Patent Application
20230114609
This application relates generally to plant-based cheese products.
Some commercially available plant-based cheese products include a starch-based gel. These typical plant-based cheese products often do not exhibit functional characteristics expected of dairy-based cheeses, including melting and stretching at cooking temperatures. Rather, at cooking temperatures, the starch-based gels in these products generally do not soften enough to resemble the melting behavior of dairy cheese. At higher cooking temperatures, the starch-based gels in these products generally lose their structure so that the product resembles a sauce rather than a melted dairy cheese. Additionally, these typical plant-based cheese products often have a dull appearance rather than the shiny appearance typical of dairy-based processed cheese (hereinafter “conventional processed cheese”). These plant-based cheese products are not as well accepted by consumers who expect a cooking and eating experience that replicates dairy-based cheeses.
Further, some commercially available plant-based cheese products do not have a nutritional content, and particularly a protein content, that is comparable to the protein content of dairy-based cheeses. Processed cheeses typically include from 13 wt % to 20 wt % crude protein, and dairy-based natural cheeses may include from 15 wt % to 40 wt % crude protein. As example, semi-hard dairy-based natural cheeses, such as natural cheddars, may include from 20 wt % to 30 wt % crude protein, hard dairy-based natural cheeses, such as natural parmesans, may include from 35 wt % to 40 wt % crude protein, and semi-soft dairy-based natural cheeses, such as natural fetas and natural mozzarellas, may include about 15 wt % crude protein. Commercially available plant-based cheese products typically include less than 2 wt % crude protein. Including higher amounts of protein can present significant manufacturing challenges, as well as adversely impact flavor, textural, and structural properties at different temperatures. These plant-based cheese products are not as well accepted by consumers who expect a nutritional content that is similar to dairy-based cheeses.
Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. Certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.
Described herein are plant-based cheese products. The plant-based cheese products have a protein content that is comparable to the protein content in dairy-based cheeses. Further, it has been unexpectedly found that a plant-based cheese product with characteristics consistent with consumer expectations for a dairy-based cheese, such as melting and stretching at cooking temperatures, can be obtained through use of a combination of a plant-based protein in an amount of about 10 wt % to about 25 wt % crude protein, a waxy starch including at least 70 wt % amylopectin, and a fat.
In one approach, the plant-based cheese product includes: a plant-based protein present in an amount within the range of about 10 wt % to about 25 wt % crude protein, based on the total weight of the plant-based cheese product; a waxy starch comprising at least 70 wt % amylopectin, based on a total weight of the waxy starch, wherein the waxy starch is at least partially gelatinized; and a fat.
The plant-based cheese product disclosed herein may be formed into any desirable shape. In some examples, the plant-based cheese product is in the form of a cheese block, a sliced cheese, a diced cheese, or a shredded cheese.
The plant-based cheese product includes a plant-based protein. Any suitable plant-based protein may be used in the plant-based cheese product. In some embodiments, the plant-based protein comprises one or more of faba protein, chickpea protein, mungbean protein, soy protein, zein protein, lupin protein, canola protein, pea protein, lentil protein, and flax protein. In one embodiment, the plant-based protein comprises faba protein.
In some approaches, the plant-based protein can be in the form of an isolate, a concentrate, or a flour, though the precise form of the plant-based protein is not believed to be particularly limited. Generally, protein isolates have a higher crude protein content than protein concentrates. In one embodiment, the plant-based protein may be in the form of an isolate. When the plant-based protein is in the form of an isolate, a higher wt % (e.g., about 10 wt % to about 25 wt %) of crude protein may be achieved in the plant-based cheese product for a given amount by weight of the isolate versus a concentrate, as well as minimize any deleterious effects (e.g., off flavors) due to any non-protein components of the protein isolate.
In some embodiments, the plant-based protein is the only source of protein in the plant-based cheese product. In this respect, in some embodiments, the plant-based cheese product includes no animal proteins, including, for example, casein and whey.
In one approach, the plant-based protein is present in an amount within the range of about 10 wt % to about 25 wt % crude protein, based on the total weight of the plant-based cheese product. In another approach, the plant-based protein is present in an amount within the range of about 12 wt % to about 25 wt %, about 14 wt % to about 25 wt %, about 15 wt % to about 25 wt %, about 16 wt % to about 25 wt %, about 18 wt % to about 25 wt %, about 20 wt % to about 25 wt %, about 10 wt % to about 23 wt %, about 12 wt % to about 23 wt %, about 14 wt % to about 23 wt %, about 15 wt % to about 23 wt %, about 16 wt % to about 23 wt %, about 18 wt % to about 23 wt %, about 20 wt % to about 23 wt %, about 10 wt % to about 20 wt %, 12 wt % to about 20 wt %, about 14 wt % to about 20 wt %, about 15 wt % to about 20 wt %, about 16 wt % to about 20 wt %, about 18 wt % to about 20 wt %, about 10 wt % to about 18 wt %, 12 wt % to about 18 wt %, about 14 wt % to about 18 wt %, about 15 wt % to about 18 wt %, or about 16 wt % to about 18 wt % crude protein based on the total weight of the plant-based cheese product. The amount of crude protein in a plant-based protein ingredient may depend on the form of the ingredient (e.g., whether the ingredient is in the form of an isolate, a concentrate, or a flour). Therefore, for purposes herein, plant-based protein refers to the crude protein content, i.e., the amount of protein contributed by the ingredient that delivers the plant-based protein. For instance, the faba protein isolate product commercially available from AGT Food & Ingredients (Canada) includes about 90% protein and about 10% non-protein components. If a plant-based cheese product includes about 18 wt % faba protein isolate product (AGT Food & Ingredients), the plant-based cheese product will include about 16 wt % plant-based protein, for percentage purposes herein. As another example, the commercially available ARTESA® chickpea protein product includes about 60% protein and about 40% non-protein components. For instance, if a plant-based cheese product includes about 13 wt % ARTESA® chickpea protein product, the plant-based cheese product will include about 8 wt % plant-based protein, for percentage purposes herein.
The plant-based cheese products further include a waxy starch. Any suitable waxy starch may be used in the plant-based cheese product. In some examples, the waxy starch comprises one or more of a native waxy maize, a tapioca starch, and a casava starch. In some embodiments, the waxy starch comprises native waxy maize. Additionally, or alternatively, the waxy starch comprises one or more of a tapioca starch and a casava starch.
The waxy starch includes at least 70 wt % amylopectin, based on the total weight of the waxy starch. In some approaches, waxy starch includes at least 80 wt % or at least 90 wt % amylopectin, based on the total weight of the waxy starch.
The waxy starch is at least partially gelatinized in the plant-based cheese product. As used herein, “partial gelatinization” or similar term means that the starch has begun to swell and lose some of the crystalline structure. The at least partially gelatinized starch contributes to the plant-based cheese product exhibiting functional characteristics expected of dairy-based cheeses. For example, the at least partially gelatinized starch, in combination with the protein and fat content, may enable the plant-based cheese product to have a structure and/or functionality similar to dairy-based cheese products at refrigerated and room temperatures, while melting and stretching at cooking temperatures.
Generally, the level of gelatinization of the starch can be adjusted based on desired properties in the final plant-based cheese product, as described in further detail below. The degree of gelatinization can be any suitable amount, such as about 20% or more, about 25% or more, about 30% or more, about 35% or more, about 40% or more, about 45% or more, about 50% or more, about 55% or more, about 60% or more, about 65% or more, about 70% or more, about 75% or more, about 80% or more, about 85% or more, about 90% or more, and about 95% or more. However, smaller degrees of gelatinization will more closely approximate granular starch and may not take full advantage of the stretch and melting properties of some embodiments of the plant-based cheese products. In general, the starch need not be fully gelatinized to provide desirable melting and stretching properties to the plant-based cheese product. The level of starch gelatinization may be measured, for instance, by differential scanning calorimetry (DSC), optical microscopy, X-ray diffraction, or other suitable technique.
In one approach, the waxy starch is present in an amount within the range of about 5 wt % to about 20 wt %, based on the total weight of the plant-based cheese product. In another approach, the waxy starch is present in an amount within the range of about 10 wt % to about 20 wt %, about 5 wt % to about 16 wt %, about 10 wt % to about 16 wt %, or about 12 wt % to about 16 wt %, based on the total weight of the plant-based cheese product.
In some examples, the plant-based cheese product further includes exopolysaccharide (EPS). In some embodiments, the plant-based cheese product further includes EPS when the plant-based cheese product includes the waxy starch in an amount within the range of about 5 wt % to about 10 wt %. In one approach, the EPS may be produced by L. lactis strain 329, deposited as ATCC PTA-120552 and described in U.S. Pub. No. 2020/0068914 which is incorporated herein by reference. Additionally, or alternatively, the EPS may be included in the plant-based cheese product in an aqueous liquid or water. The EPS may be included in the plant-based cheese product in an amount (by dry weight of the EPS) greater than 0 wt % to about 0.5 wt %, based on the total weight of the plant-based cheese product.
The plant-based cheese product further includes a fat. Any suitable fat may be used in the plant-based cheese product. In some embodiments, fat comprises one or more of coconut oil, shea oil, shea stearin, shea olein, shea butter, palm oil, palm oil fraction, sunflower oil, cocoa butter, and cottonseed glycerolysis. In one embodiment, the fat comprises coconut oil. In another embodiment, the fat comprises coconut oil and sunflower oil.
