DSC thermographs (as partially shown in
Further structural and compositional analysis of the NEPI and the commercially available hemp protein products, as measured by SDS-PAGE gel electrophoresis is shown in
The NEPI refrigerated slurry obtained form Example 1 were sent to a commercial spray dryer for drying. ALFA LAVAL type spray dryer with nozzles having a 1200 lb per hour water removal capacity was used to dry the powders. The refrigerated product was pumped into a jacketed 250 gallon tank which used a water temperature set to hold the jacket at 155F. The tank had a slow agitator and the product took several hours to heat approximately 200 gallons of the concentrate edestin slurry at 30%. Once the product achieved temperature it was sent to another tank which fed the dryer. It should be noted that the NEPI dries very easily with no sticking to the walls of the dryer. Final outlet temperature of the dried product was 85F. The composition of the dry product is given in Table 2 below for each of the NEPI (WG and HHG) products obtained from Example 1.
Protein Hydrosols are readily made in a 5 gallon plastic bucket by adding 14 lbs of water that had been pre-heated to 140F. To the water is slowly added 14 lbs of the NEPI dry powder with agitation using a hand held industrial homogenizing wand of ¼ horsepower. Homogenizing is maintained until the all the powder has been added. The temperature, now at 130 F, to which after approximately 15 minutes of holding, is added 7 lbs of canola oil all at once, and the mixture briefly blended with the homogenizing wand for approximately 1 minute or until the slurry appears to be well blended and the oil incorporated as a uniform emulsion.
Example 4 discloses formulations comprising the liquid matrix used for producing various types of meat analogs. According to the present disclosure, depending on the ratios of protein, fat and water, different types of meat analog products can result, including plant based meat analog targets that replicate seafood, white meat, dark meat, egg and cheese.
With regard to Table 4, the water content target is between 35 wt % and 75 wt %. The minimum 70 wt % globular native plant protein having an albumin content of less than 15 wt %, preferably less than 5 wt %. The liquid matrix temperature should be maintained at 140° F. from mix blend through processing. Due to the ability of native seed oil proteins, which in Table 4 may be native edestin, the amount of fat may be varied to obtain different types of meat analog products. The structural features of the resultant products are similar to those of the material that they were duplicating. For example, seafood texture was white in color having a very elastic structure similar to a raw shrimp or scallop. The white meat was white, and had a texture similar to what would be expected of a partially cooked chicken filet. The dark meat was slightly light brown in color and again had the texture similar to a chicken thigh, with more fat and moisture compared to the white meat. The egg was similar to what would be expected for scrambled eggs and was also white in color. The cheese was similar to a cheese curd and actually squeaky when bitten into a piece similar to fresh cheese curds.
Retort conditions were over 15 minutes from a temperature of 77F to a peak of 270F and decreased to 95F at 15 minutes. Pressure was 0.20 bar at 1 minute and increased to 3.0 bar at 4 minutes and decreased to 0.8 bar at 15 minutes. The machine used was a SUNDRY RETORT TYPE: AP-95, SERIAL NUMBERS: 705.
Colorimeter- Chroma Meter CR-400 - Konica Minolta 2021-12-03
Colorimeter- Chroma Meter CR-400 - Konica Minolta 2021-12-03
The protein-fat hydrosol from Example 3 was used in a Power 100 Source Technology extruder set for 6 lbs a minute flow rate and a 3 MM screw auger diameter at 185F to create a structure gel having the appearance and texture of white meat chicken. See
The present disclosure unexpectedly demonstrates that a surprisingly superior hemp based structured protein product can be produced using only 3 ingredients: hemp grain, oil, and water. A hemp meat analog produced according to the present disclosure is herein shown to replicate chicken in terms of color, texture and taste to a surprising degree. Commercially available protein products, some of which claim to produce excellent meat analogs, did not compare to the native edestin protein isolate in terms of taste, color or texture, when used for this purpose.
No commercially available products were uncovered that used only hemp protein to produce a meat analog. Further, the prior art teaches that hemp protein alone is not a viable protein for producing structured protein food products such as meat and dairy analogs. The present disclosure demonstrates that this is not the case.
As used herein, the articles “a” and “an” when used herein, for example, “an anionic surfactant” or “a fiber” is understood to mean one or more of the material that is claimed or described.
“Basis Weight” is the weight per unit surface area (in a machine-direction/cross-direction plane) of a sample of web-like material (on one side), expressed in grams/meter2 (gsm). Basis weight may be specified in manufacturing specifications, and also may be measured, and reflects the weight of the material prior to addition of any liquid composition.
“Web-like structure” as used herein means a web or sheet hydrogel containing the elements of at least threads, sheets and container sidewall adjacent sections or bottom adjacent sections.
“Container” as used herein means an object capable of containing a liquid protein-fat hydrosol and is capable of being used in a microwave oven.
“Container material” as used herein may include material that can hold liquid and may be comprised of preferably food grade material capable of being used in a microwave oven, including, but not limited to, plastic, such as Acrylic or Polymethyl Methacrylate (PMMA), Polycarbonate (PC), Polyethylene (PE), Polypropylene (PP), Polyethylene Terephthalate (PETE or PET), Polyvinyl Chloride (PVC), Acrylonitrile-Butadiene-Styrene (ABS); paper, paper blended with a material such as a plastic that allows for heat treatment or can hold boiling water and paper containers that include polylactic acid (PLA) as opposed to conventional plastics; and ceramic material including glazed and unglazed ceramics; glass, including microwaveable glass and other materials as would be known to one of ordinary skill in the art.
“Expansion ratio” as used herein means Vmax of the protein hydrosol or protein-fat hydrosol after microwave heating divided by Vi of the protein hydrosol or protein-fat hydrosol. As used herein, volume measurements of expanded products will include voids formed by gas bubbles, unless otherwise indicated.
Final volume (Vf) as used herein means the volume of the protein-fat hydrogel in the container after microwave heating as measured from the final height (Hf), which as used herein means the highest point on the container where material is bound after collapse.
Final meniscus center volume (Vmc) as used herein means the volume of the protein-fat hydrogel in the container after microwave heating as measured after collapse from the top surface of the collapsed material in the container after microwave heating is terminated. This calculation may be an estimate and may not always be an accurate measure of the volume because there may be significant variation in shape from run to run even when all conditions are identical.
