Patent Application
20210289813
This invention relates to a meat substitute, specifically a meat substitute comprising two or more sources of plant protein, or a meat substitute comprising one or more sources of plant protein and a fruit, fruit powder, or chia seed extract, or a low allergen meat substitute that is optionally free of soy and optionally free of other allergenic ingredients.
There are a range of meat substitutes available that use plant proteins to form substances having a meat-like texture, typically mimicking or attempting to mimic the fibrous qualities found in animal protein, particularly muscle fibres.
The majority of such products are formed using soy protein, together with a number of other additives to enhance flavour and texture, such as gluten and/or wheat based products.
Soy protein concentrates and isolates are known in the industry as an effective ingredient for use in extrusion processes as soy exhibits particular behaviours that allow formation of meat substitutes having a desirable fibrous texture. For this reason soy is often used, either alone or in combination with other protein powders to form meat substitute products.
US 20080268112 A1 for example discloses a range of different protein powders that may be used in conjunction with a soy protein to form a meat substitute, or combination meat substitute product.
WO 2014081285 entitled “Method for texturizing vegetable fibres and proteins” discloses the use of a plant fibre such as carrot fibre with a high water content in combination with a protein extract such as soy to provide a meat substitute.
Soy is known to act well under extrusion to create a “meat” like texture and has therefore been prevalent in the meat substitute/analogue industry. In addition, gluten is also commonly used to create a product having a suitable texture. However, one disadvantage with such a product is the growing prevalence of allergic reactions or intolerances towards soy, gluten and other ingredients commonly used in the preparation of meat substitutes.
Removing soy presents challenges in the formation of products having a desirable texture and mouth feel and further research is required to determine low allergen ingredients having the characteristics to create a desirable meat substitute.
It is an object of the invention to provide an improved or alternative meat substitute product.
The inventions described and claimed herein have many attributes and embodiments including, but not limited to, those set forth or described or referenced in this Summary of the Invention. It is not intended to be all-inclusive and the inventions described and claimed herein are not limited to or by the features or embodiments identified in this Summary of the Invention, which is included for purposes of illustration only and not restriction.
Accordingly, one aspect of the invention relates to an extruded meat substitute composition comprising, consisting essentially of, or consisting of one or more sources of plant protein, one or more sources of lipid, one or more sources of carbohydrate, and water, wherein the one or more sources of carbohydrate may in some embodiments comprise fruit, fruit powder or chia seed extract, or any combination of any two or more thereof.
Another aspect of the invention relates to an extruded meat substitute composition comprising, consisting essentially of, or consisting of two or more sources of plant protein selected from the group consisting of one or more pea protein powders, one or more chickpea protein powders, one or more broad bean protein powders, and one or more gluten powders, one or more sources of lipid, and water.
Another aspect of the invention relates to a method of producing an extruded meat substitute composition, the method comprising, consisting essentially of, or consisting of
(1) providing an admixture, preferably comprising one or more sources of plant protein, one or more sources of lipid, and water, and optionally one or more sources of carbohydrate, wherein the one or more sources of carbohydrate may comprise fruit, fruit powder or chia seed extract, or any combination of any two or more thereof,
(2) extruding the admixture to produce an extruded meat substitute composition.
Another aspect of the invention relates to use of fruit or fruit powder in a method of producing an extruded meat substitute composition to maintain or increase one or more of the tensile strength and hardness of the extruded meat substitute composition.
Any one or more of the following embodiments may relate to any one or more of the above aspects, in any combination.
In various embodiments, the extruded meat substitute composition may comprise fibrous structures, such as a compact fibrous mat resembling cooked animal muscle.
In various embodiments the one or more sources of plant protein may comprise, consist essentially of, or consist of vegetable, fruit, or cereal protein, or any combination of any two or more thereof.
In various embodiments the one or more sources of plant protein may comprise, consist essentially of, or consist of two or more, or three or more, or four or more separate sources of vegetable, fruit, or cereal protein, or any combination of any two or more thereof.
In various embodiments the one or more sources of plant protein may comprise, consist essentially of, or consist of legume, alfalfa, clover, pea, chickpea, cow pea, earth pea, sweet pea, pigeon pea, bean, broad bean, kidney bean, soybean, lentil, lupin, mesquite, cocoa, carob, nut, peanut, almond, potato, gluten, cereal, maize, rice, wheat, wheat gluten, barley, sorghum, millet, oat, rye, triticale, buckwheat, fonio, quinoa, hemp, fungal, algal, or seawead protein, a protein concentrate thereof, a protein isolate thereof, a hydrolysate thereof, or any combination of any two or more thereof. A preferred gluten is cereal gluten, preferably wheat gluten.
For example, the one or more sources of plant protein may comprise protein of seeds of plants of the genus Vicia, Phaseolus, Vigna, Cicer, Pisum, Lathyrus, Lens, Lablab, Glycine, Psophocarpus, Mucuna, Cyamopsis, Canavalia, Macrotyloma, Lupinus, or Arachis, or any combination of any two or more thereof.