In some approaches, the fat is in the form of one or more solid fats or a combination of one or more solid fats and one or more liquid oils. As used herein, solid fats refer to fats that are solid at room temperature (e.g., about 20° C.), and liquid oils refer to fats that are in liquid form at room temperature (e.g., about 20° C.). In some examples, the fat has a solid fat content in the range of about 32% to about 95% at 10° C. (based on the total weight of the fat). In other examples, the fat has a solid fat content in the range of about 70% to about 85% at 10° C. (based on the total weight of the fat). Additionally, or alternatively, the fat has a solid fat content in the range of about 28% to about 80%, in another aspect about 32% to about 55%, at 20° C. (based on the total weight of the fat). Additionally, or alternatively, the fat has a solid fat content in the range of 0% to about 20%, in another aspect about 0% to about 15%, at 30° C. (based on the total weight of the fat). Additionally, or alternatively, the fat has a solid fat content in the range of 0% to about 5% or 0% to less than 5% at 40° C. (based on the total weight of the fat).
In some examples, the fat has a solid fat content in the range of about 32% to about 95% at 10° C., about 28% to about 80% at 20° C., 0% to about 20% at 30° C., and 0% to about 5% at 40° C. (based on the total weight of the fat). In some examples, the fat has a solid fat content in the range of about 70% to about 85% at 10° C., about 32% to about 55% at 20° C., 0% to about 15% at 30° C., and 0% to less than 5% at 40° C. (based on the total weight of the fat).
The solid fat contents of exemplary fat components that may be used in the plant-based cheese products are shown below in Table 1. The fat components may be used alone or in combination, as needed, to provide a desired solid fat content at 10° C., 20° C., 30° C., and/or 40° C.
In some approaches, the fat is in the form of an oleogel. In some of these approaches, an additional component (e.g., ethyl cellulose) may be added to the fat to form the oleogel.
In one approach, the fat is present in an amount within the range of about 15 wt % to about 30 wt %, based on the total weight of the plant-based cheese product. In other approaches, the fat is present in an amount within the range of about 19 wt % to about 27 wt %, about 19 wt % to about 25 wt %, about 20 wt % to about 27 wt %, or about 20 wt % to about 25 wt %, based on the total weight of the plant-based cheese product.
In some embodiments, the plant-based cheese product further includes a wax having a melting point less than 80° C. In some embodiments, the plant-based cheese product further includes a wax having a melting point less than 70° C. or less than 60° C. Any suitable wax may be used in the plant-based cheese product. In some embodiments, wax comprises one or more of orange wax, rice bran wax, sunflower wax, beeswax, and candelilla wax. In other embodiments, wax comprises one or more of beeswax and candelilla wax. In on embodiment, the wax comprises candelilla wax.
In some approaches, the combination of the fat and the wax has a crystallization temperature below 60° C. In other approaches, the combination of the fat and the wax has a crystallization temperature within the range of 5° C. to 60° C. In these approaches, the plant-based cheese product resembles a non-melted dairy-based cheese below the crystallization temperature and a melted dairy-based cheese above the crystallization temperature.
In some embodiments, the plant-based cheese product includes no animal products, such as beeswax.
In one approach, the wax is present in an amount within the range of about 0.5 wt % to about 5 wt %, based on the total weight of the fat. In another approach, the wax is present in an amount within the range of about 0.5 wt % to about 2.5 wt % or about 0.5 wt % to about 2 wt %, based on the total weight of the fat.
In some embodiments, the plant-based cheese product further includes ethyl cellulose. In some of these examples, the ethyl cellulose and the fat form an oleogel.
In one approach, the ethyl cellulose is present in an amount within the range of about 0.1 wt % to about 2 wt %, based on the total weight of the fat. In another approach, the ethyl cellulose is present in an amount within the range of about 0.5 wt % to about 1.5 wt %, based on the total weight of the fat.
In some approaches, including the wax and/or the ethyl cellulose, has surprisingly been found to significantly reduce the oil loss (i.e., the separation of oil from the other ingredients) of the plant-based cheese product when the plant-based cheese product is heated.
In some examples, the plant-based cheese product further includes an acidulant in an amount effective to provide a pH of the plant-based cheese product of about 4.5 to about 5.5. In other examples, the plant-based cheese product further includes an acidulant in an amount effective to provide a pH of the plant-based cheese product of about 4.8 to about 5.5, and in another aspect about 4.8 to about 5.0. Any suitable acidulant may be used. In one example, the acidulant comprises one or more of citric acid, malic acid, acetic acid, phosphoric acid, sorbic acid, and lactic acid. In some approaches, the lactic acid is not produced via fermentation in a dairy-based media.
In some embodiments, the plant-based cheese product may further include additional components. Examples of additional components that may be included in the plant-based cheese product include one or more of a salt, an antimicrobial agent, flavoring agents, and colors.
Also disclosed herein is a method of making the plant-based cheese product. In one approach, the method includes: dissolving a first amount of a plant-based protein in an aqueous liquid (e.g., water) to form a plant-based protein solution or suspension; heating a fat to form a melted fat; emulsifying the plant-based protein solution or suspension with the melted fat to form an emulsion; adding a second amount of the plant-based protein and a waxy starch to the emulsion and mixing to form a mixture; heating and mixing the mixture for a time effective to at least partially gelatinize the waxy starch to form a heated mixture; and cooling the heated mixture to form the plant-based cheese product; wherein the plant-based cheese product comprises about 10 wt % to about 25 wt % crude protein, based on a total weight of the plant-based cheese product; and wherein the waxy starch comprises at least 70 wt. % amylopectin, based on a total weight of the waxy starch.
The method includes dissolving a first amount of a plant-based protein in an aqueous liquid (e.g., water) to form a plant-based protein solution or suspension. Whether a solution or suspension is formed may depend, at least in part, on the solubility of the plant-based protein. In some embodiments, the plant-based protein solution or suspension includes from about 2% w/v to about 8% w/v of the plant-based protein. In other embodiments, the plant-based protein solution or suspension includes from about 4% w/v to about 6% w/v of the plant-based protein. The first amount of the plant-based protein may be selected to achieve the desired % w/v of the plant-based protein in the plant-based protein solution or suspension.
In one approach, the first amount of the plant-based protein is about 15 wt % to about 50 wt %, based on the total weight of the plant-based protein in the plant-based cheese product. In another approach, the plant-based protein is about 15 wt % to about 40 wt %, about 15 wt % to about 35 wt %, about 15 wt % to about 33 wt %, about 15 wt % to about 30 wt %, about 15 wt % to about 25 wt %, about 15 wt % to about 20 wt %, about 20 wt % to about 50 wt %, about 20 wt % to about 40 wt %, about 20 wt % to about 35 wt %, about 20 wt % to about 33 wt %, about 20 wt % to about 30 wt %, about 20 wt % to about 25 wt %, about 25 wt % to about 50 wt %, about 25 wt % to about 40 wt %, about 25 wt % to about 35 wt %, about 25 wt % to about 33 wt %, about 25 wt % to about 30 wt %, about 30 wt % to about 50 wt %, about 30 wt % to about 40 wt %, about 30 wt % to about 35 wt %, about 30 wt % to about 33 wt %, about 33 wt % to about 50 wt %, about 33 wt % to about 40 wt %, about 33 wt % to about 35 wt %, about 35 wt % to about 50 wt %, about 35 wt % to about 40 wt %, or about 40 wt % to about 50 wt %, based on the total weight of the plant-based protein in the plant-based cheese product.
The method further includes heating a fat to form a melted fat. In some examples, the heating of the fat is to a temperature within the range of about 35° C. to about 60° C.
In some examples, the method further includes adding a wax having a melting point less than 80° C. to the fat. In some of these examples, the wax is added to the fat before the fat is heated to form the melted fat. In others of these examples, the wax is added to the fat while the fat is heated to form the melted fat. In others of these examples, the wax is added to the fat after the fat is heated to form the melted fat. In some examples, the wax includes one or more of orange wax, rice bran wax, sunflower wax, beeswax, and candelilla wax. In some examples, the wax includes candelilla wax.
In some approaches, the method further includes adding ethyl cellulose to the fat. In some of these approaches, the ethyl cellulose is added to the fat before the fat is heated to form the melted fat. In others of these approaches, the ethyl cellulose is added to the fat while the fat is heated to form the melted fat. In others of these examples, the ethyl cellulose is added to the fat after the fat is heated to form the melted fat. In some embodiments, the method further includes forming an oleogel from the ethyl cellulose and the fat.
The method also includes emulsifying the plant-based protein solution or suspension with the melted fat to form an emulsion. In some approaches, the emulsion is a homogenous mixture or a substantially homogenous mixture. In some approaches, the emulsion is uniform in color and/or has no visible oil separation. The length and intensity of the emulsifying may be selected to produce such an emulsion. It is not presently believed that a particular oil droplet size needs to be achieved to provide a suitable emulsion.
The method includes adding a second amount (at least in some approaches, the remaining amount) of the plant-based protein and a waxy starch to the emulsion and mixing to form a mixture. At least part of the second amount of the plant-based protein may dissolve in the mixture. Additionally, or alternatively, at least part of the second amount of the plant-based protein may be suspended in the mixture. Whether at least part of the second amount of the plant-based protein is dissolved and/or at least part of the second amount of the plant-based protein is suspended in the mixture may depend, at least in part, on the solubility of the plant-based protein. The second amount of the plant-based protein may be selected to achieve the desired crude protein amount in the plant-based cheese product. The waxy starch includes at least 70 wt. % amylopectin, based on a total weight of the waxy starch. In some examples, the waxy starch includes one or more of a native waxy maize, a tapioca starch, and a casava starch. In some examples, the waxy starch includes native waxy maize. In some examples, the waxy starch includes one or more of a tapioca starch and a casava starch.