“Hydrogel meniscus” as used herein means a full or partial meniscus, or concavity, formed from hydrogel material that may be present after microwave heating in accordance with the present disclosure. The hydrogel meniscus may be formed from a top layer of hydrogel material. This top layer may be referred to as, without being bound by theory, a protein film or protein-oil film. This definition may include a full or partial meniscus as may be formed when gas bubbles and hydrogel material collapse when microwave heating is stopped. At this point, a certain amount of hydrogel material may be bound to the sidewall of the container while a portion of the hydrogel in the center of the container may fall to a level below that of the maximum height of the material bound to the sidewall of the container, thereby forming a meniscus or partial meniscus having a having a crescent, or concave, shape. Generally, the center of this meniscus, which may be approximately at the center of the container, may be the bottom of the meniscus or partial meniscus. The meniscus may have a meniscus depth as measured from the bottom of the concave portion of the meniscus to the final height (Hf) of the hydrogel, measured at the highest point at which the hydrogel is bound to the sidewall of the container after microwave heating.
“Inclusion” as used herein means an edible material that may be included in the preparation of the hydrogel.
“Layer” as used herein means one thickness, course, or fold of protein-containing material laid or lying over or under another.
“Meniscus ratio” as used herein means the meniscus depth divided by the final height (Hf) of the protein-fat hydrogel in the container.
“Microwave oven” as used herein means a form of electromagnetic radiation with wavelengths ranging from about one meter to one millimeter corresponding to frequencies between 300 MHz and 300 GHz respectively. In all cases, microwaves may include the entire SHF band (3 to 30 GHz, or 10 to 1 cm) at minimum. Typically, consumer ovens work around a nominal 2.45 gigahertz (GHz)—a wavelength of 12.2 centimeters (4.80 in) in the 2.4 GHz to 2.5 GHz ISM band—while large industrial or commercial ovens often use 915 megahertz (MHz)-32.8 centimeters (12.9 in). With respect to the present disclosure, all wavelengths of microwave radiation are contemplated, while preferably, commonly used microwave radiation for cooking food products in a domestic, commercial or industrial setting may be utilized.
“Particulate” as used herein means a granular substance or powder.
“Predominate” or a form thereof, with respect to a proportion of a component of a structure or composition, means that the component constitutes the majority of the weight of the structure or composition.
“Visually discernible” as used herein means visible to the naked eye.
Herein, where the quantity of a component of a fibrous web-like structure is expressed in “X weight percent” or “X percent by weight,” or an abbreviated or shortened form thereof, the quantity means that the component’s weight constitutes X percent of the total weight of the material in which it is included.
“z-direction” with respect to a web or a fibrous web structure means the direction orthogonal to the general plane defined by the web-like structure.
Container 2100 should be capable of sufficiently holding a hot water 2002. In some embodiments, container 2100 may be similar to a paper Chinet® Comfort Cup® that is food grade and suitable for use in the microwave. In other embodiments the paper container 2100 may contain polylactic acid (PLA), and may be an Amazon® Basics Compostable 20 oz. Hot Paper Cup containing PLA. Container 2100 may be disposable, recyclable or compostable. In some embodiments container 2100 may be comprised of various types of paper, as would be known to one of ordinary skill in the art. In other embodiments container 2100 may be comprised of plastic. In some embodiments this plastic may be an Oster® 24 oz. plastic polycarbonate measuring cup pitcher w/lid for an immersion stick blender, wherein the inner wall of the Oster® container may sufficiently roughened by regular blender use over a period time such that the protein-fat hydrogel can bind the container sidewall 2102. A new Oster® 24 oz. plastic pitcher also binds the Other microwaveable material may include china, pottery, glass, ovenproof glass, glass ceramic, paper, silicone, and thermoplastics. In some embodiments, container 2100 may have a rough interior, such that protein-fat hydrogel 120 may bind or adhere to its surface.
In some embodiments, container 2100 may be comprised of material suitable for heating food products in the microwave while simultaneously insulating the container such that the outside temperature of container 2100 remains at less than 140° F., or cool enough to handle comfortably, when the inside material after cooking reaches 150° F. to 212° F. Preferable material may include ceramic, HDPE, polypropylene, double or triple walled paper containers or similar material. The material may preferably be recyclable and environmentally sustainable. In some embodiments, preferred containers 2100 may be double and triple walled paper containers 2100. An example of a ceramic container 2100 for use in accordance with the present disclosure is the W&P PORTER® ceramic mug having a protective silicone sleeve. An example of a polypropylene container that is microwavable but does not insulate, for use in the present disclosure, may be the CHOICE 32-ounce microwavable contact translucent round deli container. One example of a tri-layered paper container that is microwavable and insulated is the Chinet Comfort Cup®.
In some embodiments, container 2100 may preferably be comprised of a coarse or rough surface material, such as paper. The fibrous or textured or roughened nature of container 2100, in some embodiments, may allow for both binding and rapid cooling of expanded protein-fat hydrosol 2110 and protein-fat hydrogel 120 to container sidewall 2102, as shown in
In some embodiments container 2100 may be transparent, such that the protein-fat hydrosol 114 may be observed to expand and to rise within container 2100 during heating in a microwave. Visual observation of the full expansion and rise of expanded protein-fat hydrosol 2110 during heating in a microwave, and stopping heating at a visual cue such as a peak in the visual rise, or a rise to a desired level, may, in some embodiments, be included as part of microwave texturizing process 2000.
In some embodiments, container 2100 may have different shapes for producing certain types of meat or dairy analogs, such as a chicken breast shape or the shape of chicken nuggets. In some embodiments, container 2100 may have specific dimensions desirable for certain types of meat products. For example, in some embodiments, where the amount of protein-fat hydrosol 114 added to container 2100 was 110 grams of water, container 2100 may preferably have a base diameter to height ratio of approximately 1 to 2.5 and a base diameter to top diameter ratio of approximately 1 to 1.5; and wherein a container volume may preferably be approximately 16 ounces. In some embodiments, container 2100 may be generally cylindrical, with an open top, and have a diameter of approximately between 2 inches to 3.5 inches.
Other embodiments may produce meat analogs of different types, including seafood, white meat, and dark meat, as is shown and described in U.S. Pat. App. No. 17/551,163 to Mitchell Ellis, which is incorporated by reference herein in its entirety; and more particularly in Example 4 of U.S. Pat. App. No. 17/551,163 to Mitchell Ellis, which is incorporated by reference herein in its entirety.
In some embodiments, a preferred size for container 2100 may be a 16 ounce or 32 ounce container 2100, having a diameter of 2 to 4 inches, to support use of a conventionally sized immersion blender, and a height of approximately 5 inches to 8 inches. Container 2100 size and shape may vary to suit the quantity of protein-fat hydrosol 114 used in microwave texturizing process 2000. The preferred amount of protein-fat hydrosol 114 for use may vary and is related to microwave time, settings, and the size of container 2100. Preferably, a minimum amount of microwave time is desired to solidify, or set, protein-fat hydrogel 120, which may also be referred to herein as a structured protein food product or meat analog. Even heating, or even distribution of heat, within the protein-fat hydrosol 114 is desirable. Expansion, or gaseous rise, of the melting protein-fat hydrosol 114 is important to achieve elongation of the hydrogel that allows protein-fat hydrogel 120, when set, to have the appearance of fibers. Without being bound by theory, it may be that expansion and solidification may occur simultaneously in the present microwave texturizing process 2000, and the expanded product may be set, or further set, by the rapid addition of cold water 128, thereby cooling protein-fat hydrogel 120 to a more rigid, malleable state. After the setting of protein-fat hydrogel 120, preferably no residual liquid or material remains in container, indicating a complete and uniform distribution of heat during heating.