The one or more sources of plant protein may comprise comminuted plant material, such as comminuted vegetable, fruit, or cereal material, a slurry, or a powder. The slurry may comprise at least about 0.1, 1, 5, 10, 20, 30, 40, or 50% or more solids by weight, and useful ranges may be selected between these values. The powder may be a non-agglomerated, agglomerated, roll-compacted, lyophilised, drum dried, spray dried or foam spray dried powder. The powder may comprise whole tissue, a protein concentrate, or protein isolate.
A whole tissue protein powder, a protein concentrate powder, or a protein isolate powder may comprise at least about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 99, or 100% protein by weight, and useful ranges may be selected between any of these values (for example about 10 to about 100, about 20 to about 100, about 30 to about 100, about 40 to about 100, about 50 to about 100, about 60 to about 100, about 70 to about 100, or about 80 to about 100%).
In various embodiments the one or more sources of plant protein may comprise, consist essentially of, or consist of a first source of plant protein, such as those described herein, and a second separate source of plant protein comprising gluten.
In various embodiments the one or more sources of plant protein may comprise, consist essentially of, or consist of pea protein, chickpea protein, broad bean protein, or gluten, or any combination of any two or more thereof. A preferred gluten is wheat gluten. In one embodiment the source of plant protein may comprise, consist essentially of, or consist of pea protein and gluten, broad bean protein and gluten, chickpea protein and gluten, pea protein, broad bean protein, and gluten, or pea protein, broad bean protein, chickpea protein, and gluten. In one embodiment, the pea protein, broad bean protein, chickpea protein or gluten comprises, consists essentially of, or consists of pea protein powder, broad bean protein powder, chickpea protein powder or gluten powder, the powder optionally comprising a protein concentrate or isolate powder. The powders preferably comprise at least about 60, 65, 70, 75, 80, 85, 90, 95, 99, or 100% protein by weight, and useful ranges may be selected between any of these values (for example, about 60 to about 100, about 65 to about 100, about 70 to about 100, about 75 to about 100, or about 80 to about 100%).
In various embodiments the one or more sources of lipid may comprise, consist essentially of, or consist of one or more plant oils, one or more animal oils, one or more marine oils, or one or more algal oils, or one or more extracts thereof, or one or more hydrolysates thereof, or any combination of any two or more thereof.
In various embodiments the one or more sources of lipid may comprise, consist essentially of, or consist of a plant fat or oil, such as coconut, corn, cottonseed, canola, rapeseed, olive, palm, peanut, ground nut, safflower, sesame, soybean, sunflower, nut, hazelnut, almond, cashew, macadamia, pecan, pistachio, walnut, melon seed, gourd seed, bottle gourd, buffalo gourd, pumpkin seed, watermelon seed, acai, blackcurrant seed, borage seed, evening primrose, carob seed, amaranth, apricot, argan, artichoke, avocado, babassu, ben, borneo tallow nut, cohune, coriander seed, flax, flax seed, coriander seeds, grape seed, hemp, kapok seed, kiwifruit, lallemantia, meadowfoam seed, linseed, mustard, okra seed, perilla seed, pequi, pine nut, poppyseed, prune kernel, quinoa, ramtil, rice bran, tea, or wheat germ oil, or any combination of any two or more thereof.
In various embodiments a marine oil may comprise, consist essentially of, or consist of shellfish, fish, or marine algal oil, or any combination of any two or more thereof. In one embodiment the fish is selected from anchovy, baikal, bloater, cacha, carp, eel, eulachon, herring, Hoki, hilsa, jack fish, katla, kipper, mackerel, orange roughy, pangas, pilchard, black cod, salmon, sardine, shark, sprat, trout, tuna, whitebait, or swordfish, or any combination of any two or more thereof.
In various embodiments the extruded meat substitute composition or admixture may be substantially free of soy or components derived therefrom.
In various embodiments the extruded meat substitute composition or admixture may be substantially free of gluten or components derived therefrom.
The phrase “substantially free” is intended to mean that a composition described herein contains less than about 1, 0.75, 0.5, 0.25, 0.2, 0.175, 0.15, 0.125, 0.1, 0.075, 0.05, 0.025 or 0.01% by weight of the stated component (including, for example, soy and/or gluten), and useful ranges may be selected between any of these values (for example, about 0.01 to about 1, about 0.01 to about 0.75, about 0.01 to about 0.5, about 0.01 to about 0.2, about 0.01 to about 0.175, about 0.01 to about 0.15, about 0.01 to about 0.125, about 0.01 to about 0.1, or about 0.01 to about 0.075%).
In various embodiments, the one or more sources of carbohydrate may comprise, consist essentially of, or consist of plant carbohydrate, plant carbohydrate powder, plant polysaccharide, plant polysaccharide powder, pectin, pectin powder, fruit, fruit powder, fruit pectin powder, Cucurbitaceae fruit, Solanaceae fruit, Cucurbitaceae fruit powder, Solanaceae fruit powder, Cucurbitaceae fruit pectin powder, Solanaceae fruit pectin powder, chia seed extract, or any combination of any two or more thereof.
In various embodiments the fruit may comprise, consist essentially of, or consist of one or more of whole fruit, peeled or skinned fruit, seedless or seed-free fruit, or fruit flesh, or any combination of any two or more thereof.