In some embodiments, the method further includes adding an acidulant to the emulsion or the mixture. In some of these embodiments, the acidulant is added in an amount effective to provide a pH within the range of about 4.5 to about 5.5 in the plant-based cheese product. In some of these embodiments, the acidulant includes one or more of citric acid, malic acid, acetic acid, phosphoric acid, sorbic acid, and lactic acid.
The method further includes heating and mixing the mixture for a time effective to at least partially gelatinize the waxy starch to form a heated mixture. The heating and mixing the mixture may be continued until the desired characteristics of the plant-based cheese product are achieved. For example, the longer the mixture is heated and mixed (at a temperature above the starch gelatinization temperature), greater hardness of the plant-based cheese product may be achieved. Also, use of higher temperatures during the heating and mixing step may result in greater hardness of the plant-based cheese product. The increase in hardness of the plant-based cheese product as the mixture is heated and mixed, may be due, at least in part, to the increase in degree of starch gelatinization that occurs as the mixture is heated and mixed for longer periods of time and/or at higher temperatures.
The method also includes cooling the heated mixture to form the plant-based cheese product. In some approaches, the plant-based cheese product is cooled to refrigeration temperatures.
In some embodiments, the method further includes filling the heated mixture into a container prior to the cooling step.
In another aspect, the methods may further include adding one or more of salt, a preservative, colorant, and flavor.
The method described herein may also further include cutting the plant-based cheese product into various shapes and sizes, such as blocks, slices, cubes, shreds, and the like.
The methods described herein can be modified to provide a desired hardness of the plant-based cheese product. In this respect, the methods can be advantageously used to simulate the hardness characteristics typical of various types of dairy-based cheeses, including, for example, processed cheese, hard cheese, semi-soft, soft, and soft-ripened cheese, as defined by 21 C.F.R. § 133.102 to § 133.196.
In some embodiments, the plant-based cheese product has a hardness consistent with consumer expectations for a conventional (dairy-based) processed cheese or a dairy-based semi-hard natural cheese (e.g., a dairy-based natural mild cheddar cheese). As used herein, the term “hardness” refers to the force of a sample (at 5° C.) measured when compressed by 50% in accordance with the method described below in the Examples (Texture Analysis).
In some examples, the plant-based cheese product has a hardness within the range of about 15 N to about 118 N, about 15 N to about 103 N, or about 15 N to about 90 N, when compressing the plant-based cheese product by 50%. In other examples, the plant-based cheese product has a hardness within the range of about 15 N to about 25 N or about 70 N to about 95N, when compressing the plant-based cheese product by 50%. Generally, hardness values in the range of to about 15 N to 103 N are similar to conventional dairy-based processed cheeses. Hardness values in the range of about 86 N to about 118 N are similar to conventional dairy-based natural cheeses.
In some approaches, the plant-based cheese product has a hardness within the range of about 19 N to about 21 N, when compressing the plant-based cheese product by 50%. In these approaches, the hardness of the plant-based cheese product may be considered to be consistent with consumer expectations for the hardness of a conventional (dairy-based) processed cheese. In some approaches, the plant-based cheese product has a hardness within the range of about 76 N to about 90 N, when compressing the plant-based cheese product by 50%. In these approaches, the hardness of the plant-based cheese product may be considered to be consistent with consumer expectations for the hardness of a dairy-based natural mild cheddar cheese. In other approaches, the plant-based cheese product has a hardness within the range of about 19 N to about 21 N or within the range of about 76 N to about 90 N, when compressing the plant-based cheese product by 50%.
In some embodiments, the plant-based cheese product has a melt percentage consistent with consumer expectations for a conventional (dairy-based) processed cheese or a dairy-based semi-hard natural cheese (e.g., a dairy-based natural mild cheddar cheese). As used herein, the term “melt percentage” refers to percent increase in diameter of a sample measured when heated in accordance with the method described below in the Examples (Disk Melt Test (Modified Schreiber Test)).
In some approaches, the plant-based cheese product has a melt percentage within the range of about 65% to about 185%. In other approaches, the plant-based cheese product has a melt percentage within the range of about 80% to about 185%, about 98% to about 185%, about 110% to about 185%, about 65% to about 155%, 80% to about 155%, about 98% to about 155%, or about 110% to about 155%. In these approaches, the melt percentage of the plant-based cheese product may be considered to be consistent with consumer expectations for the melt percentage of a conventional (dairy-based) processed cheese and/or a dairy-based semi-hard natural cheese (e.g., a dairy-based natural mild cheddar cheese).
In some embodiments, the plant-based cheese product has an oil loss consistent with consumer expectations for a conventional (dairy-based) processed cheese or a dairy-based semi-hard natural cheese (e.g., a dairy-based natural mild cheddar cheese). As used herein, the term “oil loss” refers to the oil loss score of a sample measured when heated in accordance with the method described below in the Examples (Oil Loss).
In some approaches, the plant-based cheese product has an oil loss of 6 or less. In these approaches, the oil loss of the plant-based cheese product may be considered to be consistent with consumer expectations for the oil loss of a dairy-based semi-hard natural cheese (e.g., a dairy-based natural mild cheddar cheese). In some approaches, the plant-based cheese product has an oil loss of 4 or less, 2 or less, or 1 or less. In some approaches, the plant-based cheese product has an oil loss of 0. In these approaches, the oil loss of the plant-based cheese product may be considered to be consistent with consumer expectations for the oil loss of a conventional (dairy-based) processed cheese.
In some embodiments, the plant-based cheese product has a Tan δ value at 80° C. consistent with consumer expectations for a conventional (dairy-based) processed cheese or a dairy-based semi-hard natural cheese (e.g., a dairy-based natural mild cheddar cheese). As used herein, the term “Tan δ value” refers to the quotient of the loss modulus (G″) and the elastic modulus (G′) (i.e., G″/G′) of a melting profile of a sample measured in accordance with the method described below in the Examples (Rheometer Temperature Sweep).
In some approaches, the plant-based cheese product has a Tan δ value greater than 0.2 at 80° C. In other approaches, the plant-based cheese product has a Tan δ value greater than 0.4 at 80° C. or greater than 0.6 at 80° C. In these approaches, the Tan δ value at 80° C. of the plant-based cheese product may be considered to be consistent with consumer expectations for the Tan δ value at 80° C. of a conventional (dairy-based) processed cheese and/or a dairy-based semi-hard natural cheese (e.g., a dairy-based natural mild cheddar cheese).
In some embodiments, the plant-based cheese product has a stretch at 80° C. consistent with consumer expectations for a conventional (dairy-based) processed cheese or a dairy-based semi-hard natural cheese (e.g., a dairy-based natural mild cheddar cheese). As used herein, the term “stretch” refers to the distance a sample extends before breaking when subjected to an axial pull in accordance with the method described below in the Examples (Axial Pull).
In some approaches, the plant-based cheese product has a stretch of at least 20 mm at 80° C. In other approaches, the plant-based cheese product has a stretch of at least 25 mm at 80° C., at least 30 mm at 80° C., or at least 35 mm at 80° C. In these approaches, the stretch at 80° C. of the plant-based cheese product may be considered to be consistent with consumer expectations for the stretch at 80° C. of a conventional (dairy-based) processed cheese and/or a dairy-based semi-hard natural cheese (e.g., a dairy-based natural mild cheddar cheese).
The plant-based cheese product, the plant-based protein, the waxy starch, the fat, the wax, the ethyl cellulose, and the acidulant may each be described above in any of the examples disclosed herein.
Cheeses may be cooked and processed using any conventional equipment, including the use of a laydown cooker, kettle, or other device. Shredding and packaging may also be accomplished with conventional equipment.
To further illustrate the present disclosure, examples are given herein. It is to be understood that these examples are provided for illustrative purposes and are not to be construed as limiting the scope of the present disclosure.
In the following Examples, each of the example plant-based cheese products were prepared according to the following method.
Each example plant-based cheese product included a plant-based protein, a waxy starch, a fat, water, and an acidulant. Each example plant-based cheese product included about 16 to 18 wt % crude protein, based on a total weight of the plant-based cheese product.
The total volume of water was put into a large beaker followed by the addition of the appropriate amount of dry plant-based protein to make a 5% (w/v) protein solution or suspension. The solution or suspension was mixed on a stir plate at 400 rpm until combined. The total amount of fat was melted until liquid. The melted fat was poured in to the 5% protein-water solution or suspension and homogenized at 20,000 rpm using a Polytron® handheld homogenizer (POLYTRON® PT 1300D V3, KINEMATICA) for 1 minute. An emulsion was formed. The emulsion was added to a Thermomix® TM6™ thermomixer and mixed at speed of 2 to 2.5. During this time, half of the remaining dry plant-based protein and half of the dry waxy starch were added to the thermomixer, and mixed until fully combined and no dry powder remained. An acidulant solution was added to the thermomixer and mixed for 30 seconds. Then, the remaining dry plant-based protein and dry waxy starch were added and mixed until smooth. The mixing was stopped, and the sides were scraped when necessary to ensure proper mixing. Each resulting mixture was between 160 g and 170 g.