After addition 112 of the hot water, or hot water 2002, to container 2100, NEPI 250 or a similar base material, which may be flavored NEPI 250, may be added to hot water 2002, or similar liquid, in container 2100. NEPI 250 may be produced as described in U.S. Pat. App. No. 17/551,163 to Mitchell Ellis, titled “Native Edestin Protein Isolate And Use As A Texturizing Ingredient”, which is incorporated herein by reference in its entirety; and where the method of NEPI 250 extraction is more particularly described in paragraphs [0071] through [0080], [00151] through [00162] and
When NEPI 250 is added to hot water 2002, hot water 2002 may in some embodiments preferably be at a temperature of between approximately 60° C.-80° C., or between75° C. and 85° C. ; generally, when NEPI 250 is added, hot water 2002 should have a temperature that allows for rapid protein hydration and interaction with hot water 2002, but a temperature not hot enough to cause granulation of NEPI 250. NEPI 250 may not function properly in microwave texturizing process 2000 if heated to temperatures above approximately 70° C., where granulation may occur, and therefore temperatures at or below approximately 80° C. for hot water 2002 in container 2100 prior to addition of NEPI 250 are desirable. If hot water 2002 is at 80° C. when NEPI 250 is added, the temperature of the mixture may rapidly drop to approximately 70° C. when NEPI 250 is added, thereby preventing interference with the function of NEPI 250 in microwave texturizing process 2000.
In some embodiments, it may be important that NEPI 250 is added to hot water 2002 after hot water 2002 is already in container 2100. The ratio of hot water 2002 to NEPI 250 may vary depending on the desired texture and type of meat analog, as may be described in U.S. Pat. App. No. 17/551,163 to Mitchell Ellis, titled “Native Edestin Protein Isolate And Use As A Texturizing Ingredient”, which is incorporated by reference herein in its entirety.
In one embodiment, water is first added to a container 2100 and the water alone is heated in a microwave. To a NEPI 250 concentrate, additional water is added, and the mixture is then heated gently to a target temperature of 60° C. Oil 110 may then be added to the mixture. Optionally, the protein-fat hydrosol 114 mixture may then be cooled and then preheated gently to 60° C. before microwaving.
The present disclosure utilizes a protein-containing solution, protein hydrosol 108 or more preferably protein-fat hydrosol 114, to produce a protein-fat hydrogel 120 in a microwave oven. The protein-fat hydrosol 114, under the conditions described in the present disclosure, will form a uniquely protein-fat hydrogel 120 when heated in a microwave oven. In some embodiments, oil 110 may not be added to protein hydrosol 108 and the process will be performed without addition of oil 110. Important conditions for production of the claimed protein-fat hydrogel 120 may include the content of a protein-fat hydrosol 114, the amount or volume of the protein-fat hydrosol 114 in a container 2100, container size and shape, the material from which the container is comprised, power settings of a microwave oven, and the type, or structure, of the microwave oven. Other conditions that may be important for the production of the protein fat hydrogel 120, which may also be referred to as structured protein food product 120, include the addition of additives to the protein-fat hydrosol 114, including particulates or inclusions, the presence or absence of a lid on the container during heating, the temperature of the protein-fat hydrosol 114 prior to microwave heating, and different types of homogenizers to prepare the protein-fat hydrosol 114. The addition of salt to the protein-fat hydrosol 114 may also impact the final product by, in some embodiments, increasing expansion rate. These elements that may be important to the production of the protein-fat hydrogel 120 are not exclusive, and additional elements may be included or considered, as would be understood by one of ordinary skill in the art.
An important element of the product and process of the present disclosure is that the protein-fat hydrosol 114, as it is heated in a microwave oven, forms voids 2124 within the protein-fat hydrosol 114 as the protein-fat hydrosol 114 volumetrically expands. These voids may have diameters, or widths, of at least 1 mm, or at least 2 mm or at least 5 mm. Volumetric expansion, which may be herein also referred to as expansion in short, of the protein-fat hydrosol 114, for the purposes of the present disclosure, is defined as at least portions of the protein-fat hydrosol 114 rising vertically within a chamber of container 2100. Without being bound by theory, the expansion of protein-fat hydrosol 114 during microwave heating is likely related to the formation of pockets of steam within the melting hydrosol protein film, which form gas bubbles within protein-fat hydrosol 114. Under certain conditions, in accordance with the present disclosure, protein-fat hydrosol 114 will expand, or rise within container 2100, to at least approximately 2 times, or approximately 3 times, or approximately 4 times, or approximately 5 times, or approximately 6 times, or approximately 7 times its original volume.
During microwave heating, protein-fat hydrosol 114 may first start to “melt” making a film structure which then entraps the water molecules. As the water molecules then reach the temperature of 100° C. forming a gas, the protein film then starts to expand until it reaches a temperature at which it may set, or may have substantially all of protein-fat hydrosol 114 be set. Setting may be defined as a transition from a liquid state to a solid state, where the solid state may initially remain moldable while hot or warm. Once set, in a moldable or unmoldable solid state, according to the present disclosure, the product is referred to as a protein-fat hydrogel 120, or protein hydrogel 108 if no fat has been added. Further heating beyond the point at which the protein-fat hydrogel 120 is set may cause deterioration of the quality of the protein-fat hydrogel 120, or structured protein food product 120.
Referring now to
In some embodiments, a flavoring may be added 114 to NEPI 250 either before or after addition of NEPI 250 to hot water 2002. In some embodiments, bulk preparation of protein-fat hydrosol 114 can be performed in any blender (Waring® or other) according to the preferred blend ingredients, quantity, and blend procedures. To set protein-fat hydrosol 114 to form protein-fat hydrogel 120, however, a preferred amount of the protein-fat hydrosol 114 should be added to a preferred size and shape of container 2100 for the preferred microwave power setting and time in order to achieve the desired result described herein.
After blending 2018 for a minimum time in order to allow for complete hydration and opening of protein, as evidenced by a smooth and uniform emulsion without visible particulates or granules being observed and thereby forming a suitable protein hydrosol 108, oil 110 may be added 120 to protein hydrosol 108 (2020). Oil 110 may be added in varied amounts, according to a desired product type, as described in in U.S. Pat. App. No. 17/551,163 to Mitchell Ellis and in the examples below. Many different types of oils 160 may be used, including sunflower oil, coconut oil, olive oil and other vegetable or animal oils. The type of oil 110 may depend on the desired type of meat product analog. For example, bacon grease may be added to protein hydrosol 108 if a pork meat analog is desired.