In various embodiments the fruit may comprise, consist essentially of, or consist of fresh, dried, comminuted, slurried, or powdered fruit, or any combination of any two or more thereof. The powder may comprise a fruit concentrate, isolate, and/or hydrolysate. The powder may be a non-agglomerated, agglomerated, roll-compacted, lyophilised, drum dried, spray dried or foam spray dried powder.
In various embodiments the fruit may comprise, consist essentially of, or consist of one or more true berry fruits, one or more Cucurbitaceae fruits, one or more Solanaceae fruits, one or more Solanoideae fruits, one or more citrus fruits, one or more aggregate fruits, one or more multiple fruits, one or more accessory fruits, or any combination of any two or more thereof.
In various embodiments the fruit may comprise, consist essentially of, or consist of one or more Cucurbitaceae fruits, one or more Solanaceae fruits, or one or more Solanoideae fruits, or any combination of any two or more thereof.
In various embodiments the fruit may comprise, consist essentially of, or consist of one or more Cucurbitaceae fruits selected from cucumber, gourd, melon, pumpkin, or squash, or any combination of any two or more thereof. In one embodiment the fruit comprises, consists essentially of, or consists of Cucurbitaceae fruit flesh powder.
In various embodiments the fruit may comprise, consist essentially of, or consist of one or more Solanoideae fruits selected from tomato, potato, eggplant, or Capsicum spp., or any combination of any two or more thereof. In one embodiment the fruit comprises, consists essentially of, or consists of Solanoideae fruit flesh powder.
In a preferred form of the invention the fruit extract includes fruit derived from the Cucurbitaceae family or Solanaceae family.
More preferably, the fruit extract includes extracts derived from tomato, gourd, eggplant and capsicum from the Solanaceae family and pumpkin gourd, cucumber and squash from the Cucurbitaceae family.
In a preferred form of the invention the fruit extract is pumpkin powder derived from the Curcubita genus of plant.
More preferably, the pumpkin powder is derived from Curcubita maxima, Curcubita pepo or Curcubita moschata.
Even more preferably the pumpkin powder is derived from Curcubita maxima.
In various embodiments, the extruded meat substitute composition or admixture may comprise, consist essentially of, or consist of at least about 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90% by weight on a dry basis of one or more sources of plant protein, and useful ranges may be selected between any of these values (for example, about 20 to about 90, about 30 to about 90, about 40 to about 90, about 50 to about 90, about 60 to about 90%).
In various embodiments the extruded meat substitute composition or admixture may comprise, consist essentially of, or consist of, on a dry basis,
(1) about 50 to about 90% by weight plant protein powder, preferably pea protein powder, or
(2) about 50 to about 90% by weight broad bean protein powder, or
(3) about 50 to about 90% by weight chickpea protein powder, or
(4) about 50 to about 90% of a mixture of pea protein powder and gluten powder, or
(5) about 50 to about 90% of a mixture of broad bean protein powder and gluten powder, or
(6) about 50 to about 90% of a mixture of chickpea protein powder and gluten powder, or
(7) about 50 to about 90% of a mixture of pea protein powder, broad bean protein powder, and gluten powder, or
(8) about 50 to about 90% of a mixture of chickpea protein powder, broad bean protein powder, and gluten powder, or
(9) about 50 to about 90% of a mixture of pea protein powder, chickpea protein powder, and gluten powder, or
(10) about 50 to about 90% of a mixture of pea protein powder, broad bean protein powder, chickpea protein powder, and gluten powder.
In various embodiments, the pea protein powder, broad bean protein powder, chickpea protein powder, or gluten powder may comprise, consist essentially of, or consist of about 60 to about 100% by weight protein.
In various embodiments, the extruded meat substitute composition or admixture may comprise, consist essentially of, or consist of about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15% by weight on a dry basis of one or more sources of lipid, and useful ranges may be selected between any of these values (for example, about 1 to about 15, about 2 to about 12, about 3 to about 10, about 3 to about 8%).
In various embodiments, the extruded meat substitute composition or admixture may comprise, consist essentially of, or consist of about 0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15% by weight on a dry basis of one or more sources of carbohydrate, and useful ranges may be selected between any of these values (for example, about 1 to about 15, about 2 to about 12, about 2 to about 10, about 2 to about 8, about 3 to about 10, about 3 to about 8%).
In various embodiments, the extruded meat substitute composition or admixture may comprise, consist essentially of, or consist of about 0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15% by weight on a dry basis fruit or fruit powder, and useful ranges may be selected between any of these values (for example, about 1 to about 15, about 1 to about 12, about 1 to about 10, about 1 to about 8, about 2 to about 10, about 2 to about 8, about 2 to about 6%). Preferably the fruit comprises pumpkin powder and/or tomato powder.
