CN117642082A

CN117642082A - Extruded food product comprising vegetable protein and hydrocolloid

Info

Publication number: CN117642082A
Application number: CN202280037432.2A
Authority: CN
Inventors: S·索洛里奥; T·弗耶雷德; D·斯坦贝克; C·隆德; T·斯纳贝; K·丰查伦; U·K·马德森; R·K·康纳利
Original assignee: Dupont Nutrition America; International Nutrition And Health Denmark Private Ltd; Solae LLC
Current assignee: Dupont Nutrition America; International Nutrition And Health Denmark Private Ltd; Solae LLC
Priority date: 2021-05-26
Filing date: 2022-05-25
Publication date: 2024-03-01

Abstract

The present disclosure relates to an extrudate comprising, on a moisture free basis, based on the weight of the extrudate, (a) from about 60 wt.% to about 90 wt.% vegetable protein; (b) From about 1 wt% to about 10 wt% of a hydrocolloid, wherein the hydrocolloid is selected from the group consisting of: alginate, pectin, agar, methylcellulose, and mixtures thereof; and (c) optionally, no more than about 14% by weight starch. The present disclosure also relates to a dry mix composition comprising, on a moisture free basis, based on the total weight of the dry mix composition, (a) from about 65 wt% to about 98 wt% of a vegetable protein material; (b) From about 1 wt% to about 10 wt% of a hydrocolloid, wherein the hydrocolloid is selected from the group consisting of: alginate, pectin, agar, methylcellulose, and mixtures thereof; and (c) optionally, no more than about 14% by weight starch.

Description

Extruded food product comprising vegetable protein and hydrocolloid

Cross Reference to Related Applications

The present application claims priority from U.S. patent application 63/193,135, filed on 5 months at 2021, and from European patent application 21193271, filed on 8 months at 2021, 26, the contents of both of which are incorporated herein by reference in their entirety for all purposes.

Background

Technical Field

The present disclosure relates to an extrudate made from vegetable proteins, an extrusion process for preparing such extrudate, a composition for use in an extrusion process for preparing such extrudate, and a method for preparing a food product, such as a meat substitute food product, by using such extrudate.

Description of related Art

Puffed low moisture structured meat analog products are well known in the art and they are typically prepared by heating a mixture containing proteinaceous material and other ingredients, as well as water, under mechanical shear and pressure in a cooking extruder and extruding the mixture through a die. After extrusion, the extrudate typically expands and contracts based on the extrusion conditions and the rheological properties of the extruded material.

The formation of the extrudate will depend on the choice of extrusion ingredients, such as the combination of proteins, carbohydrates, fibers, etc., as well as the design and placement of the extrusion cooking apparatus. Typical extrusion processes are designed and run using steady state conditions to make similar products in a continuous-based process; these products have similar properties in shape and external dimensions.

Extrusion cooking devices have long been used to manufacture a variety of edible products and other products, such as human meals and animal feeds. The extruder includes an elongated barrel and one or more internally flighted axially rotatable extrusion screws therein. The outlet of the extruder barrel is equipped with a single or multiple openings in the extrusion die. In use, material to be processed is fed into and through an extruder. As the material exits the one or more extruder die openings, the material is shaped and typically may be further slit using a rotating cutter assembly. Alternatively, the puffed protein product may be cut into smaller extrudates, such as pieces, pellets, bars, filaments, etc., for use as food, food ingredients, or meat replacement applications.

In use, the material to be processed is fed into and through the extruder barrel and subjected to elevated temperature, increased pressure and increased shear. The material exits the one or more extruder die openings in rope form, which is thoroughly cooked and ready for further processing to produce the desired end product. Typical textured protein processed extrudate or "rope" products are homogeneous products having organoleptic characteristics as consumer hesitant processed foods, synthetic or non-natural food products. Such uniform "rope" products require further processing to produce the desired consumer product to determine the final form or shape, such as blocks, strips, filaments, etc. By additional processing, these products typically look like processed, synthetic or non-natural food products.

Thus, there is a need to produce better alternative structured protein products that have the organoleptic characteristics of irregular external shapes and irregular internal structures of non-synthetic appearance to mimic natural structured foods for meat substitute or meat analog food applications.

Disclosure of Invention

The present disclosure provides an extrudate comprising, on a moisture free basis, based on the weight of the extrudate, (a) from about 60 wt.% to about 90 wt.% vegetable protein; (b) From about 1 wt% to about 10 wt% of a hydrocolloid, wherein the hydrocolloid is selected from the group consisting of: alginate, pectin, agar, methylcellulose, and mixtures thereof; and (c) optionally, no more than about 14% by weight starch.

The present disclosure also provides a dry mix composition comprising, on a moisture free basis, based on the total weight of the dry mix composition, (a) from about 65 wt% to about 98 wt% vegetable protein material; (b) From about 1 wt% to about 10 wt% of a hydrocolloid, wherein the hydrocolloid is selected from the group consisting of: alginate, pectin, agar, methylcellulose, and mixtures thereof; and (c) optionally, no more than about 14% by weight starch.

The present disclosure also provides an extrusion method comprising: (a) contacting the dry-blended composition of the present disclosure with water to form a feed mixture, (b) feeding the feed mixture into an extruder to form a molten extrudate, and (c) extruding the molten extrudate through an extrusion die to produce an extrudate.

The present disclosure also provides a method of preparing a hydrated extrudate. The method includes hydrating an extrudate of the present disclosure in an aqueous solution to form the hydrated extrudate.

Detailed Description

The foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as defined in the appended claims. Other features and advantages of any one or more embodiments will be apparent from the following detailed description, and from the claims.

As used herein, the terms "comprise," "include," "have," or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Furthermore, unless explicitly stated to the contrary, "or" means an inclusive or, and not an exclusive or. For example, the condition a or B is satisfied by any one of the following: a is true (or present) and B is false (or absent), a is false (or absent) and B is true (or present), and a and B are both true (or present).

Moreover, "a/an" is used to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In case of conflict, the present specification, including definitions, will control. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, suitable methods and materials are described below. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.

Where an equivalent, concentration, or other value or parameter is given as either a range, preferred range, or a series of upper preferable values and/or lower preferable values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or preferred value and any lower range limit or preferred value, regardless of whether ranges are separately disclosed. When numerical ranges are recited herein, unless otherwise stated, the ranges are intended to include the endpoints thereof, and all integers and fractions within the range. For example, when a range of "1 to 10" is recited, the recited range should be interpreted as including ranges of "1 to 8", "3 to 10", "2 to 7", "1.5 to 6", "3.4 to 7.8", "1 to 2 and 7-10", "2 to 4 and 6 to 9", "1 to 3.6 and 7.2 to 8.9", "1-5 and 10", "2 and 8 to 10", "1.5-4 and 8", and the like.

Although the compositions and methods are described herein as "comprising" various components or steps, the compositions and methods may also "consist essentially of" or "consist of" the various components or steps, unless otherwise indicated.

Before addressing details of the embodiments described below, some terms are defined or clarified.

As used herein, the term "wt%" means weight percent.

As used herein, the term "GDL content" means the total amount by weight of glucono-delta-lactone, gluconic acid, and one or more gluconate in a material on a moisture free basis based on the weight of the material.

As used herein, the term "on an anhydrous basis" means the weight of a material after it has been dried to completely remove all moisture, e.g., the water content of the material is 0%, with reference to a particular weight. In particular, the weight of the material on a moisture free basis can be obtained by weighing the material after placing the material in an oven at 45 ℃ until the material reaches a constant weight.

Vegetable protein

As used herein, the term "plant protein" refers to a protein derived from a plant. Examples of plants include beans, canola, sunflower, sorghum, rice, amaranth, potato, tapioca, arrowroot, canna, lupin, cereals such as wheat, corn/maize, oat, barley, millet, triticale, buckwheat, rye, peanut, lupin, canola, cassava (cassea), hemp, and grass. In some embodiments, the vegetable protein may be derived from seeds of legumes such as soybeans, mung beans, chickpeas, lentils, and peas. In some embodiments, the vegetable protein is selected from the group consisting of: soy protein, pea protein, potato protein, wheat gluten, lentil protein, fava bean protein, rice protein, canola protein, corn protein, jackfruit protein, sunflower protein, chickpea protein, and combinations thereof. In some embodiments, the vegetable protein is selected from the group consisting of: soy protein, pea protein, potato protein, and combinations thereof. In some embodiments, the vegetable protein is soy protein. In some embodiments, the vegetable protein is a mixture of soy protein and potato protein. In some embodiments, the vegetable protein is pea protein. In some embodiments, the vegetable protein comprises, consists essentially of, or consists of soy protein. In some embodiments, the vegetable protein comprises at least 80 wt%, 85 wt%, 90 wt%, 92 wt%, 95 wt%, 98 wt%, or 99 wt% soy protein based on the weight of the vegetable protein.

The vegetable protein material is used in the extrusion process of the present disclosure to prepare the extrudate. In some embodiments, the plant protein material comprises at least about 60 wt%, 70 wt%, 80 wt%, or 90wt% plant protein based on the weight of the plant protein material on a moisture free basis. In some embodiments, the vegetable protein material is selected from the group consisting of: soy protein material, pea protein material, and combinations thereof. Suitable pea protein materials may be selected from the group consisting of: pea protein isolate, pea protein concentrate and combinations thereof.

Suitable soy protein materials that may be used in the extrusion process of the present disclosure to prepare extrudates may be selected from the group consisting of: soy protein isolate, soy protein concentrate, soy flour, soy flakes, soy grits, soy meal, and combinations thereof. The main difference between these soy protein materials is the degree of refining and/or particle size. Soy Protein Isolate (SPI) has the highest degree of "soy" purity of all soy protein materials and comprises at least about 90wt% soy protein on a moisture free basis based on the weight of the soy protein isolate. In some embodiments, the soy protein isolate comprises, consists essentially of, or consists of: about 90 wt.% to about 92 wt.% soy protein, about 0.5 wt.% to about 1.0 wt.% oil, about 3 wt.% to about 4 wt.% carbohydrate, about 4 wt.% to about 5 wt.% ash, and about 0.1 wt.% to about 0.2 wt.% fiber, based on the weight of the soy protein isolate on a moisture free basis.

The soy protein concentrate comprises about 65 wt.% to about 90 wt.% soy protein and about 3.5 wt.% to about 20 wt.% soy cotyledon fiber, based on the weight of the soy protein concentrate on a moisture free basis. As used herein, the term "soy flour" refers to a ground form of defatted soy. In some embodiments, the soy flour comprises about 49 wt.% to about 60 wt.% soy protein and less than about 1 wt.% oil, based on the weight of the soy flour on a moisture free basis. In some embodiments, the soy flour is ground very finely such that less than about 1wt% of the soy flour remains on a 300 mesh (U.S. standard) screen. The soy flour typically has a particle size of less than about 150 μm. The soy grits typically have a particle size of from about 150 μm to about 1000 μm. The soybean meal typically has a particle size greater than about 1000 μm.

In some embodiments, the soy protein material that can be used in the extrusion process of the present disclosure to prepare the extrudate is selected from the group consisting of: soy protein isolate, soy protein concentrate, soy flour, and combinations thereof. In some embodiments, the soy protein material is selected from the group consisting of: soy protein isolate, soy protein concentrate, and combinations thereof. In some embodiments, the soy protein material is a soy protein isolate.

Hydrocolloid

As used herein, the term "hydrocolloid" means a substance, typically a polysaccharide that is colloidally dispersible in water, that alters the rheology of the water by increasing the viscosity of the substance used and/or inducing its gelation. In some embodiments, the hydrocolloid in the present disclosure is selected from the group consisting of: alginate, pectin, agar, methylcellulose, gellan gum (e.g., low acyl gellan gum), curdlan gum, and mixtures thereof. In some embodiments, the hydrocolloid is selected from the group consisting of: alginate, pectin, agar, methylcellulose, and mixtures thereof. In some embodiments, the hydrocolloid is an alginate. In some embodiments, the hydrocolloid is a mixture of alginate and pectin. In some embodiments, the hydrocolloid is pectin. In some embodiments, the hydrocolloid comprises, consists essentially of, or consists of an alginate. In some embodiments, the hydrocolloid comprises at least 80 wt%, 85 wt%, 90 wt%, 92 wt%, 95 wt%, 98 wt%, or 99 wt% alginate, based on the weight of the hydrocolloid.

In particular, alginates derived from brown seaweed are linear unbranched biopolymers consisting of (1-4) -linked beta-D-mannuronic acid (M) and alpha-L-guluronic acid (G) residues. Alginate consists of homopolymer blocks of consecutive G residues, consecutive M residues or alternating M and G residues, such as MMMM, GGGG and GMGM. The number of G residues relative to the sum of G and M residues is referred to as the G content. Similarly, the percent content of M residues is referred to as M content, such that the G content and the M content constitute 100%. In some embodiments, the alginate has a G content of at least 20%, or at least 25%, or at least 30%, or at least 32%, or at least 35%, or at least 38%, or at least 40%, or at least 42%, or at least 45%, or at least 48%, or at least 50%, or at least 52%, or at least 55%, or at least 57%, or at least 60%. In some embodiments, the alginate has a G content of no more than 75%, or no more than 72%, or no more than 70%, or no more than 68%, or no more than 65%, or no more than 62%, or no more than 60%, or no more than 58%, or no more than 55%, or no more than 52%, or no more than 50%, or no more than 48%, or no more than 45%, or no more than 42%, or no more than 40%.

"alginate" is a term commonly used for salts of alginic acid, but it may also refer to all derivatives of alginic acid and alginic acid itself. In some embodiments, the alginate in the present disclosure has a molecular weight such that the alginate in sodium alginate form exhibits a viscosity in the range of 50-1,000mpa.s when measured at 1wt% using a brookfield rv type (e.g., RVT, RVF, RVTDV) at 20 ℃, with a suitable shaft being used for the viscosity range in question. Based on the equipment model and viscosity range, one of ordinary skill in the art can readily determine the appropriate axis for viscosity determination. In some embodiments, such alginate in the form of sodium alginate exhibits a viscosity of from 200 mPa-s to 600 mPa-s when so measured. In some embodiments, two or more types of alginate may be used in combination. In some embodiments, a single type of alginate is used.

