CA1038225A - Juicy sausage analog and process - Google Patents

Abstract

ABSTRACT OF THE INVENTION
Disclosed are a juicy sausage analog and its method of preparation. The sausage analog of the present invention has at least three distinct phases: a continuous gel phase, a sub-stantially discontinuous fat phase, and a discontinuous chewy proteinaceous phase. According to the process, solidified fat particles, particles of a chewy proteinaceous component, and a precursor of the continuous gel phase are mixed and coarsely chopped to obtain a substantially uniformly heterogeneous distri-bution of the particulate material within the continuous gel phase precursor. The resulting coarsely chopped blend is formed into a substantially cohesive sausage analog by coagulating the contin-uous gel phase precursor.

Description

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The present invention relates to a juicy sausage analog and a method for preparing the same; more particularly, the present invention relates to a juicy sausage analog prepared primarily from vegetable protein sources but having a heterogeneous, meat-like texture similar to that of pork sausage, and a method for preparing the same.
In recent years, considerable research has focused upon developing new technology for producing meat-like, protein-containing foods from various vegetable and animal protein sources.
Economics provides a major incentive. It would clearly be advantageous to substitute the more efficient process of growing vegetable protein for the rather inefficient process by which animals convert the proteinaceous vegetable materials into meat.
This is especially true where the ever-increasing human popula-tion is feared to be out distancing our ability to provide grazing land for meat-producing animals. Moreover, recent efforts have also been directed to avoiding certain natural products which may be undesirable from religious, ethnic or health reasons.
Boyer, in U.S. Patent 2,682,466, discloses the forma-tion of synthetic meat products containing quantities of vegetable -protein filaments. These protein filaments are made by forcing a colloidal protein dispersion through a porous membrane, such as ;~
a spinnerette, into a coagulating bath causing precipitation in filament form. The filaments are assembled into a meat-like product by employing binding materials, including cereals and protein.
Anson and Pater, holders of numerous U.S. Patents, i including U.S. Patent Nos. 2,802,737; 2,813,024; 2,813,025;

2,830,902; and 2,833,651; disclose protein containing products resembling meat. Integral to their products is the formation of a "chewy protein gel". The chewy protein gel is made by adjust-ing a gel precursor such as soy or peanut concentrates to a pH
of above about 6.0, followed by heating to convert to the chewy .

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protein gel. Various additives including protein filaments, flavoring ingredients, etc., may be incorporated into the synthe-tic meat products.
Kjelson, in U.S. Patent No. 3,343,963, teaches the formation of high protein food products resembling chopped ground meats by assembling spun edible protein fibers and binding them with a heat-set mass consisting of albumen, gluten and particulate oil seed material.
Another worker, Hartman, in U.S. Patent 3,320,070 has ~ 10 taught the manufacture of bacon-like products from man-made fibers of coagulated vegetable protein with a binder including albumen and an edible proteinate.
More recently, Leidy, et al. in U.S. Patent Nos.

3,711,2~1; 3,712,837; and 3,719,498; and Hai, et al. in UOS.
Patent No. 3,719,499; teach the formation of sausage analogs. In each of these references it is desired to simulate the essentially homogeneous texture of meat-sausage products prepared from meat emulsions.
There is a present need for a juicy sausage analog which more closely simulates the heterogeneous character of many other types of sausages, such as pork sausage.
Accordingly the present invention provides an improved juicy sausage analog having a heterogeneous texture comprised of at least three distinct phases and a method for prepariny the same. The process, in its broad aspects, comprises: a) provid-ing particles of a solidified fat; b) providing particles of a chewy proteinaceous component comprising coagulated vegetable protein and from about 20~ to about 70~ water; c) providing as a precursor of a continuous gel phase, a uniform blend comprising water and heat coaguable protein and flavor; d) mixing the fat particles, the chewy proteinaceous component particles, and the continuous gel phase precursor sufficiently to blend the ingredients and then coarsely chopping the resulting blend to obtain a ~03~225 substantially uniformly heterogeneous distribution of the particulate material within the continuous gel phase precursor;
and e) forming the resulting coarsely chopped blend into a sub- ;
stantially cohesive sausage analog by coagulating the continuous gel phase precursor.
The production of the juicy sausage analog having a heterogeneous texture accordîng to the present invention depends upon the application of several necessary processing techniques to a compositional formulation having several necessary and disting-uishing features.
To provide the heterogeneous texture of the sausageanalog to make it similar to heterogeneous meat sausages, it is ; necessary to provide at least three distinct phases: a discon-tinuous proteinaceous phase, a continuous gel phase, and a sub- ;
stantially discontinuous fat phase. The formulation and utiliza-tion of these three phases in the sausage analog product of the ;
present invention and its method of preparation will be described ~ ;
below with specific reference to a pork sausage type analog; ~ ;