After addition of oil 110, the mixture of protein hydrosol 108 and oil 110 may then be blended 2022, in a manner as previously described, to form protein-fat hydrosol 114. Protein-fat hydrosol 114 may, in some embodiments, have the appearance of a thick pudding, prior to refrigeration and setting of a pudding. Over-blending of protein-fat hydrosol 114 may reduce the viscosity of the protein-fat hydrosol 114 to that of a loose milkshake. After blending, protein-fat hydrosol 114 may, in some embodiments, preferably be held at a temperature of approximately between 65° C. and 70° C., or between 0.5° C. and 23° C. Holding the protein-fat hydrosol 114 at temperatures between 0.5° C. and 23° C. or 65° C. and 70° C. delays microbial growth.
Protein-fat hydrosol 114 may then be heated in a microwave oven 2026, and optionally container 2100 may be covered by an indicator lid 2024. The microwave oven may be a standard household microwave oven. In some embodiments, the microwave oven may be set to 50% power; where, in some embodiments, the run time in the microwave oven may be approximately 1 to 2 minutes, or more preferably 1 min 30 sec.
In a conventional microwave, variable power levels add flexibility to microwave cooking. Each power level provides microwave energy for a certain percent of the time. For example, power level 7 provides microwave energy 70% of the time. Power level 3 is energy 30% of the time.
In one embodiment, a complete cook is desired, such that no residual material remains in container 2100 after heating. In some embodiments, a double walled container 2100 may be desirable to prevent a user from burning hands during removal of container 2100 after heating. In some embodiments, a coozie or container jacket, such as might be used with a beer can, may be used to hold container 2100 after heating.
Protein-fat hydrogel 120, or protein hydrogel, in the case where no fat is included in protein-fat hydrogel 120, may also be referred to herein, in some embodiments, as a meat analog 120. Heating in the microwave oven may preferably be stopped at a point where expanded protein-fat hydrosol 2110 reaches a particular height, where a particular amount of hydrosol material is in an expanded state, prior to a collapse when heating stops. Material in the expanded state may be defined as material that is not in the container bottom adjacent section 2400, where the container bottom adjacent 2400 section may be defined as material that is essentially uniform and in contact with the container bottom and is not part of the container sidewall adjacent section, where container sidewall adjacent section may be defined as material that is generally bound or adhered to the sidewall, but is not part of the threads and sheets that are more centrally located in container 2100. At the time when the predominate amount of protein-fat hydrosol 114 is set, in some embodiments, at least approximately 99% of material is in the expanded state, in other embodiments 98%, in other embodiments 97%, in other embodiments 96%, in other embodiments 95%, in other embodiments 94%, in other embodiments 93%, in other embodiments 92% in other embodiments 91% in other embodiments 90% in other embodiments 89%, in other embodiments 88%, in other embodiments 87% in other embodiments 86%, in other embodiments 85%, in other embodiments 84% in other embodiments 83% in other embodiments 82% in other embodiments 81% in other embodiments 80% in other embodiments 79% in other embodiments 78% in other embodiments 77% in other embodiments 76% in other embodiments 75% in other embodiments 74% in other embodiments 73% in other embodiments in other embodiments 72% in other embodiments 71% in other embodiments 70% in other embodiments 65% in other embodiments 60% in other embodiments 55% in other embodiments 50% and in other embodiments approximately at least 40% of protein-fat hydrosol 114.
Further heating may lead to dehydration of protein-fat hydrogel 120 and an inferior final product. Having the proper parameters of material and container 2100 shape may allow for a preferred product at a maximum height of expanded protein-fat hydrosol 2110. Adherence of expanded protein-fat hydrosol 2110 to container sidewall 2102 may be important for production of an appropriately structured, or textured, protein-fat hydrogel 120, or structured protein food product 120. Too much oil 110 in protein-fat hydrosol 114 may cause expanded protein-fat hydrosol 2110 to fail to adhere to container sidewall 2102, resulting in a more dense, solid, unstructured mass of protein-fat hydrogel 120, like a plug, lacking in desired texture.
In one embodiment, a preferred microwave texturizing process 2000 may include minimal heating time to generate a fully cooked protein-fat hydrogel 120, where no residual material is left after removal of protein-fat hydrogel 120, and this may be indicated by a maximum volume increase, or vertical rise for expanded protein-fat hydrosol 2110. When used with microwave texturizing process 2000, other protein materials, including soy or pea protein isolates, and other hemp protein isolates tested, as disclosed in U.S. Pat. App. No. 17/551,163 to Mitchell-Ellis, failed to generate a comparable expanded protein-fat hydrosol 2110, or a significant vertical rise, and did not result in an acceptable protein-fat hydrogel 120. Other hemp protein isolates tested, such as those produced by VICTORY HEMP and HEMPLAND formed products with a loose texture and low elasticity and could not be considered as functional meat or dairy analogs.
Examples are included herein for exemplary purposes only, and the process may be varied as would be understood by one of ordinary skill in the art. In example 8, 100 mL of protein-fat hydrosol 114 was heated with the microwave oven power set to 5. As observed through a clear plastic container during heating at power 5 in the Bosch microwave oven, after the first 30 second cycle, 10 seconds into the second cycle the protein-fat hydrosol 114 begins to noticeably expand and rise within container 2100 and then collapses at the 45 second point when the magnetron shuts off. In the third 30 second cycle, after approximately 5 seconds, at the 1 min 5 sec point, protein-fat hydrosol begins expanding again. At about the 1 min 20 second point protein-fat hydrosol sets and collapses.
For the present disclosure, the maximum protein-fat hydrosol 114 volume (Vmax) is defined by the approximate maximum volume to which the protein-fat hydrosol 114 expands prior to collapse, which generally occurs when microwave heating is stopped. It is possible that Vmax could be increased, in some cases by additional, heating, however, for the present disclosure, Vmax is defined as the maximum volume which is achieved for a particular process, rather than the absolute maximum volume that may be achievable during heating and expansion. Vmax may be measured using the approximate maximum protein-fat hydrosol 114 height (Hmax) to which protein-fat hydrosol 114 rises in container 2100 during heating in a microwave oven.