In some embodiments, the hydrocolloid is pectin. In some embodiments, the pectin is sugar beet pectin, that is, the pectin is extracted or derived from sugar beet. In some embodiments, the pectin is a citrus peel pectin, that is, the pectin is extracted or derived from citrus peel. In some embodiments, the pectin is apple pomace pectin, that is, the pectin is extracted or derived from apple pomace. The pectin may be hydrolyzed pectin or unhydrolyzed pectin. In some embodiments, the pectin is an amidated pectin, such as an amidated pectin having a DE of no more than 50.

The main component of pectin is galacturonic acid. The Degree of Esterification (DE) of pectin is the number of esterified carboxyl groups per 100 equivalents of galacturonic acid. In some embodiments, the pectin has an average Degree of Esterification (DE) of at least 15, or at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60. In some embodiments, the pectin has an average Degree of Esterification (DE) of no more than 80, or no more than 75, or no more than 70, or no more than 65, or no more than 60, or no more than 55, or no more than 50, or no more than 45.

In some embodiments, the hydrocolloid is agar. In some embodiments, the hydrocolloid is methylcellulose.

Calcium ion

Calcium ions (Ca) in the present disclosure ²⁺ ) The source of (a) may be a calcium-containing compound. In some embodiments, the source of calcium ions is a sparingly soluble calcium compound. As used herein, the term "sparingly soluble" when applied to a calcium compound means that the calcium compound has a low solubility product, as defined below. The solubility product is the product of the equilibrium molar concentrations of the ions in a saturated solution of the compound in water. The "low solubility product" as used in the practice of the present invention is typically no more than 10 at 25 °c ^-2 Preferably not more than 10 ^-3 More preferably not more than 10 ^-4 . In some embodiments, the sparingly soluble calcium compound is selected from the group consisting of: calcium sulfate, calcium phosphate (e.g., dicalcium phosphate), calcium citrate, calcium carbonate, calcium silicate, calcium sulfide, calcium tartrate, and mixtures thereof. In some embodiments, the sparingly soluble calcium compound is selected from the group consisting of: calcium sulfate, dicalcium phosphate, calcium carbonate and mixtures thereof. Slightly soluble calcium compounds in the present disclosure include anhydrous and hydrated compounds.

In some embodiments, the source of calcium ions is a calcium-containing compound selected from the group consisting of: calcium alginate, calcium sulfate, calcium carbonate, calcium phosphate, dicalcium phosphate, calcium chloride, (encapsulated) calcium lactate and mixtures thereof. In some embodiments, the source of calcium ions is calcium alginate. The calcium-containing compound may be encapsulated or unencapsulated.

Chelating and acidifying agents

The alginate gels immediately in the presence of divalent cations such as calcium ions. Thus, it is important to control the presence of calcium ions during extrusion so that the desired properties of the extruded product are obtained. This can be achieved by using slow-release calcium compounds, such as slightly soluble calcium compounds, optionally in combination with chelating agents.

Chelating agents are chelating agents that typically have a higher affinity for calcium ions than alginate. In some embodiments, the chelating agent is selected from the group consisting of: tetrasodium pyrophosphate (TSPP), trisodium phosphate (TSP), disodium phosphate (DSP), sodium Hexametaphosphate (SHMP), trisodium citrate, sodium Tripolyphosphate (STPP), sodium carbonate, ethylenediamine tetraacetic acid (EDTA), sodium gluconate, potassium gluconate, and mixtures thereof. In some embodiments, the chelating agent is selected from the group consisting of: tetrasodium pyrophosphate (TSPP), trisodium phosphate (TSP), disodium phosphate (DSP), sodium Hexametaphosphate (SHMP), trisodium citrate, and mixtures thereof. Chelating agents in the present disclosure include anhydrous chelating agents and hydrated chelating agents.

Alternatively, the presence of calcium ions can be controlled by using slightly soluble calcium compounds that become more soluble at lower pH, such as calcium carbonate and dicalcium phosphate, in combination with acidulants (pH control agents/chelating agents), such as glucono-delta-lactone (GDL). The acidulant lowers the pH over time, releasing calcium ions from the calcium carbonate and dicalcium phosphate in a controlled manner. In some embodiments, the acidifying agent is GDL. In some embodiments, the acidulant comprises, consists essentially of, or consists of GDL. In some embodiments, the acidulant comprises at least 80 wt%, 85 wt%, 90 wt%, 92 wt%, 95 wt%, 98 wt%, or 99 wt% GDL based on the weight of the acidulant.

Starch and fiber

Starch and/or fiber may be used in the extrusion methods of the present disclosure to prepare extrudates. They can alter the internal and external structure of the extrusion product, help to improve the flowability of the feed mixture during extrusion, and alter the stability of the extrudate flow through the die configuration. The starch in the present disclosure may be a native starch and/or a modified starch. In some embodiments, the starch is selected from the group consisting of: tapioca starch (e.g., natural tapioca starch), wheat starch, potato starch (e.g., natural potato starch), corn starch, rice starch, pea starch, barley starch, arrowroot starch, and mixtures thereof. In some embodiments, the starch is selected from the group consisting of: tapioca starch, wheat starch, potato starch, and mixtures thereof. In some embodiments, the starch is tapioca starch. In some embodiments, the starch comprises, consists essentially of, or consists of tapioca starch. In some embodiments, the starch comprises at least 80 wt%, 85 wt%, 90 wt%, 92 wt%, 95 wt%, 98 wt%, or 99 wt% tapioca starch based on the weight of the starch.

As used herein, the term "additive fiber component" means a component (used in the extrusion process of the present disclosure to prepare an extrudate) that comprises dietary carbohydrate fibers, such as Insoluble Dietary Fibers (IDF) and Soluble Dietary Fibers (SDF). The added fiber component used in the extrudate may be derived from, for example, wheat bran, corn bran, whole grain, bread, cereals, vegetables such as cabbage, carrot and sprouts (such as brussels sprouts), fruits such as apples, bananas and citrus, seaweed, mushrooms, oats, barley and legumes such as soybeans and peas. For clarity, in the present disclosure, the added fiber component does not include a plant protein material, such as a soy protein material (e.g., soy protein isolate and soy protein concentrate), which may contain fibers.

In some embodiments, the additional fiber component is selected from the group consisting of: soybean fiber, citrus fiber, pea fiber, and mixtures thereof. In some embodiments, the additional fiber component is selected from the group consisting of: soybean fiber, citrus fiber, and mixtures thereof. In some embodiments, the soy fiber is soy cotyledon fiber. In some embodiments, the added fiber component is citrus fiber.

Extrusion material

The present disclosure provides an extrudate suitable for use in a meat substitute product comprising, on a moisture free basis, based on the weight of the extrudate, (a) from about 60 wt.% to about 90 wt.% vegetable protein; (b) From about 1 wt% to about 10 wt% of a hydrocolloid, wherein the hydrocolloid is selected from the group consisting of: alginate, pectin, agar, methylcellulose, and mixtures thereof; and (c) optionally, no more than about 14% by weight starch. It has been found that extrudates containing high concentrations of vegetable proteins, hydrocolloids and additional ingredients such as starch, fiber, calcium compounds, etc. can be manufactured with the desired internal and external structure to simulate non-manufactured irregular whole muscle blocks, cubes, bars, cubes, etc. meeting sensory attributes in the final application. The extrudate of the present disclosure has improved characteristics in terms of the organoleptic characteristics of the irregular exterior shape and the irregular interior structure, thereby simulating the appearance of a non-fabricated, naturally structured food of meat.

As used herein, the term "extrudate" means the product of an extrusion process. The extrusion method may be a High Moisture Extrusion (HME) method or a Low Moisture Extrusion (LME) method. As used herein, the term "low moisture extrusion" means an extrusion process performed with less than 40wt% (based on the total weight of the extruded material) of moisture (water or a combination of water and other liquid) in the extruded material. This extrusion process is also known as a direct puffing process. As used herein, the term "low moisture extrudate" means an extrudate produced by a low moisture extrusion process. The extrudate product from low moisture extrusion is typically a puffed puck that takes on a honeycomb structure and has a sponge-like structure and absorbs water rapidly. In some embodiments, the extrudate is a low moisture extrudate.

As used herein, the term "high moisture extrusion" means an extrusion process performed with more than 50wt% (based on the total weight of the extruded material) of moisture (water or a combination of water and other liquid) in the extruded material. As used herein, the term "high moisture extrudate" means an extrudate produced by a high moisture extrusion process. In some embodiments, the extrudate is a high moisture extrudate.

The extrudate in the present disclosure comprises from about 60 wt.% to about 90 wt.% vegetable protein, based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate comprises at least about 60 wt%, 62 wt%, 64 wt%, 66 wt%, 68 wt%, 70 wt%, 72 wt%, 74 wt%, 76 wt%, 78 wt%, 80 wt%, or 82 wt% vegetable protein based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate comprises no more than about 90 wt%, 89 wt%, 88 wt%, 87 wt%, 86 wt%, 85 wt%, 83 wt%, 81 wt%, 79 wt%, 77 wt%, 75 wt%, 73 wt%, or 71 wt% vegetable protein based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate comprises from about 70 wt.% to about 90 wt.%, from about 76 wt.% to about 86 wt.%, or from about 80 wt.% to about 90 wt.% vegetable protein, based on the weight of the extrudate on a moisture free basis. In some embodiments, the vegetable protein is soy protein.

In some embodiments, the extrudate comprises from about 70 wt.% to about 95 wt.%, or from about 75 wt.% to about 94 wt.%, or from about 80 wt.% to about 94 wt.% soy protein isolate, based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate comprises at least about 65 wt%, 70 wt%, 72 wt%, 75 wt%, 76 wt%, 77 wt%, 78 wt%, 79 wt%, 80 wt%, 81 wt%, 82 wt%, 83 wt%, 84 wt%, 85 wt%, or 86 wt% of the soy protein isolate based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate comprises no more than about 97 wt%, 96 wt%, 95 wt%, 94 wt%, 93 wt%, 92 wt%, 91 wt%, or 90 wt% soy protein isolate based on the weight of the extrudate on a moisture free basis.

In some embodiments, the soy protein isolate is used in an extrusion process to prepare an extrudate, and the extrudate comprises no more than 3 wt.%, 2 wt.%, or 1 wt.% oil, based on the weight of the extrudate on a moisture-free basis. In some embodiments, the extrudate comprises no more than 2 wt%, 1 wt%, 0.5 wt%, or 0.2 wt% fibers based on the weight of the extrudate on a moisture free basis.

In some embodiments, the extrudate comprises no more than about 20 wt%, 16 wt%, 14 wt%, 13 wt%, 12 wt%, 11 wt%, 10 wt%, 9 wt%, 8 wt%, 7 wt%, or 6 wt% starch, based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate comprises at least about 0.001 wt%, 0.01 wt%, 0.1 wt%, 0.5 wt%, 1 wt%, 2 wt%, 3 wt%, 4 wt%, or 5 wt% starch, based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate comprises from about 1 wt.% to about 14 wt.%, or from about 1 wt.% to about 10 wt.%, or from about 2 wt.% to about 9 wt.%, or from about 3 wt.% to about 8 wt.% starch, based on the weight of the extrudate on a moisture free basis.

The extrudate in the present disclosure comprises from about 1 wt.% to about 10 wt.%, or from about 1 wt.% to about 8 wt.%, or from about 1 wt.% to about 7 wt.%, or from about 2 wt.% to about 6 wt.% hydrocolloid, based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate comprises at least about 1 wt%, 1.5 wt%, 2 wt%, 2.5 wt%, 3 wt%, 3.5 wt%, or 4 wt% hydrocolloid based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate comprises no more than about 10 wt%, 9 wt%, 8 wt%, 7 wt%, 6.5 wt%, 6 wt%, 5.5 wt%, 5 wt%, 4.5 wt%, or 4 wt% hydrocolloid based on the weight of the extrudate on a moisture free basis. In some embodiments, the hydrocolloid is an alginate, which may be present in the extrudate in the form of alginic acid, derivatives of alginic acid, and/or salts of alginic acid such as one or more of calcium alginate, potassium alginate, and sodium alginate. In some embodiments, the alginate is present in the extrudate in the form of sodium alginate and calcium alginate. In some embodiments, the alginate is present in the extrudate in the form of calcium alginate. In some embodiments, the hydrocolloid is a combination of sodium alginate and calcium alginate.

In some embodiments, the hydrocolloid comprises, consists essentially of, or consists of an alginate, and the extrudate further comprises calcium ions. The calcium in the extrudate may be in the form of calcium alginate and other calcium-containing compounds. In some embodiments, the extrudate has a calcium content in the range of from about 0.01% to about 10%, or from about 0.05% to about 5%, or from about 0.1% to about 3%, or from about 0.1% to about 2%, or from about 0.2% to about 1%, or from about 0.3% to about 1%, or from about 0.4% to about 1%, or from about 0.5% to about 0.9%. In some embodiments, the extrudate has a calcium content of at least about 0.01%, 0.02%, 0.05%, 0.08%, 0.1%, 0.15%, 0.2%, 0.25%, 0.3%, 0.35%, 0.4%, 0.45%, or 0.5%. In some embodiments, the extrudate has a calcium content of no more than about 10%, 8%, 6%, 5%, 4%, 3%, 2%, 1.5%, 1.2%, 1%, 0.9%, 0.8%, 0.7%, or 0.6%.

In some embodiments, the extrudate comprises from about 1 wt.% to about 10 wt.%, from about 2 wt.% to about 8 wt.%, or from about 4 wt.% to about 6 wt.% calcium alginate, based on the weight of the extrudate on a moisture-free basis. In some embodiments, the extrudate comprises at least about 0.2 wt%, 0.5 wt%, 1 wt%, 2 wt%, 3 wt%, or 4 wt% calcium alginate, based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate comprises no more than about 15 wt%, 12 wt%, 10 wt%, 9 wt%, 8 wt%, 7 wt%, 6 wt%, 5 wt%, or 4 wt% calcium alginate, based on the weight of the extrudate on a moisture free basis.

In some embodiments, the hydrocolloid is pectin (e.g., pectin having an average DE of at least 50), and the extrudate has a calcium content of no more than about 0.5%, 0.4%, 0.3%, 0.2%, 0.1%, 0.08%, 0.05%, 0.02%, or 0.01%. In some embodiments, the extrudate is substantially free of calcium ions or free of calcium ions.