however, it is to be understood that analogs of other hetero-geneous, meat-containing sausages can be produced according to the present invention.
The continuous gel phase must be one which gels efficiently to provide a cohesive matrix for binding the discon-- tinuous fat and protein phase materials. Additionally, to assure consumer and governmental acceptance of the analog product, it is preferably of high nutritional value. Additionally, the contin-uous gel phase should preferably contain flavoring materials incorporated therein to provide the desired meat-like flavor consistently throughout. The continuous gel phase should have a chewy meat-like consistency to resemble the texture and mouthfeel of the analogous portion of meat in sausages. The sources of vegetable material as for example, defatted oil seeds, and may .: .: . '- ~ ' ~38~Z5 include soy, peanuts, cottonseed, peas, etc. The vegetable protein is in concentrated form and is preferably bland; and, in the case of soy, unwanted flavors are removed. Additionally, various animal sources can be employed as a protein source for this phase. Typical of these are whey, blood albumin, sodium caseinate, casein, lactalbumin, collagen, fish protein, and egg protein, especially egg albumin. Preferably, the continuous gel phase will comprise a combination of vegetable and animal protein materials. The most highly preferred combination which has given especially desirable results, is a combination of soy isolate with egg albumin. These materials perform well when employed at a weight ratio of from about 10:1 to about 1:10, preferably about 5:1 to about 1:5, most preferably from about 2:1 to about 1:2.
Most any flavoring material commonly employed in meat or to provide a meat-like flavoring can be employed in the con-tinuous gel phase according to the present invention. Prominent among these materials are hydrolyzed vegetable protein, artificial and natural meat flavoring, black pepper, white pepper, coriander, mace, nutmeg, rosemary, sugars, red pepper, sage, salt, mono-sodiumglutamate, sodiuminosinate, sodium guanylate and the like.
The discontinuous proteinaceous phase has for its purpose the introduction of chewy meat or gristle-like chunks into the sausage analog. These chunks, by their very nature as - chewy components, tend to remain in the mouth for extended periods relative to the other ingredients of the sausage. There-fore, it is preferable that these chunks or particles be infused throughout with the necessary flavoring materials to simulate the taste characteristics of meat particles from meat sausages which remain in the mouth in particulate form after the majority of the sausage has been mastica~ed. To provide their necessary texture and mouthfeel the discontinuous proteinaceous phase must neces-~0382Z5 sarily be present as particles of chewy, meat-like material.
This material can by of a variety of types such as an expanded wheat gluten/soy grit/flour mixture prepared as described in Example I of U.S Patent 3,719,496; protein granules as described in U.S. Patent No. 3,102,031; texturized vegetable protein strips prepared as described in U.S. Patent Application No. 309,301 filed November 24, 1972; Tofu; Kori Tofu; or spun protein fibers as discussed in U.S. Patent No. 2,682,466. Preferably, the ex-panded wheat gluten/soy grit/flour ingredient is employed. This material is typically employed in particulate form at a moisture content of from about 20% to about 70% water, more preferably from about 35% to about 65~. To provide the proper mouthfeel, the particles are coarsely chopped. Preferably those particles will have a size distribution, based on U.S. mesh sizes, allowing a substantial majority to pass through a No. 3/8 sieve and be collected on a No. 40 sieve, more preferably they will pass through a No. 2-1/2 sieve and be collected on a No. 20 sieve. As noted, the particles of the discontinuous protein phase ingredient preferably contain sufficient flavoring materials infused therein to supply a lasting flavoring to the material as it is being chewed. Typical of the flavoring materials and enhancers which can be employed are salt, monosodium glutamate, brown sugar, pepper and other like flavorings.
The juiciness of the sausage analog is critically reIated, among other things, to the fat content. It is therefore necessary to provide fat of suitable composition and in suitable physical form such that it contributes to the juiciness of the sausage analog without adversely affecting other physical attributes of the sausage. The fat is necessarily one which is solid at normal room temperatures r but which does not melt at such a high temperature that it causes an undesirable coating of :: ' . . ' ~038;Z25 the mouth and a resulting greasy taste and mouthfeel in the product. The preferred fats are those which melt no lower than about 70F and no higher than about 120F. More preferably, the fats should melt at a temperature within the range of from about 90F to about 105F. Typical of the fats which can be employed are rendered and non-rendered animal fats such as lard, suet, tallow and the like. Additionally, many of the hydrogenated vegetable oils, such as those normally employed in whipped top-pings, can be employed. For example, coconut oil which has been hydrogenated to have a melting point of from about 90F to about 100F is suitable. Further exemplary of vegetable fats which can be employed are hydrogenated cottonseed oil, hydrogenated corn oil, hydrogenated olive oil, etc. This listing of oils is by no means exhaustive, but merely exemplary of materials which may be readily employed by those skilled in the art. The particular fat is limited only to the use of fats having the proper melting characteristics as noted above and which do not adversely affect the other physical characteristics of the sausage. It has been found that the most desirable physical form for the fat in the ;-sausage analog is obtained by reducing the fat in solidified form to obtain substantially discrete particles.
These three separate phase ingredients are combined to provide the juicy sausage analog of the present invention. The fat and discontinuous proteinaceous phases are generally present at weight ratios in the final product of from about 10:1 to about 1:10, preferably from about 5:1 to about 1:5, and most preferably from about 2:1 to about 1:2. The total weight of these two dis-¢ontinuous phases to the weight of the continuous gel phase in the final product typically falls within the range of from about 10:1 to about 1:10, preferably from about 5-1 to about 1:5, and most preferably from about 2:1 to about 1:2.
According to the broad aspects of the process, the particles of solidified fat and the particles of the chewy -~

