AU2021273665A1

AU2021273665A1 - Production of heat stable plant chicken meat analogous without added flavouring materials

Info

Publication number: AU2021273665A1
Application number: AU2021273665A
Authority: AU
Inventors: Gaurav Sharma; Reena Sharma
Original assignee: Shandi Global Pty Ltd
Current assignee: Shandi Global Pty Ltd
Priority date: 2020-11-27
Filing date: 2021-11-27
Publication date: 2022-06-16

Abstract

PRODUCTION OF HEAT STABLE PLANT CHICKEN MEAT ANALOGOUS WITHOUT ADDED FLAVOURING MATERIALS The present invention provides methods of production of heat stable plant chicken meat analogous without added flavouring materials.

Description

PRODUCTION OF HEAT STABLE PLANT CHICKEN MEAT ANALOGOUS WITHOUT ADDED FLAVOURING MATERIALS

Technical Field

[1] The present invention generally relates to methods of producing a meat substitute and in particular to methods of production of heat stable plant chicken meat analogous without added flavouring materials.

Background

[2] Animal farming has a profound negative environmental impact. Currently, it is estimated that 30% of earth's land surface is dedicated to animal farming and that livestock account for % of total terrestrial animal biomass. Due to this massive scale, animal farming accounts for more than 18% of net greenhouse gas emissions. Animal farming may be the largest human source of water pollution, and animal farming is by far the world's largest threat to biodiversity. It has been estimated that if the world's human population could shift from a meat containing diet to a diet free of animal products, 26% of Earth's land surface would be freed for other uses. Moreover, the consumption of meat also has a profound negative impact on human health. Various types of diseases are well known to be transmitted to humans from animals.

[3] Further, hunger is a worldwide problem, yet the world's 4 major commodity crops (soybeans, maize, wheat, and rice) already supply more than 100% of the human population's requirements for calories and protein, including every essential amino acid.

[4] The health benefits of a vegetarian diet are well established. If the human population would shift to a more vegetarian diet, there would be a decrease in health care costs. Further, the shift to a vegetarian diet would massively reduce water and energy consumption which makes it more sustainable in comparison to raising animals for meat. Therefore, plant based meat substitutes seem to be a sustainable source of proteins and could be palatable to a large group of people.

[5] The traditional production of meat substitutes consists mainly of two stages: the preparation of the emulsion and the formation of a shredded mass. Emulsions are typically prepared by mixing protein, salt, fat and other ingredients, chopping and emulsifying to form a protein substrate that encapsulates the fat and insoluble ingredients. The emulsion is then heated under pressure directed in a specific direction. This pressure helps to align and direct the protein chains and form a three-dimensional network. This heat denatures the protein and irreversibly cures the substrate, thus maintaining the final chopped product in its shape.

[6] Conventional emulsion preparation is disadvantageous in that it involves many processing steps, requires considerable equipment, and usually requires a large labor force. Their processing steps exfoliate and break frozen meat, grind meat and additional red meat and / or fat, mix dry powder ingredients, mix these dry ingredients with moist ingredients and warm. Some of the equipment needed for this processing method is a freezer, grinder, mixer, pump, and refrigeration truck.

[7] Another limitation in conventional methods for producing meat substitutes from meat emulsions is due to unevenness in the composition of the frozen blocks of raw ingredients, mainly beef, chicken, and other by-products of the meat industry, Unevenness occurs in the repeated composition.

[8] Many meat substitute recipes include sulfate in the form of elemental sulfur, potassium sulfide and sodium sulfide. This sulfate improves the texture of the shredded mass because it enables cross-protein cross-linking through the formation of intermolecular disulfide bonds. On the other hand, the sulfate compound to produce a real-looking meat mass are offset by the negative impact on the taste and aroma of the meat substitute.

[9] Further, a traditional method of preparing a textured protein product comprising preparing an alkaline slurry of a protein source and precipitating the product by changing the pH and temperature of the slurry. However, although this method provides a product having a flesh-like texture, this method does not provide a product that has a real meat-like appearance that includes separably arranged fibers of a plurality of filaments.

[10] The traditional way for preparation of a meat emulsion product containing real fiber, produces a meat emulsion containing fine fat particles coated with protein dissolved from meat ingredients. However, such methods are labor intensive and can vary in the final product depending on the nature of the raw meat that can be used.

[11] The preparation of a fermented food product is having a sponge-like internal texture by forming a fermented and gelled mixture. However, this processing method does not produce a food product with a real meaty appearance that contains fibers that are separably arranged in a plurality of filaments; rather, the product produced has a "skin-like" character. A solid chopped mass with a surface texture comprising.