In embodiments where the extrudate comprises alginate and calcium ions, the extrudate optionally further comprises a chelating or acidifying agent, that is, the chelating or acidifying agent may be used in the extrusion process to prepare the extrudate. Those skilled in the art will appreciate that some or all of the chelating agent may be converted to a different compound (product) during the extrusion process. For example, after extrusion, some or all of the disodium phosphate may become calcium phosphate (product), and some or all of the pyrophosphate may become phosphate (product). Those skilled in the art will also appreciate that some or all of the glucono-delta-lactone (GDL) may be hydrolyzed to gluconic acid and/or salts (products) thereof during the extrusion process. By "the extrudate comprises a chelating agent" it is meant that the extrudate comprises a chelating agent (if residues are present after extrusion) and its corresponding product in the extrusion. Similarly, "the extrudate contains an acidulant" means that the extrudate contains the acidulant (if residues are present after extrusion) and its corresponding product in extrusion.

In some embodiments, the extrudate comprises a chelating agent. In some embodiments, the extrudate comprises a chelating agent selected from the group consisting of: tetrasodium pyrophosphate (TSPP), trisodium phosphate (TSP), disodium phosphate (DSP), sodium Hexametaphosphate (SHMP), trisodium citrate, and mixtures thereof. In some embodiments, the extrudate comprises an acidulant. In some embodiments, the extrudate comprises an acidulant that is glucono-delta-lactone (GDL). In some embodiments, the extrudate comprises gluconic acid and/or salts thereof. In some embodiments, the extrudate comprises a chelating agent that is present in the extrudate as a phosphate compound.

The amount of chelating agent used in the extrusion process to prepare the extrudate is typically less than the stoichiometric amount of bound calcium ions. In some embodiments, the amount of chelating agent (i.e., chelating agent and its corresponding product in the extrusion) present in the extrudate ranges from about 20% to about 85%, or from about 30% to about 80%, or from about 40% to about 75%, or from about 50% to about 75% of the stoichiometric amount. By "(stoichiometric amount of chelating agent) is meant the amount of chelating agent required to bind the amount of calcium ions present in the extrudate. In some embodiments, the amount of chelating agent present in the extrudate is at least about 10%, 20%, 30%, 40%, 50%, 60%, or 70% of the stoichiometric amount. In some embodiments, the amount of chelating agent present in the extrudate is no more than about 90%, 85%, 80%, 75%, 70%, or 65% of the stoichiometric amount.

In some embodiments, the extrudate comprises from about 0.1 wt.% to about 10 wt.%, or from about 0.2 wt.% to about 8 wt.%, or from about 0.4 wt.% to about 5 wt.%, or from about 0.5 wt.% to about 3 wt.% of the acidulant, based on the weight of the extrudate on a moisture-free basis. In some embodiments, the extrudate comprises at least about 0.05 wt%, 0.1 wt%, 0.2 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, or 0.8 wt% acidulant based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate comprises no more than about 15 wt%, 12 wt%, 10 wt%, 9 wt%, 8 wt%, 7 wt%, 6 wt%, 5 wt%, 4 wt%, 3 wt%, or 2 wt% acidulant based on the weight of the extrudate on a moisture free basis.

In some embodiments, the extrudate has a GDL content in the range of from about 0.1% to about 10%, or from about 0.2% to about 8%, or from about 0.4% to about 5%, or from about 0.5% to about 3%. In some embodiments, the extrudate has a GDL content of at least about 0.05%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, or 0.8%. In some embodiments, the extrudate has a GDL content of no more than about 15%, 12%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, or 2%.

In some embodiments, the extrudate consists essentially of: based on the weight of the extrudate on a moisture free basis, (a) soy protein material such that the extrudate comprises from about 75 wt.% to about 85 wt.% soy protein; (b) from about 1% to about 5% by weight of alginate; (c) From about 1 wt% to about 10 wt%, or from about 2 wt% to about 8 wt% of starch, such as tapioca starch; (d) A calcium content of from about 0.1 wt% to about 5 wt%, or from about 0.2 wt% to about 4 wt%, or from about 0.2 wt% to about 3 wt%, or from about 0.3 wt% to about 2 wt%; and (e) from about 1% to about 3% by weight of fiber. In some embodiments, the soy protein material is a soy protein isolate and component (a) is from about 81% to about 94% soy protein isolate.

In the present disclosure, the claimed extrudate (dry or hydrated) has the fundamental and novel features that the claimed extrudate has a full muscle texture, providing the appearance and eating experience of a non-fabricated, natural structured food of meat. For example, the dried extrudate has a water binding ratio of at least about 3. For another example, the hydrated extrudate has an average shear strength of at least about 2500 or 3000 grams. For another example, the hydrated extrudate comprises at least about 40% by weight of macrostructural fiber elements (strands, flakes, and chunks).

In some embodiments, the extrudate comprises, consists essentially of, or consists of: from about 82 wt.% to about 94 wt.%, or from about 84 wt.% to about 92 wt.% soy protein isolate, based on the weight of the extrudate on a moisture free basis; (b) From about 1 wt% to about 5 wt%, or from about 2 wt% to about 4 wt% alginate; (c) From about 2 wt% to about 10 wt%, or from about 3 wt% to about 8 wt% of starch, such as tapioca starch; (d) From about 0.1 wt% to about 1 wt%, or from about 0.2 wt% to about 0.8 wt% calcium ions; and (e) optionally a GDL content of from about 0.3 wt% to about 3 wt%, or from about 0.5 wt% to about 2 wt%.

In some embodiments, the extrudate comprises, consists essentially of, or consists of: from about 80 wt.% to about 96 wt.%, or from about 84 wt.% to about 94 wt.%, or from about 88 wt.% to about 92 wt.% soy protein isolate, based on the weight of the extrudate on a moisture free basis; (b) From about 2 wt% to about 10 wt%, or from about 3 wt% to about 8 wt%, or from about 4 wt% to about 6 wt% calcium alginate; and (c) from about 2 wt% to about 10 wt%, or from about 3 wt% to about 8 wt%, or from about 4 wt% to about 6 wt% of a starch, such as tapioca starch. In some embodiments, such extrudates are free of chelating and/or acidifying agents. In some embodiments, such extrudates are free of phosphate compounds, sulfate compounds, citrate compounds, glucono-delta-lactone, gluconic acid, and/or one or more gluconate salts. It has been unexpectedly found through experimentation that calcium alginate alone can be used as a gelling agent in the extrusion process of the present disclosure to produce an extrudate having a texture similar to that produced with the gelling system of "sparingly soluble calcium compound + sodium or potassium + chelating agent or acidulant". Such extrudates have improved characteristics in terms of the organoleptic characteristics of the irregular exterior shape and the irregular interior structure, thereby simulating the appearance of a non-fabricated, naturally structured food of meat.

In some embodiments, the extrudate comprises, consists essentially of, or consists of: from about 75 wt.% to about 90 wt.%, or from about 80 wt.% to about 90 wt.% soy protein isolate, based on the weight of the extrudate on a moisture free basis; (b) From about 3 wt% to about 8 wt%, or from about 4 wt% to about 6 wt% alginate; (c) From about 3 wt% to about 8 wt%, or from about 4 wt% to about 6 wt% starch, such as tapioca starch; (d) From about 0.4 wt% to about 1.2 wt%, or from about 0.5 wt% to about 1 wt% calcium ions; and (e) from about 0.7 wt% to about 3 wt%, or from about 1 wt% to about 2.5 wt% pyrophosphate and phosphate.

In some embodiments, the extrudate further comprises no more than about 6 wt%, 5 wt%, 4 wt%, 3 wt%, or 2 wt% of an additional fibrous component based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate further comprises at least about 1 wt%, 2 wt%, 3 wt%, 4 wt%, or 5 wt% of an additional fibrous component based on the weight of the extrudate on a moisture free basis.

In some embodiments, the extrudate is dry. In some embodiments, the extrudate has a water content of no more than about 12wt%, 10wt%, 8wt%, 6wt%, 4wt%, 2wt%, or 1wt%, based on the total weight of the extrudate. In some embodiments, the extrudate has a water content of from about 1wt% to about 12wt%, or from about 2wt% to about 6wt%, based on the total weight of the extrudate.

In some embodiments, the extrudate is substantially free of sulfate ions or free of sulfate ions. In some embodiments, the extrudate comprises no more than about 2wt%, 1wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% sulfate ions based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate is substantially free of phosphate ions or free of phosphate ions. In some embodiments, the extrudate comprises no more than about 2wt%, 1wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% phosphate ions based on the weight of the extrudate on a moisture free basis.

In some embodiments, the extrudate is substantially free of starch or free of starch. In some embodiments, the extrudate comprises no more than about 2wt%, 1wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% starch, based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate is substantially free of fibers or free of fibers. In some embodiments, the extrudate comprises no more than about 2wt%, 1wt%, 0.8 wt%, 0.7 wt%, 0.6 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% of fibers based on the weight of the extrudate on a moisture free basis. For clarity, in the present disclosure, the fibers and added fiber components do not include protein fibers formed during the extrusion process of the present disclosure.

In some embodiments, the extrudate is substantially pectin-free or pectin-free. In some embodiments, the extrudate comprises no more than about 2 wt%, 1 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% pectin based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate is substantially free of chelating agents or free of chelating agents. In some embodiments, the extrudate comprises no more than about 2 wt%, 1 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% chelating agent, based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate is substantially free of acidulant or free of acidulant. In some embodiments, the extrudate comprises no more than about 2 wt%, 1 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% acidulant based on the weight of the extrudate on a moisture free basis.

In some embodiments, the extrudate is substantially gluten-free or gluten-free. In some embodiments, the extrudate comprises no more than about 2 wt%, 1 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% gluten, based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate is substantially free of animal-derived ingredients (e.g., eggs) or free of animal-derived ingredients. In some embodiments, the extrudate comprises no more than about 2 wt%, 1 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% animal-derived ingredients (e.g., eggs) based on the weight of the extrudate on a moisture free basis. In some embodiments, the extrudate is substantially free of protein or free of protein. In some embodiments, the extrudate comprises no more than about 2 wt%, 1 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% protein based on the weight of the extrudate on a moisture free basis.

In some embodiments, the extrudate may further comprise a flavoring and/or a fragrance. In some embodiments, the extrudate resembles meat chunks, such as irregular meat chunks, or pieces of varying piece size lengths between 1-4 cm. In some embodiments, the extrudate has a weight of from about 0.30g/cm ³ To about 0.70g/cm ³ Or from about 0.30g/cm ³ To about 0.60g/cm ³ Or from about 0.30g/cm ³ To about 0.50g/cm ³ Is a density of (3). In some embodiments, the extrudate has a water binding ratio of at least about 3. In some embodiments, the extrudate has a water binding ratio in the range of from about 2 to about 6, or from about 2 to about 5, or from about 3 to about 6.

As used herein, the term "macrostructural fiber elements" means meat-like strands, flakes and chunks formed by the extrusion process of vegetable proteins with the aid of hydrocolloids. As used herein, the term "strand" means a macrostructural fiber element strand, particularly a protein strand, that is formed during extrusion of a protein material, typically by protein-protein interactions. Without wishing to be bound by theory, it is believed that the protein-protein interactions are such that the protein interacts or attaches itself in a head-to-tail, or head-to-head, or tail-to-tail fashion. Protein-protein interactions are such that proteins interact or attach in a side-by-side fashion, but to a lesser extent than protein sheets. The physical size of the protein strands from a dried extrudate sheet having an average dimension of about 3cm long by about 2cm wide of OOBR (object-oriented bounding rectangle) is typically greater than about 1/3 of the length of the dried extrudate sheet OOBR. The width of the protein strands is typically less than about 0.2cm to about 1cm wide. The thickness of the protein strands is typically less than about 0.2cm.

As used herein, the term "sheet" means a sheet of macrostructural fibrous elements, particularly soy protein sheets, also typically formed by protein-protein interactions during extrusion of the soy protein material. It is believed that the protein-protein interactions are such that the protein itself interacts or attaches in a head-to-tail, or head-to-head, or tail-to-tail fashion. Protein-protein interactions are such that proteins interact or attach in a side-by-side fashion, but to a greater extent than protein strands. The physical size of the protein flakes from hydrated extrudate flakes having an average OOBR size of about 3cm long by about 2cm wide prior to hydration is typically greater than 1/3 of the OOBR length of about 1cm long or of the dried extrudate flakes. The width of the protein flakes is typically greater than about 1cm wide. The thickness of the protein sheet is typically less than about 0.2cm.

As used herein, the term "mass" means a mass of macrostructural fibrous elements, especially protein masses, also typically formed during extrusion of a protein material by protein-protein interactions. It is believed that the protein-protein interactions are such that the proteins interact themselves in a head-to-tail, or head-to-head, or tail-to-tail fashion With or attached to, but to a lesser extent than, the protein strands. Protein-protein interactions are such that proteins interact or attach in a side-by-side fashion, but to a greater extent than protein strands. The physical size of the protein chunks from hydrated extrudate pieces having an average OOBR size of about 3cm long by about 2cm wide prior to hydration is typically greater than about 1cm long and less than 2cm long or 2/3 of the OOBR length of the dried extrudate pieces. The width of the protein chunks is typically greater than about 1cm or the OOBR length of the dried extrudate sheet ¹ / ₂ . The thickness of the protein chunks is typically greater than about 0.2cm and less than about 1cm or the OOBR length of the dried extrudate sheet ¹ / ₂ 。

In some embodiments, the extrudate (dried or hydrated) comprises substantially aligned macrostructural fiber elements (i.e., strands, flakes, and masses); and/or wherein the arrangement of macrostructural fiber elements is such that on average at least 55% of the fiber elements in the extrudate abut each other at an angle of less than 45 ° when viewed in a horizontal plane; and/or the hydrated extrudate is characterized by an average shear strength of at least 1400 grams; and/or the dry extrudate has about 0.30g/cm ³ To about 0.70g/cm ³ Is a density of (3); and/or the hydrated extrudate has at least 15% of the filament characteristics of a sheet having a length of 2.5cm or greater.

It will be appreciated that the combination of formulation ingredients, and in particular the combination of vegetable proteins and hydrocolloids, in the extrusion process will be able to produce a structured protein product (i.e. extrudate) comprising protein fibers substantially aligned into macrostructural fiber elements in a manner similar to animal meat.

