METHODS OF SEPARATING FAT FROM SOY MATERIALS AND COMPOSITIONS PRODUCED THEREFROM

Abstract

Disclosed are methods for separating a fat-enriched fraction and a reduced-fat extract from soy materials. Also disclosed are a fat-enriched fraction, a crude oil, a degummed oil, soy gums, a reduced-fat soy extract, reduced-fat soy protein compositions and food products comprising the reduced-fat extracts or reduced-fat protein compositions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic flow diagram showing a method of fractionating soy material to produce soy-based milk. Dashed lines represent alternative or optional steps in the process.

FIG. 2 is a schematic flow diagram showing a method of fractionating soy material to produce a reduced-fat soy protein and a fat fraction using acid precipitation. Dashed lines represent alternative or optional steps in the process.

FIG. 3 is a schematic flow diagram showing a method of fractionating soy material to produce a reduced-fat soy protein and a fat fraction using filtration. Dashed lines represent alternative or optional steps in the process.

FIG. 4 is a schematic flow diagram showing a method of processing the fat-enriched fraction to produce soy oils and gums. Dashed lines represent alternative or optional steps in the process.

Claims

1. A method of processing a soy material, comprising: a) aqueously extracting the soy material to produce an extract; andb) centrifugally separating the extract into a fat-enriched fraction and a reduced-fat soy extract.

2. The method of claim 1, wherein the method is continuous or semi-continuous.

3. The method of claim 1, wherein the extraction and separation steps are performed substantially concurrently.

4. The method of claim 1, wherein the aqueous extraction comprises contacting the soy material with an aqueous solution.

5. The method of claim 4, wherein the aqueous solution has an ionic strength of about 0.10 N or less.

6. The method of claim 5, wherein the aqueous solution is substantially free of demulsifiers.

7. The method of claim 5, wherein the extract comprises fat capable of being centrifugally separated from the extract without requiring the addition of demulsifiers.

8. The method of claim 7, wherein the reduced-fat extract has a protein to fat ratio of at least about 4 to 1.

9. The method of claim 1, wherein the extract has a pH in the range of about 6.0 to about 10.5.

10. The method of claim 9, wherein the pH is greater than about 7.0.

11. The method of claim 9, wherein the pH is about 9.0 or less.

12. The method of claim 1, wherein step (a) is performed at a temperature in the range of about 32° F. to about 200° F.

13. The method of claim 12, wherein the temperature is between about 80° F. and about 150° F.

14. The method of claim 12, wherein the temperature is between about 90° F. and about 145° F.

15. The method of claim 1, wherein the soy material is a substantially full fat soy material.

16. The method of claim 1, wherein the soy material is a partially defatted soy material.

17. The method of claim 16, wherein the soy material is partially defatted by a hot press.

18. The method of claim 16, wherein the soy material is partially defatted by a cold press.

19. The method of claim 16, wherein the soy material is partially defatted by high pressure liquid extraction.

20. The method of claim 1, wherein the soy material is milled prior to aqueous extraction.

21. The method of claim 20, wherein the milled soy material comprises a flour.

22. The method of claim 4, wherein the aqueous solution is substantially free of demulsifiers.

23. The method of claim 1, wherein the extract comprises fat capable of being centrifugally separated from water in the aqueous extract without requiring the addition of demulsifiers.

24. The method of claim 23, wherein the reduced-fat extract has a protein to fat ratio of at least about 4 to 1.

25. The method of claim 1, wherein step (b) is performed using a three phase separator.

26. The method of claim 1, wherein the extract comprises an insoluble fiber, further comprising centrifugally separating at least a portion of the insoluble fiber from the extract of step (a) prior to step (b) to form an insoluble fiber fraction.

27. The method of claim 26, wherein step (b) is performed using a three phase separator to produce the fat-enriched fraction, the reduced-fat extract and a protein-fat sediment.