Once the mixture was completely smooth, the heating method was started. Each example plant-based cheese product was produced according to one of the following heating methods (i.e., T1, T2, T3, T4, T5, T6, or T7).
For each heating method, the Thermomix® TM6™ thermomixer was set to a speed of 2.0 and to a temperature of 40° C. Upon reaching 40° C., the set temperature was increased to 50° C. Upon reaching 50° C., the set temperature was increased to 60° C. Upon reaching 60° C., the set temperature was increased to 70° C. Upon reaching 70° C., the mixing was stopped, and the bottom of the thermomixer was scraped.
Then, the thermomixer was set to a speed of 0.5 and to a temperature of 80° C. Upon reaching 80° C., the mixing was stopped, and the bottom of the thermomixer was scraped. The thermomixer was again set to a speed of 0.5 and to a temperature of 80° C. After mixing for 30 seconds, the mixing was stopped, and the bottom of the thermomixer was scraped. Then, the thermomixer was set to a speed of 3.5 and to a temperature of 80° C. After mixing for 30 seconds, the mixing was stopped, and the bottom of the thermomixer was scraped. Then, the thermomixer was set to a speed of 0.5 and to a temperature of 80° C. After mixing for 1 minute and 30 seconds, the mixing was stopped, and the bottom of the thermomixer was scraped. Then, the thermomixer was again set to a speed of 0.5 and to a temperature of 80° C. After mixing for 1 minute and 30 seconds, the mixing was stopped, and the bottom of the thermomixer was scraped.
Then, the thermomixer was set to a speed of 0.5 and to a temperature of 80° C. After mixing for 30 seconds, the thermomixer was set to a speed of 2.0. After mixing for 30 seconds, the thermomixer was set to a speed of 3.5. After mixing for 30 seconds, the thermomixer was set to a speed of 2.5. After mixing for 30 seconds, the thermomixer was set to a speed of 1.5. After mixing for 1 minute, the mixing was stopped, and the bottom of the thermomixer was scraped.
The example plant-based cheese products that were produced according to heating method T1 were taken at this point from the thermomixer and cooled. The heating method T1 lasted for about 14 minutes.
For the example plant-based cheese products that were produced according to heating methods T2, T3, T4, T5, T6, or T7, the thermomixer was set to a speed of 0.5 and to a temperature of 80° C. After mixing for 2 minutes, the mixing was stopped, and the bottom of the thermomixer was scraped.
The example plant-based cheese products that were produced according to heating method T2 were taken at this point from the thermomixer and cooled. The heating method T2 lasted for about 16 minutes.
For the example plant-based cheese products that were produced according to heating methods T3, T4, T5, T6, or T7, the thermomixer was set to a speed of 0.5 and to a temperature of 80° C. After mixing for 2 minutes, the mixing was stopped, and the bottom of the thermomixer was scraped.
The example plant-based cheese products that were produced according to heating method T3 were taken at this point from the thermomixer and cooled. The heating method T3 lasted for about 18 minutes.
For the example plant-based cheese products that were produced according to heating methods T4, T5, T6, or T7, the thermomixer was set to a speed of 0.5 and to a temperature of 80° C. After mixing for 2 minutes, the mixing was stopped, and the bottom of the thermomixer was scraped.
The example plant-based cheese products that were produced according to heating method T4 were taken at this point from the thermomixer and cooled. The heating method T4 lasted for about 20 minutes.
For the example plant-based cheese products that were produced according to heating methods T5, T6, or T7, the thermomixer was set to a speed of 0.5 and to a temperature of 80° C. After mixing for 2 minutes, the mixing was stopped, and the bottom of the thermomixer was scraped.
The example plant-based cheese products that were produced according to heating method T5 were taken at this point from the thermomixer and cooled. The heating method T5 lasted for about 22 minutes.
For the example plant-based cheese products that were produced according to heating methods T6 or T7, the thermomixer was set to a speed of 0.5 and to a temperature of 80° C. After mixing for 2 minutes, the mixing was stopped, and the bottom of the thermomixer was scraped.
The example plant-based cheese products that were produced according to heating method T6 were taken at this point from the thermomixer and cooled. The heating method T6 lasted for about 24 minutes.
For the example plant-based cheese products that were produced according to heating method T7, the thermomixer was set to a speed of 0.5 and to a temperature of 80° C. After mixing for 2 minutes, the mixing was stopped, and the bottom of the thermomixer was scraped.
The example plant-based cheese products that were produced according to heating method T7 were taken at this point from the thermomixer and cooled. The heating method T7 lasted for about 26 minutes.
After the heating method, each example plant-based cheese product was refrigerated for 24 hours at temperature of 4° C. to 5° C.
Texture profile analysis (TPA) is a standard technique used to obtain sensory characteristics of food. TPA mimics the first two bites of chewing by compressing the food to a desired level of deformation. The TPA test was used to determine the hardness of the example plant-based cheese products, commercial plant-based cheeses, and commercial dairy-based cheeses. The hardness of each sample was equal to the peak force of the first compression.
For the analysis of the example plant-based cheese products, samples were prepared using a cylindrical die cutter with a 20 mm diameter, followed by trimming to 10 mm in height. For commercial samples that were pre-sliced, the die cutter was used to cut samples which were then stacked to reach 10 mm in height. All samples were kept at 5° C. and analyzed within 1 to 5 minutes of being cut. The sample disks were analyzed using a TA.XT2 texture analyzer (Stable Micro systems, Texture Technologies Corp. Scarsdale, N.Y., USA) fitted with a 75 mm cylindrical plate and 30 kg load cell. The samples were compressed to 50% of their original height at a crosshead speed of 1.00 mm/s with 5 seconds rest between compressions. The data was recorded in newtons and analyzed using Exponent software.
The meltability (i.e., melt percentage) of the example plant-based cheese products, commercial plant-based cheeses, and commercial dairy-based cheeses was measured using a modified Schreiber test. Samples were cut with a cylindrical 20 mm die cutter, then trimmed to be 10 mm in height. Samples that were in slice form were cut to be the same 20 mm in diameter and stacked to be 10 mm in height. The samples were kept at 5° C. For each sample, a template 100 mm in diameter was printed with increasing concentric circles as well as lines at 45° angels on white printer paper. The template was placed at the bottom of a petri dish facing up. The sample was then placed on top of the template and covered with the corresponding glass top and placed in the refrigerator at 5° C. for 10 minutes. The samples were then transferred to an oven pre heated to 232° C. (i.e., 450° F.) for 5 minutes. The samples were removed and allowed to cool before the diameter of the spread at four different angles was taken. The average of the measurement was used to calculate the meltability by determining the % increase in diameter from the initial 20 mm.
Oil loss for the example plant-based cheese products, commercial plant-based cheeses, and commercial dairy-based cheeses was measured based on the saturation of Schreiber disk paper that occurred during the melt. A numeric value from 1 to 7 was allotted based on the number of rings on the paper that were saturated with oil.
Oscillatory shear strain tests and temperature sweeps were performed on the example plant-based cheese products, commercial plant-based cheeses, and commercial dairy-based cheeses using a rotational rheometer (MRC 302, Anton Paar, Graz, Austria) fit with a 20 mm parallel plate geometry (PP20/S). To avoid slip, the top and bottom plates were affixed with 40 and 600 grit sandpaper, respectively, and a small amount of super glue was used to adhere the sample. The samples were less than 3 mm in height and were compressed between the plates with an axial force not exceeding 5 N. The normal force was then reduced to 0.25 N and held for 3 minutes to allow the sample to relax. Peltier plates and a forced air hood (Anton Paar, Graz, Austria) were used to control the temperature.
Amplitude sweeps were first performed at 5° C., 25° C. and 50° C. on commercial Kraft® Single slices to determine the liner viscoelastic region (LVR). The sweep was performed at a logarithmic rate from 0.01 to 200% strain as a constant frequency of 1 Hz.
A frequency sweep from 1 to 10 Hz was then carried at 0.1% strain.
To investigate the melting profile of the example plant-based cheese products, commercial plant-based cheeses, and commercial dairy-based cheeses, a temperature sweep from 5 to 80° C. at a rate of 5° C. per minute was carried out at 0.1% strain, at a frequency of 1 Hz with a constant normal force of 0.25 N to adjust for sample melting.
The variables obtained for all tests were elastic modulus (or storage modulus) (G′), loss modulus (or plastic modulus) (G″) and Tan δ (i.e., G″/G′) and the data was analyzed using RheoCompass™ Software.
The extensibility or stretch of the example plant-based cheese products, commercial plant-based cheeses, and commercial dairy-based cheeses was measured using a rotational rheometer (MRC 302, Anton Paar, Graz, Austria) with Peltier plates and a forced air hood (Anton Paar, Graz, Austria) used for temperature control. The rheometer was fit with a 20 mm parallel plate geometry (PP20/S) and pre heated to 80° C. To avoid slip, the top and bottom plates were affixed with 40 and 600 grit sandpaper, respectively, and a small amount of super glue was used to adhere the sample. 5 mm samples were used and compressed between the plates with an axial force not exceeding 5 N. The normal force was then reduced to 0.25 N. The samples were held for a total of 6 minutes at 80° C. with a constant 0.1% strain and applied normal force 0.25 N. The applied force ensured constant contact with the sample during melting, as the gap decrease was limited to a height of 3 mm. After heating, an axial pull was performed where the top parallel plate geometry moved upwards at a speed of 1500 μm/s. The Normal force (N) and Gap (mm) was recorded during the pull using RheoCompass™ Software. Additionally, a video recording of the axial pull was done using the camera of an iPhone XS (Apple Inc.). The gap size of the instrument was recorded in the same frame as sample stretch, and the gap at which the sample broke was used as the break point. Total stretch was measured by the following equation:
Stretch (mm)=Breakpoint (mm)−Starting gap after heating (mm)
First, the hardness, melt percentage, and oil loss of commercial dairy-based cheeses, Kraft® Single (a processed cheese) and Cracker Barrel® Natural (mild/medium) Cheddar were measured. The results of these measurements are shown in Table 2.