As used herein, the term "substantially aligned" in reference to an arrangement of vegetable protein fibers or macrostructure fiber elements means that the vegetable protein fibers or macrostructure fiber elements present in the extrudate (dried or hydrated) abut each other at an angle of less than about 45 ° when viewed in a horizontal plane. Typically, the extrudate (dried or hydrated) comprises substantially aligned vegetable protein fibers, and an average of at least 55% of the vegetable protein fibers present in the extrudate (dried or hydrated) are substantially aligned. In another embodiment, an average of at least 60% of the vegetable protein fibers present in the extrudate (dry or hydrated) are substantially aligned. In another embodiment, an average of at least 70% of the vegetable protein fibers present in the extrudate (dry or hydrated) are substantially aligned. In another embodiment, an average of at least 80% of the vegetable protein fibers present in the extrudate (dry or hydrated) are substantially aligned. In yet another embodiment, an average of at least 90% of the vegetable protein fibers present in the extrudate (dry or hydrated) are substantially aligned. Methods for determining the degree of protein fiber alignment are known in the art and include visual determinations based on microscopic images.

Dry mix composition

The present disclosure also provides a dry mix composition (formulation) suitable for use in the extrusion process of the present disclosure, such as low moisture extrusion, to prepare the extrudate of the present disclosure. The dry mix composition comprises, on a moisture free basis, based on the total weight of the dry mix composition, (a) from about 65 wt% to about 98 wt% vegetable protein material; (b) From about 1 wt% to about 10 wt% of a hydrocolloid, wherein the hydrocolloid is selected from the group consisting of: alginate, pectin, agar, methylcellulose, and mixtures thereof; and (c) optionally, no more than about 14% by weight starch. A dry mix composition is a dry mix of its components or ingredients. The dry mix composition typically comprises at least about 60 wt%, 70 wt%, 75 wt%, 80 wt%, or 85 wt% vegetable protein, such as soy protein, based on the total weight of the dry mix composition on a moisture free basis.

The dry mix composition comprises from about 65 wt% to about 98 wt%, or from about 70 wt% to about 95 wt%, or from about 75 wt% to about 94 wt%, or from about 80 wt% to about 94 wt% vegetable protein material, based on the total weight of the dry mix composition, on a moisture free basis. In some embodiments, the dry mix composition comprises at least about 65 wt%, 67 wt%, 69 wt%, 71 wt%, 73 wt%, 75 wt%, 77 wt%, 79 wt%, 81 wt%, 83 wt%, 85 wt%, or 86 wt% vegetable protein material based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition comprises no more than about 98 wt%, 97 wt%, 96 wt%, 95 wt%, 94 wt%, 93 wt%, 92 wt%, 91 wt%, 90 wt%, 89 wt%, or 88 wt% vegetable protein material based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the vegetable protein material is a soy protein material. In some embodiments, the soy protein material is selected from the group consisting of: soy protein isolate, soy protein concentrate, and combinations thereof. In some embodiments, the soy protein material is a soy protein isolate. In some embodiments, the dry mix composition comprises no more than 3 wt%, 2 wt%, or 1 wt% oil, based on the total weight of the dry mix composition on a moisture free basis.

In some embodiments, the dry mix composition comprises no more than about 20 wt%, 16 wt%, 14 wt%, 13 wt%, 12 wt%, 11 wt%, 10 wt%, 9 wt%, 8 wt%, 7 wt%, or 6 wt% starch, based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition comprises at least about 0.001 wt%, 0.01 wt%, 0.1 wt%, 0.5 wt%, 1 wt%, 2 wt%, 3 wt%, 4 wt%, or 5 wt% starch, based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition comprises from about 1 wt% to about 14 wt%, or from about 1 wt% to about 10 wt%, or from about 2 wt% to about 9 wt%, or from about 3 wt% to about 8 wt% starch, based on the total weight of the dry mix composition on a moisture free basis.

The dry mix composition comprises from about 1 wt% to about 10 wt%, or from about 1 wt% to about 8 wt%, or from about 1 wt% to about 7 wt%, or from about 2 wt% to about 6 wt% hydrocolloid, based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition comprises at least about 1 wt%, 1.5 wt%, 2 wt%, 2.5 wt%, 3 wt%, 3.5 wt%, or 4 wt% hydrocolloid based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition comprises no more than about 10 wt%, 9 wt%, 8 wt%, 7 wt%, 6.5 wt%, 6 wt%, 5.5 wt%, 5 wt%, 4.5 wt%, or 4 wt% hydrocolloid based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the hydrocolloid is an alginate selected from the group consisting of: calcium alginate, potassium alginate, sodium alginate, and combinations thereof. In some embodiments, the hydrocolloid is calcium alginate. In some embodiments, the hydrocolloid is sodium alginate. In some embodiments, the hydrocolloid is a mixture of sodium alginate and calcium alginate.

In some embodiments, the hydrocolloid comprises, consists essentially of, or consists of an alginate, and the dry mix composition further comprises a calcium-containing compound. In some embodiments, the calcium-containing compound is selected from the group consisting of: calcium alginate, calcium sulfate, calcium carbonate, calcium phosphate, dicalcium phosphate, calcium chloride, (encapsulated) calcium lactate and mixtures thereof. In some embodiments, the calcium-containing compound is a sparingly soluble calcium compound. In some embodiments, the dry mix composition comprises from about 0.1 wt% to about 10 wt%, or from about 0.2 wt% to about 8 wt%, or from about 0.5 wt% to about 6 wt%, or from about 1 wt% to about 5 wt% of the sparingly soluble calcium compound, based on the total weight of the dry mix composition, on a moisture free basis. In some embodiments, the dry mix composition comprises at least about 0.05 wt%, 0.1 wt%, 0.2 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, 0.8 wt%, 0.9 wt%, 1 wt%, 1.2 wt%, 1.5 wt%, 1.8 wt%, or 2 wt% of the sparingly soluble calcium compound, based on the total weight of the dry mix composition on a moisture-free basis. In some embodiments, the dry mix composition comprises no more than about 10 wt%, 9 wt%, 8 wt%, 7 wt%, 6 wt%, 5 wt%, 4 wt%, 3 wt%, or 2 wt% of the sparingly soluble calcium compound, based on the total weight of the dry mix composition, on a moisture free basis. In some embodiments, the sparingly soluble calcium compound is selected from the group consisting of: calcium sulfate, dicalcium phosphate, calcium carbonate and mixtures thereof.

In some embodiments, both the hydrocolloid and the calcium-containing compound are calcium alginate, and the dry-mix composition comprises from about 1 wt% to about 10 wt%, from about 2 wt% to about 8 wt%, or from about 4 wt% to about 6 wt% calcium alginate, based on the total weight of the dry-mix composition on a moisture-free basis. In some embodiments, the dry mix composition comprises at least about 0.5 wt%, 1 wt%, 2 wt%, 3 wt%, or 4 wt% calcium alginate, based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition comprises no more than about 15 wt%, 12 wt%, 10 wt%, 9 wt%, 8 wt%, 7 wt%, or 6 wt% calcium alginate, based on the total weight of the dry mix composition on a moisture free basis.

In some embodiments, the hydrocolloid is pectin (e.g., pectin having an average DE of at least 50), and the dry mix composition is substantially free of calcium-containing compounds (such as sparingly soluble calcium compounds) or free of calcium-containing compounds. In some embodiments, the dry mix composition comprises no more than about 0.5 wt%, 0.4 wt%, 0.3 wt%, 0.2 wt%, 0.1 wt%, 0.08 wt%, 0.05 wt%, 0.02 wt%, or 0.01 wt% of the calcium-containing compound, based on the total weight of the dry mix composition, on a moisture-free basis.

In embodiments wherein the dry mix composition comprises an alginate and a calcium-containing compound, such as a sparingly soluble calcium compound, the dry mix composition optionally further comprises a chelating or acidifying agent. In some embodiments, the dry mix composition comprises a chelating agent. In some embodiments, the dry mix composition comprises a chelating agent selected from the group consisting of: tetrasodium pyrophosphate (TSPP), trisodium phosphate (TSP), disodium phosphate (DSP), sodium Hexametaphosphate (SHMP), trisodium citrate, and mixtures thereof. In some embodiments, the dry mix composition comprises an acidulant. In some embodiments, the dry mix composition comprises glucono-delta-lactone (GDL) as an acidulant.

The amount of chelating agent present in the dry mix composition is typically less than the stoichiometric amount of calcium ions present in the dry mix composition in combination as a calcium-containing compound, such as a sparingly soluble calcium compound. In some embodiments, the amount of chelating agent present in the dry mix composition ranges from about 20% to about 85%, or from about 30% to about 80%, or from about 40% to about 75%, or from about 50% to about 75% of the stoichiometric amount. By "(stoichiometric amount of chelating agent) is meant the amount of chelating agent required to bind the amount of calcium ions present in the dry mix composition. In some embodiments, the amount of chelating agent present in the dry mix composition is at least about 10%, 20%, 30%, 40%, 50%, 60%, or 70% of the stoichiometric amount. In some embodiments, the amount of chelating agent present in the dry mix composition is no more than about 90%, 85%, 80%, 75%, 70%, or 65% of the stoichiometric amount.

In some embodiments, the dry mix composition comprises from about 0.1 wt% to about 10 wt%, or from about 0.2 wt% to about 8 wt%, or from about 0.4 wt% to about 5 wt%, or from about 0.5 wt% to about 3 wt% acidulant, based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition comprises at least about 0.05 wt%, 0.1 wt%, 0.2 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, or 0.8 wt% acidulant, based on the total weight of the dry mix composition on a moisture-free basis. In some embodiments, the dry mix composition comprises no more than about 15 wt%, 12 wt%, 10 wt%, 9 wt%, 8 wt%, 7 wt%, 6 wt%, 5 wt%, 4 wt%, 3 wt%, or 2 wt% acidulant, based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the acidulant is glucono-delta-lactone (GDL).

In some embodiments, the dry mix composition consists essentially of or consists of: from about 81 wt% to about 94 wt% soy protein isolate, based on the total weight of the dry blend composition, on a moisture free basis; (b) From about 1% to about 5% by weight of an alginate, such as sodium alginate and/or potassium alginate; (c) From about 1 wt% to about 10 wt%, or from about 2 wt% to about 8 wt% of starch, such as tapioca starch; (d) From about 1% to about 10%, or from about 1% to about 8%, or from about 1% to about 6%, or from about 1% to about 4% by weight of a calcium-containing compound selected from the group consisting of calcium carbonate, calcium alginate, calcium sulfate, and mixtures thereof; and (e) from about 1% to about 3% by weight of fiber. In the present disclosure, the claimed dry mix compositions have one or more of the basic and novel features that enable the formation of the disclosed extrudates by extrusion methods.

In some embodiments, the dry mix composition comprises, consists essentially of, or consists of: from about 82 wt% to about 94 wt%, or from about 84 wt% to about 92 wt% soy protein isolate, based on the total weight of the dry blend composition, on a moisture free basis; (b) From about 1 wt% to about 5 wt%, or from about 2 wt% to about 4 wt% of an alginate, such as sodium alginate and/or potassium alginate; (c) From about 2 wt% to about 10 wt%, or from about 3 wt% to about 8 wt% of starch, such as tapioca starch; (d) From about 0.3 wt% to about 3 wt%, or from about 0.5 wt% to about 2 wt% calcium carbonate; and (e) optionally from about 0.3 wt% to about 3 wt%, or from about 0.5 wt% to about 2 wt% glucono-delta-lactone (GDL).

In some embodiments, the dry mix composition comprises, consists essentially of, or consists of: from about 80 wt.% to about 96 wt.%, from about 84 wt.% to about 94 wt.%, or from about 88 wt.% to about 92 wt.% of soy protein isolate, based on the total weight of the dry mix composition on a moisture free basis; (b) From about 2 wt% to about 10 wt%, or from about 3 wt% to about 8 wt%, or from about 4 wt% to about 6 wt% calcium alginate; and (c) from about 2 wt% to about 10 wt%, or from about 3 wt% to about 8 wt%, or from about 4 wt% to about 6 wt% of a starch, such as tapioca starch. In some embodiments, such dry mix compositions are free of chelating and/or acidifying agents. It has been unexpectedly found through experimentation that calcium alginate alone can be used as a gelling agent in the extrusion process of the present disclosure to produce an extrudate having a texture similar to that produced with the gelling system of "sparingly soluble calcium compound + sodium or potassium + chelating agent or acidulant". Such extrudates have improved characteristics in terms of the organoleptic characteristics of the irregular exterior shape and the irregular interior structure, thereby simulating the appearance of a non-fabricated, naturally structured food of meat.

In some embodiments, the dry mix composition comprises, consists essentially of, or consists of: from about 75 wt.% to about 90 wt.%, or from about 80 wt.% to about 90 wt.% of soy protein isolate, based on the total weight of the dry mix composition on a moisture free basis; (b) From about 3 wt% to about 8 wt%, or from about 4 wt% to about 6 wt% of an alginate, such as sodium alginate and/or potassium alginate; (c) From about 3 wt% to about 8 wt%, or from about 4 wt% to about 6 wt% starch, such as tapioca starch; (d) From about 1 wt% to about 7 wt%, or from about 2 wt% to about 5 wt% calcium sulfate (hydrated or anhydrous); and (e) from about 0.7 wt% to about 3 wt%, or from about 1 wt% to about 2.5 wt% of a chelating agent selected from the group consisting of: tetra sodium pyrophosphate (TSPP), trisodium phosphate (TSP), disodium phosphate (DSP), sodium Hexametaphosphate (SHMP), and mixtures thereof.

In some embodiments, the dry mix composition further comprises no more than about 6 wt%, 5 wt%, 4 wt%, 3 wt%, or 2 wt% of an additional fibrous ingredient, based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition further comprises at least about 0.5 wt%, 1 wt%, 2 wt%, 3 wt%, 4 wt%, or 5 wt% of an additional fibrous ingredient, based on the total weight of the dry mix composition, on a moisture free basis. In some embodiments, the added fiber component is citrus fiber.

The dry mix composition is dry. In some embodiments, the dry mix composition has a water content of no more than about 10wt%, 8wt%, 6wt%, 4wt%, 2wt%, or 1wt%, based on the total weight of the dry mix composition. In some embodiments, the dry mix composition has a water content of from about 1wt% to about 10wt%, or from about 2wt% to about 6wt%, based on the total weight of the dry mix composition.

In some embodiments, the dry mix composition is substantially free of sulfate ions or free of sulfate ions. In some embodiments, the dry mix composition comprises no more than about 2wt%, 1wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% sulfate ions based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition is substantially free of phosphate ions or free of phosphate ions. In some embodiments, the dry mix composition comprises no more than about 2wt%, 1wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% phosphate ions, based on the total weight of the dry mix composition, on a moisture free basis.