In various embodiments the extruded meat substitute composition or admixture may comprise, consist essentially of, or consist of, on a dry basis,
(1) about 50 to about 90% by weight plant protein powder, preferably pea protein powder, and about 1 to about 10 or about 15% by weight carbohydrate powder, preferably fruit or fruit powder, or
(2) about 50 to about 90% broad bean protein powder, and about 1 to about 10 or about 15% by weight fruit or fruit powder, or
(3) about 50 to about 90% by weight chickpea protein powder, and about 1 to about 10 or about 15% by weight fruit or fruit powder, or
(4) about 50 to about 90% of a mixture of pea protein powder and gluten powder, and about 1 to about 10 or about 15% by weight fruit or fruit powder, or
(5) about 50 to about 90% of a mixture of broad bean protein powder and gluten powder, and about 1 to about 10 or about 15% by weight fruit or fruit powder, or
(6) about 50 to about 90% of a mixture of chickpea protein powder and gluten powder, and about 1 to about 10 or about 15% by weight fruit or fruit powder, or
(7) about 50 to about 90% of a mixture of pea protein powder, broad bean protein powder, and gluten powder, and about 1 to about 10 or about 15% by weight fruit or fruit powder, or
(8) about 50 to about 90% of a mixture of chickpea protein powder, broad bean protein powder, and gluten powder, and about 1 to about 10 or about 15% by weight fruit or fruit powder, or
(9) about 50 to about 90% of a mixture of pea protein powder, chickpea protein powder, and gluten powder, and about 1 to about 10 or about 15% by weight fruit or fruit powder, or
(10) about 50 to about 90% of a mixture of pea protein, broad bean protein, chickpea protein powder, and gluten powder, and about 1 to about 10 or about 15% by weight fruit or fruit powder.
As above, in various embodiments, the pea protein powder, broad bean protein powder, or gluten powder comprises, consists essentially of, or consists of about 60 to about 100% by weight protein.
In various embodiments the fruit or fruit powder may be Cucurbitaceae fruit or fruit powder, preferably pumpkin or pumpkin powder, or Solanaceae fruit or fruit powder, preferably tomato or tomato powder.
In various embodiments, the admixture before or during extrusion may comprise, consist essentially of, or consist of at least about 30, 35, 40, 45, 50, 55, 60, 65, 70, or 75% by weight water, and useful ranges may be selected between any of these values (for example, about 30 to about 60, about 30 to about 65, about 30 to about 70, or about 30 to about 75).
In various embodiments, the extruded meat substitute composition may comprise, consist essentially of, or consist of about at least about 30, 35, 40, 45, 50, 55, 60, 65, 70, or 75% by weight water, and useful ranges may be selected between any of these values (for example, about 30 to about 60, about 30 to about 65, about 30 to about 70, or about 30 to about 75).
In various embodiments, extrusion may be carried out in an extruder comprising two or more barrel sections preceding an extrusion die, and extrusion may be carried out at a temperature of up to about 100, 110, 120, 130, 140, 150, 16, 170, 180, 190, or 200° C. in one or more of the barrel sections preceding the extrusion die, and useful ranges may be selected between any of these values (for example, about 100 to about 200, about 110 to about 190, about 110 to about 180).
Preferably, the meat substitute includes 0.1-15% of pumpkin powder as dry ingredients. More preferably, the meat substitute includes 1-5% of pumpkin powder as dry ingredients.
In further embodiments the meat substitute further includes tomato extract. More preferably the tomato extract is tomato powder. Even more preferably, the meat substitute includes 1-5% of tomato powder as dry ingredients.
In further preferred embodiments of the invention the plant derived protein extract is selected from pea, broad bean, potato, rice, lupin, water lentil, chickpea, and/or oat.
More preferably the meat substitute comprises dry ingredients having at least 75% by weight of a protein extract.
More preferably, the protein extract is pea protein.
Alternatively the dry ingredients comprise 20-80% by weight pea protein extract and/or 20-80% by weight broad bean protein extract.
More preferably the dry ingredients comprise 40-60% by weight pea protein and/or 20-60% by weight broad bean protein extract.
Preferably the lipid is selected from rice bran oil, coconut oil, sunflower oil, canola oil, flax seed oil and palm oil or algae oil.
In a preferred formulation, the extruded meat substitute includes 75-85% by weight pea protein.
In various embodiments the extruded meat substitute composition or admixture may further comprise, consist essentially of, or consist of one or more gums such as a plant gum. In various embodiments the gum may be selected from the group comprising xanthan gum, agar, alginate, cassia, dammar, pectin, beta-glucan, glucomannan, mastic, chicle, psyllium, spruce gum, gellan gum, acacia gum, guar, gum, locust bean gum, carrageenans, gum arabic, karaya gum, ghatti gum, tragacanth gum, konjac gum, tara gum, pullulan, chia seed gum, fatted chia gum (FCG), or partially defatted chia gum (PDCG), or any combination of any two or more thereof.
In various embodiments, the extruded meat substitute composition or admixture may further comprise, consist essentially of, or consist of about 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10% by weight on a dry basis of one or more gums, and useful ranges may be selected between any of these values (for example, about 1 to about 10, about 2 to about 10, about 3 to about 10, about 3 to about 8%).
In various embodiments the extruded meat substitute composition or admixture may further comprise, consist essentially of, or consist of one or more food grade starches, such as a cereal starch, rice starch, wheat starch, maize starch, potato starch, cassava starch, or any combination of any two or more thereof.