[12]Plant based meat substitutes have largely failed to cause a shift to a vegetarian diet. The current state of the art for meat substitute compositions involves the extrusion of soy/grain mixture, resulting in products which largely fail to replicate the experience of cooking and eating meat. Common limitations of these products are a texture and mouthfeel that are more

homogenous than that of equivalent meat products. Further, as the products must largely be sold pre-cooked, with artificial flavors and aromas built in, they fail to replicate aromas, flavors, and other key features associated with cooking meat. As a result, these products appeal mainly to a limited consumer base that is already committed to vegetarianism/veganism but have failed to appeal to the larger consumer segment accustomed to eating meat.

[13]Accordingly, there is a need in the art to develop methods for production of heat stable plant chicken meat analogous without added flavouring materials.

Summary

[14]According to a first embodiment of the present invention, there is provided a method of obtaining a plant-based chicken in a spongy fibrous gel texture with a high protein content and a high fiber content. The method of obtaining a plant based chicken comprising the steps of, mixing at least one protein component and at least on fibrous component to obtain at least a substantially homogeneous particulate pre-mixed mixture in a powder form, mixing the pre mixed particulate mixture with water at a temperature below the denaturation temperature of

the protein component for at least substantially uniform hydration of the at least one protein component and the at least one fibrous component and obtaining a substantially homogeneous hydrated mass from the at least one protein component and the at least one fibrous component and a steam and vacuum treatment of the hydrated mass at a temperature

above the temperature of denaturation of the protein component. Further, the method comprises the steps of, dividing hydrated mass into at least two parts, wherein isolating a first hydrated mass by at least one cysteine and specific amino acid, adding at least one plant lipid component and at least one dextrose component into the first isolated hydrated mass and centrifugation and filter reaction treatment of the first isolated hydrated mass to produce at least one chicken boiled flavour or at least one chicken roasted flavour, isolating a second hydrated mass using column to remove at least one carbohydrate component, adding at least one concentrate mixed bean protein component, at least one agar component, at least one konjac component, at least one arabic component, at least one lycopene component, at least one mineral standardized extracts, at least one non glutinous wheat component, at least one barley fiber component and at least one dehydrated jack fruit into the second hydrated mass, hot air injection and concentration treatment for cooking the at least one chicken boiled flavour or the at least one chicken roasted flavour with the second hydrated mass to produce at least one spongy fibrous gel texture and molding the at least one spongy fibrous gel texture to form out a special shape.

[15]According to a second embodiment of the present invention, there is provided a method of obtaining a plant-based chicken in a fibrous cake texture with a high protein content and a high fiber content. The method of obtaining a plant based chicken comprises the steps of, mixing at least one protein component and at least on fibrous component to obtain at least a substantially homogeneous particulate pre-mixed mixture in a powder form, mixing the pre mixed particulate mixture with water at a temperature below the denaturation temperature of the protein component for at least substantially uniform hydration of the at least one protein component and the at least one fibrous component and obtaining a substantially homogeneous hydrated mass from the at least one protein component and the at least one fibrous component, and a steam and vacuum treatment of the hydrated mass at a temperature above the temperature of denaturation of the protein component. Further, the method comprises the steps of, dividing hydrated mass into at least two parts, wherein isolating a first hydrated mass by at least one cysteine and specific amino acid, adding at least one plant lipid component and at least one dextrose component into the first isolated hydrated mass, centrifugation and filter reaction treatment of the first isolated hydrated mass to produce at least one chicken boiled flavour or at least one chicken roasted flavour, isolating a second hydrated mass using column to remove at least one carbohydrate component, adding at least one concentrate mixed bean protein component, at least one agar component, at least one konjac component, at least one arabic component, at least one lycopene component, at least one mineral standardized extracts, at least one non glutinous wheat component, at least one moringa ex, at least one barley fiber component and at least one dehydrated jack fruit into the second hydrated mass, dehydration treatment for cooking the at least one chicken boiled flavour or the at least one chicken roasted flavour with the second hydrated mass to produce at least one fibrous cake texture and extruding the at least one fibrous cake texture to form out a special shape.

[16]In an aspect, the protein component and the fiber component are chosen from groups, consisting of dry green peas, chickpeas, yellow beans, vigna mungo, pigeon peas and kidney beans.

[17]In another aspect, the process for mixing water into the pre-mixed particulate includes adding the enzymes into the water, selected from the group, consisting of protease, lipase and amylase.

Brief Description of Drawings

[18]At least one example of the invention will be described with reference to the accompanying drawings, in which:

[19]Figure 1 illustrates a method of obtaining a plant-based chicken in a spongy fibrous gel texture with a high protein content and a high fiber content, in accordance with an embodiment of the present invention;

[20]Figures 2 illustrates a method of obtaining a plant-based chicken in a fibrous cake texture with a high protein content and a high fiber content, in accordance with an embodiment of the present invention; and

[21]It should be noted that the same numeral represents the same or similar elements throughout the drawings.