Then, examples of the plant-based cheese product disclosed herein were prepared. The example plant-based cheese products had the general formula S1, S2, S3, S4, or S5 and were prepared with heating method T3, T4, T5, T6, or T7. A 1 M citric acid solution was added as the acidulant to each example plant-based cheese product in an amount effective to keep the pH below 5.5.
The faba protein isolate was obtained from AGT Food & Ingredients. The lupin protein isolate was obtained from ProLupin GmbH. The soy protein isolate included about 88% protein and was obtained from DuPont. The soy protein concentrate included about 84% protein and was obtained from DuPont. The mungbean protein isolate was obtained from Fuji Plant Protein Labs. The native waxy maize was 100% Waxy Maize Starch obtained from MyProtein. The coconut oil was refined, organic, non-GMO coconut oil (Nutiva® Nurture Vitality™, Nutiva Inc., Richmond, Calif.).
Each of the formulas S1, S2, S3, S4, and S5 is shown in Table 3, with the wt % of each ingredient that was used (based on the total weight of the plant-based cheese product).
The hardness, melt percentage, and oil loss of the example plant-based cheese products were measured. The results of the hardness measurements are shown in Table 4. The results of the melt percentage measurements are shown in Table 5. The results of the oil loss measurements are shown in Table 6. In each of Tables 4 through 6, each example plant-based cheese product is identified by the formula and the heating method used to prepare the example plant-based cheese product.
The hardness of the example plant-based cheese products (Table 4) was similar across the different protein isolates. All formulas were able to reach hardness values in the range of the Kraft® Single at about 20N, except for formula S4, containing soy protein concentrate. All formulas were also able to reach hardness values similar to the Cracker Barrel® Natural Cheddar, except for formula S5, containing mungbean protein.
The hardness values indicates that multiple plant-bases proteins can be used for creating the plant-based cheese product.
Sample meltability is an important indicator to the viability of the protein for use in the formulation. The goal is to have a large spread occur during the melting process, in order to be similar to commercial cheese.
As shown in Table 5, the meltability of the formulas varied. However, formula S1, containing faba protein, had significant melt. The other formulas, except for formula S2, containing lupin protein, were able to achieve some melt.
All the samples experienced oil loss during the melting (Table 6). Formula S2, containing lupin protein experiencing the least oil loss. This may be attributed to the samples having no melt or softening, which suggests that the lupin protein may interact or bind the oil in a different way. The oil loss that is observed for the formulas containing other proteins is acceptable for the samples prepared by heating methods T6 and T7, as they have hardness values similar to the Cracker Barrel® Natural Cheddar, which also experienced significant oil loss.
Overall, the samples containing the faba protein isolate had the best meltability, with an achievable hardness range that can be similar to both a Kraft® Single and Cracker Barrel® Natural Cheddar. The oil loss observed for all samples were more similar to that of a natural cheese over a processed cheese.
Additional examples of the plant-based cheese product were prepared. The example plant-based cheese products had the general formula S6 and were prepared with heating method T3, T4, T5, T6, or T7. The zein protein isolate was added during the ramping of the thermomixer from a speed of 0.5 for 30 seconds, to a speed of 2.0 for 30 seconds, to a speed of 3.5 for 30 seconds, to a speed of 2.5 for 30 seconds, then to a speed of 1.5 for 1 minute. A 1 M citric acid solution was added as the acidulant to each example plant-based cheese product in an amount effective to keep the pH below 5.5.
The faba protein isolate was obtained from AGT Food & Ingredients. Zein protein (food grade) from corn (FloZein Products, Ashburnham, Mass.) was used as the zein protein isolate. The native waxy maize was 100% Waxy Maize Starch obtained from MyProtein. The coconut oil was refined, organic, non-GMO coconut oil (Nutiva® Nurture Vitality™, Nutiva Inc., Richmond, Calif.).
The formula S6 is shown in Table 7, with the wt % of each ingredient that was used (based on the total weight of the plant-based cheese product).
The hardness, melt percentage, and oil loss of the example plant-based cheese products prepared with formula S6 were measured. The results of the hardness, melt percentage, and oil loss measurements are shown in Table 8. In Table 8, each example plant-based cheese product is identified by the heating method used to prepare the example plant-based cheese product.
The samples had hardness values in the hardness range that would be similar to processed and natural cheeses. For the samples prepared with heating methods T3 and T4, the melt slightly increased over the samples prepared with formula S1 and heating methods T3 and T4, but the sample hardness was also slightly softer, which could indicate an easier ability to melt and deform. The melt of the sample prepared with heating method T6 was not different from the sample prepared with formula S1 and heating method T6, but the melt of the sample prepared with heating method T7 decreased over the sample prepared with formula S1 and heating method T7. The sample prepared with heating method T7 also had greater hardness over the sample prepared with formula S1 and heating method T7. The samples prepared with formula S6 also had oil loss similar to the samples prepared with formula S1.
Additional examples of the plant-based cheese product were prepared. The example plant-based cheese products had the general formula S7, S8, S9, S10, S11, or S12 and were prepared with heating method T3, T4, T5, T6, or T7. The additive was used in the initial emulsion, except for the zein protein isolate, which was instead added at the beginning of the mixing process with the other dry ingredients. A 1 M citric acid solution was added as the acidulant to each example plant-based cheese product in an amount effective to keep the pH below 5.5.
The faba protein isolate was obtained from AGT Food & Ingredients. The milled faba protein was produced by ball milling the dry faba protein isolate for 72 hours at −20° C. Before milling, the particle size in the faba protein isolate ranged from 25 μm to 17 μm. After milling the particle size decreased to 10 μm to 90 μm.
The lupin protein isolate was obtained from ProLupin GmbH. The flax protein concentrate was obtained from Glanbia. The faba protein concentrate was obtained from Ingredion. The lecithin was Sunlec®25 (Perimondo LLC, Florida, New York, USA). Zein protein (food grade) from corn (FloZein Products, Ashburnham, Mass.) was used as the zein protein isolate.
The native waxy maize w was 100% Waxy Maize Starch obtained from MyProtein. The coconut oil was refined, organic, non-GMO coconut oil (Nutiva® Nurture Vitality™, Nutiva Inc., Richmond, Calif.).
Each of the formulas S7, S8, S9, S10, S11, and S12 is shown in Table 9, with the wt % of each ingredient that was used (based on the total weight of the plant-based cheese product).
The hardness, melt percentage, and oil loss of the example plant-based cheese products were measured. The results of the hardness measurements are shown in Table 10. The results of the melt percentage measurements are shown in Table 11. The results of the oil loss measurements are shown in Table 12. In each of Tables 10 through 12, each example plant-based cheese product is identified by the formula and the heating method used to prepare the example plant-based cheese product.
The samples prepared with formula S7 had some reductions in oil loss and reductions in the melt as compared to the samples prepared with formula S1.
The samples prepared with formula S8 and heating methods T5 and T6 resulted in a slight reduction of oil loss as compared to the samples prepared with formula S1 and heating methods T5 and T6.
The samples prepared with formula S9 and heating methods T3, T4, T6, and T7 had increased meltability as compared to the samples prepared with formula S1 and heating methods T3, T4, T6, and T7. The sample prepared with formula S9 and heating method T7 had slightly decreased hardness over the sample prepared with formula S1 and heating method T7. The samples prepared with formula S9 had similar oil loss to the samples prepared with formula S1.
The samples prepared with formula S10 had increased the meltability and increased the oil loss as compared to the samples prepared with formula S1. The samples prepared with formula S10 did not have a hardness similar to the hardness of the Cracker Barrel® Natural Cheddar.
The samples prepared with formula S11 had melt and oil loss similar to the melt and oil loss of the samples prepared with formula S1. The samples prepared with formula S11 also had decreased hardness as compared to the samples prepared with formula S1.
The samples prepared with formula S12 did not have a hardness similar to the hardness of the processed cheese or the Cracker Barrel® Natural Cheddar. The samples prepared with formula S12 also did not reduce the oil loss as compared to the samples prepared with formula S1.
Additional examples of the plant-based cheese product were prepared. The example plant-based cheese products had the general formula S13, S14, S15, S16, S17, S18, S19 or S20 and were prepared with heating method T3, T4, T5, T6, or T7. A 1 M citric acid solution was added as the acidulant to each example plant-based cheese product in an amount effective to keep the pH below 5.5.
The faba protein isolate was obtained from AGT Food & Ingredients. The native waxy maize was 100% Waxy Maize Starch obtained from MyProtein.