In some embodiments, the dry mix composition is substantially free of starch or free of starch. In some embodiments, the dry mix composition comprises no more than about 2wt%, 1wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% starch, based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition is substantially free of fibers or free of fibers. In some embodiments, the dry mix composition comprises no more than about 2wt%, 1wt%, 0.8 wt%, 0.7 wt%, 0.6 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% of fibers based on the total weight of the dry mix composition on a moisture free basis.

In some embodiments, the dry mix composition is substantially pectin-free or pectin-free. In some embodiments, the dry mix composition comprises no more than about 2 wt%, 1 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% pectin, based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition is substantially free of chelating agents or free of chelating agents. In some embodiments, the dry mix composition comprises no more than about 2 wt%, 1 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% chelating agent, based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition is substantially free of acidulant or free of acidulant. In some embodiments, the dry mix composition comprises no more than about 2 wt%, 1 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% acidulant, based on the total weight of the dry mix composition, on a moisture free basis.

In some embodiments, the dry mix composition is substantially gluten-free or gluten-free. In some embodiments, the dry mix composition comprises no more than about 2 wt%, 1 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% gluten, based on the total weight of the dry mix composition on a moisture free basis. In some embodiments, the dry mix composition is substantially free of animal-derived ingredients (e.g., eggs) or free of animal-derived ingredients. In some embodiments, the dry mix composition comprises no more than about 2 wt%, 1 wt%, 0.5 wt%, 0.2 wt%, or 0.1 wt% animal-derived ingredients (e.g., eggs) based on the total weight of the dry mix composition on a moisture free basis.

Extrusion process

The dry mix composition is suitable for mixing with water to form a feed mixture suitable for extrusion. The present disclosure also provides an extrusion method of making the extrudate of the present disclosure. The extrusion method comprises the following steps: (a) Contacting the dry-blended composition of the present disclosure with water to form a feed mixture; (b) Feeding the feed mixture into an extruder to form a melt extruded mass; and (c) extruding the molten extrudate through an extrusion die to produce an extrudate. In some embodiments, the extrusion process is a low moisture extrusion process. In some embodiments, the extrudate produced in step (c) is further dried.

In some embodiments, the components (i.e., ingredients) of the dry mix composition are introduced into a mixing tank to combine and mix the components to form the dry mix composition. The dry blend composition is then transferred to a hopper from which the dry blend is introduced with moisture into a preconditioner to form a feed blend. The feed mixture is then fed into an extrusion apparatus (i.e., an extruder) where it is processed under mechanical pressure generated by the extruder's screw to form a molten extruded mass. The molten extrudate exits the extruder through an extrusion die to form an extrudate. In some embodiments, the molten extrusion material exits the extrusion die in a discontinuous manner. In some embodiments, the molten extrudate is shaped by a die arrangement and cut with rotating blades as it exits. In some embodiments, the shape and size of the extrudate is formed by increasing the shear rate of the extruder to create a discontinuous pattern and/or adjusting the cutter speed of the rotating blades.

Hydration process and hydrated extrudate

The present disclosure also provides a method of preparing a hydrated extrudate. The method includes hydrating the extrudate of the present disclosure in an aqueous solution, such as water, to form the hydrated extrudate. As used herein, the term "hydrated" or "rehydrated" when applied to an extrudate means an extrudate that is hydrated or rehydrated in an aqueous solution comprising water, optionally drying the extrudate. In some embodiments, the aqueous solution comprises at least about 80%, 85%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, or 99% water, based on the weight of the aqueous solution. In some embodiments, the aqueous solution is water. In some embodiments, the aqueous solution further comprises a fragrance and/or flavor. In some embodiments, the extrudate is dried prior to the hydration step.

In some embodiments, the hydration process is performed by hydrating about one part by weight of the extrudate (e.g., a dry extrudate) in about three parts by weight of the aqueous solution. The hydration process may be carried out at ambient pressure or under vacuum. In some embodiments, the hydration process is performed under vacuum, such as at about 20% to about 100% vacuum (about-0.2 bar to about-1 bar), or at about 20% to about 50% vacuum (about-0.2 bar to about-0.5 bar), or no more than about 50% vacuum (-0.5 bar), or at least about 20% vacuum (about-0.2 bar).

In some embodiments, the hydration time (duration of the hydration process) is from about 30 minutes to about 180 minutes, or from about 60 minutes to about 120 minutes, or from about 90 minutes to about 120 minutes. In some embodiments, the hydration process is performed by immersing the extrudate in an aqueous solution. In some embodiments, the extrudate may be hydrated by adding 3 parts by weight water and 1 part by weight extrudate to a vacuum bag, and then sealing the vacuum bag on a vacuum packaging machine, such as a webmatic vacuum packaging machine. The sealed bag is frequently shaken and turned over throughout the hydration process to ensure uniform hydration.

Typical shelf-stable structured plant protein products require rehydration and are generally uniform for end use. These products exhibit a spongy texture during rehydration; this feature provides negative organoleptic attributes to the final meat substitute application. This problem presents challenges and would require further processing and reconstitution to eliminate the breathable texture and improve the overall texture to simulate a full muscle product; in addition, these products need to be shaped to meet the appearance and sensory attributes of the end application.

The present disclosure provides descriptions and compositions of extrudates, which are irregularly shaped, shelf-stable, structured plant protein products. When the extrudate of the present disclosure is (re) hydrated with water, flavoring and/or color, the resulting hydrated extrudate is a ready-to-use meat substitute food product having an appearance similar to a full muscle product, such as chunks, cubes, filaments, strips, and the like.

As used herein, the term "dry extrudate" refers to an extrudate (e.g., a low moisture extrudate) after drying and before hydration or rehydration. "dry extrudate" may sometimes be referred to herein simply as an extrudate or low moisture extrudate. Typically, the dried extrudate has a water content of less than about 12wt%, preferably less than about 10wt%, based on the total weight of the extrudate.

In some embodiments, the hydrated extrudate comprises at least about 15wt% of segments comprising macrostructural fiber elements comprising strands at least about 1cm long or having a length of 1/3 of a dried extrudate, and/or sheets at least about 1cm long or having a length of 1/3 of a dried extrudate and at least 1cm wide or having a width of 1/2 of a dried extrudate, and/or sheets at least about 1cm long or having a length of 1/3 of a dried extrudate or at least 1cm wide or having a width of a dried extrudate ¹ / ₂ Width and up to 1cm thick or withThere is a 1/2 thickness block of dry extrudate.

The total amount of strands, flakes and chunks can be determined by a filament characterization test in which they appear as "large flakes". In some embodiments, the hydrated extrudate comprises from about 20wt% to about 70wt%, or from about 22wt% to about 65wt%, or from about 24wt% to about 60wt%, or from about 40wt% to about 65wt%, or from about 45wt% to about 60wt% of the macrostructure fiber elements (strands, flakes, and pieces), based on the weight of the hydrated extrudate. In some embodiments, the hydrated extrudate comprises at least about 15wt%, 20wt%, 22wt%, 24wt%, 26wt%, 28wt%, 30wt%, 32wt%, 34wt%, 36wt%, 38wt%, 40wt%, 42wt%, 44wt%, 46wt%, or 48wt% of the macrostructure fiber elements (strands, sheets, and pieces) based on the weight of the hydrated extrudate. In some embodiments, the hydrated extrudate comprises no more than about 75wt%, 70wt%, 68wt%, 66wt%, 64wt%, 62wt%, 60wt%, 58wt%, 56wt%, or 54wt% of the macrostructural fiber elements (strands, sheets, and pieces) based on the weight of the hydrated extrudate.

In some embodiments, the hydrated extrudate has an average shear strength of at least about 1400 grams, such as at least about 1500, 1600, 1700, 1800, 1900, 2000, 2200, 2400, 2600, 2800, 3000, 3200, 3400, 3600, or 3800 grams. In some embodiments, the hydrated extrudate has an average shear strength of no more than about 6000, 5500, 5000, 4800, 4600, 4400, 4200, 4100, 4000, or 3900 grams. In some embodiments, the hydrated extrudate has an average shear strength in the range of from about 2000 to about 5500 grams, or from about 2500 to about 5000 grams, or from about 3000 to about 4500 grams.

Many aspects and embodiments have been described above and are merely illustrative and not restrictive. After reading this specification, skilled artisans will appreciate that other aspects and embodiments are possible without departing from the scope of the present invention.

Examples

The concepts described herein will be further described in the following examples, which do not limit the scope of the invention as described in the claims.

Analytical methods and terms

As used herein, the term "density" means a density determined by a salt displacement method as described below. All length measurements are in millimeters (mm), all volume measurements are in milliliters (ml), and all weight measurements are in grams (g). The salt is granular salt with the following particle size distribution:

salt (from about 1.29 g/cm) was added using a container of known volume and known weight (tare) ³ Up to about 1.40g/cm ³ Is added to a depth of about 5 mm. A known weight of extrudate is added to the top of the salt, but not to contact the walls of the vessel. Salt is added to the container to the point of overflow, the filled container on the table is tapped to wrap the salt around the extrudate, and a spatula is used to flush the salt with the rim of the container. The weight of the filled container was recorded and the weight of the extrudate and tare were subtracted to give the weight of salt in the filled container. The weight of the salt is divided by the density of the salt to give the volume of salt in the filled container. The volume of salt is subtracted from the known volume of the vessel to obtain the volume of extrudate in the vessel. Dividing the weight of the extrudate by the volume of the extrudate to obtain its density in g/cm ³ 。

As used herein, the term "water binding ratio" means the amount of water that the extrudate can hold or bind during 60 minutes of hydration at room temperature. It is therefore described as the ratio of (mass of water held)/(mass of extrudate). The water binding ratio at 60 minutes hydration time was determined by the following procedure: about 10 to 15 pieces of the dried extrudate sample are weighed [ W1] and the extrudate sample is hydrated with enough water at room temperature (e.g., 7 parts water to 1 part extrudate sample) such that the extrudate sample is completely submerged under water throughout the 60 minute hydration process. During hydration, the extrudate sample may be kept submerged with a suitable substance, such as a water container. After hydration, the hydrated extrudate samples were drained on mesh #8 (2.38 mm) or #10 (2.00 mm) 8"x2" screens for at least 10 seconds, up to 1 minute, and then weighed [ W2]. The water bonding ratio was [ (W2-W1)/W1 ].

As used herein, the term "water content" means the amount of moisture in a material. The water content may be determined by a.o.c.s. (american society of oleochemists (American Oil Chemists Society)) office Method, ba 2a-38 (1997), which is incorporated herein by reference in its entirety for all purposes. According to this method, the water content of the material may be measured by passing 1000g samples of the abrasive material through a 6x6 splitter (rildledivider) available from Seedboro Equipment company (Seedboro Equipment co., chicago, illinois) in Chicago, il. 100g of the sample was then immediately placed in an airtight container and weighed. 5 grams of the sample ("sample weight") was weighed onto a tare moisture measuring dish (30 minimum, approximately 50x20 mm with a close fitting sliding lid-available from Sargent-Welch company (Sargent-Welch co.). The assay dish containing the sample was placed in a forced air oven and dried at 130±3 ℃ for 2 hours. The dish was then removed from the oven, immediately capped, and cooled to room temperature in a desiccator. The dish was then weighed to obtain the dry weight. The water content was calculated according to the following formula: water content (%) =100 x [ (sample weight-dry weight)/sample weight ].

As used herein, the term "calcium content" means the amount by weight of elemental calcium in a material on a moisture free basis based on the weight of the material. The terms "calcium" and "calcium ion" may be used interchangeably in this disclosure. The amount of calcium in the material can be determined by ICP emission spectroscopy (ICP-OES), using Official Methods of Analysis of AOAC INTERNATIONAL [ analytical method legal for international AOAC ], variants of methods 984.27, 985.01 and 2011.14 (international AOAC, gaithersburg, maryland, USA (AOAC INTERNATIONAL, gaithersburg, MD, USA)), which is incorporated herein by reference in its entirety for all purposes. The sample is dry ashed, wet ashed or read directly. If dry ashing is performed, the sample is placed in a muffle furnace (mux furnace) and set to maintain 500 ℃ until ashing is completed. The resulting ash was treated with concentrated hydrochloric acid, dried and redissolved in hydrochloric acid solution. If wet ashing is performed, the sample is digested with nitric acid, hydrochloric acid, and/or hydrogen peroxide in a microwave oven or on a hot plate. The amount of calcium element was determined by ICP spectrometry by comparing the emission of the sample with the emission of calcium element in the standard solution.

The "protein content" or "amount of protein" in a material (e.g., soy protein content or amount of soy protein) can be determined according to a.o.c.s. (american society of oleochemistry) Method Bc 4-91 (1997), aa 5-91 (1997), or Ba 4d-90 (1997), each of which is incorporated herein by reference in its entirety for all purposes, which determines the total nitrogen content of a sample of the material as ammonia and the protein content as 6.25 times the total nitrogen content of the sample.

The Nitrogen-Ammonia-protein modification Kjeldahl method [ Bc 4-91 (1997), aa 5-91 (1997), and Ba 4d-90 (1997) used in the determination of the soybean protein content can be performed with powder or ground soybean material samples as follows. From 0.0250-1.750 grams of soy material was weighed into a standard Kjeldahl flask (Kjeldahl flash). A commercially available catalyst mixture of 16.7 grams potassium sulfate, 0.6 grams titanium dioxide, 0.01 grams copper sulfate, and 0.3 grams pumice was added to the flask, and then 30 milliliters of concentrated sulfuric acid was added to the flask. Zeolite was added to the mixture and the soy material sample was digested by heating the flask in a boiling water bath for about 45 minutes. During digestion, the flask should be rotated at least 3 times. Water (300 ml) was added to the sample in the flask and the sample was cooled to room temperature. Standardized 0.5N hydrochloric acid and distilled water were added to the distillate-receiving flask, with the hydrochloric acid and distilled water being sufficient to cover the end of the distillation outlet tube at the bottom of the receiving flask. Sodium hydroxide solution was added to the digestion flask in an amount sufficient to render the digestion solution strongly alkaline. The digestion flask was then immediately connected to a distillation outlet tube, the contents of the digestion flask were thoroughly mixed by shaking and heated to the digestion flask at a boiling rate of about 7.5-min until at least 150 milliliters of distillate was collected. The contents of the receiving flask were then titrated with 0.25N sodium hydroxide solution using 3 or 4 drops of methyl red indicator solution (0.1% ethanol solution). Blank determination of all reagents was performed simultaneously with the sample, similarly in all respects, and correction was made for the blank determined on the reagents. The nitrogen content of the sample was determined according to the following formula: nitrogen (%) = 1400.67x [ [ (equivalent concentration of standard acid) x (volume of standard acid (ml) for sample)) ] [ (standard base volume required to titrate 1ml of standard acid (ml) minus standard base volume required to titrate reagent blanks carried by the method and distilled into 1ml of standard acid) x (equivalent concentration of standard base) ] [ (volume of standard base (ml) for sample) x (equivalent concentration of standard base) ] ]/(milligrams of sample). The protein content was 6.25 times the nitrogen content of the sample.