In various embodiments, the extruded meat substitute composition or admixture may comprise, consist essentially of, or consist of about 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10% by weight on a dry basis of one or more food grade starches, and useful ranges may be selected between any of these values (for example, about 1 to about 10, about 2 to about 10, about 3 to about 10, about 3 to about 8%).
More preferably, the formulation further includes xanthan gum and/or pectin and/or konjac corm powder.
In further preferred embodiments the meat substitute composition includes chia seed extract. More preferably the meat substitute composition includes chia seed gum. More preferably the gum is fatted chia gum (FCG) or partially defatted chia gum (PDCG).
Preferably, the meat substitute is substantially free of wheat or wheat derived products.
In one embodiment the invention relates to an extruded meat substitute composition formed from a plant derived protein extract, a lipid, water and chia seed extract, wherein the composition is substantially free of soy or components derived therefrom.
Preferably, the extruded meat substitute is substantially free of gluten or components derived therefrom.
In further preferred embodiments the meat substitute composition includes chia seed gum. More preferably the gum is a fraction of chia seed gum selected from fatted chia gum (FCG) or partially defatted chia gum (PDCG).
In one embodiment the invention relates to an extruded meat substitute composition formed from a plant derived protein extract, a lipid, water and tomato extract, wherein the composition is substantially free of soy or components derived therefrom.
Preferably, the extruded meat substitute is substantially free of gluten or components derived therefrom.
Preferably, the meat substitute is substantially free of wheat or wheat derived products. Preferably, the meat substitute includes 0.1-15% of tomato powder as dry ingredients. More preferably, the meat substitute includes 1-5% of tomato powder as dry ingredients.
In various embodiments the extruded meat substitute composition may further comprise, consist of, or consist essentially of one or more flavourings, one or more spices, one or more colourings, one or more micronutrients, one or more vitamins, one or more minerals, one or more emulsifiers, one or more stabilisers, one or more antioxidants, or one or more texturisers, or any combination of any two or more thereof. Such ingredients are well known in the art.
In various embodiments, the extruded meat substitute composition or admixture may comprise, consist essentially of, or consist of about 0.1, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10% by weight on a dry basis of any of such ingredients, and useful ranges may be selected between any of these values (for example, about 0.1 to about 10, about 1 to about 10, about 2 to about 10, about 3 to about 10, about 3 to about 8%).
In various embodiments the one or more flavourings may comprise, consist of, or consist essentially of one or more animal meat flavours, such as chicken, beef, lamb, or pork flavours, a yeast extract, or salt, onion, or garlic flavours, or any combination of any two or more thereof.
In various embodiments the extruded meat substitute composition may comprise a hardness of about 175, 200, 225, 250, 275, 300, 325, 350, 375, 400, 425, 450, 475, 500, 525, 550, 575, 600, 625, 650, 675, 700, 725, 750, 775, or 800 kPa, when a 4 by 20 by 30 mm portion is subjected to a Warner Bratzler blade shear test from a blade height of 40 mm, at a test speed of 1 mm·s−1, a pre-test speed of 10 mm·s−1 and a post-test speed of 2 mm·s−1, and useful ranges may be selected between any of these values (for example, about 175 to about 800 kPa).
In various embodiments the extruded meat substitute composition may comprise a tensile strength of about 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.8, 8, 8.5, 9, 9.5, or 10 kPa, when a 4 by 10 by 80 mm portion is subjected to a stretch test clamped between grips 40 mm apart, at a test speed of 0.5 mm·s−1, a pre-test speed of 1 mm·s−1 and a post-test speed of 10 mm·s−1, and useful ranges may be selected between any of these values (for example, about 0.5 to about 10, about 1 to about 10, about 1.5 to about 10, or about 2 to about 10).
The term “comprising” as used in this specification means “consisting at least in part of”. When interpreting each statement in this specification that includes the term “comprising”, features other than that or those prefaced by the term may also be present. Related terms such as “comprise” and “comprises” are to be interpreted in the same manner.
It is intended that reference to a range of numbers disclosed herein (for example, 1 to 10) also incorporates reference to all rational numbers within that range (for example, 1, 1.1, 2, 3, 3.9, 4, 5, 6, 6.5, 7, 8, 9 and 10) and also any range of rational numbers within that range (for example, 2 to 8, 1.5 to 5.5 and 3.1 to 4.7) and, therefore, all sub-ranges of all ranges expressly disclosed herein are hereby expressly disclosed. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.
Further aspects of the invention, which should be considered in all its novel aspects, will become apparent to those skilled in the art upon reading of the following description which provides at least one example of a practical application of the invention.
One or more embodiments of the invention will be described below by way of example only, and without intending to be limiting, with reference to the following drawings, in which:
The meat substitute formulation of the present invention has been developed as an improved formulation that produces an extruded meat substitute having improved characteristics of texture, resilience, moisture and mouth feel over existing products. The preferred product of the present invention is a low allergen product, preferably formed without soy or without soy and gluten, each of which are well known allergens.
One of the important factors in producing a meat substitute product that will appeal to both vegetarian and non-vegetarian consumers is the texture of the product. The ideal meat substitute has the fibrous quality of meat, while retaining moisture and flavour during cooking.