Description of Embodiments

[22] The present invention aims to provide a method of obtaining a plant-based chicken in different textures with a high protein content and a high fiber content. The fibrous components and protein components are mixed by a grinder to obtain a powder form. The water is added in the powder form mixture to obtain a hydrated mass. This hydrated mass is treated by a steam and vacuum to remove undesirable components. Further, the steamed hydrated mass is divided into two parts so that one hydrated mass will be used to create chicken boiled flavor or chicken roasted flavor without adding any chemical components and second hydrated mass will be isolated from unwanted components like carbohydrates and sugar etc. Then, the second hydrated mass with other required components are mixed with at least one flavor of chicken boiled or chicken roasted obtained from the first hydrated mass by a hot air injection and concentration treatment to produce a spongy fibrous gel texture. Additionally, the second hydrated mass with other required components are mixed with at least one flavor of chicken boiled or chicken roasted obtained from the first hydrated mass by dehydration treatment to produce a fibrous cake texture.

[23]In this regard the invention below has been discussed with the help of figures for clarity. However, a skilled addressee would appreciate that the invention is not limited to particular types of implementations that have been discussed below and may be equally applicable to many different implementations without departing from the scope of the present invention.

[24]Figure 1 illustrates a method of obtaining a plant-based chicken in a spongy fibrous gel texture with a high protein content and a high fiber content, in accordance with an embodiment of the present invention. The method comprises mixing the protein components and the fibrous components (100) to obtain a substantially homogeneous particulate pre mixed mixture in a powder form (105), mixing the pre-mixed particulate mixture with water at a temperature below the denaturation temperature of the protein component for a substantially uniform hydration of the protein components and the fibrous components (100) and obtaining a substantially homogeneous hydrated mass (110) from the protein components and the fibrous components (100), and a steam and vacuum treatment (115) of the hydrated mass at a temperature above the temperature of denaturation of the protein component. The protein components and the fiber components (100) may have selected from the groups, but are not limited to dry green peas, chickpeas, yellow beans, vigna mungo, pigeon peas and kidney beans.

[25] The process for mixing water (110) into the pre-mixed particulate may include adding the enzymes into the water, selected from the group, but are not limited to protease, lipase and amylase.

[26] The method further comprises dividing hydrated mass (120) into two parts, wherein isolating a first hydrated mass by cysteine and specific amino acids (125), adding plant lipid components and dextrose components (130) into the first isolated hydrated mass, centrifugation and filter reaction treatment of the first isolated hydrated mass (135) to produce a chicken boiled flavour or chicken roasted flavour, isolating a second hydrated mass using column (140) to remove carbohydrate components, adding desired components (145) into the second hydrated mass, hot air injection and concentration treatment (150) for cooking the chicken boiled flavour or chicken roasted flavour with the second hydrated mass to produce the spongy fibrous gel textures and molding (155) the spongy fibrous gel textures to form out a special shape. The added desired components (145) in a second isolated hydrated mass may have selected from groups but are not limited to mixed bean protein components, agar components, konjac components, arabic components, lycopene components, mineral standardized extracts, glutinous wheat components, barley fiber components and dehydrated jack fruits.

[27]Figures 2 illustrates a method of obtaining a plant-based chicken in a fibrous cake texture with a high protein content and a high fiber content, in accordance with an embodiment of the present invention. The method comprises mixing the protein components and the fibrous components (200) to obtain a substantially homogeneous particulate pre-mixed mixture (205) in a powder form, mixing the pre-mixed particulate mixture with water at a temperature below the denaturation temperature of the protein component for a substantially uniform hydration of the protein components and the fibrous components (200) and obtaining a substantially homogeneous hydrated mass (210) from the protein components and the fibrous components (200) and a steam and vacuum treatment (215) of the hydrated mass at a temperature above the temperature of denaturation of the protein component. The protein components and the fiber components (200) may have selected from the group, but are not limited to dry green peas, chickpeas, yellow beans, vigna mungo, pigeon peas and kidney beans. The process for mixing water (210) into the pre-mixed particulate may include adding the enzymes into the water, selected from the group, but are not limited to protease, lipase and amylase.