As used herein, the term "patch size" is intended to refer to 2-dimensional measurements of the length, width, and area of irregularly shaped patches provided by a multispectral imaging analyzer system that combines illumination, camera, and computer techniques with advanced digital image analysis and statistics. A suitable multispectral imaging analyzer system for making these measurements is the Videometer Lab model 4 developed and manufactured by Videometer A/S Inc. (Denmark). The extrudate samples (dried or hydrated) were randomly placed 3 pieces into a petri dish without contact and submitted to videomerlab for imaging and image processing. The sheet size is expressed in terms of length, width and area of each individual sheet. The area measurement is the number of pixels in a tile multiplied by the area of the pixel, the latter resulting from calibration of the camera system. The length and width are defined relative to an object-oriented bounding rectangle (OOBR) of the tile, where the object direction is defined as a feature vector direction of the first principal component. Each extrudate sample had 5 different petri dishes, a total of 15 pieces were imaged, and the results of the average piece size dimensions were reported.

As used herein, the term "shear strength" measures the ability of a textured protein to form a fibrous network that is strong enough to impart a meat-like texture and appearance to the formed product. Shear strength is measured in grams. Shear strength was determined by the following procedure: the extrudate sample was weighed and placed in a heat sealable bag and hydrated with 3 times the weight of the room temperature tap water sample. The bag was evacuated to 150mm Hg and sealed and the sample water was allowed to run for about 12 to about 24 hours. The hydrated sample is removed and placed on the texture analyzer substrate such that the texture analyzer knife cuts across the sample diameter. Further, the sample should be oriented under the texture analyzer knife such that the knife cuts perpendicular to the long axis of the textured sheet. A suitable knife for cutting the extrudate is a model TA-45 incisor blade manufactured by Texture Technologies company (U.S.). A suitable texture analyser for performing this test is the ta.tx.plus model manufactured by stable microsystems limited (Stable Micro Systems ltd., uk) equipped with a 5, 30, 50 or 100Kg load cell. In this test, shear strength is the maximum force required to penetrate the sample in grams. Each extrudate sample was run 10 times and the average results reported.

As used herein, the term "macroreticular fiber elements (i.e., strands, flakes and chunks) present in the extrudate are meant. In the filament characterization test, the shredded extrudate sheet containing macroscopically structured fibrous elements appears as "large sheets" that are physically larger than shredded extrudate sheets lacking macroscopically structured fibrous elements. The hydrated extrudate comprises at least about 15% by weight of the large flakes based on the weight of the hydrated extrudate. The large pieces were determined by a filament characterization test. Filament characterization is a test that generally determines the percentage of large pieces formed in an extrudate. Filament characterization provides an additional means to quantify the degree of alignment of vegetable protein fibers in the extrudate. In general, as the percentage of flakes increases, the degree of alignment of vegetable protein fibers within the extrudate typically increases. Conversely, as the percentage of flakes decreases, the degree of vegetable protein fibers aligned within the extrudate typically also decreases.

The procedure for the filament characterization test is as follows: using only a whole piece, about 150g of the dried extrudate sample was weighed, placed in a heat sealable plastic bag, and about 450g of 25℃water was added. The bag was vacuum sealed at about-150 mm Hg (about 20% vacuum or about-0.2 Bar) and the extrudate was hydrated for 60 minutes. The hydrated extrudate was placed in a 5 quart bowl of a heavy-duty bench mixer equipped with a single-blade flat paddle and the hydrated extrudate was mixed at 130rpm for 2 minutes. Suitable mixers for carrying out this test are 325W kitchen auxiliary heavy mixers model KM14G0 or model Pro 500. Scraping the side surfaces of the paddle and the bowl, and putting the scraped things back to the bottom of the bowl. Mixing and scraping were repeated 2 times. A 50 to 200g portion of the mixture was removed from the bowl and weighed. The mixture was divided into 1 out of 5 groups. Group 1 is a group of strands, wherein the strands are at least 1cm long and at most 1cm wide and at most 0.2cm thick or as defined in the present disclosure. Group 2 is a panel wherein the panels are at least 1cm long and at least 1cm wide and at most 0.2cm thick or as defined in the disclosure. Group 3 is a group of blocks, wherein the blocks are 1 to 2cm long and 0.5cm to 1cm wide and greater than 0.2cm thick or as defined in the present disclosure. Group 4 is a largely complete hydrated extrudate sheet of a size greater than the mass. The remaining mixtures are group 5. The percentage of large pieces is determined by: the total weights of group 1 + group 2 + group 3 are added, multiplied by 100 and divided by the total weight of group 1 + group 2 + group 3 + group 4 + group 5.

The extrudate sheet analysis function may be further characterized by, for example, X-ray tomography, which provides visual recordings of internal structures and provides quantitative measurements of void space and wall thickness. Magnetic Resonance Imaging (MRI) is a potential alternative analysis of hydrated extrudates. Microscopy may also be used.

Example 1

The extrudate samples of the present disclosure were produced by a low moisture extrusion process and analyzed and compared to commercially available samples. Extrudate samples were produced by using the corresponding samples of dry blended compositions (formulations) shown in table 1. The amounts of the components (ingredients) in table 1 are weight percent based on the total weight of the dry blend composition on a moisture free basis.

TABLE 1 samples of dry mix compositions for preparing corresponding samples of extrudates

Two reference samples were used for comparison. Reference 1 is a commercially available low moisture extrudate containing wheat gluten. Reference 2 is the same as reference 1 except that it was produced using the same extrusion process on the same pilot scale equipment as samples 1-5 in table 1.

Typical low moisture extrusion methods follow these typical steps: the components as listed in table 1 were dry blended using a blending apparatus to form a dry blended composition that was conveyed by air transfer or auger to a fixed bin and then further conveyed to a feed bin typically located above the extruder. The extruder system may be a single extruder or a twin extruder with a preconditioner above the inlet of the extruder. The dry mix composition (dry feed) is introduced into an extruder or preconditioner and if the preconditioner is part of an extrusion system, water and/or other liquids may be added directly into the extruder barrel or at two locations. Low moisture extrusion is considered to be a water or liquid/dry feed ratio of <40% (0.4 parts water-liquid/1 part dry feed rate). The total water added between the preconditioner and the extruder will account for the total water ratio. The dry mix composition is contacted or mixed with water (and optionally other liquids) to form a feed mixture into an extruder.

The low moisture extrusion process is typically performed using medium to high shear screw configuration profiles, and the amount of energy in the profile is selected according to the final product attributes and the components used in the dry blend composition. After addition of the feed mixture, the extruder is typically rotated at >200rpm to obtain sufficient mechanical energy to bring the extrudate temperature to >100 ℃; most commonly the extrudate temperature is >120 ℃ and the pressure in the extruder cone region is >100psi to achieve product texturing/puffing. The feed mixture is converted into a molten extrudate in an extruder under high temperature, high pressure and mechanical shear.

As the molten extrudate exits the extrusion die, the partially superheated and pressurized water is converted to steam, which is then flushed and formed into bubbles, thereby creating a network of extrudate (honeycomb-like air-permeable structure). The extrudate is typically segmented/cut using a rotary cutter to provide the appropriate particle size or dimensions of the final extrudate product. Additional mills or size reduction equipment can be used after die cutting to obtain the correct particle size, form and structure of the final extrudate product. After sizing, the extrudate product air is typically passed into a dryer to reduce the water content to a shelf stable range, typically <12wt% and preferably <10wt%.

Extrusion method for preparing extrudate samples: the components of each sample of the dry blend composition were blended in a horizontal ribbon blender having a capacity of 300 lbs of TD415 (daqi company (DODGE OF Mishawaka, ind.) of Mi Shawa card, indiana) for 30 minutes to form a dry blend composition that was a homogeneous mixture of the components. Each dry blend composition was fed manually into a feed bin and mechanically transferred to an extruder hopper and then fed into a preconditioner at 70KG/Hr. (1.16 Kg/Min). Steam was injected into the preconditioner at 5% dry basis (about 3Kg/Hr. steam) to achieve a downcomer preconditioner temperature of 45-50 ℃. This temperature is measured by a thermocouple located at the discharge end of the preconditioner. Water was added to the preconditioner and a constant flow was maintained at a 15wt% dry basis addition rate of 10.5Kg/Hr. (0.18 Kg/Min). The residence time of the dry mix composition in the preconditioner is about 4 minutes, wherein the dry mix composition is contacted or mixed with water to form a feed mixture into the extruder.

The preconditioned dry blend composition (i.e., feed mixture) is then fed into the extruder using a transition to prevent leakage, excess dust, and ensure consistent flow into the extruder. The extrusion process was performed using a Wenger TX-52 twin screw extruder (19/1L/D ratio) manufactured by Wenger manufacturing company (Wenger Manufacturing inc., sabotha, KS) of sassa Bei Sa, kansasa. The extruder barrel temperature was maintained at the following settings: zone 1 (60 ℃ to 70 ℃), zone 2 (80 ℃ to 100 ℃), zone 3 (120 ℃ to 130 ℃) and zone 4 (120 ℃ to 130 ℃). The high shear screw configuration was used to produce the low moisture extrudates shown in table 2: a transfer-inlet, a transfer-zone 1, a transfer/mix and compress-zone 2, a mix/shear/compress-zone 3, and a compress/mix/shear-zone 4. During the extrusion process, water was pumped into the first part of the extruder in 8wt% to 10wt% dry basis and the extruder speed was adjusted between 350-400rpm to achieve good texturing. The extruder cone pressure was 200-300psi and the motor load was 28% -35%.

The melt-extruded substance formed in the extruder is extruded through an extrusion die. One 2 inch die extension and two 9mm die inserts, one insert positioned on each side of the extruder screw, formed into the rope shape of the extrudate, and then at the die exit, 1 flexible blade co-rotated at 300-500rpm to obtain the length of extrudate.

The extrudate product was dried in a continuous single pass buchner Dryer (Proctor Dryer) at 260°f-270°f for a residence time of 20 minutes to achieve a final extrudate product water content of <10 wt.%, and then packaged for final meat replacement applications. The analysis results of the final extrudate product are shown in table 2.

TABLE 2 analytical characterization of low moisture extrudates prepared with corresponding samples of dry blend compositions in TABLE 1

* This sample was slow to hydrate and did not hydrate completely after a 60 minute hydration time, almost all tablets had significant hard spots when handled. After a hydration time of 120 minutes, its water binding ratio was 2.89, but it was still not completely hydrated, and almost all sheets had a significant hard spot when handled. Like other samples of extrudates, overnight hydration of this sample resulted in a water binding ratio of > 3.5. In contrast, the reference 2 sample was completely hydrated at 60 minutes, and the water binding ratio was hardly changed at the hydration time of 120 minutes, which was a value of 2.87.

+this sample had an additional 26wt% in group 4: most of the complete tablet.

Additional notes: ref.2 means a reference 2 sample; db means dry basis (on moisture-free basis); av means average; s. means the sample.

Analytical characterization of reference 2 samples and samples 1-5 of the extrudates of the present disclosure showed that the results of water content, average dry flake area, average dry flake length, and average dry flake width were within the same range. Although reference 2 contained wheat gluten, samples 1-5 showed a dry protein content in the same range or up to 6.9wt% higher than reference 2, whereas samples 1-5 did not contain gluten. Samples 1-5 had a higher average dry sheet density (g/cm) ³ ). Samples 2-5 showed a higher water binding ratio at 60 minutes as compared to the reference 2 sample. Samples 2-5 had more than twice the average shear strength compared to the reference 2 sample, indicating that the extrudates of samples 2-5 had a stronger fibrous macrostructure, thereby simulating the texture of non-fabricated, naturally structured foods for meats in a better manner than reference 2. Samples 1-5 had significantly higher fiber macrostructure bulk content than reference 2, simulating the texture of non-fabricated, naturally structured foods for meats in a better manner than reference 2.

Example 2

The extrudate samples of the present disclosure (samples 2, 3, and 4) were hydrated and cooked and compared to the commercial reference 1 sample for sensory evaluation. Before processing the extrudate into a dietary component, hydration is required to soften the extrudate and render it edible and change the stage from a dry form to a moist and fibrous form. A sample of hydrated extrudate was prepared by hydrating (soaking) the corresponding sample of dry extrudate in an aqueous solution comprising water and flavor shown in table 3. The amounts of the ingredients in table 3 are weight percent based on the total weight of the dry extrudate and the aqueous solution.

Table 3: composition of hydrated low moisture extrudate

Annotation: ref.1 means hydrating a reference 1 sample; s. means the sample.

All dry flavors and fragrances as given in table 3 were dispersed in hydration water with 10% flake ice using a Bamix hand blender at speed 2 until no dry nuggets were present and the resulting aqueous solution achieved a uniform appearance. The blending time was about 1min. The dry extrudate and aqueous solution are combined in a tumbler system Simatic into a cylinder with a vacuum lid. The tumbler system is located in a cooling chamber having a maximum temperature of 4 ℃. The vacuum cap was attached and vacuum was applied at-1 bar vacuum pressure (about 100% vacuum). The cylinder is directed into each space by a rotating rubber roller. By programming the settings in the control panel, all the rollers are activated at the same adjustable speed and direction: forward rotation was set at 30,7rpm for 10 minutes, and reverse rotation was set at 30,7rpm for 10 minutes. This cycle of changing forward and reverse rotations continues until all extrudates are fully hydrated. The tumbling/hydration times vary from sample to sample and are between 90 and 120 minutes. The size of the extrudate influences the sensory evaluation results. Thus, the hydrated extrudate was cut with a knife to achieve uniform size (normalized size) for all the different samples.

The cooking method is divided into two sub-steps. The first step is to flash fry the hydrated extrudate pieces and vegetables separately. Vegetables include sliced ginger and carrot, sliced white cabbage, frozen red/green/yellow pepper, salt and garlic. For both available sections, the fryer Joni food line was preheated at setting 3/10. 5% vegetable rapeseed oil was preheated and the hydrated extrudate was placed into a pan. Each portion was fried for 8 minutes while scraping and flipping frequently to make the baking uniform. After this, the vegetables were fried in the same setting.