In general, the protein-fat hydrosol 114 may expand with a top surface maintaining a somewhat uniform height across the container. Gas bubbles make the top surface partially nonuniform; however, a height for the top surface, as it rises and reaches a peak height, may be observed and estimated. The final height as used herein has a different meaning than the maximum height, where final height (Hf) is the highest level to which protein-fat hydrogel 120 is bound to the container sidewall 2102 of the container. The initial protein-fat hydrosol 114 volume (Vi) is the volume of the protein-fat hydrosol 114 in the container prior to microwave heating. The initial height of the protein-fat hydrosol 114 in the container prior to microwave heating is denoted as Hi.
When the protein-fat hydrosol 114 sets after Vmax is reached it has a nonuniform web-like structure 2160, as shown in
As shown in
In one embodiment of the present disclosure, at the time of protein-fat hydrosol 114 setting, substantially all of the protein-fat hydrosol 114 had expanded from the bottom surface of the container and was present in either container adjacent sidewall sections 2300, threads 2130 or sheets 2128, such that the lower portion of the protein-fat hydrogel 120 does not noticeably take on the shape of the bottom of container 2100. In some embodiments, at the time of setting, the percentage of protein-fat hydrosol 114 pooled in the bottom of the container is approximately 5%, or more preferably 10%, or more preferably 15%. A mass of protein-fat hydrogel 120 at the bottom of container 2100 may generally be considered as undesirable for most purposes of the present disclosure.
In some embodiments, voids 2124 may be present between portions of the hydrogel 120. These voids 2124 may be caused by the presence of gas bubbles within protein-fat hydrosol 114 at the time of setting. Without being bound by theory, these gas bubbles may be comprised of steam caused by microwave heating of the protein-fat hydrosol 114. In some embodiments, voids 2124 may be heterogenous in shape and size, and may provide a desirable nonuniform structure to the hydrogel 120. The voids 2124 may create layers 2200, as shown in
As shown in
As shown in
The hydrogel meniscus ratio may be a useful tool for assessing the quality of protein-fat hydrogel for particular uses, such as for producing an acceptable meat analog. The hydrogel meniscus ratio range may be between 0 and 1. There also may be no hydrogel meniscus 2121 formation at all. The hydrogel meniscus ratio is calculated as the ratio of hydrogel meniscus depth 2127 divided by hydrogel final height (Hf) 2122.
No meniscus formation may exist when at least a portion of the bottom of the meniscus is flat against the bottom surface of the container, disrupting the shape of the meniscus curve at the bottom end.
The hydrogel meniscus ratio is 1 when the bottom tip of the meniscus just contacts the bottom of container 2100. The hydrogel meniscus ratio is 0 when the top layer, or protein-oil film 2131, is flat and equal in height to Hf. Here the meniscus depth is 0, leading to a hydrogel meniscus ratio of 0/1, where 1 is Hf.
According to the present disclosure, a hydrogel meniscus ratio of between approximately 0.3 to 0.7 may be preferred for meat analog production. This ratio was calculated using the process of the present disclosure with an Oster® plastic 24 ounce pitcher and substantially optimal protein-fat hydrosol 114 composition, and some variance may be expected under different conditions, as elsewhere discussed in the present disclosure. A hydrogel meniscus ratio of higher than 0.7 generally indicates an undercooked product for a meat analog product, while a hydrogel meniscus ratio of less than 0.3 generally indicates an overcooked product for a meat analog product. In certain cases, however, overcooked products may be desirable.
Hydrogel meniscus formation appears to be unique to the process of the present disclosure, in that other protein isolates tested, including soy protein isolate, potato protein isolate and other commercially available hemp protein isolates were not capable of forming a hydrogel meniscus under the conditions tested and described in the present disclosure.
In some embodiments, a protein-fat hydrogel meniscus range of between approximately 0.3-0.7 may be preferred; in some embodiments, a range of between approximately 0.4-0.6 may be preferred, in some embodiments a range of between approximately 0.45 to 0.55 may be preferred, in some embodiments a hydrogel meniscus of approximately 0.5 may be preferred. In some embodiments, a hydrogel meniscus ratio of between 0.2 and 0.8 may be preferred. In some embodiments, a hydrogel meniscus ratio of between 0.3 and 0. In some embodiments the presence of a hydrogel meniscus ratio of between 0-1 may be preferred. In some embodiments no hydrogel meniscus may exist.
Additionally, certain chemical compounds, including carbonate compounds and salts, may increase expansion in the present disclosure, and may alter hydrogel meniscus ratio. Such alterations are considered as within the scope of the present invention, even if they may alter claimed ranges. In some of the embodiments of the present disclosure, where spray dried NEPI powder was used, for example, 1% calcium carbonate was added to NEPI 250 to a concentration of 1%. The addition of calcium carbonate, with increasing concentration, may enhance expansion of protein-fat hydrosol. This may be the result of formation of carbon dioxide gas in the material during microwave heating leading to increased expansion. In some embodiments, calcium carbonate may be added for flavor purposes.
For example, protein isolates such as soy and pea, under the conditions of the present disclosure, without being bound by theory, may not form a hydrogel meniscus 2121 due to a lack of expansion and concomitant fibration and texturization along the container sidewall. Formation of hydrogel meniscus 2121, or a significant and substantial hydrogel meniscus 2121, requires significant binding to container sidewall 2102, coupled with a high degree of gas bubble formation within protein-fat hydrogel 120. Prior art materials may not be capable of accomplishing this. Meniscus ratio as used herein means the ratio of the meniscus depth divided by the final height (Hf) of the protein-fat hydrogel 120, as evidenced by the height of protein-fat hydrogel 120 bound to container sidewall 2102.
After heating in the microwave oven is stopped, protein-fat hydrogel 120 may be rapidly immersed in cold water (temperatures typical of household cold running water between 50° F. and 70° F. may be sufficient to cool the product by rapidly reducing the product temperature below 100° F.). Cold tap water, as would ordinarily be dispensed from a household kitchen sink, may generally be sufficient in terms of temperature. Meat analog 120 may then be separated from container 2100 by, in some embodiments, using a spatula to scrape around the inner portion of container sidewall 2102. Meat analog 120 may then be removed from container 2100 by spatula or by hand.
Meat analog 120 may, in some embodiments have a texture similar to that of a poached chicken breast. It is an advantage of the present disclosure, that in some embodiments, voids 2124 may be present at, or immediately adjacent to, the bottom surface of the container, such that the finished product does not have the appearance of being molded in the shape of the bottom of the container. Avoidance of a molded appearance substantially improved the aesthetic appeal of protein-fat hydrogel 120.
Conditions which may produce a microwave texturized protein-fat hydrogel 120 that is not fully molded into the shape of the bottom of the container may vary depending on a number of variables including, but not limited to, the amount of starting material, the size and shape of the container, the material of which the container is comprised, the type of microwave oven, the power of the microwave oven, the temperature of the starting material, and other variables as would be understood by a person having ordinary skill in the art, and where routine optimization could produce a product that does not appear to be fully molded to the bottom of the container. In some embodiments, partial molding of the material to the bottom of the container may be acceptable.