28. The method of claim 1, further comprising processing the fat-enriched fraction to produce a crude oil.

29. The method of claim 28, further comprising processing crude oil to produce soy gums and a degummed oil.

30. The method of claim 29, further comprising processing the degummed oil to produce an oil.

31. The method of claim 1, further comprising drying the reduced-fat extract.

32. The method of claim 31, wherein drying comprises at least one of evaporating or spray drying.

33. The method of claim 1, further comprising fractionating the reduced-fat fraction.

34. The method of claim 33, wherein fractionating the reduced fat extract produces a reduced-fat glycinin-rich fraction.

35. The method of claim 33, wherein fractionating the reduced-fat extract produces a reduced-fat beta-conglycinin-enriched fraction.

36. The method of claim 1, further comprising concentrating the reduced-fat extract and separating the reduced-fat extract to produce a first reduced-fat soy protein composition and an aqueous fraction.

37. The method of claim 36, wherein concentrating and separating comprise: adding acid to the reduced-fat extract to produce a first curd and a whey; andseparating the first curd from the whey to produce a first reduced-fat soy protein composition.

38. The method of claim 37, further comprising: washing the first reduced-fat soy protein composition to produce a second reduced-fat soy protein composition.

39. The method of claim 36, wherein concentrating and separating comprise: filtering the reduced-fat extract to produce a first reduced-fat soy protein composition.

40. The method of claim 39, further comprising: subjecting the first reduced-fat soy protein composition to ultrafiltration, microfiltration or diafiltration.

41. The method of claim 36, further comprising washing the first reduced-fat soy protein composition to produce a second reduced-fat soy protein composition.

42. A reduced-fat soy extract produced according to the method of claim 1.

43. The reduced-fat soy extract of claim 42, wherein the extract comprises at least about 55% dry weight protein.

44. The reduced-fat soy extract of claim 42, wherein the extract comprises about 15% or less dry weight fat.

45. The reduced-fat soy extract of claim 42, wherein the extract comprises about 10% or less dry weight fat.

46. The reduced-fat soy extract of claim 42, wherein the extract comprises a protein to fat ratio of at least 5 to 1.

47. The reduced-fat soy extract of claim 42, wherein the extract comprises a protein to fat ratio of at least 8 to 1.

48. The reduced-fat soy extract of claim 42, wherein the extract comprises a protein to fat ratio of at least 12 to 1.

49. The reduced-fat soy extract of claim 42, wherein the soy material is a substantially full fat soy material.

50. The reduced-fat soy extract of claim 42, wherein the soy material is a cold pressed soy material.

51. The reduced-fat soy extract of claim 42, wherein the soy material is a high pressure liquid extracted soy material.

52. The reduced-fat soy extract of claim 42, wherein the soy material is a hot pressed soy material.

53. A reduced-fat soy protein composition comprising at least 65% dry weight protein produced according to the method of claim 36.

54. The reduced-fat soy protein composition of claim 53, wherein the composition comprises at least about 85% dry weight protein.

55. The reduced-fat soy protein composition of claim 53, wherein the composition comprises about 15% or less dry weight fat.

56. The reduced-fat soy protein composition of claim 53, wherein the composition comprises about 10% or less dry weight fat.

57. The reduced-fat soy protein composition of claim 53, wherein the composition comprises a protein to fat ratio of at least 5 to 1.

58. The reduced-fat soy protein composition of claim 53, wherein the composition comprises a protein to fat ratio of at least 8 to 1.

59. The reduced-fat soy protein composition of claim 53, wherein the composition comprises a protein to fat ratio of at least 12 to 1.

60. The reduced-fat soy protein composition of claim 53, wherein the soy material is selected from a substantially full fat soy material and a high pressure liquid extracted soy material.

61. The reduced-fat soy protein composition of claim 60, wherein the soy material is a substantially full fat soy material.

62. The reduced-fat soy protein composition of claim 60, wherein the soy material is a high pressure liquid extracted soy material.

63. The reduced-fat soy protein composition of claim 60, the composition having a protein:water gel strength at least about 20% higher than that of a soy protein composition prepared from hot pressed soy material.

64. The reduced-fat soy protein composition of claim 60, the composition comprising at least about 80% dry weight protein and having a protein:water gel strength of at least about 2.2 newtons, as measured by the method of Example 11.

65. The reduced-fat soy protein composition of claim 60, the composition comprising at least about 80% dry weight protein and having a protein:water gel strength of at least about 2.40 newtons, as measured by the method of Example 11.