[28] The method further comprises dividing hydrated mass (220) into two parts, wherein isolating a first hydrated mass by cysteine and specific amino acids (225), adding plant lipid components and dextrose components (230) into the first isolated hydrated mass, centrifugation and filter reaction treatment (235) of the first isolated hydrated mass to produce a chicken boiled flavour or chicken roasted flavour, isolating (240) a second hydrated mass using column to remove carbohydrate components, adding desired components (245) into the second hydrated mass, dehydration treatment (250) for cooking the chicken boiled flavour or the chicken roasted flavour with the second hydrated mass to produce fibrous cake textures and extruding (255) the fibrous cake textures to form out a special shape. The added desired components (245) in a second isolated hydrated mass may have selected from groups but are not limited to mixed bean protein components, agar components, konjac components, arabic components, lycopene components, mineral standardized extracts, glutinous wheat components, barley fiber components and dehydrated jack fruits.

[29] The present invention offers a number of advantages. Firstly, it provides a cost effective and easy to implement solution to the existing problems. It is an advantage of the present invention that the process uses specific ratio of amino acids and blend it with specific reducing sugars and do partial maillard, so that while cooking, the meaty flavour is developed during process like real meat. Hence, the present invention does not require any artificial flavouring and also deliver ture meat feel. Additionally, the present invention uses specific ratio of multiple plant proteins sources and does controlled hydrolysis to provide high digestivity index up to 8+, which is better than natural chicken meat and close to dairy, while plant protein concentrates have very poor digestive Index around 5-6. Additionally, the present invention is the incubation of enzymes and food proteins to reduce the allergenicity of food proteins. Moreover, the present invention creates a bitter-free hydrolyzate from a proteinaceous substrate with an amino acid composition.

[30]Various modifications to these embodiments are apparent from the description to those skilled in the art. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments but is to be providing broadest scope consistent with the principles and the novel and inventive features disclosed and/or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention.

Claims

CLAIMS: The claims defining the invention are as follows:

1. A method of obtaining a plant-based chicken in a spongy fibrous gel texture with a high protein content and a high fiber content, comprising the steps:

mixing at least one protein component and at least on fibrous component to obtain at least a substantially homogeneous particulate pre-mixed mixture in a powder form;

mixing the pre-mixed particulate mixture with water at a temperature below a denaturation temperature of the protein component for at least substantially uniform hydration of the at least one protein component and the at least one fibrous component and obtaining a substantially homogeneous hydrated mass from the at least one protein component and the at least one fibrous component;

a steam and vacuum treatment of the hydrated mass at a temperature above the temperature of denaturation of the protein component;

dividing hydrated mass into at least two parts:

isolating a first hydrated mass by at least one cysteine and specific amino acid;

adding at least one plant lipid component and at least one dextrose component into the first isolated hydrated mass; and

centrifugation and filter reaction treatment of the first isolated hydrated mass to produce at least one chicken boiled flavour or at least one chicken roasted flavour;

isolating a second hydrated mass using column to remove at least one carbohydrate component;

adding at least one concentrate mixed bean protein component, at least one agar component, at least one konjac component, at least one arabic component, at least one lycopene component, at least one mineral standardized extracts, at least one non glutinous wheat component, at least one barley fiber component and at least one dehydrated jack fruit into the second hydrated mass; hot air injection and concentration treatment for cooking the at least one chicken boiled flavour or the at least one chicken roasted flavour with the second hydrated mass to produce the at least one spongy fibrous gel texture; and molding the at least one spongy fibrous gel texture to form out a special shape; wherein the at least one protein component and the at least one fiber component are chosen from groups, consisting of dry green peas, chick peas, yellow beans, a vigna mungo, pigeon peas and kidney beans; wherein the process for mixing water into the pre-mixed particulate includes adding enzymes into the water, selected from the group, consisting of a protease, a lipase and an amylase.

2. A method of obtaining a plant based chicken in a fibrous cake texture with a high protein content and a high fiber content, comprising the steps:

dividing hydrated mass into at least two parts:

adding at least one plant lipid component and at least one dextrose component into the first isolated hydrated mass; and centrifugation and filter reaction treatment of the first isolated hydrated mass to produce at least one chicken boiled flavour or at least one chicken roasted flavour; isolating a second hydrated mass using column to remove at least one carbohydrate component; adding at least one concentrate mixed bean protein component, at least one agar component, at least one konjac component, at least one arabic component, at least one lycopene component, at least one mineral standardized extracts, at least one non glutinous wheat component, at least one moringa ex, at least one barley fiber component and at least one dehydrated jack fruit into the second hydrated mass; dehydration treatment for cooking the at least one chicken boiled flavour or the at least one chicken roasted flavour with the second hydrated mass to produce at the least one fibrous cake texture; and extruding the at least one fibrous cake texture to form out a special; wherein the at least one protein component and the at least one fiber component are chosen from groups, consisting of dry green peas, chick peas, yellow beans, vigna mungo, pigeon peas and kidney beans; wherein the process for mixing water into the pre-mixed particulate includes adding enzymes into the water, selected from the groups, consisting of protease, lipase and amylase.