The use of known extrusion processes to create such meat substitutes are well known, however individual ingredients used within the formulations can perform quite differently when subject to the mixing, heating, and high shear pressures associated with extrusion, resulting in a wide variety in the quality of the product.
Soy has long been used as the plant protein of choice to create meat substitutes. Soy performs very well in the extrusion process and typically produces chicken like compositions having a fibrous structure. Soy is widely used due to its important functional properties such as the gelling/textural capabilities, water absorption, fat absorption, emulsification, elasticity, and colour control that soy brings to the final products.
Without the use of soy, the formation of such fibrous meat substitutes is more difficult. Soy-free products on the market today are typically in the form of meat substitute crumbles, or ground meat substitutes which don't have the same texture requirements as a chunk or slice of meat substitute does, as each piece is too small for aligned fibres to be required.
Similarly, gluten plays an important role in producing a high quality extruded meat substitute, improving structure within the product, reducing moisture loss and improving flavour using its ingredient carrying capabilities.
It has therefore been a challenge of the present invention to develop a product maintaining the characteristics of the traditional soy and gluten based product, while optionally omitting these two allergenic ingredients in certain embodiments.
The inventors have discovered that use of two or more sources of plant protein, or the introduction of one or more sources of carbohydrate such as a fruit extract, preferably having soluble fibre in the form of pectin, may aid in meat substitutes having improved overall textures, particularly in the absence of soy proteins. In particular, plant proteins such as pea and bean, and fruit extracts from the families Cucurbitaceae and Solanaceae appear to produce particularly effective results. More specifically, the addition of pumpkin powder and/or tomato powder to the formulation has resulted in significant improvements in the way the product performs during the extrusion process and in the characteristics of the final product, in the absence of soy, or soy and gluten.
Pumpkin powder is produced from the fruit of the genus of herbaceous vine Curcubita, while tomato powders are produced from the fruit of nightshade genus Solanum. Industrially, both pumpkin and tomato powder are formed by the application of a thin film of liquid onto a heated drum resulting in cold water soluble powder, which is then drum dried.
Pumpkin powder is typically used as a substitute for fresh pumpkin and can be reconstituted with water to produce a pumpkin puree. It is also known for use in baking to produce a pumpkin flavour or colour.
Similarly, tomato powder can be used to impart a range of colours to product depending on the species of tomato used.
It has since been determined by the inventors that the addition of an amount of pumpkin powder and/or tomato powder in an extruded non-soy meat substitute produces not only an attractive colour, but improves the quality and texture of the finished extruded product.
A number of different pumpkin powder varieties are available on the market, manufactured from a range of different pumpkin species. The most common species available in the powder form are Curcubita Pepo, Curcubita maxima, or Curcubita moschata, with powder used in the current invention preferably derived from the flesh of the pumpkin. However, powder derived from the seed portion, skin or combinations thereof are also considered to fall within the scope of this invention.
Of the pumpkin varieties available, Curcubita maxima (C. maxima) has shown to have specific properties over and above those of other Curcubita varieties that result in extruded meat substitute products having particularly appealing textures and moisture retention. It should be understood by those skilled in the art that while C. maxima has particularly favourable properties over other particular types of pumpkin, the addition of pumpkin powder itself, derived from any Curcubita variety is expected to impart improvements in extruded meat substitute products over and above known ingredients and should be considered to fall within the scope of this invention.
The composition of C. maxima pumpkin when compared to Curcubita Pepo or Curcubita moschata, has been determined in a first instance by the Ministry for Agriculture, Forestry and Fisheries in the Republic of Korea. A breakdown of the compositions found in this study is seen below.
C. pepo
C. moschata
C. maxima
1) Values are mean ± SD. Different superscript letters within a row indicate significant differences by Duncan's multiple range test (P < 0.05).
indicates data missing or illegible when filed
When compared to Curcubita Pepo or Curcubita moschata, the flesh of C. maxima has a higher percentage of carbohydrate, fat, protein and fibre. The overall moisture content is less, however as the product is to be used in powder form during the manufacturing process, this is less important.
In addition to the percentages of fat, protein and carbohydrate in the pumpkin. C. maxima has been shown to have a greater pectin content when compared to C. moschata. A study by Gonçalves, E. M et al from DTIA, Instituto Nacional de Engenharia, Tecnologia e Inovação. Portugal entitled “INFLUENCE OF MATURITY STAGE ON TEXTURE, PECTIN COMPOSITION AND MICROSTRUCTURE OF PUMPKIN”, while primarily looking at the changes in pectin levels during pumpkin storage, also concluded that C. maxima, when compared to C. moschata has both a higher pectin level, and a higher ratio of water soluble fraction and total pectin as a percentage.
Water soluble fibre such as pectin is thought to improve the performance of the meat substitutes during the extrusion process, and impart improved characteristics to the structure and alignment of the plant protein fibres. The pectin provided in fruit extracts such as those disclosed herein result in improved non-soy meat substitute formulations that have yet to be achieved elsewhere. Selection of extracts such as C. maxima that can provide increased levels of such macronutrients will further enhance the performance of the ingredients in the final products.