The second step is to combine the fried extrudate with the vegetables and finally heat the dish. The fried extrudate and vegetables were combined in a 1:2 ratio in a covered gastro tray. Final heating was carried out in a random oven at 150 ℃ for 45 minutes with a moisture/dry heat balance of 50%/50%. After the final heating, the heat was reduced to 85 ℃, the lid was still open and kept warm until consumption or a maximum of 3 hours. The reference chicken breast cooking method is the same as the extrudate cooking method except that the chicken does not need to be hydrated, so the spices and flavors are added without the addition of water.

Nine participants participated in the sensory evaluation link. The evaluation link is first introduced to study participants to understand and describe chicken-like properties. An uncoded cooked reference chicken breast sample was given to the participants to familiarize with the morphology, texture, and texture of the chicken. In this way they can return a reference and repeatedly taste at any time for memory purposes throughout the evaluation process. The cooked reference 1 sample and the cooked extrudate sample were incubated and provided one at a time in random order with unidentifiable codes. Participants were asked to evaluate the proximity of the reference 1 and extrudate samples to the chicken breast references (considering aroma, appearance, flavor and texture) in a range from 0 to 10 (10 is true chicken breast). The grading of chicken-like attributes is registered in the phone software EyeQuestion by scanning the QR code, and once the grading is given, cannot be changed. During this link, no conversation or exchange of comments is allowed between the participants, as each score represents a fair judgment of the individual. Scores were automatically collected and are shown in table 4.

Table 4: scoring of chicken-like attributes

Sample of	Scoring of chicken-like attributes
		Reference 1 sample	5.24
Extrudate sample 2	6.26
		Extrudate sample 3	6.33
Extrudate sample 4	6.46

Example 3

The extrudate samples of the present disclosure (samples 1, 2, 3, 4, and 5) were hydrated and compared to references 1 and 2 for sensory (eating experience) evaluation. The extrudate needs to be sufficiently hydrated for reliable evaluation. The extrudate is added to a vacuum bag. Tap water was added to the vacuum bag in a ratio of 1 part by weight extrudate to 3 parts by weight water. After the addition of water, the bag was sealed on a webmatic vacuum packaging machine at ambient pressure. After packaging, the bag is frequently shaken and turned over throughout the hydration process to ensure uniform hydration. In some cases, the bags were placed in a 4 ℃ cooler overnight prior to evaluation. Hydration was continued until each extrudate piece was completely hydrated and evaluation was not started. Complete hydration was determined by random extrusion through the bag around the extrudate sheet. When there is no hard spot, complete hydration is achieved and the hydration process is complete.

Commercial reference 1 samples were used to enable sensory evaluation participants to return references for memory purposes. All samples were aligned with the sample code and evaluation was started. The actual evaluation procedure was to place a piece of each sample into the mouth and evaluate the physical characteristics during biting and chewing. The evaluation parameters and vocabulary for scoring are defined in table 5 as the overall perception of the overall eating experience for each sample compared to a commercial reference 1 sample hydrated under the same conditions. The eating experience may be described as a 360 ° overall experience including visual appearance, first mouth, chewiness, mouthfeel, cell wall structure, fiber dimension, tenderness, and sheet size. The sum of overall perceptions was converted to a scale score of 1-10, where 1 was defined as completely disliked and 10 was defined as perfectly cooked chicken. An example of defining a score may be a sample that exhibits near perfect eating quality with excellent tenderness, fiber, color, and size, with a score of 8. However, if one parameter (such as mouthfeel) affects the overall score in a negative direction, the final score will be 7. Scores were collected from participants and are shown in table 6.

TABLE 5 attribute definition to generate overall preference for attributes

TABLE 6 scoring of the overall preference of cold water extrudate samples

Sample of	Overall preference scoring
		Reference 1 sample	3.5
Reference 2 sample	2.0
		Extrudate sample 1	5.5
Extrudate sample 2	7.0
		Extrudate sample 3	7.0
Extrudate sample 4	7.0
		Extrudate sample 5	6.0

Example 4

The extrudate samples of the present disclosure (samples 1, 2, 3, 4, and 5) were hydrated and compared to reference 2 for sensory evaluation. The extrudate needs to be sufficiently hydrated for reliable evaluation. The extrudate is added to a vacuum bag. Tap water and salt were mixed to form an aqueous solution having a salt concentration of 0.45wt%, and the aqueous solution was added to a vacuum bag in a ratio of 1 part by weight of extrudate to 3 parts by weight of aqueous solution. After the addition of the aqueous solution, the bag was sealed on a webmatic vacuum packaging machine at ambient pressure. After packaging, the bags were turned over frequently during the first hour and left overnight in a 4 ℃ cooler before heating and evaluation.

The sensory profiles of extrudate samples 1-5 and reference 2 were compared using descriptive analysis according to the general guidelines for establishing sensory profiles (ISO-13299,2016). The sensory panel consisted of seven trained evaluators tested, selected and trained according to the general guidelines for selection, training and supervision of selected and expert sensory evaluators (ISO-8586,2012). Samples were evaluated inside and outside the mouth according to the attributes described in table 7. All attributes were evaluated on unstructured scales (0-15), with the evaluators trained to correspond to the extremes in the sample set at anchor values of 1.5 and 13.5.

TABLE 7 sensory Properties

The sample was heated in its vacuum bag for 20 minutes at 80 ℃ using a water bath. The sample material was separated into 60 ml beakers and consumed at 60 ℃. Each evaluator received approximately 20 grams of sample material that was blind-labeled with a 3-digit code to hide the sample identity. In three replicates, one sample was provided at a time in random order, and the evaluator evaluated all properties of each sample. The results given in table 8 show the average attribute scores for seven evaluators and three replicates.

TABLE 8 attribute scoring

Annotation: ref.2 means hydrating a reference 2 sample; s. means the sample.

Hardness obtained by pressing with fork: the results from the sensory panel evaluation indicated that extrudate samples 1, 2, 3, 4, and 5 all produced a harder product than reference 2 (when pressed with the back of the fork) to simulate the texture of non-fabricated, natural structured foods for meats in a better manner than reference 2.

Hardness-first mouth: the results from the sensory panel evaluation indicated that extrudate samples 1, 2, 3, 4, and 5 all produced a product that was harder than reference 2 at the first bite, simulating the texture of non-fabricated, naturally structured foods for meats in a better manner than reference 2.

Chewing strength: the results indicate that all extrudate samples have similar or higher resistance to mastication with molar teeth than reference 2. Extrudate samples 2, 3, 4 and 5 showed higher resistance to chewing than reference 2, simulating the texture of non-fabricated, naturally structured foods for meats in a better manner than reference 2.

Hard: the results indicate that all extrudate samples 1-5 were similar or higher in the force required to bite through the sheets than reference 2. The extrudate samples 2, 3, 4 and 5 were all higher in hardness than reference 2, simulating the texture of non-fabricated, naturally structured foods for meats in a better manner than reference 2.

Spongy feel-bite: the sponges of extrudate samples 1, 2, 3, 4, and 5 were all lower than reference 2, simulating the texture of non-fabricated, naturally structured foods for meats in a better manner than reference 2.

Solubility: extrudate samples 2, 3, 4 and 5 were all more soluble when chewed, and this meant that it was easier to prepare for swallowing in the mouth when chewed, simulating the texture of non-fabricated, naturally structured foods for meat in a better manner than reference 2.

Example 5

The extrudate of the present disclosure was hydrated and cooked, and its texture was analyzed by comparison with chicken (cooked) and reference 1 (also hydrated and cooked in the same manner as the extrudate of the present disclosure).

The dried low moisture extrudate sample pieces were weighed and the actual weights (W1) were recorded. The flavoring (masking soy flavoring, umami flavoring, drumstick flavoring) and salt are dissolved to form an aqueous solution. The sample pieces were placed in a plastic bag containing an aqueous solution, sealed under 20% vacuum, and hydrated with an aqueous solution having a dry sample piece to aqueous solution ratio of 1:3. Complete hydration was ensured by occasional rotation of the bag and storage overnight at refrigerated conditions (4 ℃). Hydrated sample pieces (333 g) were cooked with 7g oil. The pan was preheated for 1min at a high heat setting and the samples were cooked for 4min. The sample was stirred intermittently and turned over to ensure uniform baking.

Cooking chicken with the following procedure: (1) Removing skin, excessive fat and tendons from chicken body, cutting into pieces in the shape of extrudate sample, adding salt and vacuumizing 100%, and placing in refrigerator overnight; (2) Preheating the pot for 1min under high heat, adding 7g of oil, adding 500g of chicken and frying for 7min, intermittently stirring chicken slices and turning over to prevent the surface of the chicken from being excessively baked; (3) putting the fried chicken in a refrigerator for cooling; (4) 100g portions were packaged in sachets and stored refrigerated until texture analysis measurements were made.

The samples were reheated in a water bath set at 80 ℃ for 20min prior to texture analysis. Texture analysis was performed according to the following procedure.

The texture analyser (TA-XT Plus C manufactured by stable microsystems limited (uk)) was equipped with an Ottawa Cell with a bottom plate perforated by a drain hole of 6.5mm diameter, a top plate of 6x6cm attached to the compression arm of the instrument, and a collection tray. The hydrated sample pieces were evenly distributed on the bottom of the Ottawa Cell chamber and compressed by lowering the top plate (downstroke) at a rate of 1mm/s until a force of 10kg was reached. This force was maintained on the sample for a holding time of 2 minutes. After the hold time, the force is removed by raising the top plate (upstroke) at a rate of 1 mm/s. The pressed hydrated sample pieces were then removed from the Ottawa Cell and weighed (W3). The Pressed Hydration Ratio (PHR) was determined as follows:

the force curves recorded during the compression experiments were analyzed to obtain a first gradient (Grad 1), gradient ratio, creep strain and restoring force 1. Each measurement was repeated at least 4 times on fresh samples and the average was calculated. The results (average) from the texture analysis measurements are summarized in table 9. The index of the large difference between reference 1 and chicken represents a characteristic sensitive to the difference determined by sensory evaluation. Thereafter, the relevant characteristics are:

1. A first gradient (Grad 1) representing sheet stiffness, such as resistance to deformation and drainage. This corresponds to the sensory experience of the hardness of the first mouth. A high value corresponds to a high hardness of the first port, while a low value of the first gradient corresponds to a softer feel experience of the first port.

2. The ratio of the first gradient to the second gradient (Grad 2), referred to as gradient ratio, represents the relative recovery of the water-depleted sheet with respect to the deformation imposed on the wet sheet.

3. Creep strain, which is the strain obtained during the 10kg hold phase of the experiment, represents the compliance of the sheet (irreversible strain of the protein scaffold and sustained irreversible moisture loss).

4. Restoring force 1 represents the work recovered by the sheet from deformation versus compression work.

Creep strain, gradient 1, gradient ratio, and restoring force 1 in table 9 demonstrate that the extrudates of the present disclosure (samples 2 and 4) have texture characteristics that are closer to chicken than commercial product reference 1.

Table 9: texture analysis index of low moisture extrudates

Index (I)	Unit (B)	Sample 2	Sample 4	Chicken meat	Reference 1
						Creep strain	％	3.560	3.317	5.627	2.250
Gradient 1	kg/％	0.835	0.874	0.688	1.273
						Gradient ratio	--	0.201	0.225	0.162	0.243
Restoring force 1	--	0.22	0.216	0.188	0.243
						PHR	--	2.849	2.789	--	2.899

It should be noted that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more other activities may be performed in addition to those described. Moreover, the order of activities recited need not be the order in which they are performed.

In the foregoing specification, concepts have been described with reference to specific embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. Accordingly, the specification is to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present invention.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. The benefits, advantages, solutions to problems, and any feature or features that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as critical, required, or essential features of any or all the claims.

It is appreciated that certain features, which are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination.

Examples

For further explanation, additional non-limiting embodiments of the present disclosure are set forth below.

For example, embodiment 1 is an extrudate, such as a low moisture extrudate, comprising, on a moisture free basis, based on the weight of the extrudate, (a) from about 60 wt.% to about 90 wt.% of a vegetable protein, such as soy protein and/or pea protein; (b) From about 1 wt% to about 10 wt% of a hydrocolloid, wherein the hydrocolloid is selected from the group consisting of: alginate, pectin, agar, methylcellulose, and mixtures thereof; and (c) optionally, no more than about 14% by weight starch, such as from about 1% to about 14% by weight starch.

Embodiment 2 is an extrudate as set forth in embodiment 1 wherein the hydrocolloid comprises or is an alginate and the extrudate further comprises calcium ions.

Embodiment 3 is the extrudate as set forth in any one of the preceding embodiments wherein the extrudate comprises at least about 60%, 62%, 64%, 66%, 68%, 70%, 72%, 74%, 76%, 78%, 80%, or 82% vegetable protein.

Embodiment 4 is the extrudate as set forth in any one of the preceding embodiments wherein the extrudate comprises no more than about 90%, 89%, 88%, 87%, 86%, 85%, 83%, 81%, 79%, 77%, 75%, 73%, or 71% vegetable protein.

Embodiment 5 is an extrudate as set forth in any one of the preceding embodiments wherein the extrudate comprises at least about 1%, 1.5%, 2%, 2.5%, 3%, 3.5%, or 4% hydrocolloid.

Embodiment 6 is an extrudate as set forth in any one of the preceding embodiments wherein the extrudate comprises no more than about 10%, 9%, 8%, 7%, 6.5%, 6%, 5.5%, 5%, 4.5%, or 4% hydrocolloid.

Embodiment 7 is an extrudate as set forth in any preceding embodiment wherein the hydrocolloid comprises or is a combination of sodium alginate and calcium alginate.

Embodiment 8 is the extrudate as set forth in any one of embodiments 1 or 3-6 wherein the hydrocolloid comprises or is pectin and the extrudate optionally comprises calcium ions.

Embodiment 9 is the extrudate as set forth in any one of embodiments 1 or 3-6 wherein the hydrocolloid comprises or is agar.

Embodiment 10 is the extrudate as set forth in any one of embodiments 1 or 3-6 wherein the hydrocolloid comprises or is methylcellulose.

Embodiment 11 is the extrudate as set forth in any one of embodiments 1 or 3-6 wherein the hydrocolloid is calcium alginate.

Embodiment 12 is an extrudate as set forth in any of the preceding embodiments wherein the extrudate comprises no more than about 13%, 12%, 11%, 10%, 9%, 8%, 7%, or 6% starch.