' 10382~5 proteinaceous component are mixed with the precursor of the con-tinuous gel phase which comprises a uniform blend comprising water, coaguable protein and flavor. The blend of these ingre-dients may then be coarsely chopped to obtain a substantially uniformly heterogeneous distribution of the particulate material within the continuous proteinaceous phase precursor. This coarsely chopped blend is then preferably heated to coagulate the continuous gel phase precursor sufficiently to form a substantially ;
- cohesive sausage anolog.
In providing the fat phase particles, the normally solid fat is first melted and a flavoring and/or coloring is optionally added at this point. The fat phase ingredients are then thorough-ly blended. The fat is then reduced to substantially discrete particles in solidified form by passing it through a meat grinder or other suitable particulating device. A preferred particulating device is a BUFFALO* meat grinder employing a dieplate having 1/16"
openings therein. The optional flavoring and coloring material can be added to the liquid fat as noted to provide a color and flavor similar to that of natural meat fat. Preferably the fat is colored a light brown color to obscure its identification in the final product as a distinct phase. Thus, although the solid fat will be present in the final product in a substantially discon-tinuous phase, the sausage will have the appearance of being ` nearly uniform in color.
The discontinuous proteinaceous phase is prepared for mixing with the other sausage analog ingredients by hydrating it to within the range of from about 20% to about 70% based on its - total hydrated weight. Preferably the moisture content will be from about 35~ to about 65%. Because it is preferable to have the flavor uniformly present throughout ~he particles of the discontinuous proteinaceous phase, the hydrating water preferably contains suitable fla~oring materials.
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In a preferred embodiment of the method of this inven-tion, an expanded high protein constituent containing wheat gluten, soy grits and flour, made in accordance with the procedure of Example I in U.S. Patent 3,719,499 is employed as the discontinuous proteinaceous phase. This expanded protein material is hydrated in an aqueous solution of flavoring materials to a moisture content of from about 20% to about 70% based upon the weight of the hydra-ted product. ~he hydrated product is then coarsely chopped in a suitable device such as a BUFFALO* meat grinder or a HOBART* silent I0 cutter. The chopping device is preferably operated to reduce the expanded protein material to particles. Preferably these particles will have a size distribution~ based on U.S. mesh sizes, allowing a substantial majority to pass through a No. 3/8 sieve and be collected on a No. 40 sieve, more preferably they will pass through a No. 2-1/2 sieve and be collected on a No. 20 sieve.
The continuous gel phase precursor is prepared by dry blending the dry ingredients which comprise the protein components and flavoring materials and adding water and mixing. The water is preferably added slowly to provide a uniform blend free from lumps of dried material. In a preferred embodiment, dried egg albumin and a soy isolate are mixed at a weight ratio of about 1:1 along with flavoring materials such as hydrolyzed vegetable protein, black pepper, sage, etc., before admixing with an amount of water to obtain a total moisture content for this phase of from about 25% to about 85%, preferably from about 65% to about 75%. The coagulable protein, e.g. the albumin and soy isolatel are generally present in an amount of from about 5% to about 25%, preferably from about 10% to about 15%.
At this point the particulate fat phase ingredient and the particulate protein phase ingredient are preferably mixed with the continuous gel phase precursor in a suitable mixing device such as a HOBART* mixer to uniformly blend the ingredients. If desired, the blended ingredients may then be coarsely chopped in a suitable *Trademark .~ . .