Utilizing the process described in the present disclosure with protein isolates other than those that are effective with the present disclosure may generally result in a final product that is molded in the shape of the bottom of the container, and that cannot be shaped after microwave heating, unlike the protein-fat hydrogel 120 of the present disclosure. Full molding of other protein isolate material to the bottom of the container using protein isolates prepared according to the present disclosure, but with ineffective protein isolate starting material, has been observed with soy protein isolates, potato protein isolates, commercially available hemp protein isolates and other protein isolates. In some embodiments, a thin, or insubstantial layer of protein-fat hydrogel 120 material may be present at the bottom of the material that may be molded to the shape of the bottom of the container but may thin or flimsy such that at least part of its shape is lost upon being removed from the container.
Meat analog 120 may, in some embodiments, be sliced and eaten without further cooking, for example, in a salad. Meat analog 120 may also be sautéed and browned in a pan, as a chicken breast may be browned and sautéed.
As shown in
In some embodiments, insert projection 2510 may have a peninsula shape relative to container sidewall, and form sidewall projection 2510b, such that projection 2510 may extend from a sidewall to a center of container 2100 to form a horseshoe-shaped chamber that hot water 2002 may occupy. Insert 2500 may have other geometric shapes, including rectangular or triangular. Insert 2500 may be comprised of a microwavable material, as previously disclosed herein. Insert 2500 may have an insert base 320 shaped to correspond to container base. Insert base 2520 may provide stability to insert 2500. Insert 2500 may be removable, or foldable and connected to container sidewall 2102 or container base 2104, to allow access to immersion blender 2600 (as shown in
In some embodiments, an indicator lid 2700, as shown in
With regard to
With regard to the source of NEPI 250 material from which the microwave texturized protein-fat hydrogel 120 is produced, a spray dried powder or concentrate may be used, as have been described previously herein. In some embodiments, NEPI 250 powder may be more effective than NEPI 250 concentrate at texturizing protein-fat hydrogel 120 in a microwave oven.
Without being bound by theory, shorter microwave heating times produce a superior final product. Therefore, producing a sufficiently protein-fat hydrogel 120 in the shortest possible heating time may be desirable. Superior texturization may be correlated with the degree of expansion of the material during microwave heating.
In some embodiments, as shown in
In some embodiments, the present disclosure contemplates the use of protein isolates made from seeds or grains that may have similar properties to Edestin, as described in the present application. This may include the globulins of pumpkin and squash (Cucurbita moschata and Cucurbita maxima), watermelon (Citrullus vulgaris), cucumber (Cucumis Sativus), tobacco and cottonseed, among others.
In some embodiments, after microwave heating and prior to cooling with water, protein-fat hydrogel 120 may be shaped 2034, as shown in
Shaping may be performed in container 2100. In some embodiments, shaping may allow for a user to eliminate a molded appearance of the hydrogel 120 that initially takes on the shape of the bottom of container 2100. Protein-fat hydrogel 120 may be shaped to have a structure resembling, for example, a chicken breast, or other shape that may be more aesthetically appealing or more convenient for consumption.
In some embodiments, calcium carbonate may be added to the NEPI 250, which may in some conditions increase the expansion ratio of the protein-fat hydrosol 114. Without being bound by theory, calcium carbonate may act as a catalyst to promote expansion of the protein-fat hydrosol 114. Calcium carbonate, sodium carbonate and sodium hydroxide may increase expansion and fibration when combined with NEPI 250. Calcium chloride appears to have no effect on the expansion ratio. In some embodiments, addition of calcium carbonate to protein-fat hydrosol 114 at approximately 0.5% may cause a significant increase in expansion ratio. More or less of certain carbonate compounds or other expansion increasing compounds may cause a relative increase related to the amount of compound added to protein-fat hydrosol 114.
Using a NEPI 250 concentrate or dried NEPI 250 that has been rehydrated and opened with hot water, in combination with oil 110 to form a thickened hydrosol, when placed in a microwaveable container, dish, or tube and exposed to microwaves sufficient to first heat the water sufficient to “melt” or transition the hydrosol-gel and form the protein-oil film sufficient to hold the water within the film such that as the water turns to gas, it can be entrapped within the film forcing an expansion of the film and subsequent cooling resulting in a solid set of the hydrogel. Consequently, heating the NEPI 250, water, and oil 110 hydrosol blend to a temperature above the boiling point of water, may create a fibrated structure resembling that of a cooked meat.
It has been disclosed in the previous application U.S. Pat. App. No. 17/551,163 that specifically NEPI, when hydrated, opened and blended with oil to form a hydrosol, upon direct or indirect external heat source such as from a stovetop, oven, frying pan, steam, pressure extrusion or IR heating, for example, would set the hydrosol to a hydrogel. Surprisingly, we found that the protein-fat hydrosol 114 suspension when heated with microwaves, (as for example in a microwave oven), a unique and unexpected fibrated structure was formed. It is hypothesized, that the water encapsulated within the hydrated protein-fat hydrosol 114 suspension, upon microwave activation initially causes the water molecules to heat protein-fat hydrosol 114 to a transition point at which the setting or “melting” of the protein-fat hydrosol 114 is initiated.
As the water molecules continue to convert to steam (gas), they may be uniquely now trapped within the setting hydrogel. The gas may expand the setting or melting hydrosol 114 until protein-fat hydrogel 120 is fully set. An analogous example may be in the glass blowing industry, where air is blown into a globule of liquid molten glass to expand the glass before the liquid glass becomes a solid upon cooling. An infinite number of shapes and forms may then result. However, just like in blowing glass, the temperature of the glass and amount and rate of the addition of the gas may be important to achieve the desired results.
Heating the protein-fat hydrosol 114 too fast, (between the temperatures of the formation of the transition melt and the formation of steam) may cause the hydrosol 114 to transition to the hydrogel 120 too fast without formation of the hydrosol 114 “melt”, which can then trap or entrain existing water during the set to the hydrogel 120. Agitation may exacerbate this effect. The slower this process, the more water may be entrained and cause a greater initial expansion. In a case where the temperature of the interior water remains just below 100° C., or the boiling point of water, the maximum amount of water can be entrained. When the water temperature exceeds the boiling point of water, the resulting gas starts to expand the transitioning protein-fat hydrosol 114 “melt”, which may now be partly comprised of a protein-fat hydrogel 120, until protein-fat hydrogel 120 set is complete. Cooling the protein-fat hydrogel 120 may finalize and stabilize the set from the melt.
Described herein are conditions using a microwave oven that allow for the entrainment of the water when going from protein-fat hydrosol 114 to protein-fat hydrogel while simultaneously allowing for the gas being formed to force the expansion of the melted protein-fat hydrosol 114, thereby creating unique structures that simulate the texture and strands normally associated with meat.