A number of trials have been conducted to determine if the addition of pumpkin powder, specifically
C. maxima results in the formation of improved soy free, and/or soy free and gluten free meat substitute products.
The pumpkin powder used in the following examples is C. maxima pumpkin powder, however pumpkin powders from a range of different species may be used as they are still thought to provide improved quality of meat substitutes over meat substitutes without pumpkin powder. Other powders and ingredients were commercially available plant protein powders and ingredients.
A range of different products have been trialed using a number of soy protein alternatives, together with products including and excluding gluten. Initial trials with the addition of pumpkin powder to the formulations have been undertaken and seven samples prepared and analysed.
Each sample was extruded using the basic process as described below. The resulting products were evaluated and the characteristics of each scored to determine the best formulation.
The meat substitutes exemplified in the present invention are formed using an extrusion process which is described in further detail below with regard to
As can been seen from
During extrusion processing dry ingredients are fed into the heated barrel of the extruder 100 at ambient temperature T1 at a constant rate from a mass flow feeder 125.
The dry ingredients are then mixed with water at water injection point 130. The water is introduced at a constant rate approximately 100 mm down the barrel from the screws.
As the ingredients move through the process the temperature of the sections increase and the ingredients are exposed for a short period to high temperature, pressure and shear.
Upon the application of heat, shear and pressure the protein material is denatured and aligns into fibres that resemble meat.
The denatured fibres then progress into die section 200. Die 200 is preferably a water cooled die where the hot product containing up to 60% moisture is cooled and fibration and texturisation of the product is finalised.
The extruded product is then cut into the required size as determined by the potential end use, for example cubes, slices, strips or chunks, packaged and stored under standard conditions.
A Stable Micro Systems texture analyser (SMS TaXT-2+) is used to measure the hardness and tensile strength of the samples.
When analysis is conducted on fried samples, the frying process is conducted after cooking the samples using a stovetop and an oiled pan. Substitute samples are fried for approximately one minute on each side, while any meat control sample is fried until cooked through.
Samples are cut to about 4 mm thick, 10-20 mm wide and about 30 mm long. The texture analyser is fitted with a straight shearing knife blade (Warner Bratzler blade, HDP/WBR). The initial height of the blade is set to 40 mm, with a test speed of 1 mm·s−1, a pre-test speed of 10 mm·s−1 and a post-test speed of 2 mm·s−1. One sample is placed under the blade at a time and the test is started. The hardness (kPa) of the sample is measured, taken to be the maximum force required to cut the sample.
Fried chicken was found to have a hardness in the order of 100-125 kPa.
Samples are cut to about 4 mm thick, 10-20 mm wide, and 60-80 mm long. The texture analyser is fitted with two tensile grips. The distance between the grips is set to 40 mm, with a test speed of 0.5 mm·s−1, a pre-test speed of 1 mm·s−1 and a post-test speed of 10 mm·s−1. One sample is placed between the clamps at a time, with the clamps being tightened to the point where the sample is held so as to not slip out when stretched, but not so tight as to crush the sample. The test is started and the tensile strength (kPa) of the sample is measured, taken to be the maximum force required to fracture the sample.
Fried chicken was found to have a tensile strength in the order of 6-8 kPa.
The first sample prepared was a standard soy and gluten containing product, produced without any pumpkin powder as a baseline for comparing the new formulations.
The second and third samples prepared substitute the soy protein for pea protein and broad bean protein and include the addition of pumpkin powder.
Samples 4-7 show a number of soy and gluten free formulations tested and the corresponding results. All formulations include pumpkin powder (C. maxima) with variations in the remaining ingredients evaluated.
The resulting products were evaluated according to their similarity with real pieces of chicken using a range of criteria as set out below, and texture may be analysed as set out above. The criteria were weighted according to importance and the results collated. For each criteria, a score of −5 to +5 was selected and the score multiplied by the weight to arrive at the total weighted score.
Samples 2 and 3 show the favourable results of a soy-free formulation containing gluten in similar quantities to the soy and gluten containing sample 1. The addition of the pumpkin powder to the formulation appears to have resulted in the product having an overall improved score when assessed on the texture, taste and aroma when compared to the soy and gluten formulation. These results give a good indication of the benefits pumpkin powder is imparting to the final product, as the similarity in gluten quantities between samples 1, 2 and 3 has stayed very similar.
Samples 4-7 show favourable characteristics that are similar to those found in the soy and gluten containing product (sample 1), with weighted scores higher when based on taste and texture scores. These samples 4-7 were formed using either broad bean protein or pea protein. This indicates that the manufacture of a low allergen meat substitute that includes pumpkin powder that performs as well, if not better than a soy and gluten containing alternative is possible.
Early results also indicate that the removal of soy and the addition of a different protein, together with pumpkin powder produces a product having distinctly improved aroma.
Based in the experimental data to date, the addition of pumpkin powder to the formulations, in conjunction with other ingredients may be a key factor in producing a favourable low allergen meat substitute.