66. The reduced-fat soy protein composition of claim 60, the composition having an oil emulsion strength at least about 20% higher than that of a soy protein composition prepared from hot pressed soy material.

67. The reduced-fat soy protein composition of claim 60, the composition comprising at least about 80% dry weight protein and having an oil emulsion strength of about 1.1 newtons or higher, as measured by the method of Example 12.

68. The reduced-fat soy protein composition of claim 60, the composition comprising at least about 80% dry weight protein and having an oil emulsion strength of about 1.3 newtons or higher, as measured by the method of Example 12.

69. The reduced-fat soy protein composition of claim 61, the composition having a surface hydrophobicity at least about 15% higher than that of a soy protein composition prepared from hot pressed soy material.

70. The reduced-fat soy protein composition of claim 61, wherein the surface hydrophobicity of the composition is at least about 30% higher than that of a soy protein composition prepared from hot pressed soy material.

71. The reduced-fat soy protein composition of claim 61, the composition comprising at least about 80% dry weight protein and having a surface hydrophobicity slope of at least about 100, as measured by the method of Example 7.

72. The reduced-fat soy protein composition of claim 53, wherein the soy material is a hot pressed soy material.

73. The reduced-fat soy protein composition of claim 53, wherein the soy material is a cold pressed soy material.

74. A fat-enriched fraction produced according to the method of claim 1.

75. The fat-enriched fraction of claim 74, wherein the soy material is a substantially full fat soy material.

76. A crude oil produced according to the method of claim 28.

77. The crude oil of claim 76, wherein the crude oil is prepared from a non-hexane extracted soy material.

78. The crude oil of claim 77, the crude oil having a free fatty acid value of about 1.0 or less as measured by the method of Example 8.

79. The degummed oil produced according to the method of claim 29.

80. The degummed oil of claim 79, wherein the degummed oil is prepared from a non-hexane extracted soy material.

81. The degummed oil of claim 80, the degummed oil having a free fatty acid value of about 1.0 or less as measured by the method of Example 8.

82. Soy gums produced according to the method of claim 29.

83. The soy gums of claim 82, wherein the soy material is a substantially full fat soy material.

84. The protein-fat sediment produced according to the method of claim 27.

85. The reduced-fat glycinin-enriched fraction produced according to the method of claim 34.

86. The reduced-fat beta-coglycinin-enriched fraction produced according to the method of claim 35.

87. A soy protein composition comprising at least about 65% dry weight protein, produced from a non-hexane, non-alcohol treated soy material having a Protein Dispersibility Index of at least about 60%.

88. The composition of claim 87, wherein the composition comprises a fat content of about 15% or less dry weight.

89. The composition of claim 87, wherein the composition comprises a fat content of about 10% or less dry weight.

90. The composition of claim 87, wherein the composition comprises at least 85% dry weight protein.

91. The composition of claim 87, wherein the soy material is selected from a substantially full fat soy material and a high pressure liquid extracted soy material.

92. The composition of claim 91, wherein the soy material is a substantially full fat soy material.

93. The composition of claim 91, wherein the soy material is a high pressure liquid extracted soy material.

94. The composition of claim 91, the composition having a protein:water gel strength at least about 20% higher than that of a soy protein composition prepared from hot pressed soy material.

95. The composition of claim 91, the composition comprising at least about 80% protein and having a protein:water gel strength of at least about 2.2 newtons, as measured by the method of Example 11.

96. The composition of claim 91, the composition having an oil emulsion strength at least about 20% higher than that of a soy protein composition prepared from hot pressed soy material.

97. The reduced-fat soy protein composition of claim 91, the composition comprising at least about 80% dry weight protein and having an oil emulsion strength of about 1.1 newtons or higher, as measured by the method of Example 12.

98. The reduced-fat soy protein composition of claim 92, the composition having a surface hydrophobicity at least about 15% higher than that of a soy protein composition prepared from hot pressed soy material.

99. The reduced-fat soy protein composition of claim 92, the composition having a surface hydrophobicity at least about 30% higher than that of a soy protein composition prepared from hot pressed soy material.