device such as a BUFFALO* meat grinder having a dieplate with 3/8" orifices therein, to obtain a substantially uniformly hetero-geneous distribution of the particulate material within the con-tinuous proteinaceous phase precursor. Also, the fat phase and discontinuous proteinaceous phase particles can be subjected to an initial, similar mixing and chopping sequence before mixing with the continuous gel phase precursor.
The resulting coarsely chopped blend is then ready for heat-setting in any suitable form. Preferably the coarsely chopped blend is formed into sausage links in conventional sausage stuffing apparatus. The sausage casing, typically from about 15 to 24 mm in diameter, can contain a soluble dye or coloring material which will migrate into the sausage analog to provide a cooked meat appearance. It is necessary at this stage in the process to coagulate the continuous gel phase precursor to form a substan-tially cohesive sausage analog. ~his is preferably accomplished by use of an autoclave at a temperature within the range of from about 212F to about 235F for a time of from about 15 minutes to about 35 minutes. It is possible, of course, to use any other suitable heating means such as micro wave heating, hot air, atmospheric steam, or boiling water. The heating should be sufficient to provide coagulation without significant dehydration.
Alternatively, other known coagulation means, such as chemical means, can be employed.
~ here an inedible casing material has been employed, it is desirable to strip the casing from the analog after heating.
The resulting sausage analog is then frozen and packaged for dis-tribution. It is possible to distribute the product in refrig-erated form without freezing, however, freezing at the present time appears to offer the greatest economy and effectiveness.
More specifically, freezing improves shelf life, flavor and texture.

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The following Example is presented for the purpose of further illustrating and explaining t~le present invention and is not to be taken as limiting in any sense. Unless otherwise indi-cated, all parts and percentages are by weight.
EXAMPLE I
To form a juicy, pork-sausage-type analog, the following constituents are employed:
Fat Phase %