Based on the results provided the addition of xanthan gum and pectin provides further structure to the products. In a further alternative embodiment of the invention the meat substitute composition includes the addition of Konjac corm powder (or Konjac root powder). Konjac corm powder is obtained from the tubers of various species of Amorphophallus. It is a soluble dietary fiber that is similar to pectin in structure and function and consists mainly of a hydrocolloidal polysaccharide, glucomannan. Addition of Konjac corm powder also resulted in providing further structure to the product. Pectin, xanthan gum and konjac corm powder are soluble fibres, suggesting that increases in soluble fibre in the formulations provides beneficial results during the extrusion process.
When compared to C. pepo and C. moschata, C. maxima has significantly higher levels of fibre in the flesh and even greater levels in the seed powder.
The addition of pumpkin powder to the meat substitutes of the present invention aides in uptake of moisture and flavour during the cooking process, providing a more satisfying and tastier final product. The increased levels of carbohydrate, fibre, fat and protein in C. maxima provide improvements in the overall structure of the finished product, with carbohydrate and fibre levels in particular resulting in a more resilient, better textured product.
The addition of pumpkin powder to the meat substitutes of the present invention may also aid in increasing the shelf life of the product. Pumpkin powder is known to have antibacterial properties, which in turn may result in the reduction of pathogenic growth during storage.
In replacing soy in the present invention, a range of different vegetable proteins may be used, including pea, broad bean, chick pea, potato, rice, lupin, water lentil or oat. Each of these protein isolates may substitute soy in the meat substitutes of the present invention, with the quantities of pumpkin powder used with each of the different protein isolates.
In an alternative formulation of the invention, the meat substitute includes tomato extract, preferably in the form of tomato powder derived from either the flesh or seeds of the tomato. Tomato powder contains similar levels of carbohydrate, fat and protein to pumpkin powder and may be sourced in a range of colours.
The inclusion of tomato powder either in place of pumpkin powder, or in conjunction with pumpkin powder allows for the colour of the meat substitute to be altered. This is particularly useful when forming meat substitutes to replace different types of meat. For example, a chicken substitute may be best formed using a larger proportion of the yellow pumpkin powder, or a tomato powder formed from a yellow tomato species, while a beef substitute may include a dark red tomato powder which will impart a deeper colour to the meat substitute to more effectively resemble a beef product.
Similarly, the relative compositions of pumpkin and tomato powder may be altered to produce varying colours within the extruded product. In a further alternative embodiment of the invention the meat substitute composition includes chia seed (Salvia hispanica L.) extract. Chia seed gum is the preferred extract given its smoothness, compared to the use of ground chia seed which can produce small particles in the finished product which detract from the optimum texture and look of the product.
Chia seed gum provides additional stabilising properties to the meat substitute formulation to control viscosity and ultimately the final texture of the product which is particularly beneficial in the absence of gluten. Chia seed gum can be separated into two fractions, gum with fat (FCG) and partially defatted gum (PDCG).
PDCG has a higher protein, ash and carbohydrate content than FCG, and has higher water binding and water holding capacities. The use of PDCG in the formulations of the present invention and similarly in other meat substitute formulations excluding pumpkin powder may improve the texture and mouthfeel of the final product, both in the cooked and uncooked state due to the additional water-binding properties imparted by the chia seed gum.
FCG has a greater oil-holding capacity and water absorption capacity compared to PDCG and is less viscous than PDCG. These properties may also impart different characteristics on the final product when compared to PDCG. In particular the improved oil-holding capacity may increase the ability of the final product to retain flavour more effectively during the cooking process.
By tailoring the use of the different chia gum fractions to the proposed end use of the meat substitute product the properties of each can be used advantageously. For example, a pre-flavoured product that is ready to cook immediately may be formed using the PDCG, while a product designed to be sold flavourless and have the user introduce their own flavour during the cooking process may be formed using the FCG with the greater oil-holding capacity.
In a further embodiment, there is also provided an extruded meat substitute product formed from a plant derived protein extract, a lipid, water and chia seed extract, wherein the composition is substantially free of gluten or components derived therefrom. In this embodiment the chia seed extract, preferably gum, improves the texture and mouthfeel of the finished product in the absence of pumpkin powder. The properties of chia seed extract as described in further detail above may result in an improved product over and above those currently known in the art.
The inclusion of pumpkin powder, tomato powder and/or chia seed gum in an optionally gluten-free and optionally soy-free meat substitute product as disclosed above imparts improved characteristics over such products currently available at the time of filing. It is envisaged that the inclusion of each of these ingredients in varying ratios allows for changes in colour characteristics of the final product, while retaining the improvements in the texture, appearance and flavour of both the cooked and uncooked finished product.
The meat substitute formulations described above have improved texture, mouthfeel and flavour over low or non-allergenic meat substitute products currently available. Where in the foregoing description reference has been made to integers or components having known equivalents thereof, those integers are herein incorporated as if individually set forth.
It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be included within the present invention.
The entire disclosures of all applications, patents and publications cited above, if any, are herein incorporated by reference.
Reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that that prior art forms part of the common general knowledge in the field of endeavour in any country in the world.
| Number | Date | Country | Kind |
|---|---|---|---|
| 712268 | Sep 2015 | NZ | national |
| 714665 | Nov 2015 | NZ | national |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15759858 | Mar 2018 | US |
| Child | 17243715 | US |