The sunflower oil was Selection™ sunflower oil (Imported for Metro Brands, Montreal (Quebec), Toronto (Ontario)). The coconut oil was refined, organic, non-GMO coconut oil (Nutiva® Nurture Vitality™, Nutiva Inc., Richmond, Calif.). The cocoa butter was refined and bleached cocoa butter (JB Cocoa Sdn. Bhd. (Johor, Malaysia)). The shea stearin and the shea olein were each obtained from AAK® (Malmo, Sweden).
The cotton seed glycerolysis product was produced from a reaction in which cottonseed oil in combination with glycerol undergoes a chemical reaction to produce a product that is high in monoglycerides (MGs) and diglycerides (DGs). The cotton seed glycerolysis product was obtained from the University of Guelph (Ontario, Canada).
Each of the formulas S13, S14, S15, S16, S17, S18, S19 and S20 is shown in Table 13, with the wt % of each ingredient that was used (based on the total weight of the plant-based cheese product).
The hardness, melt percentage, and oil loss of the example plant-based cheese products were measured. The results of the hardness measurements are shown in Table 14. The results of the melt percentage measurements are shown in Table 15. The results of the oil loss measurements are shown in Table 16. In each of Tables 14 through 16, each example plant-based cheese product is identified by the formula and the heating method used to prepare the example plant-based cheese product.
The samples prepared with formula S13 were able to achieve a similar hardness to processed cheese when the T6 heating method was used. The samples prepared with formula S13 also had less melt and reduced oil loss as compared to the samples prepared with formula S1. This is likely due to the samples being incredibly soft, and paste like allowing for better oil-binding.
The samples prepared with formula S14 were able to achieve a similar hardness to processed cheese when the T6 heating method was used. The samples prepared with formula S14 also had less melt than the samples prepared with formula S1 and experienced oil loss.
The samples prepared with formula S15 had reduced fat and increased water. The samples prepared with formula S15 were able to achieve a similar hardness to processed cheese when the T7 heating method was used. The samples prepared with formula S15 also had less melt than the samples prepared with formula S1 and experienced oil loss.
The samples prepared with formula S16 had reduced fat and increased plant-based protein and waxy starch. The samples prepared with formula S16 had similar hardness and melt to the samples prepared with formula S1. The samples prepared with formula S16 also had some reductions in oil loss as compared to the samples prepared with formula S1, likely due to a lower amount of oil being present in the formulation.
The samples prepared with formula S17 had a hardness and meltability similar to the samples prepared with formula S1. The samples prepared with formula S17 also experienced slightly less oil loss than the samples prepared with formula S1. This may be due to the different crystallization of the cocoa butter, or because it tends to be a more viscous oil, which could have slightly changed how it was structured in the sample.
The samples prepared with formula S18 had decreased hardness as compared to the samples prepared with formula S1. The samples prepared with formula S18 also had good meltability, but a large amount of oil loss.
The samples prepared with formula S19 had decreased hardness as compared to the samples prepared with formula S1. The samples prepared with formula S19 also had good meltability, but a large amount of oil loss. The visual appeal of the samples was very similar to what is desired in the appearance of processed cheese.
The samples prepared with formula S20 had low hardness. The samples prepared with formula S20 were able to melt and exhibited only a small amount of oil loss.
Additional examples of the plant-based cheese product were prepared. The example plant-based cheese products had the general formula S21, S22, S23, S24, S25, S26, or S27 and were prepared with heating method T3, T4, T5, T6, or T7. A 1 M citric acid solution was added as the acidulant to each example plant-based cheese product in an amount effective to keep the pH below 5.5.
In some of the example plant-based cheese products, ethyl cellulose (EC) was used to make an oleogel to use as the fat. To make the EC oleogels, the oil (e.g., coconut oil) and EC powder were heated to about 140° C., which is above the glass transition temperature of EC to allow the polymer to form an open conformation and create a network that physically entraps the liquid oil phase. The sample was heated at 140° C. until no visible EC particles remains (approximately 20 minutes). The ethyl cellulose (EC) used was 45 cp ETHOCEL™ Standard 45 (The Dow Chemical Company, Mich., USA).
In some of the example plant-based cheese products, a wax (beeswax or candelilla wax) was used to structure the oil, which was then used as the fat. The beeswax was Yellow Beeswax NF PAC (KOSTER KEUNEN®, Watertown, Conn., USA). The candelilla wax was Candelilla Wax NF (KOSTER KEUNEN®, Watertown, Conn., USA).
The faba protein isolate was obtained from AGT Food & Ingredients. The native waxy maize was Waxy No 1 obtained from Tate & Lyle. The coconut oil was refined, organic, non-GMO coconut oil (Nutiva® Nurture Vitality™, Nutiva Inc., Richmond, Calif.). The shea stearin was obtained from AAK® (Malmo, Sweden).
Each of the formulas S21, S22, S23, S24, S25, S26, and S27 is shown in Table 17, with the wt % of each ingredient that was used (based on the total weight of the plant-based cheese product). The amount of the EC or wax indicated was based on the total weight of the fat.
The hardness, melt percentage, and oil loss of the example plant-based cheese products were measured. The results of the hardness measurements are shown in Table 18. The results of the melt percentage measurements are shown in Table 19. The results of the oil loss measurements are shown in Table 20. In each of Tables 18 through 20, each example plant-based cheese product is identified by the formula and the heating method used to prepare the example plant-based cheese product.
In the samples prepared with formulas S21 through S24, different concentrations of EC in coconut oil were explored and used as oleogels in the samples. The samples prepared with formulas S21 through S24 were able to reach hardness levels similar to that of processed cheese, but only the samples prepared with formulas S22 (1% EC in coconut oil) and S23 (0.5% EC in coconut oil) reached hardness values close to that of the Cracker Barrel® Natural Cheddar. The meltability for all the samples prepared with formulas S21 through S24 also had slight decreases as compared to the samples prepared with formula S1. However, the samples with hardness values similar to the processed cheese, had good meltability relative to the meltability of the samples prepared with formula S1. For the samples prepared with formulas S21 (2% EC in coconut oil) and S24 (0.1% EC in coconut oil) and had no oil loss observed. For the samples prepared with formulas S22 (1% EC in coconut oil) and S23 (0.5% EC in coconut oil) there was little to no oil loss, with only small amounts observed for the samples with greater hardness values.
The samples prepared with formula S25 achieved hardness values that were similar to that of the processed cheese, but it did not get hard enough to be similar to the natural cheese. The samples prepared with formula S25 did have good meltability, and the addition of EC to the formula prevented oil loss.
The samples prepared with formulas S26 and S27 had similar hardness ranges and reached the levels of both the processed cheese and natural cheese. The samples prepared with formulas S26 and S27 also had good meltability, with the samples prepared with formula S27 (2% candelilla wax in coconut oil) having melt values similar to or exceeding the melt values of the samples prepared with formula S1. The oil loss, however, was different between the samples prepared with formula S26 and the samples prepared with formula S27. The samples prepared with formula S26 (2% beeswax in coconut oil) experienced oil loss, though it was less than the oil loss of the samples prepared with formula Si. The samples prepared with formula S27 (2% candelilla wax in coconut oil) experience less oil loss. In particular, samples prepared with formula S27 and heating methods T3 through T5 had no oil loss, and samples prepared with formula S27 and heating methods T6 and T7 had only small amounts of oil loss. It was found that the addition of waxes could modulate the oil loss in the samples.
Overall, it was found that structuring the oil using waxes and gelators (e.g. EC) can modulate the oil loss while keeping good meltability and hardness.
The hardness, melt percentage, and oil loss of commercial plant-based cheeses were also measured. The commercial plant-based cheeses were “mild cheddar analogues” from Earth Island® (NON-GMO Cheddar Style Slices, Cheese Alternative. Product of Greece. Manufactured for Earth Island®, Chatsworth, Calif.), Daiya® (Daiya® Cheddar flavour slices (DAIYA FOODS INC., Burnaby, BC)), Sheese® (Sheese® Vegan, Mature Cheddar style Slices, Non-dairy Simulated Cheese Product. KLBD Pareve. Made By: Rothesay Isle of Bute, Scotland, U.K.), and VioLife® (Violife® Cheddar Style Slices alternative to cheese. Produced in Greece By: ARIVIA S.A. Block 31 Industrial Area of Sindos, Thessaloniki, Greece.). The results of these measurements are shown in Table 21.
The hardness values of all of the commercial plant-based cheeses, except for the Daiya® plant-based cheese, were significantly greater than both the dairy-based processed cheese and the Cracker Barrel® Natural Cheddar. The meltability of all of the commercial plant-based cheeses was also significantly lower than the processed cheese, the Cracker Barrel® Natural Cheddar, and the samples prepared with formula Si. There was no oil loss observed in any of the commercial plant-based cheeses, which was similar to the oil loss of the processed cheese but not the Cracker Barrel® Natural Cheddar.
Overall, the samples prepared with formulas S22, S23 S26, and S27 (Example 5) better matched the hardness values of the processed cheese and the Cracker Barrel® Natural Cheddar than the commercial plant-based cheeses, while having superior meltability and no oil loss.
Rheometer temperature sweeps were performed for the Kraft® Single (a processed cheese), the Cracker Barrel® Natural Cheddar, the example plant-based cheese products prepared with formulas S1, S22, S26, and S27 and heating methods T3 through T7, and the commercial plant-based cheeses from Comparative Example 6 (i.e., the mild cheddar analogues from Earth Island®, Daiya®, Sheese®, and VioLife®). The temperature sweep from 5° C. to 80° C. was used to understand the melting profile of the samples. The G′ indicated the solid behavior of the system, while the G″ indicated the viscous portion.