Hydrogenated domestic vegetable oil 25.83 (soy/cottonseed, M.P. 96F + 1F) 10 Imitation sausage flavor 2.84 Discontinuous Proteinaceous Phase vital wheat gluten 4.64 wheat flour 0.98 soy grits 1.93 ammonium carbonate 0.05 salt (NaCl) 1.86 water 12.14 mono sodium glutamate 0.17 caramel color 0.17 20 brown sugar 1.72 Continuous Gel Phase soy isolate 5.86 dried egg albumen 5.51 -hydrolyzed vegetable protein 0.95 black pepper 0.38 sage 0.17 water 34.80 The fat phase was prepared by initially melting the fat at elevated temperature followed by cooling to 110F at which temperature the imitation sausage flavor is added. The flavoring material imparts a sausage flavor and a cooked-meat coloration to the fat upon solidification. After thorough blending of the fat ,~ ~

and flavoring, the blend is solidified by cooling to 40F, and then passed through a BUFFALO* meat grinder fitted with a die having 1/16" orifices therein. The fat is observed (at this point~ to be in strands.
` The discontinuous proteinaceous phase was prepared from an expanded textured vegetable protein material. This material was prepared by blending 4.64 parts of vital wheat gluten with 0.98 parts of wheat flour, 1.98 parts of soya bits, 0.05 parts of ammonium carbonate, 0.16 parts of saltr and 2.21 parts of water and extruding the resultant blend from a heated Model X-25 WENGER*
extruder. In the extruder, the blend is subjected to elevated temperature and pressure. The blend is extruded through two 3/8"
diameter dies with a recorded pressure of about lg0 psig and a temperature of approximately 300F at the die face. The extrudate was dried to a moisture content of about 4%. The dried extrudate was then soaked in an aqueous solution comprising 1~.14 parts ` water, 1.7 parts salt, 0.17 parts monosodium glutamate, 0.17 parts ` caramel color, and 1.72 parts brown sugar, wherein it is hydrated .. : .
- to a moisture content of about 60~. The resulting hydrated material is then coarsely chopped in a HOBART* silent cutter for 90 seconds to provide particles. The coarsely chopped material sh~wed the screen analysis summarized below:

Mesh SizeWt. & Retained on Screen 3/8*~ 6.4 2 1/2 13.2 3 21.5

4 23.3 35.6 Pan Trace ` 30 ~*Mostly agglomerates The continuous gel phase precursor is prepared by dry blending 5.85 parts of the soy isolate with 5.51 parts of the dried egg albumin, 0.95 parts of the hydrolyzed vegetable protein *Trademark . .

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~a;~2zs 0.38 parts of black pepper and 0.17 parts of sage. The resulting dry blend is then mixed in a ~OBART* mixer with 34.8 parts water to form a uniform aqueous continuous gel phase precursor.
The particles of fat, the particles of the discontinuous proteinaceous phase and the continuous gel phase precursor are then mi~ed for about 3 minutes at medium speed in a HOBART* mixer by passing them through a BUFFALO* meat grinder fitted with a 3/8" die, to obtain a substantially uniformly heterogeneous distribution of the particulate material within the continuous proteinaceous phase precursor. The resulting coarsely comminuted blend is then stuffed into 22 mm cellulose sausage casings and tied into 3-1/2"
links. The stuffed links were then autoclaved at 225F for 25 minutes to coagulate the continuous gel phase precursor; forming - -substantially cohesive sausage analogs. The casings were stripped and the sausage analogs were then frozen.
Many modifications and variations of this present inven-tion will be apparent to those skilled in the art upon reading the above disclosure. It is intended that all such modifications and variations be included within the scope of the invention which is defined only by the claims.
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Claims (15)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. An improved process for preparing a juicy sausage analog, having a heterogeneous texture comprised of at least three distinct phases which comprises:
a) providing particles of a solidified fat;
b) providing particles of a chewy proteinaceous component comprising coagulated vegetable protein, and from about 20% to about 70% water;
c) providing as a precursor of a continuous gel phase, a uniform blend comprising water and heat coagulable protein and flavor;
d) mixing the fat particles, the chewy proteina-ceous component particles, and the continuous gel phase precursor sufficiently to blend the ingredients and then coarsely chopping the resulting blend to obtain a substantially uniformly hetero-geneous distribution of the particulate material within the con-tinuous gel phase precursor; and e) forming the resulting coarsely comminuted blend into a substantially cohesive sausage analog by coagulating the continuous gel phase precursor.

2. A process according to Claim 1 wherein the fat has a melting point within the range of from about 70°F to about 120°F.