Embodiment 13 is an extrudate as set forth in any one of the preceding embodiments wherein the extrudate comprises at least about 0.001%, 0.01%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, or 5% starch.

Embodiment 14 is an extrudate as set forth in any preceding embodiment wherein the starch is selected from the group consisting of: tapioca starch, wheat starch, potato starch, and combinations thereof.

Embodiment 15 is an extrudate as set forth in any of the preceding embodiments wherein the extrudate further comprises an added fiber component in an amount of no more than about 6%, 5%, 4%, 3%, or 2%.

Embodiment 16 is an extrudate as set forth in any of the preceding embodiments wherein the extrudate further comprises an added fiber component in an amount of at least about 1%, 2%, 3%, 4%, or 5%.

Example 17 is an extrudate as set forth in example 15 or 16 wherein the additional fiber component is selected from the group consisting of: soybean fiber, citrus fiber, pea fiber, and combinations thereof.

Embodiment 18 is the extrudate as set forth in any one of embodiments 1-7 or 11-17 wherein the extrudate has a calcium content of at least about 0.01%, 0.02%, 0.05%, 0.08%, 0.1%, 0.15%, 0.2%, 0.25%, 0.3%, 0.35%, 0.4%, 0.45%, or 0.5%.

Embodiment 19 is the extrudate as set forth in any one of embodiments 1-7 or 11-18 wherein the extrudate has a calcium content of no more than about 10%, 8%, 6%, 5%, 4%, 3%, 2%, 1.5%, 1.2%, 1%, 0.9%, 0.8%, 0.7%, or 0.6%.

Embodiment 20 is the extrudate as set forth in any one of embodiments 1-6 or 12-19 wherein the extrudate further comprises a chelating agent selected from the group consisting of: tetrasodium pyrophosphate (TSPP), trisodium phosphate (TSP), disodium phosphate (DSP), sodium Hexametaphosphate (SHMP), trisodium citrate, and mixtures thereof.

Embodiment 21 is the extrudate as set forth in any one of embodiments 1-6 or 12-19 wherein the extrudate further comprises an acidulant (pH control agent/chelating agent) such as glucono-delta-lactone (GDL).

Embodiment 22 is an extrudate as set forth in any of embodiments 1-8 or 12-21 wherein the hydrocolloid comprises or is a combination of pectin and alginate.

Embodiment 23 is the extrudate as set forth in any one of the preceding embodiments wherein the vegetable protein is a chickpea (chick pea) protein and/or a fava bean (Viciafaba) protein.

Embodiment 24 is the extrudate as set forth in any one of the preceding embodiments wherein the vegetable protein comprises potato protein.

Embodiment 25 is an extrudate as set forth in any of the preceding embodiments wherein the extrudate has a water content of no more than about 12wt%, 10wt%, 8wt%, 6wt%, 4wt%, 2wt%, or 1wt%, based on the total weight of the extrudate.

Embodiment 26 is an extrudate as set forth in any of the preceding embodiments wherein the extrudate has a water binding ratio of at least about 3.

Embodiment 27 is an extrudate as set forth in any preceding embodiment wherein the extrudate is substantially gluten-free or gluten-free.

Embodiment 28 is an extrudate as set forth in any one of the preceding embodiments wherein the extrudate has a weight of from about 0.30g/cm ³ To about 0.70g/cm ³ Is a density of (3).

Embodiment 29 is an extrudate as set forth in any preceding embodiment wherein the extrudate comprises substantially aligned macrostructure fiber elements (strands, sheets, and pieces).

Embodiment 30 is an extrudate as set forth in any preceding embodiment wherein the extrudate comprises substantially aligned plant protein fibers and an average of at least 55% of the plant protein fibers present in the extrudate are substantially aligned.

Embodiment 31 is a dry mix composition comprising, on a moisture free basis, based on the total weight of the dry mix composition, (a) from about 65 wt% to about 98 wt% of a vegetable protein material, such as a soy protein material selected from the group consisting of: soy protein isolate, soy protein concentrate, and combinations thereof; (b) From about 1wt% to about 10wt% of a hydrocolloid, wherein the hydrocolloid is selected from the group consisting of: alginate, pectin, agar, methylcellulose, and mixtures thereof; and (c) optionally, no more than about 14% by weight starch.

Embodiment 32 is a dry mix composition as set forth in embodiment 31, wherein the dry mix composition comprises at least about 65%, 67%, 69%, 71%, 73%, 75%, 77%, 79%, 81%, 83%, 85%, or 86% vegetable protein material.

Embodiment 33 is a dry mix composition as set forth in embodiment 31 or 32, wherein the dry mix composition comprises no more than about 98%, 97%, 96%, 95%, 94%, 93%, 92%, 91%, 90%, 89%, or 88% vegetable protein material.

Embodiment 34 is a dry mix composition as set forth in any one of embodiments 31-33, wherein the dry mix composition comprises no more than about 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, or 6% starch.

Embodiment 35 is a dry mix composition as set forth in any one of embodiments 31-34, wherein the dry mix composition comprises at least about 0.001%, 0.01%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, or 5% starch.

Embodiment 36 is a dry mix composition as set forth in any one of embodiments 31-35, wherein the dry mix composition comprises at least about 1%, 1.5%, 2%, 2.5%, 3%, 3.5%, or 4% hydrocolloid.

Embodiment 37 is a dry mix composition as set forth in any one of embodiments 31-36, wherein the dry mix composition comprises no more than about 10%, 9%, 8%, 7%, 6.5%, 6%, 5.5%, 5%, 4.5%, or 4% hydrocolloid.

Embodiment 38 is a dry mix composition as set forth in any one of embodiments 31-37, wherein the hydrocolloid is an alginate selected from the group consisting of: calcium alginate, potassium alginate, sodium alginate, and combinations thereof.

Embodiment 39 is a dry mix composition as set forth in any one of embodiments 31-38, wherein the hydrocolloid is a mixture of sodium alginate and calcium alginate.

Embodiment 40 is a dry mix composition as set forth in any one of embodiments 31-37, wherein the hydrocolloid is an alginate and the dry mix composition further comprises at least about 0.05%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.2%, 1.5%, 1.8%, or 2% of a sparingly soluble calcium compound.

Embodiment 41 is the dry mix composition as set forth in any one of embodiments 31-37 or 40, wherein the hydrocolloid is an alginate and the dry mix composition further comprises no more than about 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, or 2% of a sparingly soluble calcium compound.

Example 42 is a dry mix composition as set forth in example 40 or 41, wherein the sparingly soluble calcium compound is selected from the group consisting of: calcium sulfate, calcium phosphate (e.g., dicalcium phosphate), calcium citrate, calcium carbonate, calcium silicate, calcium sulfide, calcium tartrate, and mixtures thereof.

Embodiment 43 is a dry mix composition as set forth in any one of embodiments 40-42, wherein the dry mix composition further comprises a chelating agent, such as a chelating agent selected from the group consisting of: tetrasodium pyrophosphate (TSPP), trisodium phosphate (TSP), disodium phosphate (DSP), sodium Hexametaphosphate (SHMP), trisodium citrate, and mixtures thereof.

Embodiment 44 is a dry mix composition as set forth in any one of embodiments 40-42, wherein the sparingly soluble calcium compound is calcium carbonate, and the dry mix composition optionally further comprises glucono-delta-lactone (GDL) as an acidulant.

Embodiment 45 is a dry mix composition as set forth in any one of embodiments 31-37, wherein the hydrocolloid is calcium alginate.

Embodiment 46 is a dry mix composition as set forth in any one of embodiments 31-37, wherein the hydrocolloid is pectin having an average DE of at least 50 and the dry mix composition is substantially free of calcium-containing compounds such as sparingly soluble calcium compounds or free of calcium-containing compounds.

Embodiment 47 is the dry mix composition as set forth in any one of embodiments 31-46, wherein the dry mix composition further comprises an added fiber ingredient in an amount of no more than about 6%, 5%, 4%, 3%, or 2%.

Embodiment 48 is a dry mix composition as set forth in any one of embodiments 31-47, wherein the dry mix composition further comprises an added fiber ingredient in an amount of at least about 0.5%, 1%, 2%, 3%, 4%, or 5%.

Example 49 is a dry mix composition as set forth in example 47 or 48, wherein the additional fiber component is selected from the group consisting of: soybean fiber, citrus fiber, pea fiber, and combinations thereof.

Embodiment 50 is the dry mix composition as set forth in any one of embodiments 31-49, wherein the dry mix composition has a water content of no more than about 10wt%, 8wt%, 6wt%, 4wt%, 2wt%, or 1wt%, based on the total weight of the dry mix composition.

Embodiment 51 is a dry mix composition as set forth in any one of embodiments 31-50, wherein the dry mix composition is substantially gluten-free or gluten-free.

Embodiment 52 is an extrusion method, such as a low moisture extrusion method, comprising: (a) Contacting the dry mix composition as set forth in any one of examples 31-51 with water to form a feed mixture; (b) Feeding the feed mixture into an extruder to form a melt extruded mass; and (c) extruding the molten extrudate through an extrusion die to produce an extrudate.

Embodiment 53 is a method of making a hydrated extrudate comprising hydrating an extrudate as set forth in any one of embodiments 1-30 in an aqueous solution to form the hydrated extrudate.

Embodiment 54 is a method as set forth in embodiment 53, wherein the hydrating method is performed by immersing the extrudate in an aqueous solution optionally comprising a fragrance and/or flavor.

Embodiment 55 is a method as set forth in embodiment 53 or 54, wherein the hydrating process is performed under vacuum, such as at least about 20% vacuum.

Embodiment 56 is the method as set forth in any one of embodiments 53-55, wherein the hydration time is from about 30 minutes to about 180 minutes, or from about 60 minutes to about 120 minutes, or from about 90 minutes to about 120 minutes.

Embodiment 57 is the method as set forth in any one of embodiments 53-56, wherein the hydrated extrudate comprises at least about 15wt% of segments comprising macrostructural fiber elements comprising strands at least about 1cm long or having a length of 1/3 of a dry extrudate, and/or sheets at least about 1cm long or having a length of 1/3 of a dry extrudate and at least 1cm wide or having a width of 1/2 of a dry extrudate, and/or blocks at least about 1cm long or having a length of 1/3 of a dry extrudate or at least 1cm wide or having a width of 1/2 of a dry extrudate and up to 1cm thick or having a thickness of 1/2 of a dry extrudate.

Embodiment 58 is the method of any one of embodiments 53-57, wherein the hydrated extrudate comprises at least about 15wt%, 20wt%, 22wt%, 24wt%, 26wt%, 28wt%, 30wt%, 32wt%, 34wt%, 36wt%, 38wt%, 40wt%, 42wt%, 44wt%, 46wt%, or 48wt% of the macrostructure fiber elements (strands, sheets, and pieces) based on the weight of the hydrated extrudate.

Embodiment 59 is the method as set forth in any one of embodiments 53-58, wherein the hydrated extrudate comprises no more than about 75wt%, 70wt%, 68wt%, 66wt%, 64wt%, 62wt%, 60wt%, 58wt%, 56wt%, or 54wt% of the macrostructure fiber elements (strands, sheets, and pieces) based on the weight of the hydrated extrudate.

Embodiment 60 is the method as set forth in any one of embodiments 53-59, wherein the hydrated extrudate has an average shear strength of at least about 1400 grams, such as at least about 1500, 1600, 1700, 1800, 1900, 2000, 2200, 2400, 2600, 2800, 3000, 3200, 3400, 3600, or 3800 grams.

Embodiment 61 is the method as set forth in any one of embodiments 53-60, wherein the hydrated extrudate has an average shear strength of no more than about 6000, 5500, 5000, 4800, 4600, 4400, 4200, 4100, 4000, or 3900 grams.

A ready-to-use meat alternative food product of embodiment 62, prepared according to any one of embodiments 53-61.

Claims

1. An extrudate comprising, on a moisture free basis, based on the weight of the extrudate,

(a) From about 60% to about 90% by weight vegetable protein;

(b) From about 1 wt% to about 10 wt% of a hydrocolloid, wherein the hydrocolloid is selected from the group consisting of: alginate, pectin, agar, methylcellulose, and mixtures thereof; and

(c) Optionally, no more than about 14% by weight starch.

2. The extrudate of claim 1 wherein the extrudate is a low moisture extrudate.

3. The extrudate of claim 1 or 2 wherein the vegetable protein is selected from the group consisting of: soy protein, pea protein, and combinations thereof.

4. The extrudate of any one of the preceding claims wherein the vegetable protein is soy protein.

5. The extrudate of any one of the preceding claims wherein the hydrocolloid is an alginate and the extrudate further comprises calcium ions.

6. The extrudate of any one of the preceding claims wherein the hydrocolloid is calcium alginate.

7. The extrudate of any one of claims 1-6, wherein the extrudate has a GDL content in the range of from about 0.1% to about 10%.

8. An extrudate comprising, on a moisture free basis, based on the weight of the extrudate,

(a) From about 80% to about 96% by weight of soy protein isolate;

(b) From about 2% to about 10% by weight calcium alginate; and

(c) From about 2% to about 10% by weight starch.

9. The extrudate of any one of the preceding claims wherein the extrudate comprises soy protein fibers and an average of at least 55% of the soy protein fibers present in the extrudate are substantially aligned.

10. A dry mix composition comprising, on a moisture free basis, based on the total weight of the dry mix composition,

(a) From about 65% to about 98% by weight of a vegetable protein material;

(c) Optionally, no more than about 14% by weight starch.

11. The dry mix composition of claim 10, wherein the hydrocolloid is an alginate and the dry mix composition further comprises a sparingly soluble calcium compound and a chelating agent.

12. The dry mix composition of claim 10, wherein the hydrocolloid is an alginate and the dry mix composition further comprises from about 0.3% to about 3% calcium carbonate and from about 0.3% to about 3% glucono-delta-lactone.

13. The dry mix composition of claim 10, wherein the vegetable protein material is soy protein isolate and the hydrocolloid is calcium alginate.

14. A method of extrusion, comprising:

(a) Contacting the dry mix composition of any one of claims 10-13 with water to form a feed mixture;

(b) Feeding the feed mixture into an extruder to form a melt extruded mass; and

(c) The molten extrudate is extruded through an extrusion die to produce an extrudate.

15. A method of preparing a hydrated extrudate comprising hydrating the extrudate of any one of claims 1-9 in an aqueous solution to form the hydrated extrudate.