The melting curves produced from the rheometer temperature sweeps of the Kraft® Single (a processed cheese), the example plant-based cheese product prepared with formula S1 and heating method T4, and the example plant-based cheese product prepared with formula S22 and heating method T4 are shown in
As shown in
As also shown in
The melting curves produced from the rheometer temperature sweeps of the Cracker Barrel® Natural Cheddar, the example plant-based cheese product prepared with formula S1 and heating method T7, and the example plant-based cheese product prepared with formula S22 and heating method T7 are shown in
As shown in
As also shown in
The melting curves produced from the rheometer temperature sweeps of the commercial plant-based cheeses from Comparative Example 6 (i.e., the mild cheddar analogues from Earth Island®, Daiya®, Sheese®, and VioLife®) are shown in
The melting curves produced from the rheometer temperature sweeps of the mild cheddar analogues from Earth Island® (from Comparative Example 6) and the example plant-based cheese products prepared with formulas S1 and S22 and the heating methods T4 and T7 are shown in
As shown in
However, it was observed that the G′ and G″ of the example plant-based cheese products were closer in value to each other than the G′ and G″ of commercial plant-based cheeses. In particular, at higher temperatures (e.g., 80° C.), the G′ and G″ of the example plant-based cheese products were significantly closer in value to each other than the G′ and G″ of commercial plant-based cheeses. These results indicate that the example plant-based cheese products prepared with formulas S1 and S22 and the heating methods T4 and T7 underwent greater changes in structure during heating and had more viscous behavior when heated than the commercial plant-based cheeses.
The Tan δ values were determined for the Kraft® Single (a processed cheese), the Cracker Barrel® Natural Cheddar, the example plant-based cheese product prepared with formulas S1, S22, S26, and S27 and heating methods T3 through T7, and the commercial plant-based cheeses from Comparative Example 6 (i.e., the mild cheddar analogues from Earth Island®, Daiya®, Sheese®, and VioLife®). Tan δ is the ratio of G″ to G′. Therefore, the G″ and G′ are normalized against each other which removes variability among replicates and allows for a better understanding of the melting profile. As Tan δ moves toward a value of 1, the sample becomes increasingly viscous and has better melting properties.
The Tan δ values as function of temperature (in ° C.) for the Kraft® Single (a processed cheese), the example plant-based cheese product prepared with formula S1 and heating method T4, the example plant-based cheese product prepared with formula S22 and heating method T4, and the commercial plant-based cheeses from Comparative Example 6 (i.e., the mild cheddar analogues from Earth Island®, Daiya®, Sheese®, and VioLife®) are shown in
As shown in
The trend of the Tan δ values of the example plant-based cheese products prepared with formulas S1 and S22 and heating method T4 was more similar to the Kraft® Single than the commercial plant-based cheeses. As shown in
At 80° C., each of the samples reached their maximum melt or softening. The Tan δ at 80° C. for the example plant-based cheese products prepared with formulas S1, S22, S26, and S27 and heating methods T3 through T7 are shown in Table 22. In Table 22, each example plant-based cheese product is identified by the formula and the heating method used to prepare the example plant-based cheese product. The Tan δ at 80° C. for the Kraft® Single (a processed cheese), the Cracker Barrel® Natural Cheddar, and the commercial plant-based cheeses from Comparative Example 6 (i.e., the mild cheddar analogues from Earth Island®, Daiya®, Sheese®, and VioLife®) are shown in Table 23.
The Tan δ at 80° C. for the Kraft® Single, the example plant-based cheese product prepared with formula S1 and heating method T4, the example plant-based cheese product prepared with formula S22 and heating method T4, the example plant-based cheese product prepared with formula S26 and heating method T4, and the example plant-based cheese product prepared with formula S27 and heating method T5 are also shown in
As shown in
The Tan δ at 80° C. for the Cracker Barrel® Natural Cheddar, the example plant-based cheese product prepared with formula S1 and heating method T7, the example plant-based cheese product prepared with formula S22 and heating method T7, the example plant-based cheese product prepared with formula S26 and heating method T7, and the example plant-based cheese product prepared with formula S27 and heating method T7 are also shown in
As shown in
The Tan δ at 80° C. for the Kraft® Single, the example plant-based cheese product prepared with formula S1 and heating method T4, the example plant-based cheese product prepared with formula S22 and heating method T4, and the commercial plant-based cheeses from Comparative Example 6 (i.e., the mild cheddar analogues from Earth Island®, Daiya®, Sheese®, and VioLife®) are also shown in
As shown in
The Tan δ at 80° C. for the Cracker Barrel® Natural Cheddar, the example plant-based cheese product prepared with formula S1 and heating method T7, the example plant-based cheese product prepared with formula S22 and heating method T7, and the commercial plant-based cheeses from Comparative Example 6 (i.e., the mild cheddar analogues from Earth Island®, Daiya®, Sheese®, and VioLife®) are also shown in
As shown in
Overall, the comparison of the Tan δ values clearly demonstrated the superior meltability of the example plant-based cheese products over all of the commercial plant-based cheeses. The maximum Tan δ value at 80° C. reached for the commercial plant-based cheeses was 0.18. The minimum Tan δ value at 80° C. reached for an example plant-based cheese product tested was 0.43.
Axial pulls were performed to measure the stretch of the Kraft® Single (a processed cheese), the Cracker Barrel® Natural Cheddar, the example plant-based cheese products prepared with formulas S1, S22, S26, and S27 and heating methods T3 through T7 and the commercial plant-based cheeses from Comparative Example 6 (i.e., the mild cheddar analogues from Earth Island®, Daiya®, Sheese®, and VioLife®).
The stretch measurements of the example plant-based cheese products prepared with formulas S1, S22, S26, and S27 and heating methods T3 through T7 are shown in Table 24. In Table 24, each example plant-based cheese product is identified by the formula and the heating method used to prepare the example plant-based cheese product. The stretch measurements of the Kraft® Single (a processed cheese), the Cracker Barrel® Natural Cheddar, and the commercial plant-based cheeses from Comparative Example 6 (i.e., the mild cheddar analogues from Earth Island®, Daiya®, Sheese®, and VioLife®) are shown in Table 25.
As shown in Table 24, the stretchability of all the example plant-based cheese products were very similar. This result indicates that the addition of EC and wax did not affect the stretchability of the example plant-based cheese products (as compared to the stretchability of example plant-based cheese products prepared with formula S1). This indicates that oil loss can be managed without deleteriously affecting the stretch of the example plant-based cheese product. Additionally, there was very little change in stretch across the T3 through T7 samples with the same formula. This indicates that the sample hardness does not affect the extensibility of the example plant-based cheese product.
The stretch measurements of the Kraft® Single, the example plant-based cheese product prepared with formula S1 and heating method T4, the example plant-based cheese product prepared with formula S22 and heating method T4, the example plant-based cheese product prepared with formula S26 and heating method T4, and the example plant-based cheese product prepared with formula S27 and heating method T5 are also shown in
As shown in
The stretch measurements of the Cracker Barrel® Natural Cheddar, the example plant-based cheese product prepared with formula S1 and heating method T7, the example plant-based cheese product prepared with formula S22 and heating method T7, the example plant-based cheese product prepared with formula S26 and heating method T7, and the example plant-based cheese product prepared with formula S27 and heating method T7 are also shown in
As shown in
The stretch measurements of the Kraft® Single, the example plant-based cheese product prepared with formula S1 and heating method T4, the example plant-based cheese product prepared with formula S22 and heating method T4, and the commercial plant-based cheeses from Comparative Example 6 (i.e., the mild cheddar analogues from Earth Island®, Daiya®, Sheese®, and VioLife®) are also shown in
As shown in
The stretch measurements of the Cracker Barrel® Natural Cheddar, the example plant-based cheese product prepared with formula S1 and heating method T7, the example plant-based cheese product prepared with formula S22 and heating method T7, and the commercial plant-based cheeses from Comparative Example 6 (i.e., the mild cheddar analogues from Earth Island®, Daiya®, Sheese®, and VioLife®) are also shown in
As shown in
The ability of the example plant-based cheese products to have significantly greater stretch than all of the commercial plant-based cheeses at both the 16 N to 24 N hardness range and the 76 N to 90 N hardness range is momentous. These results further demonstrate that the example plant-based cheese products can outperform the commercial plant-based cheeses.
Overall, the Examples demonstrate the successful creation of high protein plant-based cheese products using clean label ingredients. The method used to create the plant-based cheese products enabled a range of hardness values that could be similar to either a Kraft® Single or Cracker Barrel® Natural Cheddar.
It was determined that the oil modulation can be achieved using ethyl cellulose to create an oleogel as the fat component or by incorporating bee or Candelilla wax into the oil as the fat component. The oil modulators proved to have no impact on the sample hardness range but did slightly decrease the spread of the sample during melting. The rheological investigation however showed that the melting profile of the plant-based cheese products was not impacted by the oil modulators.
The Tan δ of the systems provided the best comparison of the meltability. The Tan δ of all of the investigated example plant-based cheese products had greater Tan δ values than all of the commercial plant-based cheeses. It was also discovered that all of the example plant-based cheese products with different hardness had similar Tan δ values, indicating that sample hardness does not impact the meltability.