100. The reduced-fat soy protein composition of claim 92, the composition comprising at least about 80% dry weight protein and a having surface hydrophobicity slope of about 100 or higher as measured by the method of Example 7.

101. The composition of claim 87, wherein the soy material is a hot pressed soy material.

102. The composition of claim 87, wherein the soy material is a cold pressed soy material.

103. The composition of claim 87, wherein the composition comprises about 7% or less dry weight fat.

104. The composition of claim 87, wherein the Protein Dispersibility Index is at least about 80%.

105. The composition of claim 87, wherein the composition comprises a protein to fat ratio of at least 5 to 1.

106. The composition of claim 87, wherein the protein to fat ratio is at least about 8 to 1.

107. A food product containing the soy protein composition of claim 87.

108. The food product of claim 107, wherein the food product is a confectionary product, a bakery product, an emulsified meat product, a ground meat product, an injection meat product, a meat analog product, a cereal, a bar, a dairy analog product, a beverage, a soymilk, a liquid or powdered dietetic formula, a texturized soy product, a pasta, a health nutrition supplement, or a nutrition bar.

109. The food product of claim 107, wherein the confectionary product is a candy or chocolate.

110. The food product of claim 107, wherein the bakery product is a bread, a roll, a biscuit, a cake, a yeast baked good, a cookie, a pastry, or a snack cake.

111. The food product of claim 107, wherein the injection meat product is a ham, a poultry product, a pork product, a seafood product or a beef product.

112. The food product of claim 107, wherein the emulsified meat product is a sausage, a bratwurst, a salami, a bologna, a lunchmeat, or a hot dog.

113. The food product of claim 107, wherein the ground meat product is a fish stick, a meat patty, a meatball, a ground seafood product, a ground pork product, a ground poultry product or a ground beef product.

114. The food product of claim 107, wherein the meat analog product is a meat patty, sausage, hot dog, lunchmeat, or ground crumble.

115. The food product of claim 107, wherein the dairy analog product is a milk product, a yogurt, a sour cream, a whipped topping, a ice cream, a cheese, a shake, a coffee whitener or a cream product.

116. The food product of claim 107, wherein the dietetic formula is an infant formula, a geriatric formula, a weight loss preparation, a weight gain preparation, a sports drink, or a diabetes management preparation.

117. A food product prepared from a soy protein composition comprising at least 65% dry weight protein prepared from a non-hexane, non-alcohol treated soy material having a PDI greater than 60%.

118. The food product of claim 117, wherein the soy material is a substantially full fat soy material.

119. The food product of claim 117, wherein the soy protein composition has a substantially bland taste.

120. The food product of claim 117, wherein the soy protein composition comprises at least 85% dry weight protein.

121. A soy extract comprising at least about 55% dry weight protein, the extract produced by non-hexane, non-alcohol extraction of a soy material, the soy material having a Protein Dispersibility Index of at least about 70%.

122. The extract of claim 121, wherein the soy material is a substantially full fat soy material.

123. The extract of claim 121, wherein the extract comprises a fat content of about 15% or less dry weight.

124. The extract of claim 121, wherein the extract comprises about 10% or less dry weight fat.

125. The extract of claim 121, wherein the Protein Dispersibility Index is at least about 75%.

126. The extract of claim 121, wherein the extract comprises a protein to fat ratio of at least 5 to 1.

127. The extract of claim 121, wherein the extract comprises at least about 6.25 g protein per 8 fluid ounces and less than or equal to about 1.0 g fat per 8 fluid ounces.

128. The extract of claim 121, wherein the protein to fat ratio is at least about 8 to 1.

129. The extract of claim 121, wherein the extract comprises no more than 0.5 g fat per 8 fluid ounces.

130. A food product containing the soy extract of claim 121.

131. The food product of claim 130, wherein the food product is a confectionary product, a bakery product, an emulsified meat product, a ground meat product, an injection meat product, a meat analog product, a cereal, a bar, a dairy analog product, a beverage, a soymilk, a liquid or powdered dietetic formula, a texturized soy product, a pasta, a health nutrition supplement, or a nutrition bar.