Unique to the NEPI hydrosol, is that the melting temperature of the protein-oil hydrosol, is less than the boiling point of water. Without being bound by theory, the lower melting temperature allows for the first time the water to be fully entrained within the protein-oil film 2131. High temperature extruded soy or pea isolate products typically run at between 130° C. and 140° C. to “melt” the protein and cause fibration and exit the extruder at less than 10% moisture. In this case, the water cannot be retained within the hydrosol 114 type structure, which is why the soy or pea type Texturized Vegetable Protein (TVP) is initially very low in entrapped moisture and must be rehydrated while numerous ingredients including starches and gums must be added in order to suspend and hold water.
Microwaves may not destroy the protein (the proteins and fats being microwaved have zero or no impact by microwaves). The increasing heat of the water molecules may initially cause the protein-oil film 2131 to start to set as a hydrogel, but almost simultaneously, prior to the gel being fully solidified and set, as the activated water molecules convert to a gas, and now entrapped in the setting gel being formed, causes the expansion of the hydrosol as it converted and set to the hydrogel 120. Eventually the release of some of the steam, wherein escaped steam may break open portions of the protein film resulting in a collapse of the structure, and subsequent condensation may cool the hydrogel allowing it to fully and irreversibly set after having been stretched in a unique formation. Importantly and critically, the water continues to be entrained within the hydrogel. A water activity assay using a water activity meter capable of measuring the water activity of a solid or semi- solid material such as a hydrosol or a piece of meat could be used to quantify unique water activity properties of protein-fat hydrogel 120.
It is hypothesized that a similar situation may occurring with the NEPI hydrosol upon being heated in a microwave. Unlike many other proteins including soy or pea isolates that require temperatures in excess of 140° C. in order to melt and stretch, the fact that the NEPI 250 protein-fat hydrosol 114 is able to “melt and stretch” at temperatures below the boiling point of water thereby may entrap the water as it converts to a gas and expands the forming web-like structure 2160.
In this case, we found that the lower temperature melt and set of the protein below that of the gas formation of water at 100° C., allows for the more or less simultaneous melt and expansion of the protein-oil film by the entrapped water as it turns to a gas, thereby expanding and structuring the hydrogel prior to it being cooled to its final set by either releasing f the escaping water or condensing the steam to water thereby entraining the water within the protein-oil hydrogel structure.
Additional testing may be performed to identify additional effective conditions for producing protein-fat hydrogels 120 according to the present disclosure. With regard to different hemp protein isolates, testing can be performed with commercially available hemp protein isolates such as Victory Hemp, and those described in U.S. Pat. App. No. 17/551,163 to Mitchell Ellis, to further characterize differences in capabilities. Testing may be performed under identical conditions to those described in the present disclosure and resulting texture may be observed and compared to the products resulting from the use of NEPI 250.
Further testing with oil variations from saturated to unsaturated, both plant and animal based, maybe performed under identical conditions to those described in the present disclosure and resulting texture of the product may be observed and compared to the products resulting from the use of NEPI.
Further testing of the effect of container sizes, including from 65 ml to 550 ml, where testing of the effect on texture at intervals in this range could identify different effects, where, preferably, the container shape would be consistent, but where only the diameter, or width, of the container would change. Such testing, in accordance with the methods described in the present disclosure, could identify additional benefits and advantages of the present disclosure. The ratio of container 2100 size to protein-fat hydrosol 114 starting liquid volume is important to the structure of protein-fat hydrosol 120. Microwave power may also be varied as container size changes to optimize results.
It may be important in some embodiments of the present disclosure, for preferable results, to maximize the entrapment of water in the hydrogel. In some embodiments of the present disclosure, water content of the protein-fat hydrogel 120 may correspond to the water content in conventional meat.
Additional testing of container materials may also result in different effects based on different container materials. In some embodiments of the present disclosure adherence, or binding, of the protein-fat hydrosol 114, or protein-containing material, to the inner sidewall of the container is important for texturization. Binding that is too strong may prevent effective removal of the hydrogel from the sidewall of the container and may also make cleaning difficult. Ceramic materials, particularly unglazed ceramic materials, may allow for effective microwave heating, expansion and binding of the protein-fat hydrosol 114 to the sidewall of the container, however, due to the strength of the binding of the protein-fat hydrosol 114 to the sidewall, and the presence of pores in the ceramic material, the container is difficult to clean after use. Using an unglazed ceramic material where the pores have been filled by known or unknown methods, for example, such as by soaking container 2100 in milk followed by heating to caramelize the milk and fill the pores, may produce a more effective container for use with the present disclosure.
Additional testing with regard to indicator lids 2700 may be performed to potentially identify different effects on texture for protein-fat hydrogel 120. Without being bound by theory, lids 2700 may enable and impact the entrainment of water in the protein-fat hydrogel 120 as well as the heating rate in the microwave oven. The weight, size, position, and material of a lid may be varied in accordance with the present disclosure to potentially alter texture and potentially entrain different quantities of water in the material by affecting the heating rate. In some embodiments, lids 2700 may be comprised of any microwaveable material, including, but not limited to plastic, paper, glass and ceramics. In some embodiments the lid 2700 may be positioned within the container 2100, while in other embodiments the lid 2700 may be positioned at the top of a container 2100. A lid 2700 may be adapted to rise as protein-fat hydrosol 114 expands and rises. In some embodiments, lid 2700 may be adapted to increase pressure within container 2100.
Further testing may be performed to achieve different effects with regard to the addition of flavors to the protein-containing material. In some embodiments, flavors may be added to water during the process, prior to the addition of NEPI 250 to the water. In other embodiments, flavors may be blended with the NEPI 250 powder or concentrate. In some embodiments, flavors may be blended in oil 110. In some embodiments, flavors may be blended after formation of protein-fat hydrosol 114.
The presence of albumin, or an albumin-containing complex, in hemp grain protein isolate may interfere with the ability of hemp grain protein to form a protein-fat hydrogel 120 with proper texture. Our data shows that when the albumin, or albumin containing complex, is separated from the protein fat hydrogel and then reintroduced into NEPI 250, an acceptable protein-fat hydrogel is not produced using the process described in the present disclosure. The protein-fat hydrogel 120 that has had albumin reintroduced becomes softer and less elastic when set in a microwave oven at 25% albumin 75% edestin. It may be, in some embodiments, that a very low level of albumin that may be present after production of NEPI according to the present disclosure, may improve texture; however, substantial amounts, or too much albumin or albumin containing complex, produces a lower quality product in terms of texture.