The stretch of the example plant-based cheese products was also investigated and similar trends occurred. The sample hardness and oil modulators did not affect the sample extensibility. The stretch of the example plant-based cheese products was statistically similar to the stretch of the Kraft® Single. The example plant-based cheese products also had significantly greater stretch than all of the commercial plant-based cheeses.
It was found that the example plant-based cheese products can not only outperform the commercial plant-based cheeses but can also be modulated to have hardness equal to that of the Kraft® Single with good meltability, no oil loss and equal stretch.
A plant-based cheese product comprising: a plant-based protein present in an amount within the range of about 10 wt % to about 25 wt % crude protein, based on a total weight of the plant-based cheese product; a waxy starch comprising at least 70 wt % amylopectin, based on a total weight of the waxy starch, wherein the waxy starch is at least partially gelatinized; and a fat.
The plant-based cheese product, further comprising an acidulant in an amount effective to provide a pH of the plant-based cheese product of about 4.5 to about 5.5.
The plant-based cheese product, wherein the acidulant comprises one or more of citric acid, malic acid, acetic acid, phosphoric acid, sorbic acid, and lactic acid.
The plant-based cheese product, further comprising a wax having a melting point less than 80° C.
The plant-based cheese product, wherein the wax comprises one or more of orange wax, rice bran wax, sunflower wax, beeswax, and candelilla wax.
The plant-based cheese product, wherein the wax comprises candelilla wax.
The plant-based cheese product, wherein the wax is present in an amount within the range of about 0.5 wt % to about 5 wt %, based on the total weight of the fat.
The plant-based cheese product, further comprising ethyl cellulose.
The plant-based cheese product, wherein the ethyl cellulose is present in an amount within the range of about 0.1 wt % to about 2 wt %, based on the total weight of the fat.
The plant-based cheese product, wherein the plant-based protein is present in an amount of about 14 wt % to about 20 wt % crude protein, based on a total weight of the plant-based cheese product.
The plant-based cheese product, wherein the plant-based protein comprises one or more of faba protein, chickpea protein, mungbean protein, soy protein, zein protein, lupin protein, canola protein, pea protein, lentil protein and flax protein.
The plant-based cheese product, wherein the plant-based protein comprises faba protein.
The plant-based cheese product, wherein the waxy starch is present in an amount within the range of about 5 wt % to about 20 wt %, based on the total weight of the plant-based cheese product.
The plant-based cheese product, wherein the waxy starch is present in an amount within the range of about 12 wt % to about 16 wt %, based on the total weight of the plant-based cheese product.
The plant-based cheese product, wherein the waxy starch comprises native waxy maize.
The plant-based cheese product, wherein the fat is present in an amount within the range of about 15 wt % to about 30 wt %, based on the total weight of the plant-based cheese product.
The plant-based cheese product, wherein the fat is present in an amount within the range of about 19 wt % to about 27 wt %, based on the total weight of the plant-based cheese product.
The plant-based cheese product, wherein the fat is present in an amount of about 20 to about 25 wt %, based on the total weight of the plant-based cheese product.
The plant-based cheese product, wherein the fat comprises one or more of coconut oil, shea oil, shea stearin, shea olein, shea butter, palm oil, palm oil fraction, sunflower oil, cocoa butter and cottonseed glycerolysis.
The plant-based cheese product, wherein the fat comprises coconut oil.
The plant-based cheese product, wherein the plant-based cheese product has a hardness within the range of about 19 N to about 21 N, when compressing the plant-based cheese product by 50%.
The plant-based cheese product, wherein the plant-based cheese product has a hardness within the range of about 76 N to about 90 N, when compressing the plant-based cheese product by 50%.
The plant-based cheese product, wherein the plant-based cheese product has a melt percentage within the range of about 65% to about 185%.
The plant-based cheese product, wherein the plant-based cheese product has a melt percentage within the range of about 80% to about 185%.
The plant-based cheese product, wherein the plant-based cheese product has a melt percentage of about 98% to about 185%.
The plant-based cheese product, wherein the plant-based cheese product has a melt percentage of about 110% to about 185%.
The plant-based cheese product, wherein the plant-based cheese product has a melt percentage within the range of about 65% to about 155%.
The plant-based cheese product, wherein the plant-based cheese product has a melt percentage within the range of about 80% to about 155%.
The plant-based cheese product, wherein the plant-based cheese product has a melt percentage of about 98% to about 155%.
The plant-based cheese product, wherein the plant-based cheese product has a melt percentage of about 110% to about 155%.
The plant-based cheese product, wherein the plant-based cheese product has an oil loss of 6 or less.
The plant-based cheese product, wherein the plant-based cheese product has an oil loss of 4 or less.
The plant-based cheese product, wherein the plant-based cheese product has an oil loss of 2 or less.
The plant-based cheese product, wherein the plant-based cheese product has an oil loss of 1 or less.
The plant-based cheese product, wherein the plant-based cheese product has an oil loss of 0.
The plant-based cheese product, wherein the plant-based cheese product has a Tan δ value greater than 0.2 at 80° C.
The plant-based cheese product, wherein the plant-based cheese product has a Tan δ value greater than 0.4 at 80° C.
The plant-based cheese product, wherein the plant-based cheese product has a Tan δ value greater than 0.6 at 80° C.
The plant-based cheese product, wherein the plant-based cheese product has a stretch of at least 20 mm at 80° C.
The plant-based cheese product, wherein the plant-based cheese product has a stretch of at least 25 mm at 80° C.
The plant-based cheese product, wherein the plant-based cheese product has a stretch of at least 30 mm at 80° C.
The plant-based cheese product, wherein the plant-based cheese product has a stretch of at least 35 mm at 80° C.
The plant-based cheese product, wherein the waxy starch comprises one or more of a tapioca starch and a casava starch.
The plant-based cheese product, wherein the fat comprises coconut oil and sunflower oil.
A method of making a plant-based cheese product, comprising: dissolving a first amount of a plant-based protein in an aqueous liquid to form a plant-based protein solution or suspension; heating a fat to form a melted fat; emulsifying the plant-based protein solution or suspension with the melted fat to form an emulsion; adding a second amount of the plant-based protein and a waxy starch to the emulsion and mixing to form a mixture; heating and mixing the mixture for a time effective to at least partially gelatinize the waxy starch to form a heated mixture; and cooling the heated mixture to form the plant-based cheese product; wherein the plant-based cheese product comprises about 10 wt % to about 25 wt % crude protein, based on a total weight of the plant-based cheese product; and wherein the waxy starch comprises at least 70 wt % amylopectin, based on a total weight of the waxy starch.
The method, further comprising adding an acidulant to the emulsion or the mixture.
The method, wherein the acidulant is added in an amount effective to provide a pH within the range of about 4.5 to about 5.5 in the plant-based cheese product.
The method, further comprising adding a wax having a melting point less than 80° C. to the fat.
The method, further comprising adding ethyl cellulose to the fat.
The method, further comprising forming an oleogel from the ethyl cellulose and the fat.
The method, further comprising filling the heated mixture into a container prior to the cooling step.
The method, wherein the plant-based protein solution or suspension comprises from about 2% w/v to about 8% w/v of the plant-based protein.
The method, wherein the plant-based protein solution or suspension comprises from about 4% w/v to about 6% w/v of the plant-based protein.
The method, wherein the heating of the fat is to a temperature within the range of about 35° C. to about 60° C.
The method, wherein the acidulant comprises one or more of citric acid, malic acid, acetic acid, phosphoric acid, sorbic acid, and lactic acid.
The method, wherein the wax comprises one or more of orange wax, rice bran wax, sunflower wax, beeswax, and candelilla wax.
The method, wherein the wax comprises candelilla wax.
The method, wherein the plant-based protein comprises faba protein.
The method, wherein the waxy starch comprises native waxy maize.
The method, wherein the fat comprises coconut oil.
The method, wherein the waxy starch comprises one or more of a tapioca starch and a casava starch.
The method, wherein the fat comprises coconut oil and sunflower oil.
It is to be understood that the ranges provided herein include the stated range and any value or sub-range within the stated range. For example, a range of about 10 wt % to about 25 wt % should be interpreted to include not only the explicitly recited limits of range of about 10 wt % to about 25 wt %, but also to include individual values, such as 12.35 wt %, 15.5 wt %, 18 wt %, 20.75 wt %, 23 wt %, etc., and sub-ranges, such as about 11 wt % to about 15.5 wt %, about 13.5 wt % to about 22.7 wt %, about 16.75 wt % to about 24 wt %, etc. Furthermore, when “about” is utilized to describe a value, this is meant to encompass minor variations (up to +/−10%) from the stated value.
All percentages and ratios are calculated by weight unless otherwise indicated. All percentages and ratios are calculated based on the total weight of the compound or composition unless otherwise indicated.
Reference throughout the specification to “an example,” “one example,” “another example,” “some examples,” “other examples,” and so forth, means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the example is included in at least one example described herein, and may or may not be present in other examples. In addition, it is to be understood that the described elements for any example may be combined in any suitable manner in the various examples unless the context clearly dictates otherwise.
In describing and claiming the examples disclosed herein, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.
While several examples have been described in detail, it is to be understood that the disclosed examples may be modified. Therefore, the foregoing description is to be considered non-limiting.
This application claims the benefit of U.S. Provisional Application No. 63/253,456, filed on Oct. 7, 2021.
| Number | Date | Country | |
|---|---|---|---|
| 63253456 | Oct 2021 | US |