3. A process according to Claim 2 wherein the fat has a melting point within the range of from about 90°F to about 105°F.

4. A process according to Claim 2 wherein the fat phase further comprises a flavoring material.

5. A process according to Claim 1 wherein the parti-cles of the chewy proteinaceous component are prepared by infusing a dry, fibrous proteinaceous component, comprising vegetable protein with an aqueous solution comprising flavoring to obtain a fibrous, chewy protein component having a moisture content of from about 20% to about 70% by weight.

6. A process according to Claim 5 wherein the fibrous, chewy proteinaceous component is coarsely chopped to particles having a size distribution, based on U.S. mesh sizes, allowing a substantial majority to pass through a No. 3/8 sieve and be collected on a No. 40 sieve.

7. A process according to Claim 5 wherein the fat has a melting point within the range of from about 70°F to about 120°F, and the solidified fat is reduced to substantially dis-crete fat particles.

8. A process according to Claim 6 wherein the fibrous, chewy proteinaceous component is coarsely chopped to particles having a size distribution, based on U.S. mesh sizes, allowing a substantial majority to pass through a No. 3/8 sieve and be collected on a No. 40 sieve.

9. A process according to Claim 1 wherein the pre-cursor of the continuous gel phase is prepared by blending from about 25% to about 80% water with flavoring and from about 5% to about 25% of a heat coagulable protein comprising at least soy isolate and egg albumen at a weight ratio of from about 10:1 to about 1:10, the amounts of flavoring and the protein mixture being expressed on the basis of their dry weights.

10. A process according to Claim 9 wherein particles of the chewy proteinaceous component are prepared by infusing a dry, fibrous proteinaceous component, comprising vegetable protein with an aqueous solution comprising flavoring to obtain a fibrous, chewy protein component having a moisture content of from about 20% to about 70% by weight.

11. A process according to Claim 10 wherein the fibrous, chewy proteinaceous component is coarsely comminuted to particles having a size distribution, based on U.S. mesh sizes, allowing a substantial majority to pass through a No. 3/8 sieve and be collected on a No. 40 sieve.

12. A process according to Claim 11 wherein the fat has a melting point within the range of from about 90°F to about 105°F.

13. A process according to Claim 12 wherein the parti-cles of solidified fat additionally comprise flavoring.

14. An improved process for preparing a juicy sausage analog, having a heterogeneous texture comprised of at least three distinct phases, which comprises:
a) providing particles of a solidified fat having a melting point within the range of from about 70°F to about 120°F;
b) providing particles of a fibrous, chewy pro-teinaceous component comprising coagulated vegetable protein, flavor and from about 20% to about 70% water, the fibrous, chewy protein particles having a size distribution, based on U.S. mesh sizes, allowing a substantial majority to pass through a No. 3/8 sieve and be collected on a No. 40 sieve;
c) providing as a precursor of a continuous gel phase, a uniform comprising water, heat coagulable protein and flavor;
d) mixing the fat particles, fibrous, chewy pro-teinaceous component particles, and the continuous gel phase pre-cursor sufficiently to blend the ingredients and coarsely chopping the resulting blend to obtain a substantially uniformly hetero-geneous distribution of the particulate material within the con-tinuous proteinaceous phase precursor; and e) heating the resulting coarsely chopped blend sufficiently to coagulate the continuous gel phase precursor and form a substantially cohesive sausage analog.

15. An improved juicy sausage analog having a hetero-geneous texture having at least three distinct phases comprising a continuous gel phase, a discontinuous proteinaceous phase, and a substantially discontinuous fat phase, wherein the continuous gel phase is a coagulated aqueous mixture comprising a heat coagulated protein and flavor, the discontinuous proteinaceous phase is comprised of fibrous, chewy particles comprising a coagulated vegetable protein, flavor, and from about 20% to about 70% water; and the particles having a size distribution, based on U.S. mesh sizes, allowing a substantial majority to pass through a No. 3/8 sieve and be collected on a No. 40 sieve; and the dis-continuous fat phase comprises a fat which melts at a temperature within the range of from 70°F to about 120°F.