With regard to Example 7, a plant based chicken analog was produced in accordance with the process of the present disclosure. As shown in Table 10A, for test sample 1, boiling water was added first to a ⅓ measuring container and then to a plastic container having dimensions of 2.5 inches by 8 inches, and having a capacity of 20 ounces. For test sample 2, 65.0 grams of boiling water, as indicated in Table 10A, was added first to a measuring container and then to a straight walled PYREX glass beaker having dimensions of 2.5 inches diameter by 10 inches in height, and having a capacity of 400 ml. For test samples 1 and 2, the protein hydrosol was then mixed with an immersion blender (BRAUN Multiquick MQ7025x) for approximately 1 minute.
Vegetable oil (CRISCO) was then added to the protein hydrosol for both samples, as shown in Table 1, to produce the protein-fat hydrosol. The protein to fat ratio for test sample 1 was 1.96:1. The protein to fat ratio for test sample 2 was 2.04 to 1. The samples were then mixed using an immersion blender (BRAUN Multiquick MQ7025x) for approximately 1 minute for the protein and water and about 30 seconds when adding oil to the protein hydrosol. Each sample was heated in a Bosch® microwave (Model No. HMC54151UC/05, manufactured in May, 2018). The heating time for test sample 1 was 1 min and 25 seconds. The heating time for test sample 2 was 1 minute and 58 seconds.
Based on visual observation during heating in the microwave, test sample 1 expanded and rose sufficiently as it was heated in the microwave. When heating was stopped, and the product rinsed immediately with cold water, the product was adhered to the side of the container. After cooling by immersion with cold water and scraping to remove the hydrogel, the hydrogel exhibited fibrated tendrils, and the hydrogel was over 1 inch in depth and approximately 3 inches in length. When sliced, the hydrogel resembled chicken strips of about ¼ inch by 2 inches, having good tensile strength and bite through characteristics similar to that of poached chicken.
Based on visual observation during heating in the microwave, test sample 2 expanded and rose sufficiently as it was heated in the microwave. When heating was stopped, the product was adhered to the side of the container. After cooling by immersion with cold water and scraping to remove the hydrogel, the hydrogel was firmly set so as to not produce any further changes in shape. The shape had some outer tendrils and spikes similar to what would be expected from shredded chicken meat.
Other test samples did not provide satisfactory results when proper process parameters were not used. For example, a glazed ceramic vessel having very smooth interior sidewalls, as opposed to the container material having interior sidewalls of paper and plastic containers, or preferably a microwaveable material having a rough or irregular surface, was used to both cook the hydrogel and it was apparent that the protein-fat hydrosol does expand, however it does not bind to the container sidewall as desired. However, when parchment paper was used to line the walls after the addition of the protein-fat hydrosol, the protein-fat hydrosol expanded very quickly, even to a height above the lip of the ceramic vessel, before collapsing. The meat analog product resulting from the use of parchment paper was thin but very fibrous with excellent tensile strength. There was, in this embodiment, however, no “filet” type interior for the product, but rather, a web of fibrated very thin meat slices of irregular shapes.
In Example 8, test samples 1 through 10 for a protein-fat hydrosol was prepared by U.S. Pat. App. No. 17/551,163 to Mitchell Ellis. This process may be used for preparing a chicken meat analog. The composition of the test material is shown in Table 10A.
Table 10 was formulated using the same process as Table 10A as described above.
∗UC = Under Cooked;
Example 9 shows that between approximately 17% and 38% NEPI in a solution prepared generally according to the description of example 1 is effective for producing an acceptable meat analog in accordance with the present disclosure. Example 9 shows that between approximately 0% and 50% oil in a solution prepared generally according to the description of Example 10A is effective for producing an acceptable meat analog in accordance with the present disclosure.
At least enough water must be present in the protein-fat hydrosol to sufficiently hydrate and open the NEPI. The amount of water necessary to sufficiently hydrate and open the NEPI may be approximately 30% of a protein hydrosol. The maximum concentration of water in the protein-fat hydrosol is approximately 80%.
Testing impact of Albumin Complex on the protein-fat hydrogel. Formulations used in table 20, used the product made according to procedures described in Example 7. A total of 5 meat analog samples were used in this experiment, with six replicates for each point. The pieces of meat analog made were cut to dimensions 50 × 15 × 15 mm. Values were measured using the Texturemeter (TA.XTplus, Stable Microsystems) with a 30 kg load cell, equipped with a Warner-Bratzler blade and regulated with a descent and penetration speed of 2.00 mm/sec, a penetration depth of 30 mm and a contact force of 10 g.
Equipment:
Evaluation of the effect of chemical additives on the protein-fat hydrosol. Chemical additives as shown below can affect the expansion ratio of the protein-fat hydrosol. In some cases increasing the expansion ratio and in other cases decreasing the expansion ratio of the protein-fat hydrosol.
Evaluation of the effect of container material composition and container structure including size and shape of the container. Certain container materials were effective in allowing the protein-fat hydrogel to bind or adhere to the container sidewall during and after expansion of the protein-fat hydrosol and hydrogel. Those materials were certain plastic containers including polycarbonate plastic and binding was enhanced by abrading the inner surface of the container sidewall. Paper containers were also effective at binding the protein-fat hydrosol and hydrogel.
The container shape was important to produce the desired expansion. Increases in diameter of the container had a negative synergistic effect on expansion ratio of the protein fat hydrosol, while decreasing the diameter of a plastic container had a synergistically positive effect on the expansion ratio. In one example tested a diameter of 3.25 inches was ineffective in producing an expansion, while a diameter of 2.75 was effective in producing an acceptable expansion and fibration.
Legend:
A higher microwave power produces thinner fibers.
In tables from 10 to 25 the use of the expansion description as being in units of “x” means that the height in the 24 oz Oster container has increased by a factor of “x”. This means that where 1x is 1 inch in height in the Oster container 3x will have a height of approximately 3 inches. In the Oster container a height of 4 inches in the liquid holding chamber is equivalent to approximately 500 mL. 2 inches corresponds to approximately 225 mL. 3 inches corresponds to 350 mL. 4 inches corresponds to 500 mL. 5 inches corresponds to 675 mL. Examples 7-12 utilized generally the same process of formulating NEPI as Tables 10A and B, unless otherwise indicated.
It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the scope of the following claims.
This application is a continuation-in-part of U.S. Nonprovisional Pat. Application Ser. No. 17/551,163, filed Dec. 14, 2021, which claims priority to U.S. Provisional Pat. Application Ser. No. 63/124,973, filed Dec. 20, 2020. This application claims the benefit of U.S. Provisional Pat. application Ser. No. 63/318,183, filed Mar. 9, 2022. The contents of each application are herein incorporated by reference in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| 63318183 | Mar 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17551163 | Dec 2021 | US |
| Child | 18119815 | US |
